Agriculture and Rural Development Program
Rehabilitation of Kfarshima Laboratory
MECHANICAL SYSTEM
BASIC MECHANICAL REQUIREMENTS ______________________________________________ 2
PAINTING ___________________________________________________________________ 21
ELECTRICAL WORKS FOR MECHANICAL SYSTEM _____________________________________ 24
BASIC MECHANICAL MATERIALS AND METHODS ____________________________________ 34
WELDING ___________________________________________________________________ 38
PIPES AND FITTINGS___________________________________________________________ 41
VALVES _____________________________________________________________________ 65
PIPES, FITTINGS AND VALVES - APPLICATION _______________________________________ 73
R/O WATER TREATMENT PLANT _________________________________________________ 81
SUPPORTS AND ANCHORS ______________________________________________________ 83
PUMPS _____________________________________________________________________ 87
MECHANICAL IDENTIFICATION __________________________________________________ 90
NOISE, VIBRATION & SEISMIC CONTROL __________________________________________ 97
EQUIPMENT & PIPE INSULATION _______________________________________________ 107
FIRE PROTECTION SYSTEM ____________________________________________________ 113
DUCT INSULATION ___________________________________________________________ 115
DOMESTIC AND SOFT WATER PIPING SYSTEM _____________________________________ 119
SOIL, WASTE & ROOF DRAINAGE PIPING SYSTEMS _________________________________ 126
WATER DISTRIBUTION SYSTEM _________________________________________________ 143
PLUMBING FIXTURES _________________________________________________________ 145
AIR DISTRIBUTION UNITS _____________________________________________________ 148
DUCTWORK ________________________________________________________________ 157
AIR OUTLETS AND INLETS _____________________________________________________ 178
TESTING, ADJUSTING AND BALANCING __________________________________________ 182
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BASIC MECHANICAL REQUIREMENT
PART 1 - GENERAL
1.01
SUMMARY
A.
This chapter generally specifies administrative and procedure requirements regarding
Mechanical Work. Additional requirements are specified in various chapters of Division 15
and also may be required during the execution work due to project conditions.
B.
The requirements of this Chapter do not supersede or take precedence over any provision
of the General Conditions and Supplementary General Conditions, and should any
discrepancy become apparent between these requirements and the General Conditions and
Supplementary General Conditions, the Contractor shall notify the Contracting authority in
writing, and the Contracting authority shall interpret and decide such matters in accordance
with the applicable provisions of the General Conditions and Supplementary General
Conditions.
PROJECT OUTLINE AND DESCRIPTION
A.
General
This Book of Specifications covers the General and Particular Specifications for the
Mechanical Systems of the “Rehabilitation of KFARCHIMA laboratory – Beirut,
Lebanon”.
B.
Project Outline
The project consists of an existing building of 3 floors used for offices, meeting
rooms and laboratories in addition to a new basement.
C.
General Description of the Works
The following Mechanical Systems are included in the Project:
a.
Water Supply.
b.
Sanitary Drainage.
c.
Fire Fighting.
d.
Air Conditioning.
e.
Ventilation.
as described in the following clauses and/or shown on the relevant Tender drawings.
D.
Water Supply System
1.
Domestic Cold Water
Domestic cold water is provided from the same connection as the previous
one but with a modified distribution in toilets as per new design.
Addition of RO system for the scrubbers (4No.)
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2.
Domestic Hot Water
Domestic hot water for each set of toilets is provided by means of electric
water heaters (150liters) located above false ceiling.
E.
Drainage System
Sewage system of areas aboveground is collected in two pipes networks; one
from laboratories with HDPE pipe & the other PVC from toilets discharged by
gravity into the city sewage network through non-return valve.
Sewage system of toilets located in basement is collected in one pipe network
and discharged by gravity into existing sewage sump pit. Duplex sewage
submersible pumps will lift the sewage to the ground floor level to discharge
into the main sewage network.
Rainwater will be re-habilitated and discharged by gravity at garden level.
F.
Fire Fighting System
The design of the fire protection system is made in accordance with the European
Code without contradiction with local codes and regulations.
Portable fire extinguishers are provided throughout the project with one
extinguisher for each laboratory.
G.
Air Conditioning Systems
Each office and meeting room is cooled by means of heat pump VRV (Variable
Refrigerant Volume) system. Constant airflow is distributed inside each space
by means of indoor decorative wall type units.
Split system will be provided for UPS and batteries room.
H.
Ventilation System
Exhaust air is used in Toilets, storage areas, and technical rooms by means of extract fans.
Fresh air is provided for offices, rooms and laboratories thru AHU connected to VRV system
(Air conditioned FA).
1.02 EXTENT OF WORK
The Contractor shall supply all labor, materials, equipment, tools, appurtenances, storage, services
and temporary work, necessary to completely install, in accordance with these specifications and
the drawings.
Work, materials, equipment or services not specifically mentioned in other clauses of these
specifications or elsewhere, or indicated on the drawings but found necessary for the completion
and perfect functioning of the installations must be included in the Contractor’s price.
The work shall include also operation of the installations after completion and acceptance including
maintenance and guarantee of the works as described hereinafter.
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The work shall be designed and carried out in accordance with the contract drawings and
specifications as well as the standards of the country of origin.
The following builder’s work shall be considered as part of this work :
i.
Concrete foundations and pads under pumps, and other equipment.
ii.
All Builder’s work in connection with fixing support, hangers, anchors, etc.
iii.
Cutting or forming all openings, mortar, chase, etc., in floors, walls and ceilings required for
the installation and making good after.
iv.
Painting items of equipment and exposed pipes and supports.
v.
Labeling.
1.03 SYSTEM DESCRIPTION
A.
Division 15 of this specification covers the supply and installation of the mechanical and Air
Conditioning services as shown on the design drawings and in this specification.
B.
To balance, adjust and test air moving equipment, air distribution, exhaust air systems and
other systems as herein specified.
C.
It shall be clearly understood that these specifications and design drawings are
complimentary documents, intended for the selection of equipment having the general and
specific characteristics as detailed in the documents.
D.
Unless otherwise specifically stated, the mechanical installation shall be complete, ready for
operation and fully integrated and co-ordinated with all other building items.
E.
Materials and methods included in this Chapter are of a general nature, and apply to most
systems and installations in this Contract. Refer to individual system chapters for materials
and methods specifically required for the respective systems.
F.
The systems described include the following :
1.
2.
5.
8.
9.
10.
11.
13.
14.
15.
16.
G.
Ventilation and Air Conditioning.
VRV and Ancillaries.
Water Treatment.
Domestic Cold and Hot Water
Fire Services.
Drinking Water.
Automatic Controls.
Underground Drainage.
Sanitary Soil and Waste Drainage.
Sanitary Fixtures.
Rain Water Drainage.
Air-conditioning equipment capacities are based on the following conditions:
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a)
Outdoor temperatures
In summer
95°F (35°C)
83°F (28°C)
In winter
42°F (5.6°C)
70% to 90%
Dry bulb temperature.
Dry Range
8°C
Dry bulb temperature.
Latitude
Longitude
Elevation above sea level
Prevailing winds
Wind speed
Average rainfall rate
b)
Dry bulb temperature.
Wet bulb temperature.
33° 54’ North
35° 25’ East
34 m.
North during winter & southwest during summer.
4m/s.
100mm/hr.
Indoor temperature
Summer dry bulbSummer relative
Winter dry bulb Winter relative
temp. (°C)
humidity (% RH)
temp (°C)
humidity
(% min.)
Apartment Rooms
22
40-60
22
30
Apartment Corridors 24
40-60
22
30
Public spaces
24
40-60
22
30
Kitchen/Laundry
24
--20
--Shops
24
--22
--Health Club
24-26
50
22
30
Elevator room
30
------Mechanical room
30
------Electrical room
30
------Tolerance will be as follows:
Temperature = 1°C
Relative humidity + 15%
c)
System Pressure
Domestic Water System : PN20 for pipes less than 2” (50mm) diameter.
2 1/2” (65mm) diameter and above:
- from level 50 up to roof rising stem PN16 OS &Y flanged.
- below level 50 class 150 rising stem OS&Y flanged.
Valves for:
R/O Plant
(before & after)
Soft Water
Fuel Oil System
: valves below 2” (50mm) diameter
65mm diameter and above non rising stem flanged
(valves in R/O unit stainless steel)
: (As specified for Domestic Water)
: valves below 2” (50mm) diameter (All floors)
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PN20
PN10
PN 10
Agriculture and Rural Development Program
Rehabilitation of Kfarshima Laboratory
: valves 2 ½” (65mm ) diameter and above
O.S & Y rising stem
PN 16
1.04 QUALITY ASSURANCE
A.
Materials and equipment shall conform to the latest edition of reference specifications
specified herein and to applicable codes and requirements of local authorities having
jurisdiction.
1.
2.
Mechanical equipment shall conform to the latest version of ASHRAE Standard 90A1980.
Reference Standards
a.
Provide materials and equipment listed by Underwriters’ Laboratories, Inc.
except in those cases where an Underwriters’ Laboratories listing is not
available.
b.
Comply with the latest applicable standards of the following :
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
ASME American Society of Contracting authoritys.
ARI Air-conditions and Refrigeration Institute.
ANSI - American National Standards Institute.
ASTM - American Society of Testing Materials.
AMCA - Air- moving and Conditioning Association.
AGA American Gas Association.
NEMA National Electrical Manufacturers Association.
AWS American welding Society.
NFPA National Fire Protection Association.
BS British Standards.
SMACNA Sheet Metal and Air-conditioning Contractors.
DIN Deutsches Institute for Normalisierung
FM Factory Matual.
IRR Institute of Boiler and radiator Manufacturers.
ISO International Standardization organization.
1.05 SUBMITTALS
A.
Definitions :The required submittals of this division, in addition to the definitions of the
General Conditions, and elsewhere in the contract documents, are further categorized for
convenience as follows :
1.
Product data shall include manufacturer’s latest standard printed literature such as
manufacturer’s installation instructions, catalog cuts, color charts, roughing
diagrams, wiring diagrams and performance curves on materials, equipment and
systems for this project. Product data shall include references to applicable
specification chapter and item number. Product data shall be provided in addition
to the required shop drawing submittals.
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2.
Shop drawings shall be submitted to the Contracting authority for Approval as
described hereinafter.
3.
Samples shall include physical examples of materials in complete units for visual
inspection. Samples shall indicate applicable specification chapter number and item
numbers within that chapter.
4.
Certificates shall include statements of applicability, certifying reports from
governing and testing agencies, industry standards and applicable certificates
specified in each Chapter of the specifications.
5.
Test and inspection reports shall include reports specified in each chapter of the
specifications.
6.
Miscellaneous submittals shall include submittals related directly to the work (nonadministrative) including warranties, maintenance agreements, workmanship
bonds, reports, physical work records, copies of industry standards, record
drawings, field measurement data and similar information applicable to the work
and not processed as shop drawings, product data, samples or certificates.
7.
No equipment or materials are to be purchased or delivered to site until the
required submittals have been approved.
1.06 INTENT
The purpose of the shop drawings and specification is to provide an approach for intended complete
installations, finished, fully adjusted, tested commissioned and put in perfect operating condition.
The spirit as well as the letter of the drawings and specification shall be followed, and all work shall
be executed according to the true intent and meaning of the drawings and specifications.
1.07 DISCREPANCIES AND OMISSIONS
It is the responsibility of the Contractor, to inform the Contracting authority of any discrepancies in
the drawings and specifications before signing the Contract, default of which will make him
responsible for any errors or omissions in the drawings and specifications even though these have
been approved by the Contracting authority.
All costs incurred by any changes or alterations necessitated by any errors or omissions shall be on
the Contractor’s own expense without having the right to ask the employer for any indemnity.
1.08 CONTRACTING AUTHORITY'S DRAWINGS
The Contracting authority's drawings are generally diagrammatic and include general layouts and
typical details of the various systems to be installed. No deviations from the drawings shall made
without receipt of prior written approval from the Contracting authority.
The drawings shall not be scaled. The Contractor shall base all measurements both horizontal and
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vertical from established bench marks. All work shall agree with these established lines and levels.
All measurements shall be verified on Site and checked as to correctness of same as related to the
work.
The Contractor shall check all Architectural, Structural and Electrical drawings in laying out work for
verifying the adequacy of space in which work will be installed. Maximum headroom and space
conditions shall be maintained all points. Where head room or space conditions appear inadequate
the Contracting authority shall be notified before proceeding with installation.
1.09 SHOP AND INSTALLATION DRAWINGS
Prior to starting the work the Contractor shall submit to the Contracting authority for approval
detailed shop and installation drawings showing to scale dimensions of equipment, pipes, etc. in
plan and elevation with clearances and relation of same to the space assigned. Minimum scale of
shop drawings shall be 1/50 .
Where the work will be installed in close proximity to, or will interfere with the work of other
trades, the Contractor shall coordinate space conditions to make a satisfactory adjustment. The
Contractor shall prepare composite installation drawings and chapters to a suitable scale of not less
than 1/50, clearly showing how work will be installed in relation with work of other trades.
Prior to submissions of the drawings and approximately 30 days after award of the Contract, The
Contractor shall submit lists of all equipment and materials with the names of proposed
manufactures. Lists shall show submission dates. The drawings will not be accepted prior to
submission of such lists. Drawings of interrelated items shall be submitted at approximately the
same time.
Drawings of equipment and material shall include detailed manufacturer’s drawings, cuts of
catalogues and descriptive literature, showing specifications, type, performance characteristics,
construction, component parts, dimensions, size arrangements, operating clearance, capacity,
electrical characteristics, power requirements, motor, drive and testing information. Data of a
general nature will not be accepted.
Catalogues, pamphlets or manufacturer’s drawings submitted for approval shall be clearly marked in
ink for proper identification of the item being proposed.
Deviations from the specifications and drawings shall be indicated clearly with the reason for each
deviation.
All submissions for approval shall be furnished in three copies and submitted sufficiently in advance
of requirements to allow the Contracting authority ample time for checking and approving. Failure
of the Contractor to submit the drawing in ample advance time shall not entitle him to an extension
of contract time, and no claim for extension by reason of such default will be allowed.
No equipment or material shall be purchased, delivered to the site or installed until the contractor
has in his possession the approved drawings for the particular equipment or material.
Approval rendered on drawings shall not relieve the Contractor from his responsibility to provide
equipment and material to meet the performance and quality standards as indicated on the
drawings and as described in the specification or to be of physical size to fit the space assigned for
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it.
Material not covered by drawings such as pipe, fitting and incidentals shall be submitted for
approval in letter form giving ratings and names of manufacturers.
During the progress of the work, drawings shall be submitted as required by the Contracting
authority and as specified elsewhere in this specification. These drawings shall comprise but not
necessarily be limited to concrete bases for equipment with location of anchors bolts,
manufacturers certified installation drawings and instructions, certified performance characteristics
of equipment, wiring diagrams of motor controllers and control systems, etc.
Where required by the Contracting authority the Contractor shall submit for approval samples of
material to be used and workmanship proposed. The Contractor shall not use material or
workmanship that does not correspond to the approved samples.
1.10 COORDINATION WITH OTHER TRADES
The Contractor shall plan and coordinate the work with all other trades in advance of requirements
and shall provide all necessary resources to ensure compliance with the construction program.
Contractor shall submit to the Contracting authority a set of composite coordination drawings in
plans and chapters with minimum scale of 1/50.
The Contractor shall coordinate the space requirements of all other trades involved and shall be
responsible for the sufficiency of the size of shafts and chases and adequate clearance in double
partitions, hung ceilings, etc. for the proper installation of the work.
The Contractor shall give full cooperation to all other trades to permit the work of the trades to be
installed satisfactorily and with the least possible interference or delay.
The Contractor shall furnish to other trades, as required, all necessary templates, patterns, setting
plans and shop details for the proper installation and coordination of adjacent work.
The Contractor shall undertake to make, without extra charge, minor changes and modifications in
the layout as needed to prevent conflict with work of other trades or for proper execution of the
work .
Any extra coast incurred by lack of coordination on the part of the Contractor shall be at his own
expense.
1.11 RECORD DRAWINGS
The Contractor shall submit to the Contracting authority for record a complete three set of hard
copies of the as-built drawings including three set of soft copies on CAD2008 including electrical
wiring diagrams, reflecting all the changes made from the original drawings during the progress of
the work. The drawings and electrical wiring diagrams shall show all labeled equipment, valves,
controls, instruments and electrical devices.
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1.12 INSTRUCTION & MAINTENANCE MANUALS AND SPARE PARTS LISTS
The Contractor shall furnish three copies of an instruction and maintenance manual bound in
booklets form containing the following information:
Brief description of every system and equipment with basic operating features.
Descriptive literature of all equipment and components with manufacturer’s name, model number,
capacity rating and operating characteristic.
Service manual for every major piece of equipment giving operating and maintenance instructions,
starting and shutdown instructions, lubrication instructions and possible breakdown and repairs, the
service manual shall be prepared specially by the manufacturer for the particular equipment.
Manufacturer’s list of general spare parts for every piece of equipment with unit prices.
Manufacturer’s list of recommended spare parts for Three years of operation for every piece of
equipment with unit prices.
Detailed and simplified one line, color coded flow diagrams of every system with tag number,
location and function of each valve and instrument.
The instruction manual shall be submitted in draft form to the Contracting authority for his review
and approval as to the fulfillment of the specified requirements prior to final issue.
The instruction manual shall be submitted to the Contracting authority at least four weeks in
advance of the complete date of the system to be available for the final inspection prior to
acceptance of the respective systems.
1.13 DELIVERY, STORAGE AND HANDLING
Deliver products to the project properly identified with name, model number, types, grades,
compliance labels and other information needed for identification.
1.14 EQUIPMENT AND MATERIAL QUALITY WORKMANSHIP
All equipment and material provided by the Contractor shall be new, free from defects and of the
same type, standard and quality as set forth in the specification.
Equipment and material of similar application shall be of the same manufacturer unless otherwise
specified.
All workmanship shall be of the highest standards of the industry, of accepted Contracting
authoritying practice and to the entire satisfaction of the Contracting authority. Poor workmanship
shall be rejected and the work reinstalled when in the judgment of the Contracting authority, the
workmanship is not of the highest quality.
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1.15 SUBSTITUTION OF EQUIPMENT AND MATERIAL
Reference in the drawings and specifications to any equipment or material by name, make or
catalogue number, as well as any list of approved manufacturers, shall be interpreted as
establishing a standard of quality and performance and shall not in any way be construed as an
intention to eliminate the products of other manufacturers and suppliers having approved
equivalent products.
Approval of a manufacturer does not necessarily constitute approval of his equipment as equal to
those specified. After award of Contract and before start of construction, the Contractor shall
submit for the approval of the Contracting authority a complete summary of proposed equivalent to
be furnished indicating service, manufacturer, figure number, type and pressure rating.
The Tender shall be based on the trade name and catalogue reference named in the specification
and products of the approved manufacturers. Should the Contractor wish to use any equipment,
material or products other than those specified, he should so state as an alternative to the Tender,
naming the proposed substitutions and indicating what difference, if any, will be made to the
Contract, price and detailing all differences entailed by the substitution.
All the times the Contracting authority shall be the only judge of equality between the proposed
alternative and the item specified. No alternative shall be implemented without the written
approval of the Contracting authority. The rejection of the Contracting authority to the alternative
submitted by the Contractor is unquestionable without any justification given by the Contracting
authority.
Where the Contractor proposes to use equipment other than that specified or indicated which
requires any redesign of the structure, partitions, foundations, piping, wiring or any other part of
the works, all such redesign, new drawings and detailing required shall be prepared by the
Contractor at his own expense. All additional costs resulting from such substitution if approved by
the Contracting authority in writing, shall be paid by the Contractor.
Where such approved substitution requires a different quantity or arrangement of piping, wiring,
conduit and equipment from that specified or shown on the drawings, the Contractor shall provide
all such piping, structural supports, installation, controllers, motors, starters, electrical wiring and
conduits and any other additional equipment required by the system, at no additional cost to the
Employer.
1.16 PROTECTION
The Contractor shall order all equipment from the manufacturer specifying adequate packing for
export at the factory to avoid damage during shipment to the Site.
The Contractor shall be responsible for safe storage and the adequate protection of all material and
equipment until finally installed, tested and accepted.
He shall protect work against theft, injury or damage and shall carefully store material and
equipment received on Site in their original crates or containers until they are installed. This
responsibility shall embrace any delay pending final testing of systems and equipment due to any
condition.
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The Contractor shall close open ends of work with temporary covers or plugs during construction
and storage to prevent entry of obstructing material.
The Contractor shall coordinate the protection of the work of all trades and shall be liable for any
damage sustained to other trades resulting from his work.
If any equipment is damaged during shipment be before it is tested and accepted, the Contractor
shall replace or repair the equipment depending on the extent of damage and as determined and
decided by the Contracting authority, on the Contractor’s own account and without additional cost
to the Employer.
1.17 ACCESSIBILITY
Contractor shall be responsible for determining in advance of purchase that equipment and
materials proposed for installation shall fit into the confines indicated areas, allowing adequate
space for maintenance.
All work shall be installed so as to be readily accessible for operation, maintenance and repair.
Deviations from the drawings may be made to accomplish this, after the written approval of the
Contracting authority.
Concealed valves and devices shall be grouped together in as practical a way as possible in order to
be accessible through access doors.
1.18 ACCESS DOORS
The Contractor shall arrange for access doors and frames to be provided for easy access to
concealed equipment, controls, valves, traps, vents, drains, cleanout and other devices that require
periodic operation, inspection or maintenance.
However, the dimensions and locations of access doors shall be the responsibility of the Contractor
and shall have the approval of the Contracting authority before the work is installed.
Requirements of access doors shall be submitted in sufficient advance time to be installed in the
normal course of the work.
The Contractor shall be responsible for the correct identification of access doors by means of
buttons, tabs or markers to indicate the location of concealed work. The method and schedule for
identification of access doors shall be approved by the Contracting authority.
1.19 NAMEPLATES
Each piece of equipment provided shall carry, at a conspicuous location, attached in a permanent
manner to the equipment at the factory, a certified nameplate on which shall be printed or stamped
clearly the name and address of the manufacturer, the equipment model number, serial number,
date of manufacture, Electrical characteristics, performance rating or duty, pressure, temperature
or other limitations and all other pertinent data as deemed necessary by the manufacturer for any
future reference to the equipment.
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1.20 LABELING
The Contractor shall label and identify all pipeworks, ductworks, equipment, instruments, controls,
electrical devices, valves, etc. as to duty, service or function and direction of flow.
Labels on equipment shall be of laminated bakelite with black surface and white core, with incised
lettering nomenclature written in English.
Labels shall be attached to equipment, instruments, controls, electrical devices, etc. or to adjacent
permanent surfaces, in an approved permanent manner.
The Contractor shall submit to the Contracting authority for his approval prior to installation a
schedule of all equipment, valves and devices to be labeled and the suggested nomenclature.
Controls and electrical devices shall be labeled to indicate clearly which equipment they control.
Refer to chapter 15190 for Mechanical Identification.
1.21 GUARANTEE
All works are to be guaranteed for a period of three years dated from the final acceptance of the
work by the Owner.
Repairs or replacements made under the guarantee shall bear an additional one year guarantee
dated from the final acceptance of the repair or replacement.
Provide complete warranty information for each item to include product or equipment, date of
beginning of warranty or bond, duration of warranty or bond, and names, addresses, and telephone
numbers and procedures for filling a claim and obtaining warranty services.
The guarantee is to cover perfect mechanical operation of systems, acceptable noise and vibration
levels, reasonable consumption of power, fuel and water, and perfect attainment of temperatures
and humidities within specified design conditions for HVAC systems.
If during the guarantee period any equipment or material proves defective or any part of a system
fails to function properly, equipment is to be replaced and defects and malfunctions corrected as
directed by the Contracting authority.
If during the guarantee period any piece of equipment is replaced or rebuilt, the guarantee period
for this equipment is to be extended for a new period equal to the original guarantee period.
During the guarantee period, provide necessary skills and labor to assure proper operation and to
provide regular and preventive maintenance for equipment and controls, on a continuous 24 hour
basis.
Act promptly to correct problems arising in operation of equipment or system.
Provide Owner with monthly inspection certificates of equipment, record findings on a check list
and certify that each piece of equipment has been examined, is operating as intended and has been
properly maintained as recommended by manufacturer.
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Check all controls monthly to ascertain that they function as designed.
Spare part for normal wear and tear during guarantee period are to be provided by Contractor.
1.22 MAINTENANCE
The Contractor shall provide 3 years maintenance of all the mechanical and related Electrical
systems included in this contract starting the completion of all works and issuing the final handover
of all the systems. Maintenance works shall start when the Contracting authority issue a letter for
the Contractor to proceed with the maintenance works. All systems shall be maintained by their
suppliers and not by the installer and contractor technicians.
PART 2 - PRODUCTS
2.01 MACHINERY BASES
A.
Provide concrete bases for all equipments. Dimensions and thickness of each base depends
on type of equipment and is included in calculations to be submitted for approval.
Equipment bases shall include all necessary unti vibration pads as specified in relevant
chapter.
B.
Contractor should coordinate with civil Contracting authority in charge and should have his
permission after checking the following points during calculations:
-
To check if the original slab could sustain the total load of the machines and the
floating floors as per the given loads.
In the other words, the load carrying capacity of the slab has to be fully rechecked.
-
To check again if the existing slabs on which the machines are placed are stiff
enough and not overloaded. The original slabs should not be overloaded and the
necessary precautions taken with the usual margins.
PART 3 - EXECUTION
3.01 EXAMINATION
A.
Examine conditions at the job site where Mechanical Work is to be performed to insure
proper arrangement and fit of the work. Start of work implies acceptance of job site
conditions.
3.02 PREPARATION
A.
The Contracting authority’s drawings issued with these specifications show the approximate
location of mechanical apparatus, the exact locations are subject to the approval of the
Contracting authority.
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3.03 INSTALLATION
A.
Sequence, coordinate and integrate the various elements of mechanical systems, materials
and equipment. Comply with the following requirements.
B.
Coordinate mechanical systems, equipment and material installation with other building
components.
C.
Verify dimensions by field measurements.
D.
Arrange for chases, slots and openings in other building components during progress of
construction, to allow for electrical installations.
E.
Coordinate the installation of required supporting devices and sleeves to be set in pouredin-place concrete and other structural components, as they are constructed.
F.
Sequence, coordinate and integrate installations of mechanical materials and equipment for
efficient flow of the Work. Give particular attention to large equipment requiring
positioning prior to closing in the building.
G.
Where mounting heights are not detailed or dimensioned, install systems, material, and
equipment to provide the maximum headroom possible.
H.
Coordinate connection of mechanical systems with exterior underground and overhead
utilities and services. Comply with requirements of governing regulations, franchised service
companies and controlling agencies. Provide required connection for each service.
I.
Install systems materials and equipment to conform with approved submittal data, including
coordination drawings, to greatest extent possible. Conform to arrangements indicated by
the Contract Documents, recognizing that portions of the work are shown only in
diagrammatic form. Where coordination requirements conflict with individual system
requirements, refer conflict to the Contracting authority.
J.
Install systems, materials and equipment level and plumb, parallel; and perpendicular to the
other building systems and components, where installed exposed in finished spaces.
Install mechanical equipment to facilitate servicing, maintenance and repair or replacement
of equipment components. As much as practical, connect equipment for ease of
disconnecting, with minimum of interference with other installations.
K.
N.
L.
Install access panels or doors where units are concealed behind finished surfaces. Access
panels and doors are specified in Chapter 15050 - “Basic Mechanical Materials and
Methods” .
M.
Install systems, materials and equipment giving right-of-way priority to systems required to
be installed at a specified slope.
Painting
1.
Follow manufacturer’s recommendations for surface preparation and application
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procedures for paints and finishes.
10.
2.
Thoroughly clean surfaces requiring prime painting of rust, loose scale, oil, grease
and dirt by the use of wire brushes, solvent and other required means.
3.
Do not paint on damp or frosty surfaces or during wet, foggy or freezing weather.
4.
Spread and brush paint evenly to eliminate drips, runs or sagging.
5.
Fill voids, open or hollow places and irregularities with compound.
6.
Thoroughly clean and retouch damaged or dirtied shop coat surfaces.
7.
Do not paint controls, nameplates or labels.
8.
Paint thickness is measured when dry.
9.
Machinery : Before shipment, paint machinery including fans, compressors, pumps
and motors with the manufacturer’s standard shop prime coat.
Piping
a.
O.
Prime coat steel and cast iron piping and related pipe supports, immediately
after insulation, regardless of whether or not they will be subsequently
covered with insulation and / or finished paint. Apply prime coat in
accordance with manufacture’s specifications. Do not prime galvanized
metals.
Cutting and Patching
1.
Perform cutting and patching in accordance with the provisions of the Contract
Documents. In addition to the requirements specified, the following requirements
apply:
a.
Perform cutting, fitting and patching of equipment and materials required
to :
1) Uncover Work to provide for installation of ill-timed Work.
2) Remove and replace defective Work.
3) Remove and replace Work not conforming to requirements of the
Contract Documents.
4) Remove samples of installed Work as specified for testing.
5) Install equipment and materials in existing structures.
6) Upon written instructions from the Contracting authority, uncover and
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restore Work to provide for Contracting authority observation of
concealed Work.
2.
Cut remove and legally dispose of selected electrical equipment, component and
materials as indicated, including but not limited to removal of mechanical items
indicated to be removed and items made obsolete by the new work.
3.
Protect the structure, furnishings, finishes and adjacent materials not indicated or
scheduled to be removed.
4.
Provide and maintain temporary partitions or dust barriers adequate to prevent the
spread of dust and dirt to adjacent areas.
5.
Protection of Installed Work : During cutting and patching operations, protect
adjacent installations.
6.
Patch existing finished surfaces and building components using new materials
matching existing materials and experienced Installers. Installer’s qualifications
refer to the materials and methods required for the surface and building
components being patched.
7.
Patch finished surfaces and building components using new materials specified for
the original installation and experienced Installers. Installers qualifications refer to
the materials and methods required for the surface and building components being
patched.
3.04 FIELD QUALITY CONTROL
A.
Tests
1.
Perform tests on individual equipment, systems and controls in the presence of the
Representatives of the Employer, Contracting authority and such other parties as
may have legal jurisdiction.
2.
Supply labor, materials, properly calibrated instruments, power, etc., required for
testing, unless otherwise indicated.
3.
Before conducting any tests on system or equipment, thoroughly clean the
associated systems or equipment just prior to testing.
4.
Test equipment and systems which normally operate during certain seasons during
the appropriate seasons. Where the equipment or system under test is interrelated
with and depends upon other equipment, systems, and/or controls for proper
operation, functioning and performance, operate the latter simultaneously with the
equipment or system under test.
5.
The duration of tests shall be as determined by authorities having jurisdiction, but in
no case less than the time prescribed in each chapter of the specifications.
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B.
6.
In general, apply pressure tests to piping only, before connection of fixtures,
equipment and appliances. Do not subject any piping, fixtures, equipment or
appliances to pressures exceeding their test rating.
7.
Promptly repair or replace defective work and repeat the tests until the particular
system and components parts thereof receive the approval for the Contracting
authority. Replace any damages resulting from tests, as directed by the Contracting
authority.
8.
Submit test records on reproducible sheets to the Contracting authority for
approval and include approved copy in the instruction Manual. The Contracting
authority shall approve the format of the record sheet prior to actual testing of
equipment.
9.
During tests of equipment and systems, fully instruct the Employer’s representative
on the operation and maintenance of the equipment and systems. This period is in
addition to any required special instruction, elsewhere specified.
Final Inspection
1.
At final inspection, it is essential that certain trades be properly represented
including the following :
a.
b.
c.
d.
2.
Mechanical Contractor including people thoroughly familiar with the
project, its intent, equipment and system installation and operation.
Air-conditioning equipment manufacturer.
The automatic control manufacturer representatives familiar with the
installation who can demonstrate to the Employer’s satisfaction that the
controls perform according to the specified requirements.
The Electrical Contractor’s, representatives familiar with the installation’s
wiring and interlocking.
The Mechanical Contractor shall verify the actual operation of equipment and
controls prior to final inspection
3.05 CLEANING, ADJUSTING AND BALANCING-GENERAL
A.
Thoroughly clean any apparatus before placing in operation. Restore finished surfaces if
damaged and deliver the entire installation in an approved condition.
B.
Adjust and balance systems to operate as shown and specified.
3.06 INSERTS AND SLEEVES
A.
Refer to Division 15 Chapter “ PIPES AND PIPE FITTINGS” for the installation of pipe sleeves.
B.
Inserts in concrete for supports are to be as specified in other Division 15 Chapter.
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C.
Lay out the work in accordance with approved shop drawings. Furnish and set in place, in
advance of placing of slabs or construction of walls, all inserts and sleeves necessary to
complete the Work.
D.
Pipe Sleeves : Unless otherwise indicated or specified, pipe sleeves are to be as follows :
E.
1.
General floor sleeves are to be standard weight galvanized steel pipe with bottom
and flush with surface, calked with glass wool and sealed at top and bottom with
fire rated sealant. Top end is to extend 25 mm above floor level in mechanical
rooms. Top end of sleeves is to be flush with finished floor surface in finished
rooms.
2.
Sleeves in Foundation Walls : Cast iron fabricated sleeves, flush inside and outside,
calked water tight.
3.
Sleeves in Concrete Walls : Standard weight galvanized steel pipe, flush with wall
surface at both ends, caulked with glass wool and sealed at both faces with butyl
mastic.
4.
Sleeves in Interior Partitions and Ceilings : 20 gauge galvanized steel with lock joints.
5.
Sleeves for uninsulated piping are to be approximately 20 mm larger than pipe
passing through. Sleeves for insulated piping are to be large enough to
accommodate the full thickness of the pipe covering with clearance for expansion
and contraction.
6.
Fire Rated Wall or Floor Sleeves-Galvanized Pipe : Refer to passive fire prevention
system in Chapter 15060 parragraph 2.05.
Duct Sleeves : Where ducts pass through walls and partitions, provide sheet metal sleeves
and pack tight between duct and opening with rockwool. The exposed side of ductwork is to
have galvanized 40 mm angle iron closure around duct. The angle irons are to be secured to
the wall construction. Fire rated walls shall have factory fabricated wall sleeves for fire
dampers.
3.07 EXCAVATION AND BACKFILLING PIPE TRENCHES
A.
Excavation and backfilling of trenches required for the installation of all utility services and
underground piping within the building, and to points of connection with exterior
underground utilities outside of the building, are to be performed by each trade for its work
as specified.
B.
Excavate to the required depths and grade, the bottoms of trenches to secure the required
slope for pipe lines. Rock or existing concrete, where encountered, are to be excavated to a
minimum depth of 150 mm below the bottom of pipe. Where mud or otherwise unstable
soil is encountered in the bottom of the trench which is incapable of supporting the pipe or
utility lines, such soil is to be removed to firm bearing and the trench is to be backfilled with
sand to the proper grade and tamped to provide uniformly firm support. Pipe is not to be
laid on frozen subgrade.
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C.
Trench Size: Sides of trenches at point 300 mm above the top of pipe is not to be more than
4/3 overall lateral dimension of the pipe, expressed in millimeters plus 200 mm.
Above this point the sides of trenches are to be kept as nearly vertical as possible and are to be
braced and shored to protect foundations, utility pipe lines and workmen. Where machines
are used to excavate pipe trenches, such machine excavation is to terminate 75 mm above
the invert of the pipe. Final excavation and shaping of the trench is to be performed only for
short distances in advance of the pipe laying.
D.
Separation : Separate trenches are to be provided for potable water and sewer lines.
E.
The trenches are not to be backfilled until the piping has been tested by the Contractor as
required and reviewed by the Contracting authority and any local authorities having
jurisdiction.
3.08 MAINTENANCE AND GUARANTEE OF EQUIPMENT AND SYSTEM PRIOR
TO FINAL ACCEPTANCE
A.
Take necessary measures to insure adequate protection of equipment and materials during
delivery, storage, installation and shutdown conditions. This responsibility shall include
provisions required to meet the conditions incidental to the delays pending final test of
systems and equipment under seasonal conditions.
B.
Operate the completed systems for a period of time prescribed by the Contracting authority
to determinate the capability of the equipment and controls to conform to the
requirements of the drawings and specifications.
C.
Guarantee period for mechanical works shall be three years from the date of issuance of
taking over certificate.
D.
Make final operating tests with systems in simultaneous operation and building in normal
operating modes.
3.09 TRAINING
A.
B.
B.
The Contractor shall instruct and train Owners designated personal in the operation and
maintenance of every part, device and piece of equipment in the systems with emphasis on
proper startup and shutdown procedures, preventive maintenance and lubrication
procedures with recommended lubricants, overhaul and maintenance methods, adjustment
and calibration of instruments and controls, use of special tools and safe practices.
The duration of training shall be for a total period of ninety working days, eight hours a day.
This period shall follow the final inspection date and shall not necessarily consists of a single
series of consecutive days. Apportion time between Summer, Winter, and intermediate
operating seasons as mutually agreed.
All expenses for training Owners personnel shall be at Contractor’s own cost..
Commencement date of training shall be subject to client approval.
END OF CHAPTER
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PAINTING
A.
Scope
Supply and apply all painting to the various services provided under this Contract.
Painting shall be executed in accordance with the requirements and instructions of this Chapter.
B.
General Requirements
Surfaces requiring prime painting shall be cleaned thoroughly of rust, scale, oil, grease and dirt.
Use wire brushing, sand blasting or solution cleaning as needed.
All items that have rusted or corroded shall be cleaned and/or painted to the satisfaction of the
Contracting authority. No painting shall be applied on rusted, damp or dirty surfaces.
The paint shall be evenly and well brushed out to prevent drops, runs or saggings. Care shall be
taken not to paint over controls, labels and nameplates.
C.
Paint Types & FINISHES
a- Refer to Division 9 Chapter “Painting” for paint materials, surface preparation, and application of
paint.
b-
The primer and finishing coats for painting hot surfaces shall be special heat resistant type
acrylic base paint.
The primer and finishing coats for painting cold surfaces shall be acrylic base paint.
c- Apply paint to exposed piping according to the following, unless otherwise indicated:
1- Interior, Ferrous Piping : use semigloss, acrylic-enamel finish. Include finish coat over
enamel undercoat and primer.
2- Interior, Galvanized Steel Piping : use semigloss, acrylic-enamel finish. Include two
finish coats over galvanized metal primer.
3- Interior, Ferrous Supports : use semigloss, acrylic-enamel finish. Include finish coat
over enamel undercoat and primer.
4- Exterior, Ferrous Piping : use semigloss, acrylic-enamel finish. Include two finish coats
over rust-inhibitive metal primer.
5- Exterior, Galvanized Steel Piping : use semigloss, acrylic enamel finish. Include two
finish coats over galvanized metal primer.
6- Exterior, Ferrous Supports : use semigloss, acrylic-enamel finish. Include two finish
coats over rust-inhibitive metal primer.
d- Do not paint piping specialties with factory applied finish.
e- Damage and Touchup : repair marred and damaged factory painted finishes with materials and
procedures to match original factory finish.
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f-
D.
The above shall not relieve the Contractor to supply specific paint types other than those
mentioned herein and which may be necessary to be used for specific applications.
Piping, Frames, Supports and Ductworks
All black steel piping including flanges, bolts, nuts, cast iron valves and accessories, valve wheels
and all ferrous parts are to be painted with two coats of zinc chromate primer whether or not
they are to be insulated. When bare or exposed to view, they are to be further painted with two
coats of approved oil paint.
Ductwork shall be painted inside or outside with one coat dull black fire resistant paint where
visible through air outlets or through the false ceilings.
Hangers and supports including clamps, rods, bolts, nuts etc.. to be painted with two coats of zinc
chromate primer and where exposed to view with two additional coats of approved oil paint.
All exposed uninsulated surfaces or jacket insulation shall receive two coats of primer and two
coats of finishing paint. Special etch primers shall be used for galvanized surfaces (pipes, ducts
etc....)
Unless mentioned otherwise, uninsulated and unwrapped pipes, flanges, valves, laid in trenches,
wall chases, in fill or underground, shall receive two layers of asphalt solution soaked jute applied
as follows:
E.
a.
Clean pipe surface as stated here above and apply one coat of asphalt over the bare pipe.
b.
Wrap pipe with the first asphalt soaked jute layer and apply one coat of asphalt over the
first jute layer.
c.
Repeat the above two operations for the second layer.
d.
Under tiles, protection may be replaced by embedding pipes in an asphalt cork sawdust
cement mixture.
Equipment and Panels
Equipment and panels installed under this Contract shall have two shop priming coats of corrosion
protective paint and at least two factory applied finishing coats.
All factory painted surfaces shall be cleaned thoroughly and inspected on site for scratches and
etchings and shall be retouched where necessary.
F.
Colour Coding and Identification
The finishing coat colours for exposed metallic surfaces or insulated surfaces shall conform with
the schedule:
a.
b.
All factory painted equipment
Equipment not factory painted
Keep their colour
Grey
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c.
d.
e.
Structural frames and supports
Pipe services
Ducts
Black
as per ASME colour code.
Aluminium
Piping, cables and wires shall be identified at intervals not exceeding four meters and at all
crossings through slabs and walls. Identification shall include:
-
Type of service.
Direction of flow where applicable
Size
Coloured cables and wires shall be used and the same colour shall be maintained throughout the
project for the same circuit or function. A schedule of colours shall be submitted by the Contractor
for the Contracting authority's approval and adoption.
The type and flow direction of the fluid conveyed in pipes and ducts shall be painted in red at
intervals not exceeding four meters and at all crossings through slabs and walls.
END OF CHAPTER
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ELECTRICAL WORKS FOR MECHANICAL SYSTEMS
A.
Scope
Supply and install all Electrical Works, equipment and accessories specified under the various
Mechanical Systems.
Electrical Works shall comply with any of the following standards:
-
The recommandations of the "International Electro-Technical Commission (I.E.C.) ".
The B.S.S. Code and IEE regulations.
The specifications and technical conditions described in the present book of specifications.
The general specifications for Electrical Installations of the Local Authorities.
All electrical equipment, materials, accessories, etc,... to be supplied for the Mechanical Systems,
as well as all electrical works and tests to be done shall conform also with the requirements of the
relevant Specifications for the Electrical Systems.
The scope of the Electrical Works under this chapter and executed by the Mechanical Contractor
includes the supply and installation of the followings:
B.
a.
Motor control centers (MCC), motor control panels (MCP) and control panels (CP) for each
item or system and housing all protection gear, switches and controls required for the
specified function.
b.
All cables and wires between equipment and the corresponding motor control center or
motor control panel.
c.
All electrical equipment, wiring, cables, conduits, boxes, earth connections, control
switches, starters, circuit breakers, isolating switches, relays, contactors, protective gear or
equipment, transformers, etc,... and all other necessary item or components required for
the satisfactory operation, control and protection of the systems.
Works Not Included
The following electrical items are not included and will be supplied by the Electrical Contractor.
C.
a.
Power close to each electrically operated equipment not fed from a control panel.
b.
Main feeder to the motor control centers and control panels of mechanical equipment.
General Requirements
a.
Ratings of circuit breakers serving electric motors are design values and must be checked
and readjusted, if need be, to conform with motor actual power and rating as
recommended by motors Manufacturers.
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b.
Power supply connections to vibrating or rotating machinery shall be made through
adequate metallic flexible conduits or tubings through which cables and wires shall be
drawn.
c.
Cables shall be color coded for identification. Red, Yellow and Blue shall be used for phase
conductors, Black for neutral and Green for earth conductors.
d.
Control voltage for starters and control circuits shall not exceed 220VAC.
e.
Shop and Installation Drawings are to be submitted for approval prior to ordering materials
and equipment. Drawings to include the following:
i.
Complete technical data on all motor starters, motor protection relays, sensing
units, control accessories, etc.
ii.
Instructional details of equipment, particularly motor control centers and panels
iii.
Wiring diagrams of all power and control circuits
iv.
Installation details of motor control centers and panels and of control and sensing
accessories
v.
Exact routing of power and control cables, wiring and conduits
vi.
Feeder termination details at motor control centers, starters, motors, isolating
switches, control and sensing accessories etc.
f.
Power and control wiring to run in conduit unless otherwise specified.
g.
Power and control wiring to run in separate conduits.
h.
Rigid conduits are not to terminate in nor be fastened to a motor frame or base.
j.
Flexible conduits to be used at motor connections. Allow sufficient slack to permit motor to
slide over adjustable length of motor base. Length and radius to be sufficient to permit
bending of feeder cables without damage to conductor or its insulation. Flexible conduits
are not to used in place of rigid conduit except at motor connections, unless otherwise
specified.
k.
Conduits are to be supported with conduit supports in an adequate approved manner.
l.
Conduits are not to cross pipe or vent shafts, ducts or openings. They are to be run a
minimum 100 mm away from pipes of non-electrical services.
m.
Detailed control wiring diagrams and a list of control equipment with descriptive literature
are to be submitted for approval. Free hand field wiring diagrams or sketches will not be
accepted.
n.
Circuits to be arranged to satisfy operating requirements specified for various equipment
driven by electricity and other requirements pertaining to proper functioning and
operation of equipment.
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D.
p.
Circuits to be protected with high rupturing capacity circuit breakers. Auxiliary supply for
controls, other than from main power circuit, to be effectively isolated by auxiliary contacts
on main isolator.
q.
Motors to be earthed by connecting green insulated conductor from earthing bushing in
starter to motor frame. Run earth conductor together with circuit wiring and terminate in
motor terminal box, provided earth terminal in box is connected to motor frame. If this is
not feasible, extend earth conductor through insulated bushed opening in terminal box
and connect to motor base.
r.
Equipment to be earthed by connecting non-current carrying metal parts of system to
earth source. Non-current carrying metal parts include conduits, cable trays, outlet boxes,
cabinets, enclosures, doors, grilles, and barriers protecting or shielding electrical
equipment from direct access.
s.
Detailed wiring diagram is to be fixed inside each starter enclosure cover to clearly indicate
circuits.
t.
Control and power wires are to be identified either by distinctive colored insulation,
engraved tags or other approved method.
v.
Manufacturers to be proposed by Tenderer as part of his Tender, in all cases to be
approved by Consultant.
Conduits
Size is to be minimum 20 mm unless otherwise specified.
All PVC conduits and fittings shall be manufactured and tested generally in accordance with I.E.C.
614-2-2 on BS 6099-2-2 and accessories with BS 4607, Part 5.
They shall be of the heavy duty, high impact type, non-hydroscopic self extinguishing and suitable
for installation, storage or transport at extreme temperatures.
They shall be so designed that a reliable water tight joint can be made between conduit and
fittings. A vinyl solvent cement shall be used for permanent joints and a cement of non hardening
type shall be used for expansion couplers (for surface installations).
The flexible conduits for recessed installation shall be manufactured and tested in accordance with
I.E.C.423, 614-1 and 614-2-2 and European Norm EN-500 86-2-2.
They shall be made of polyethylene having the following characteristics:
-
Temperature resistance
: min. 5°C and max 90°C.
Compressive strength
: 750 N
Mechanical impact strength : 6 J.
Flame retardant, light, pliable and supplied with a special draw wire.
Wound into coils, with different colors to facilitate the identification of different types
of circuit as per CEI Standards 64-8.
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-
External approved diameter 20mm, 25mm, 32mm and 40mm.
The rigid PVC flame retardant (M1) conduits for surface mounted installation shall be
manufactured and tested in accordance with I.E.C. 423, 614-1 and 614-2-2 and European Norm EN500 86-2-1.
They shall be made of polyvinyl chloride having the following characteristics:
-
Temperature resistance
: min. 15°C and max 60°C.
Compressive strength
: 1250 N
Mechanical impact strength : 6 J (lK07).
External approved diameter 20mm, 25mm, 32mm and 40mm.
Steel conduits are to be welded, drawn, heavy gauge, to BS 4568 Part 1 or approved equal,
galvanized internally and externally and threaded both ends.
Fittings for steel conduits are to be threaded, galvanized or cadmium plated malleable iron
specifically designed for size and type of conduit.
E.
Wires and Cables
Power wires and cables are to be 600/1000 V grade, to BS 6004 or I.E.C. 227. Single conductor
wires and multicore cables to have high conductivity tinned copper wire conductors insulated with
PVC compound, with additional PVC sheath for multicore cables.
Control wires and cables are to have conductors tinned annealed copper, minimum area 1.5 sq
mm. Insulation to be moisture resistant flame retardant PVC compound. Wires and cables to be
rated for 220 V service. Multicore cables for control and signaling to be PVC insulated copper
conductors, PVC sheathed, to BS 6346.
Control wires and cables are to be provided with special heat resistant insulation or corrosion
resistant sheath where required.
Connections to motors to be single conductor wires pulled inside conduits, or non armoured and
fixed on cable trays or supports.
Special conditions: where required high temperature resistant cables, silicone rubber, cross linked
polyethylene, or approved equal, corrosion resistant sheath is to be provided.
F.
Electric Motors
Motors are to be supplied by driven equipment manufacturer, to be as specified for equipment
concerned and specifically supplied for available supply voltage and frequency.
Motors 3 horsepower and under to be single phase and over 3 horsepower to be three phase.
Motors to be totally enclosed, fan cooled type, unless otherwise specified.
Motors are to have Class B insulation with 80 deg. C continuous temperature rise above average
ambient temperature of 40 deg. C, unless otherwise specified.
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Motors that will operate outdoors are to have Class F insulation.
Motors operating in ambient temperatures exceeding 40 deg. C to be tropicalized and derated
for satisfactory operation.
Motors to be rated for continuous operation.
Power to be adequate to operate driven equipment without motor overload under all operating
conditions and loads and throughout capacity range of equipment. Motor to be capable of
delivering full rated output when operating at voltage deviating by 5% from rated voltage at rated
frequency.
Starting and torque characteristics to be as required by driven equipment.
Speed to be as specified for equipment concerned.
Conduit terminal box on motor to be approved model for type of motor enclosure. Motor windings
to be connected to terminals in terminal box at factory. One additional earthing terminal to be
connected to motor frame.
Motor base to be adjustable where motors are directly connected to driven equipment, unless
otherwise specified. Motors connected to equipment through V-belt drive to have adjustable
sliding base. Fractional horsepower motors to have slotted mounting holes in base.
G.
Starters
The starting current of all motors above 10 hp shall not exceed twice its rated full load current,
for 15 seconds. For motors of rating 10 hp and below, the starting current shall not exceed 6
times its rated full load current, for 5 seconds.
In general, motors above 10 hp shall have assisted start in the form of Star-Delta starters of the
open transition type. Motors below 10 hp can be Direct on line Start.
Each three-phase motor shall be provided with means of automatic starting and to disconnect
the supply to the motor in case of:
a.
b.
c.
Failure of one or more phases.
Serious drop in voltage.
Flow of excess current.
All starters shall be properly derated for operation in an ambient temperature of 45C.
All starters shall be of the magnetic automatic type fitted with thermal over load relays/devices
calibrated for close motor protection.
These devices shall trip the starters in case of overload and shall not allow it to reset except
manually.
The starters shall be capable of making and breaking their rated current adequately and shall
withstand as high as 5 times their rated current for at least 10 seconds without any injury or
failure.
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The contactors shall be capable of withstanding an intermittent duty and the number of
switching cycles required in the Standards. They shall be AC3 duty rated.
The contactors shall be provided with auxiliary contacts for connection of signaling,
interlocking, and other circuits required for controls.
The enclosures of the contactors, starters, etc., as well as their installation and accessibility for
operation and repair shall be suitable for the corresponding motors with which they are
related.
The contactors shall be suitable for mounting in any position. The contacts shall be silver
plated, bounce free and fully enclosed.
All motors control gear and ancillary equipment shall be protected by thermal and magnetic
circuit breakers in addition to the protective starter mentioned above.
Where starter operating circuits and ancillary apparatus are energized by an auxiliary supply
other than the main power circuit to the motor, the isolator shall also incorporate auxiliary
contacts to effectively isolate all poles of phases of such other power supply.
All Starters not in a central panel shall have a sheet metal enclosure with a removable lid and
cover and necessary brackets for mounting on panel or wall. A clear schematic diagram of the
starter circuit shall be fixed inside the cover of each starter.
H.
Isolating Switches
Isolating switches to be non fusible, single throw type, housed in separate metallic enclosure, with
arc quenching devices on each pole capable of interrupting at least six times its rated current. They
are to simultaneously interrupt power supply to all line conductors, any neutral and control
circuits.
Isolating switches for single phase fractional horsepower motors to be double pole, dolly operated
type, rated 16/20 A at 250 V AC, quick make, quick break, with silver alloy contacts, flush or surface
mounted to suit application.
Operating mechanism to be quick make quick break type, with external operating handle
mechanically interlocked with enclosure cover to necessitate disconnecting switch to be in OFF
position for access to inside of enclosure. Means are to be provided for by passing interlocks.
Position of isolating switch to be clearly indicated on cover.
Enclosure to be general purpose type, unless otherwise indicated or required, with provision for
locking operating handle in OPEN and CLOSED positions.
Enclosures where indicated or required by location to be weatherproof totally sealed water and
dustproof type.
J.
Combination Starters Isolating Switches
Components to comprise magnetic starter, isolating switch and short circuit protection devices
required by the Standards, in approved sheet metal enclosure to suit application.
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Isolating switch operating mechanism quick make, quick break, with external operating handle
mechanically interlocked with enclosure cover necessitating disconnecting switch to be in OFF
position for access to inside of enclosure. Means are to be provided for by passing interlocks.
Position of isolating switch to be clearly indicated on cover.
Short circuit protection gear to be miniature or moulded case circuit breakers of appropriate
current rupturing capacity.
Operation of circuit breaker to be possible from outside of enclosure. Position of breaker
ON/OFF/TRIPPED to be clearly indicated by position of handle.
K.
Push Buttons
Push buttons to be one unit momentary contact START/STOP with normally open or normally
closed contacts as required by wiring diagrams and with lockout attachments. Heads to be colour
coded and STOP button to be protected. Push buttons controlling one piece of equipment to be
housed in separate enclosure.
L.
Relays
Relays to be multipole with normally open or normally closed contacts, electrically operated at
220VAC maximum, and magnetically held. Contacts to be double break, silvered type,
interchangeable from normally open to normally closed without additional parts. Relays are to be
rated at 10 A, 600 V.
M.
Circuit Breakers
Main Breaker, Feeder protection breaker and starter protection breaker will be as follow unless
otherwise specified .
Circuit breakers to be thermal magnetic type, with moulded case type for MCC and Miniature type
for MCP/CP and as described hereafter, manually operated for normal switching functions and
automatically operated under overload and short circuit conditions.
Circuit breakers to give positive trip free operation on abnormal overloads, with quick make quick
break contacts under both manual and automatic operation. Stationary and movable contacts to
be non welding silver alloy adequately protected with effective and rapid arc interruption.
Breakers of 225 amp frame size and larger to have interchangeable trip units and adjustable
instantaneous trips unless otherwise shown.
Main incoming breakers to be current operated
Multiple pole breakers to have single handle mechanism. Each pole to have inverse time delay
thermal overcurrent trip element and magnetic instantaneous overcurrent trip element for
simultaneous tripping of all poles.
Trip elements to be ambient temperature compensated type.
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N.
Motor Control Center
This specification of the MCCs relates to Type Tested Assemblies (TTA) and Partially Type Tested
Assemblies (PTTA). The switchboard shall be suitable for operating on 3 phase, 4 wires, 380 volts,
50 Hz supply. The symmetrical fault rating shall be 25 kA for 1 second. The switchboard shall be
ASTA tested at the fault rating. The switchboard shall be totally compartmentalized and
manufactured to IEC 439-1, Form 4 rated, as described hereafter. All the internal separation must
be metallic type electrozinc or Aluzinc plated.


The Main switch is installed in a separate compartment, with Power Meter showing all the
electrical characteristics;
Each outgoing feeder will include an MCCB and will be installed in a separate
compartment.
Each starter will be installed in a separate compartment and will be composed as follow:
1.
Molded Case Circuit Breaker (MCCB) Fixed Manually operated - 3 poles with rotary
handle interlocked with the door for 3 poles starters; so that the breaker must be in OFF
position before the door can be opened
2.
DOL or YD as described in the drawings.
3.
1 selector switch 3 positions Auto/Off/Hand.
4.
2 push buttons Start/Stop operational in Hand mode.
5.
2 pilot lights On/Off & Normal/Fault.
6.
Terminals for remote control Start/Stop in Auto mode
7.
Auxiliary contacts for remote signaling: Starter On/Off, Starter Normal/Fault,
Starter in Auto mode, Starter in Hand mode.
8.
Each MCC will include one voltmetric relay that stops all the starters in case of under or
over voltage.
Totally enclosed freestanding chapteral type, with chapters or compartments joined to form one
assembly. Chapters to be designed to allow other chapters to be easily added or removed.
Enclosure shall be I.E.C. 439-1 and I.E.C. 57-1/1A unless otherwise required or indicated on the
drawings or required by the equipment location.
Enclosure shall have provision for locking the operating handle in the “OPEN” and “CLOSED”
positions.
Construction to be 1.5 to 2 mm thick sheet steel, adequately reinforced and braced for maximum
rigidity, sand blasted, rust inhibited after fabrication and sprayed with one coat primer and two
coats enamel internally and externally.
Components motor control centre to include the following:
1.
Main incoming circuit breaker or isolating switch as shown on the Drawings for terminating
incoming supply cables and isolating the busbar system
2.
Main copper busbars rated as main incoming circuit breaker or as shown on the Drawings
3.
Branch copper busbars of adequate capacity to distribute power to each circuit breaker
and starter served
4.
Neutral copper busbar rated at half capacity of main busbar and distributed throughout
whole motor control centre
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5.
Earth copper busbars minimum 25 x 6 mm extending full length of motor control centre
6.
Power Meter showing all the electrical characteristics
8.
Starters, circuit breakers, push buttons, indicating lights, switches, relays, contactors and
accessories as shown on the Drawings
9.
Interconnecting and interlock wiring.
Busbars to be adequately isolated and braced to sustain maximum possible short circuit current.
Spare positions to be fully equipped cells ready for connection to motors are to be provided As
shown on the drawings
Space positions to be fully equipped cells ready to receive control unit are to be provided As shown
on the drawings. Space positions to have blank cover plates.
Starters, Switches, other components and electrical devices to be clearly labelled in English as to
number and function, with incised letters on black Bakelite with white laminated core. Labels to be
permanently fixed under each component.
Incoming line connections to be made with solderless, terminal four bolt type clamps.
Labels starters, switches, electrical devices and accessories to be clearly labelled in English as to
function and number. Labels to be permanently fixed under each component.
Schematic and wiring diagrams to be firmly fixed within motor control centre, showing each
component and cross- referenced with component labels.
Submit for approval electrical schematic diagram of whole installation, suggested layout of motor
control centre, interior wiring details and complete technical literature on all proposed
components, prior to fabrication or purchase.
P.
Motor Control Panels
The CPs shall manufactured to IEC 439-1, IP 42, Form 2a rated (Group mounted), as described
hereafter:
Each panel will have a lockable door and a cover of the same type of the enclosure; Electrozincated sheet steel 1.5 to 2 mm minimum, painted with epoxy polyester powder. Painting will be
done after manufacturing even for the inside covers.
All covers will be equipped by handles.
Each incoming and outgoing will have an engraved label that will be placed on the covers inside the
enclosures.
The height of the switchboard shall be limited to 2000 mm unless otherwise specified; the width
shall be limited to 80 cm.
Main Incoming will be Miniature Switch two or three poles with out metering but with three pilot
lamps to indicate the presence of the voltage.
CPs will not include Spares.
Each starter will be composed as follow:
1.
Miniature Circuit Breaker (MCB) Fixed Manually operated 2 or 3 poles
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2.
DOL or YD as described in the drawings.
3.
1 selector switch 3 positions Auto/Off/Hand.
4.
2 push buttons Start/Stop operational in Hand mode.
5.
2 pilot lights On/Off & Normal/Fault.
6.
Terminals for remote control Start/Stop in Auto mode
7.
Auxiliary contacts for remote signaling: Starter On/Off, Starter Normal/Fault, Starter in
Auto mode, Starter in Hand mode.
Motor control panels to be wall mounted or unit mounted, lockable type.
Panels installed outdoors to have weatherproof totally sealed water and dustproof enclosures.
Panels are to contain necessary breakers, starters, push button switches, selector switches, relays,
indicating lights, interconnecting and interlock wiring and all devices and accessories required for
automatic or manual operation of equipment as specified under equipment concerned.
Labels starters, switches, electrical devices and accessories to be clearly labelled in English as to
function and number. Labels to be permanently fixed under each component.
Schematic and wiring diagrams to be mounted in permanent approved manner on inside of panel
door. Diagrams are to show each component cross referenced with component labels.
Q.
Switches
Float switches to be level operated, heavy duty, bracket mounted type, suitable for application in
open tanks, complete with 178 mm spun copper float, brass rod, two stops, floor mounting stand,
lever and counterweight. Switch to have oil tight and dust tight enclosure and 2 pole double throw
silver contacts that open on liquid rise.
Pressure switch to be industrial, heavy duty, bellows actuated type, suitable for water service, with
contacts to close on falling pressure. Range to be 0.1 to 8 kg/cm2. Switch to be good for 1720 kPa
operating pressure and to have 6 mm pipe tap bottom connection. It is to have oil tight and dust
tight enclosure, single pole double throw contacts and setting adjustment.
Low suction pressure switch to be industrial, sensitive, low range, diaphragm actuated type,
suitable for water service, with range of 2 to 20 kPa of falling pressure, preset at factory to 3 kPa.
Switch to be good for 690 kPa operating pressure and to have 6 mm pipe tap bottom connection.
It is to have oil tight and dust tight enclosure, single pole double throw contacts, range adjustment
knob, sealing cap and range locking nut.
R.
Approved manufacturers
Subject to compliance with the above requirements, switchboard shall be the product,
manufacture and assembly of a manufacturer who is certified ISO 9000, 9001 or 9002.
The manufacturer of this equipment shall have produced similar electrical equipment for a
minimum period of ten (10) years. Local manufacturers shall be approved only if they can meet the
presented specifications, and if they are guaranted by an international company. When requested
by the Contracting authority, an acceptable list of installations with similar equipment shall be
provided demonstrating compliance with this equipment.
END OF CHAPTER
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BASIC MECHANICAL MATERIALS AND METHODS
PART 1 - GENERAL
1.01
SUMMARY
A.
Provide labor, materials, equipment and services, and perform operations required for
complete installation of basic mechanical materials and methods and related work as
indicated on the drawings and specified herein.
B.
Work Included: The work shall include, but not be limited to, the following:
1.
2.
3.
4.
1.03
QUALITY ASSURANCE
A.
1.04
Excavation for underground utilities and service
Miscellaneous metals for support of mechanical materials and equipment.
Access panels and doors in walls, ceilings and floors for access to mechanical materials
and equipment.
Mechanical equipment nameplate data.
Materials and equipment shall conform to the latest edition of reference specifications
specified herein and to applicable codes and requirements of local authorities having
jurisdiction.
SUBMITTALS
A.
Submit the following submittals in accordance with Chapter 15010 "Basic Mechanical
Requirements."
B.
Provide product data for the following products:
1.
2.
3.
Access panels and doors.
Joint sealers.
Pipe and duct sleeves.
C.
Shop drawings detailing fabrication and installation for metal fabrications, and wood
supports and anchorage for mechanical materials and equipment.
D.
Coordination drawings for access panel and door locations in accordance with Chapter
15010 "Basic Mechanical Requirements."
E.
Schedules indicating proposed methods and sequence of operations for selective demolition
prior to commencement of Work. Include coordination for shutoff of utility service, and
details for dust, fire and noise control. Coordinate sequencing with construction phasing
and Employer occupancy specified in the Contract Documents.
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1.05
DELIVERY, STORAGE AND HANDLING
A.
Deliver joint sealer materials in original unopened containers or bundles with labels
informing about manufacturer, product name and designation, color, expiration period for
use, pot life, curing time and mixing instructions for multi-component materials.
B.
Store and handle joint sealer materials in compliance with the manufacturer's
recommendations to prevent their deterioration and damage.
PART 2 - PRODUCTS
2.01
MATERIALS
A.
Mechanical Equipment Nameplate Data
B.
C.
1.
Nameplate: For each piece of mechanical equipment provide a permanent
operational data nameplate indicating manufacturer, product name, model number,
serial number, capacity, operating and power characteristics, labels of tested
compliances, and similar essential data. Locate nameplates in an accessible location,
as approved by Contracting authority.
2.
Relocate nameplates as required and approved after installation to permit easy
reading.
Sealant
a.
Provide ready-to-use silicone penetration seal that will stop passage of fire,
smoke, and water will cure in the presence of atmospheric moisture to produce
durable and flexible seal, and will form airtight and watertight bonds with most
common building materials in any combination including cement, masonry,
steel, and aluminum.
b.
Sealant Composition shall be one-part ready-to-use materials with consistency
of soft caulk at temperatures ranging from -35 to 160 F, and extension and
compression properties of plus/minus 40% of original gap.
Access Doors
1.
Steel Access Doors and Frames: Factory-fabricated and assembled units, complete
with attachment devices and fasteners ready for installation. Joints and seams shall
be continuously welded steel, with welds ground smooth and flush with adjacent
surfaces.
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2.
Frames: 16-gauge steel, with a 1 inch wide exposed perimeter flange for units
installed in unit masonry, precast or cast-in-place concrete, ceramic tile or wood
paneling.
a.
For Installation in Masonry, Concrete, Ceramic Tile, or Wood Paneling: 1 inch
wide exposed perimeter flange and adjustable metal masonry anchors.
b.
For Full-Bed Plaster Applications: Galvanized expanded metal lath and exposed
casing bead, welded to perimeter of frame.
PART 3 - EXECUTION
3.01
EXAMINATION
A.
3.02
Examine conditions at the job site where work of this chapter is to be performed to insure
proper arrangement and fit of the work. Start of work implies acceptance of job site
conditions.
PREPARATION
A.
Examine the Contract Drawings and specifications in order to insure the completeness of
the work required under this Chapter.
B.
Verify measurements and dimensions at the job site and cooperate in the coordination and
scheduling of the work of this Chapter with the work of related trades, so as not to delay job
progress.
C.
Provide templates as required to related trade for location of support and anchorage items.
D.
Preparation for Joint Sealers
1.
Thoroughly clean surfaces, removing foreign matter such as dust, oil, grease, water,
surface dirt and frost. Materials must be applied to the base surface.
2.
Prior to any priming and sealing, joints shall be masked by masking tape or other
approved means to prevent soiling of adjacent surfaces.
3.
Immediately prior to application of materials test adhesion of materials to each
substrate material and apply primer to any surface sharing poor adhesion.
4.
Where required support material with damming materials specified herein. Where
sealant materials require damming provide duct tape or compatible backer rod.
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3.03
INSTALLATION, ERECTION AND APPLICATION
A.
D.
Erection of Metal Supports and Anchorage
1.
Cut, fit and place miscellaneous metal fabrications accurately in location, alignment
and elevation to support and anchor electrical, plumbing and HVAC materials and
equipment.
2.
Attach to substrates as required to support applied loads.
Installation of Access Doors
1.
Set frames accurately in position and securely attach to supports, with face panels
plumb and level in relation to adjacent finish surfaces.
2.
Adjust hardware and panels after installation for proper operation.
3.
Location
a.
b.
3.05
3.06
Locate access doors in hung ceilings, walls, furred spaces, partitions and other
components of the structure, where required to service fire dampers, smoke
detectors, duct access doors, controls, valves, cleanouts and other items
installed under this Division of the specification.
Contractor shall coordinate the exact location and quantity with mechanical,
Contracting authorityural and electrical requirements. Access doors are not required
in suspended acoustical lay-in tile ceilings unless specifically shown.
FIELD QUALITY CONTROL
A.
Inspect seal after 48 hours for complete adhesion, and seal and correct any deficiencies.
B.
Follow manufacturer's installation instructions precisely, including 4-point field quality
control checks which consist of foam color, foam cell structure, snap time, and free foam
density.
C.
Inspect seal after 24 hours. Remove damming materials to inspect under site.
D.
Correct any deficiencies by adding foam or sealant. Reinspect after 24 hours.
ADJUSTING AND CLEANING
A.
Clean excess cured sealant from nonporous surfaces with commercial solvent such as
naphtha mineral solvents, following instructions on container label.
B.
Clean spills of liquid components with high-flash mineral spirit solvent, following
instructions on container label. Trim excess foam with sharp knife or blade.
C.
Remove equipment, materials and debris. Leave area in undamaged, clean condition.
END OF CHAPTER
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WELDING
PART 1 - GENERAL
1.01
RELATED WORK
A.
1.02
SYSTEM DESCRIPTION
A.
1.03
Division 15 : Mechanical
This chapter covers the standard of shop welding and erection welding of mechanical
equipment, steel structure, framework, supports and piping.
REFERENCES
A.
Reference Standards
The latest editions of the following standards and recommendations shall apply in
applicable parts.
1.
American Standards
a. American Welding Society ( AWS )
AWS B 1.0
AWS B 3.0
Guide for the non-destructive inspection of welds.
Welding procedure and performance qualification.
AWS D 10.4
Recommended practices for welding austenitic
chromium-nickel stainless steel piping and tubing.
AWS D 10.9
Qualification of welding procedures and welders for
piping and tubing.
b. American National Standards Institute ( ANSI )
ANSI / AWS B4.0 Standard methods for mechanical testing of welds.
ANSI B 31.3
Chemical plant and petroleum refinery piping.
c. International Institute for Welding ( IIW)
IIE XV-50 - 56E
1.04
Rules for welded constructions.
SUBMITTALS
A.
Product Data
1.
All electrode rode types, and sizes shall be given indicating the intention of use.
B.
Qualified Staff
1.
The name, certificates of standard of welding obtained, and picture of each
welder to be used in a list indicating the level of welding the person is intended
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to be used for.
2.
A simple, clearly shown, overall identification system to indicate the individual
capacity of experience.
PART 2 - PRODUCTS
2.01
OPERATORS
A.
Each operator shall wear an identification system to indicate their level of experience.
Operators shall be certified welders or from an approved governmental institute.
Records of the welding procedures and welder performance qualification tests for work
done shall be maintained by the Supplier for review.
The method and procedure adopted for welding in workshops and at the site shall be
approved before production starts.
The applicable parts of the following documents from the American Welding Society shall
apply :
AWS B 3.0
AWS D 10.9
ANSI / AWS B 4.0
B.
Processes
1.
Carbon Steel
Manual shielded, metal-arc, submerged arc, gas metal -arc, flux-cored arc, gas
tungsten arc, and other applicable welding processes and methods may be used
in the construction and fabrication of welded carbon steel equipment shall as far
as possible be prefabricated in the workshop.
For the welding of carbon steel piping, ANSI Code B 31.3 shall apply.
PART 3 - EXECUTION
3.01
FIELD QUALITY CONTROL
A.
The Standards and practices referred to are applicable.
B.
Reference is also made to the relevant system and/or material specification.
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3.02
TESTS
Contractor shall execute X-ray test at random as requested by the Contracting authority for 50
welds. If tests fail Contractor shall redo the X-ray test after re-welding till the Contracting
authority is satisfied. All tests costs are included in unit rate of pipes.
END OF CHAPTER
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PIPE & PIPE FITTINGS
1.01 RELATED WORK
A.
Division 15 - Mechanical
1.02 SYSTEM DESCRIPTION
A.
Provide labor, materials, equipment and services, and perform operations required for
complete installation of Piping and Fittings and related work as indicated on the drawings and
specified herein.
B.
Work Included: The work shall include, but not be limited to, the following:
-
UPVC pressure pipes for underground domestic cold water , well water, underground
irrigation water and pressurized sewage pipes
-
Galvanized steel pipes butt welded for condensate drains in Mechanical rooms.
-
Galvanized steel butt welded pipes for irrigation water drinking water & domestic cold
and hot distribution inside building mechanical rooms, shafts and main distribution
outside apartment.
-
Cast iron pipes for rain water and drainage water , main collection horizontal pipes and
where indicated on drawings for rain water, sewage and waste pipes in basement floors.
-
UPVC drainage pipes for Soil, waste water drainage and vent pipes and condensate
drains inside building and outdoor underground rainwater and sewage drainage and
where indicated on drawings.
-
Copper pipes for refrigeration pipes and soft water pipes.
-
Polypropelene pipes for domestic water pipes in wall and under tiles.
1.03 REFERENCES
A.
Reference Standards
The latest edition of the following standards:
1.
American Society for Testing and Materials (ASTM):
a.
ASTM A53B Welded and Seamless Steel Pipe for Ordinary Use, Specification
for Black and Hot Dipped Zinc Coated.
b.
ASTM B88 Specification for Seamless Copper Water Tube.
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2.
American National Standards Institute (ANSI): Standards as specified herein.
3.
Manufacturer's Standardization Society (MSS): Standards as specified herein.
4.
American Welding Society (AWS): Standards as specified herein.
5.
American Petroleum Institute (API): Standards as specified herein.
1.04 SUBMITTALS
A.
Product Data:
Descriptive literature for each of the actual proposed material to be used including:
B.
1.
Operating Pressure Ranges
2.
Pressure Losses.
3.
Fluid Flows.
4.
Test Reports.
5.
Certificates of approval.
Shop Drawings
Shop drawings for each of the actual proposed systems shall include the following:
1.
Working or manufacturing drawings.
2.
Calculations
3.
Installation details
4.
Connections to other services
5.
Accessories available indicating those included
6.
System diagrams.
1.05 QUALITY ASSURANCE
A.
Qualify welding processes and operators for structural steel according to AWS D1.1
"Structural Welding Code--Steel".
B.
Qualify welding processes and operators for piping according to ASME "Boiler and Pressure
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Vessel Code", Chapter IX, "Welding and Brazing Qualifications".
1.
Comply with provisions of ASME B31 Series "Code for Pressure Piping".
2.
Certify that each welder has passed AWS qualification tests for the welding
processes involved and that certification is current.
3.
Submit welder certificated signed by the Contractor certifying that welders comply
with the requirements specified above.
1.06 WORK INCLUDED ELSEWHERE
1.07
A.
Chapter 15405: Soil, Waste, and Roof Drainage Piping Systems.
B.
Chapters related to External Site Utilities .
DELIVERY, STORAGE AND HANDLING
A.
Except for concrete, corrugated metal, hub-and-spigot, clay, and similar units of pipe, provide
factory-applied plastic end caps on each length of pipe and tube. Maintain end caps through
shipping, storage and handling as required to prevent pipe-end damage and eliminate dirt and
moisture from inside of pipe and tube.
B.
Where possible, store pipe and tube inside; protect from weather. Where necessary to store
outside, elevate above grade and enclose with durable, waterproof wrapping.
C.
Protect flanges and fittings from moisture and dirt by inside storage and enclosure, or by
packaging with durable, waterproof wrapping.
PART 2 - PRODUCTS
2.01
PIPES
A.
Service Schedule
Service
Pipe Material
1.
Condensate Drain (Mechanical Rooms & Roof)
Schedule 40 Galvanized Mild Steel, Butt Welded
2.
Condensate Drain (above false ceiling)
UPVC Drainage Type (Type 2)
3.
Domestic Water (Hot, Cold & drinking water).
Schedule 40 Galvanized Mild steel, butt welded
4.
Domestic Water (Hot, Cold & drinking water) in wallsPPR
and– PN16
undertiles.
5.
Drainage and vent pipes.
UPVC Drainage Type (Type 2)
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6.
Soft Water Pipes.
Copper ASTM B88L
7.
Refrigerant Pipes.
Copper type L, ASTM B88.
B.
Sizes
1.
Unless otherwise specified pipework of 65 mm nominal bore and over shall be
welded except for fire protection system shall be with grooved end, while 50 mm
nominal bore and below the pipework shall be screwed.
2.02
PIPING MATERIALS
A.
Copper Piping
Copper pipes shall be of the seamless hard drawn tubing type L to ASTM B88 or EN1057:
1996 white label (table Y). Pipes to be used shall have been cleaned by the manufacturer
and the open ends capped to pressure cleanliness.All copper joints to be brazed with fittings
to be specially manufactured for brazing. Underground and buried copper pipes should be
plastic coated.
All copper pipes shall be marked with the manufacturer' name or trade mark.
Solder: ASTM B32, Alloy Su 95, Su 94 or E lead free.
Brazing filler Metal : AWS A5.8, Bcup, copper phospharrous or BAg, silver classication.
Flanges for copper pipes shall be cast bronze with raised ground face and bolt hole spot
faced . Flanges shall be rated at least for 1.5 times the working pressure.
Flexible connectors shall be provided on vertical pipes to take any Seismic action.
B.
Galvanized Steel Piping
Welded and seamless galvanized steel pipes shall be schedule 40 to ASTM A53 grade B.
Pipes shall be cold drawn for sizes up to 50mm diameter and hot drawn for larger sizes. Hot
drawn pipes to have wall thickness along the total length of the pipe.
All fittings elbows, tees, unions, etc. to be of same quality and weight of pipe, as specified in
paragraph “D” below.
Fittings shall be threaded up to 50 mm diameter and welded for 65mm diameter and above.
All pipes to be identified by logo, size, thickness, material and heat number.
Pipe wall thickness and weight shall be as follows:
Pipe size(inch)
Wall thickness(mm)
Weight per m
1/2
2.77
1.27
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3/4
1
11/4
11/2
2
21/2
3
4
5
6
8
10
2.87
3.38
3.56
3.68
3.91
5.16
5.49
6.02
6.55
7.11
8.18
9.27
1.69
2.50
3.39
4.05
5.44
8.63
11.3
16.07
21.77
28.26
42.55
60.30
Flexible connectors shall be provided on vertical pipes to take any Seismic action.
C.
Black Steel Piping
Black steel pipes shall be seamless schedule 40 to ASTM A106 grade B
Fittings shall be threaded up to 2" (50mm) diameter and welded end fittings for 2 1/2"
(65mm) diameter and above. Fire protection system shall have grooved ends for 65mm
diameter pipe and fittings and above. Pipes shall be cold drawn for sizes up to 50mm
diameter and hot drawn for larger sizes. Hot drawn pipes to have wall thickness along the
total length of the pipe.
Fire fighting pipes 65 mm pipes and above shall have grooved coupling with mechanical
locking device with central cavity pressure responsive gasket all subject to the Contracting
authority approval. All fittings of the system shall be UL listed, FM approved and complying
with NFPA Standard 13. All system fittings shall be furnished by the same manufacturer
All fittings shall be of ductile iron conforming to ASTM A 536 or malleable iron to ASTM A47.
All fittings elbows, tees, unions, etc. to be of same quality and weight of pipe, as specified
below
Flexible connectors shall be provided on vertical pipes to absorb any Seismic action.
D-
Galvanized & Black Steel Fittings
Pipe Fittings, Butt Welded
-
Black steel fittings from 2 ½” and larger to be steel butt-welded fittings, material ASTM
A234 grade WPB, ANSI B16.9 beveled ends.
Recommended content of impurities:
S= 15 to 20/1000
P= 15 to 20/1000
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Logo, material, thickness and heat number must be hot stamped on each piece of fittings.
All pieces of fittings to be coated with anti-rust paint.
Steel grooved end fittings:
(ASTM A 47 M) malleable iron casting, ASTM A 106 steel pipe, or pipe, or ASTM A 536 ductile
iron casting with dimensions matching steel pipe.
Pipe Fittings, Black Malleable iron
-
Black malleable iron fittings conform to : BS 6681 GR B30.06 or ASTM A197 .
Black malleable iron fittings up to 2” (50mm) to be screwed conform to BS 143 or ASME
B16.3 Class 125 or 250 as required, having taper external threads and taper internal
jointing threads conform to BS21 or ASME B1.20.1 fitting to have a full clear bore and high
factor of safety over stated working pressures.
All female outlets to have banded reinforcement.
Each piece of malleable iron fitting have to be factory tested either by pressure or
hydrostatically.
Pipe Iron Malleable Iron Galvanized
Same as black malleable iron fittings but hot-drip Zinc coated.
Coating conform to BS 729 and ASTM 153 minimum coating 600g/m2.
Galvanized fittings to be used for all sizes.
Steel flanges
Black forged steel flanges to conform to ASTM A105.
Type of flange slip-on (S/O), spirally grooved to match gasket flanges to be fully machined
after normalizing heat treatment.
Flanges to be drilled according to the matching equipment or valves:
S/O, PN10 as per BS 4504 TABLE 10/5
S/O, PN16 as per BS 4504 TABLE 16/5
Screwed bars, PN16 as per BS 4504 TABLE 16/4
Blind, PN16 as per BS 4504 TABLE 16/8C
S/O, ASA 150, ANSI B16.5, RF.
Screwed bors, PN16 as per BS4504 TABLE 16/4 hot-drip galvanized or galvanized plating.
Gaskets
Casketing material to be non asbestos to ANSI B16.21 dimensions to match corresponding
flanges as per equipment and valves scope.
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Gasket to be cut from compressed sheet jointing, thickness of sheets 1.6 to 2.5 mm
depending from sizes.
Stud Bolts, Bolts and Nuts
Alloy Carbon steel stud bolt and nuts of size below 7/8”(22mm) shall be hot forged according
to ASTM A193 GRB7, from size 7/8 and above, cold forged according to ASTM A194 GR2H.
E.
Polyethylene Pipes
High density polyethylene pipes shall be suitable for irrigation purposes. Pipes shall comply
to DIN 8074 – 8075 type 312 and shall be PN6 pressure pipe. Physical characteristic shall be
as follows:
Density
0.954 kg/m2
Yield strength
23 Mpa
All pipes shall have HP trade mark to guarantee compliance with UNI regulations.
.
F.
UPVC Pressure Piping (Type 1)
1.
Pipework :
The pipework and fittings shall be U.P.V.C. in accordance with EN 1452 suitable for
pressure pipes ( 16 bar).
Fittings shall be in accordance with EN 1452 PN 16/ DIN 8063.
The pipework and fittings shall be installed strictly in accordance with the
manufacturer’s recommendations, copies, of technical instructions on the laying of
U.P.V.C. pipework shall be obtained from the manufacturer’s Technical Service
Department before work proceeds.
When jointing pipework the spigot and socket ends shall be supported clear of the
ground to prevent dirt deposits on the joint, solvent or lubricant. Only solvent and
lubricant made by the manufacturer of the pipe shall be used.
When making flanged joints the correct flanges and seal rings shall be used with
seal gasket set square between mating flange and all bolts secured evenly.
Where solvent joints are used a mechanical joint incorporating a seal ring shall be
incorporated where necessary to allow for thermal movement.
Test pressure shall be applied to the system after a period of not less than 24
hours.
Where joints are to be made between dissimilar materials a proper purpose made
flanged adapter shall be used.
No attempt shall be made to alter or manufacture U.P.V.C. fittings on site.
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2.
Mechanical Joints:
When making a mechanical joint a check shall be made to ensure that the depth of
entry mark is indicated on every spigot before insertion into the socket, so that the
spigot enters the socket within 13/25 mm of the bottom of the socket.
The spigot end of the pipe shall be chamfered to half the wall thickness and made
with suitable hand tools provided by the manufacturer
When making a mechanical joint care shall be taken to ensure that the seal ring is
not misplaced.
Due allowance shall be made for the control of thermal movement.
3.
Solvent Joints :
When making a solvent joint the spigot and sockets shall be wiped clean and
thoroughly degreased with cleaner to remove oil, grease, etc,. after which the
spigot and socket shall have solvent adhesive applied.
The sockets and spigots shall be assembled as quickly as possible after applying the
adhesive and within forty seconds after which it shall be held together for up to five
minutes.
Special care shall be taken to prevent dirt and rubbish entering the open ends of
pipes during erection. Wrought iron screwed caps or plugs, or plastic covers only
shall be used. Wood, rag or paper plugs shall not be used. Failure to comply with
this instruction shall mean that the Contracting authority shall have the right to
order the pipework to be dismantled for as far as considered necessary and the
pipework to be cleaned internally. Such work shall be carried out by the Contractor
and all cost shall be borne by the Contractor.
The Contractor is reminded that the valve fitted to the open end of a disconnected
pipes is not considered satisfactory to prevent the entry of rubbish. The open end
shall be capped, plugged or crimped.
G.
Poly Propylene Pipe
1.
Polypropylene Pipe (Type 1)
This specification covers requirements for polypropylene random (PP-r) piping system (pipe
and fittings) for cold water and heating water pipes embedded under tiles.
Approved Manufacturer: The pipe and fitting manufacturer shall have an established quality
control program responsible for inspecting incoming and outgoing materials. The
manufacturer shall have a document control procedure, which allows for traceability of
manufactured products… It is mandatory for the manufacturer to be operating and
producing under ISO9001:2000 quality requirements.
PP-r pipe shall be manufactured from approved Raw materials in accordance with DIN 8078
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and/or prEN 12202-Part 1 and Part 2.
Heating water pipes shall be triple layer type with aluminum alloy coating inserted in the
surface layer and over lapping the pipe.
Cold water pipes shall be single PP-r layer.
PP-r pipe shall be rated PN20 Wall thickness. Mechanical Characteristics, Mean outside
diameter and out of roundness together with their tolerances must comply with DIN 8077
and /or prEN 12202-Part 2.
Pipe Packaging – All pipe sizes will be supplied in straight lengths of 4 m each. Packaging of
pipes will differ according to size.
Marking of Pipe - All pipes shall bear permanent identification markings that will remain
legible during the service life of the product. Marking on pipe shall include the following
and shall be applied at intervals of not more than 1.5 meters:
1. Trademark and Nominal diameter and thickness (i.e. APITHERM 32 x 5.4)
2. Standard PPr designation (i.e. PPr80 or PPr-type3)
3. The Standard Dimension Ratio (i.e. SDR 5 or SDR 6) and Nominal Pressure (i.e. PN20)
5. Marking the product with the applicable standards designation (i.e. DIN 8077/8078)
6. Quality System used ((i.e. ISO 900X)
7. Date and time of manufacture reference
8. Manufacturer's name and country of manufacture.
2.
Polypropylene Fittings
All fittings supplied under this scope of work must be pressure rated (PN20) and
manufactured from the same material used to manufacture pipes and shall pass all tests
required under DIN 16962/5 and/or PrEN 12202- Part 3.
Fitting Inserts - All inserts used in the manufacturing of threaded fittings must be made of
Nickel Plated Brass. All male threads must be serrated to ease the application of sealing
tape. Male threaded fittings must have PP-r coverage extending to the outer tip of the
insert (on inner surface)
Marking of Fittings- All fittings shall have permanent identification markings indicating the
following:
1- Trademark, size and pressure rating of fitting (PN20)
2- Standard PP-r designation (i.e. PPr80 or PPr-type3)
3- Day and Year stamp indicating period of manufacturing
4- Manufacturer’s Quality Control
3.
Joining Polypropylene Pipes and Fittings
Socket Fusion Joining: This procedure shall be the predominant process to be used to join
PP-r pipes to PP-r accessories. In this form of joining, which requires heating tools, a pipe
end and fitting socket are heated simultaneously to fusion temperature (260 °C) using a
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heating bush and a heating spigot, and are then pushed together. Thus resulting in a
homogeneous joint.
Electrofusion Joining: This technique shall be used strictly for repair and emergency work
only. In electrofusion, the pipe and electrofusion fitting are heated by means of resistance
wires and fused together. Power is supplied through an automatic fusion control unit
supplied by the manufacturer of fittings.
4.
System Inspection and Testing
Upon completion of a chapter of or the entire piping system, the system completed, shall be
inspected and proved tight under water pressure. The inspection must take place before
embedding or concealing the system under concrete or in walls.
For PP-r pipes, the inspection process is broken down in two chapters: visual and
operational.
Visual inspection: A visual inspection should cover, but not limited to the following basic
steps:
1- No pipe shall be secured to another pipe or used as a support for other pipes.
2- Pipes shall be laid as to prevent the formation of air locks or pockets. Where pipes are
laid above one another, cold water pipes shall be installed under hot water pipes to
prevent condensation.
3- The supply pipes for each floor and those in individual flats shall be capable of being
shut separately.
4- All inlets and outlets of completed pipe work shall be tightly closed with stoppers or
caps to prepare for operational phase of the system inspection.
Operational inspection: The visually inspected pipe work shall be filled with fresh water and
completely vented. The presence of air pockets in the system will lead to premature
explosive failure of the system with dangerous consequences to human life near the failure
point.
The operational phase of the inspection shall be carried out in two stages:
1-
First stage: a test pressure equal to the permissible working pressure plus 10 bars shall be produced
twice within 30 minutes at 10-minute interval. Then it shall be checked whether, over an additional
period of 30 minutes, the pressure has dropped by more than 2.0 bars and leakage has occurred
(ambient and testing medium temperatures must be taken in consideration when performing this test,
consult with manufacturer for correction factors).
2-
Second stage: It shall follow the first stage without interval and shall last 24 hours at a pressure of 15
bars. The system should hold a stable pressure with no variation. An overall drop of 2.0 bars is
acceptable if a stable pressure is achieved. Any other behavior indicates a leak.
2.03
PIPE FITTINGS AND SPECIALTIES
A.
General
1.
2.
3.
Refer to individual piping system chapters for required pipe fittings and specialties
not covered herein.
Fittings whether black, galvanized, copper or brass shall be compatible with the
pipework system they are connected to.
Iron fittings shall be generally of the malleable iron type: while steam and
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condensate services shall use wrought iron fittings.
B.
C.
D.
E.
Elbows, Tees, Reducers
1.
These fittings shall comply with ASTM and ANSI B16 as described in relevant
chapters of specifications. The wall thickness shall at least be as specified for the
straight pipes.
2.
All fittings shall be factory made.
3.
Unless otherwise stated, elbows shall be long radius bends with a radius of 1.5
times the nominal size, and shall be smooth and not made of welded segments.
4.
Tees up to and including an outside diameter of 323.9mm shall be of the pressed
type.
5.
Unless otherwise specified, reducers shall be made with a length L = 3 (D-d), where
L is the construction length, D the outer diameter of the large end and d that of the
small end. Unless otherwise stated, the wall thickness of a reducer shall be the
same as that of the adjacent large straight pipe.
Flanged Joints
1.
Flanges shall, unless otherwise stated be welding neck over 100mm pipe or slip on
weld for 100mm pipe and under, with raised faces complying with ANSI B16-5.
Screwed flanges can be used, but welded flanges shall be preferable.
2.
The material of the flange shall be compatible to the pipe and service the flange is
connected to.
3.
Galvanized flanges are to be screwed wherever possible. If this is not possible, black
steel flanges are to be welded to the pipework in the normal way and before final
fitting, the whole prefabricated chapter shall be proprietary hot dipped in a
galvanized bath depositing the amount of zinc specified for the galvanized tube.
4.
A corrugated brass rings for flanged joints shall match the pair of flanges they are
gasketting and shall be used between the flange faces to form the seal.
Blank Flanges and Gaskets
1.
Blank flanges shall comply with ASTM & ANSI B16-5 and shall be of the same
material as the connecting pipework.
2.
All flanges shall be gasketed whatever the size or system.
Bolts and Nuts
1.
Bolts, nuts and washers for flange connections shall be of hot dip galvanized steel.
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2.
3.
4.
5.
F.
Bolts and screws shall comply with ANSI B 18.2.1 specification ASTM A449.
Nuts shall comply with ANSI B 18.2.2.
The length of the thread protruding from the tightened nut in bolt couplings shall be
equivalent to at least half and at most once the bolt diameter.
Washers shall be placed under both nuts and bolt heads.
Unions
1.
Unions in steel pipe: Maleable iron to BS 6681 grade B30-06, ASTM A197 hexagonal
shock body with spherical seat and have female pattern, metal to metal seat, and
female threaded end with threads according to BS21 or ASME B1.20.1, for 50 mm
and smaller, and flanged connections for larger than 65mm. Unions shall be class
150 or 300 according to pipework and valve classification.
2.
Unions in copper piping shall be cast bronze, female pattern, brass to brass seat and
ground joint threaded end connections for 50mm and smaller, and flanged
connections for larger than 50mm. Unions shall be rated for class 150 or 300
according to pipework and valve classification.
2.04
HANGERS AND SUPPORTS
A.
Mechanical Installation System
1.
All installation material used for supporting and fixing mechanical pipe systems
should be of a Pre-Contracting authorityed modern flexible type that gives a tested
and reliable supporting solution without the need for welding, drilling or
subsequent galvanizing for corrosion protection.
2.
The system should provide for easy access and disassembly for future maintenance,
and shall be product of well known manufacturer
3.
The Contractor should provide shop drawings and load calculations to verify the
suitability of the system for critical load applications as per the Contracting
authority’s requirement.
4.
The system should consist of the following components:
a-
C-channels should be used as the main item for supporting pipe and duct
and runs and structures. C-channel should be made in accordance with
British Standards of width 41 mm, and height of channel shall be selected
according to load calculation, made of cold rolled steel strip of thickness 2.5
mm steel grade ST32-2 as per DIN 10025. The steel is Sendzimir galvanized
to a thickness of 20 microns. The channel in ward side should include fine
serrations that insure strong friction hold of the assemble nuts and
accessories. The channel inward side should be slotted for greater flexibility
and should include longitudinal swaging to increase rigidity and stiffness.
Double channels connected with tubular rivets shall be used where greater
strength and stiffness is required.
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Supporting distance and calculation of pipe loads for pipe nuts should be
verified by channel design in accordance with manufacturer
recommendations.
B.
b-
C-channel accessories as recommended by the channel manufacturer
should be used for assembly of various channel structures as appropriate
for the application. These accessories include fixing nuts with serration,
angles, brackets and pipe ring saddles.
c-
Pipe Ring Clamps : Galvanized, pre-Contracting authorityed pipe ring clamps
should be used for fixing all pipes to channel system or directly to the
concrete structure. The contractor should verify that the pipe supported
weight does not exceed the recommended maximum load of the clamp as
provided by the manufacturer. The clamps should consist of two half rings
suitably connected with welded on connection nut for fixing the clamp to
the threaded rod. Where copper pipes, hot water are used, the rings should
provided with a pre-fitted rubber inlay with suitable temperature resistance
characteristics for the application.
d-
Threaded Rods used should be manufactured as per DIN 976 of Steel Grade
4.6, galvanized and used to support pipe duct ring clamps onto the Cchannel or directly to concrete anchors depending on the application. The
threaded rods, nuts and flat washers used should have a clean thread and
flawless galvanized condition.
f-
Concrete Anchors: Internally threaded Anchors used for fixing threaded
rods and pipe clamps should be made from galvanized steel, anchors should
have a flared end for accurate setting flush with the surface, and should
have an intelligent expansion selection that adapts to suit strength of the
base material. Concrete stud anchors should be used for fixing C-channels
to the concrete suitable for through in-place fattening with reliable fixing.
All Concrete anchors used should be provided with full load characteristics
and used in accordance with manufacturer recommendations with regards
to application and setting details. Concrete Anchors should also be fire
rated to verify that they can withstand the required loads within the fire
integrity limits of the supporting building structure.
g-
For riser pipes, Anchor Fixed Point Clamps should be used to support the
weight of the riser pipe . Fixed Point Clamps should be used in location as
recommended by supporting system manufacturer and approved by the
Contracting authority.
Pipe Hangers, Upper Attachments
1.
Individual or continuous preset concrete inserts.
2.
Beam clamps and anchor bolts may be used for steel construction.
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3.
C.
D.
Hanger Rods
1.
Galvanized solid steel, all thread rods, with lock-nuts.( 10mm dia. Per pipe)
2.
For trapez supports submit calculation for threaded hager rod diameter with at
least 8 times load factor.
Pipe Hangers, Lower Attachments
1.
E.
F.
Self-drilling expansion shells for 75 mm pipe and smaller may be used in existing
concrete structures. See special details for larger piping.
Lower attachments for individual runs of pipe shall be as follows, unless indicated
otherwise:
a.
steel piping up to 125 mm: steel clevis;
b.
steel piping 150 mm and larger, not subject to thermal expansion: steel
clevis;
c.
steel piping 150 mm and larger, subject to thermal expansion: pipe roller
support;
d.
copper tubing, all sizes: copper-plated steel clevis, except where hanger is
installed around the outside of insulation, not in contact with pipe, where
steel clevis hangers may be used;
e.
cast iron pipe, all sizes: steel clevis.
Vertical Pipe Supports
1.
At intermediate floors use extension pipe clamps.
2.
At top of risers, use hangers as specified above.
3.
At base of risers, use stiff-leg pipe support immediately adjacent to elbow. For cast
iron soil or storm riser use solid concrete block.
Trapeze Hangers
1.
Where numerous pipes are run in parallel to one another, they may be supported
from a trapeze type hanger arrangement. Rollers supports shall be used to support
each run of piping on trapeze hangers to permit independent movement of
individual pipes.
2.
Piping supports shall consist of channels, fittings, pipe brackets, pipe rollers, pipe
clamps, post bases, stud nuts, etc., as required to properly support and hang piping.
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G.
Stiff-legs or Stanchions
1.
H.
Alignment Guides
1.
I.
Units shall be carbon steel construction, screwed, flanged, or welded connection as
required, suitable for temperatures of 274 degrees C and pressure of 8.3 MPa;.
Provide for 15 degrees angular flex and 360 degrees rotation.
Anti-Vibration Suspension Hangers
1.
K.
Guides to be constructed with steel base and T-bar with teflon or graphite plates
bonded to the steel components to allow minimum static friction and selflubrication for unlimited movement. Units shall be factory painted. Guide base shall
be welded to the pipe.
Flexible Ball Joints
1.
J.
Stiff-legs or two-leg stanchion supports shall be provided in cases where support
from overhead structure is not possible. Pipe rollers shall be provided for pipe
rigidly supported from floor.
Combination type, shall have a double-deflection neoprene element in series with a
steel coil spring; deflection of 8 mm; steel coil spring shall be selected from a 25 mm
static deflection series with a minimum additional travel of 12 mm; spring diameter
shall be large enough to permit 15 degree angular misalignment of the rod
connecting the hanger to the upper attachment without rubbing the hanger box.
Spacing of Pipe Supports
1.
Spacing Support Schedule:
The maximum spacing for pipe supports shall be as follows:
NOMINAL
HORIZONTAL (m)
VERTICAL (m)
BORE mm
STEEL
COPPER
UPVC STEEL
COPPER
UPVC
10-12
15
20-32
40-50
65-80
100 & above
1.8
2.4
2.4
2.5
2.5
1.0
1.2
1.8
2.4
2.5
2.5
0.8
0.8
1.0
1.2
1.2
1.2
1.8
2.4
2.5
2.5
2.5
0.8
1.0
1.5
1.7
1.7
2.5
2.5
2.5
2.5
2.5
Hangers and supports shall in no case be less than one (1) hanger per 2.5 m.
2.
The spacing of pipe group supports shall be based on the smallest nominal bore
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pipe using the hanger, in accordance with the spacing support schedule above.
Alternatively intermediate supports can be given to a particular pipe, if conditions
permit.
2.05 PASSIVE FIRE PREVENTION SYSTEM
A.
All openings through fire rated walls, ceilings and floors due to penetrations of mechanical
installations as well as those due to construction joints, should be sealed with fire rated
products suitable for the specific application as specified hereunder. All materials selected
shall be UL Listed.
B.
The product shall be capable of stopping the passage of fire, air gases, smoke, heat and
water through wall, floor and ceiling penetrating, cladding and expansion joints. The
product shall exhibit the minimum designed fire resistant properties.
C.
The products shall be obtained from an approved, established and proven firm and
quantities shall be applied strictly in accordance with the written instructions of the
manufacturer and to the approval of the Contracting authority.
D.
The recommended treatments for various applications shall be as follows:
1.
Metal pipe and duct crossings : the annular space around the pipe shall be packed
with UL Listed fire rated foam backing material and the ends shall be filled and
sealed with fire rated Elastic sealant according to manufacturer data. The size of the
circular opening shall be maintained as the barest minimum as recommended by
the mastic manufacturer.
2.
For non-metal pipe and conduit crossings less than 50 mm in diameter, the annular
space around the pipe shall be packed with fire rated foam as backing material. The
ends should then be filled and sealed with UL Listed in tumescent, graphite based,
fire rated mastic with expansion pressure of minimum 6 bar. The circular opening
shall be maintained strictly as the barest minimum recommended by the mastic
manufacturer.
3.
For pipes/conduits more than 50mm in diameter, the pipe/conduit shall be
wrapped with a fire rated, in tumescent, graphite, based, fire rated wrap and
applied strictly according to the manufacturer specifications, all UL Listed.
2.06 PIPE SLEEVES
A.
General
1.
Sleeves for all pipes passing through floors, walls, partitions, (except where floors
and walls are a part of fire-rated assembly) concrete beams, girders, and any other
building construction shall be provided in types as described below, and of
adequate diameter to allow minimum of 19mm clearance all around between
sleeve and pipe. When pipe is insulated, insulation shall pass continuously through
sleeve with 19 mm clearance between insulation and sleeve.
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B.
2.
Pipes passing through fire-rated walls, partitions, or floor shall be sealed, smoketight, with a fire proof compound. Insulation shall not pass through the sleeve as
specified above. Fill inner space with Rockwool insulation with fire rated compound
up to the rating of the wall. Refer to paragraph 2.05 above.
3.
Allow 50 mm of steel sleeve above F.F.L, and flush with walls.
Pipe Sleeves Material
Refer to chapter 15010 for sleeves and inserts.
1.
2.
Galvanized Schedule 40 steel pipe when installed in:
a.
concrete or masonry walls and concrete bases.
b.
beams with poured concrete fireproofing.
c.
concrete floors and mechanical equipment room floors.
d.
concrete floors with metal under deck (tack weld to deck).
18-Gage Galvanized Steel when installed in:
a.
plaster or dry wall.
b.
air plenums.
2.07 flashing
A.
Steel Flashing : 26 gauge ( 0.50 ) galvanized steel.
B.
Lead Flashing : 24.5 kg/m2 (5lb/sq.ft.) sheet lead for waterproofing, 5kg/m2 ( 1 lb/sq.ft.)
sheet lead to sound proofing.
C.
Safes: 24.5kg/m2 (5lb/sq.ft.) sheet lead or 0.20 mm (8mil) thick neoprene.
D.
Caps: Steel, 22 gauge ( 0.80 mm) minimum, 16 gauge (1.50 mm) at fire resistance structures
2.08 SEALANTS
A.
Sealant for Pipe Sleeves
1.
All sealants materials shall be a single compounds, primerless, non-sagging type in
neutral color.
2.
Polysulfide: one part, gun grade.
3.
Acrylic Latex: one part, gun grade, paintable, with a temperature range from -17 to
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+82 degrees C.
4.
Butyl: one part, gun grade, suitable for both horizontal and vertical joints.
5.
Fire rating compound similar to wall rating and as described under paragraph 2.05
of this chapter.
2.10 thermal expansion fixed point system
A.
Where metal pipes are subject to thermal expansion, particular attention should be given
and pipe runs should be studied and designed to compensate for the expansion forces and
reduce the stress on the pipes and supporting system.
B.
The contractor should provide sufficient shop drawings and load calculations to verify the
suitability of the system for critical thermal applications run as per the Contracting
authoritys requirement. Allowance for free thermal expansion distance at pipe bends
should be marked.
C.
The following components should be used to control thermal expansion :
1.
Slide Guides : Use side and Roll Connectors with integrated sliding components on
all pipe runs subject to high thermal movement. The guide should be used in
accordance with manufacturer load limits and movement limits. The slides should
be resistant to operating temperatures of the supported pipes and as specified for
valves of relevant system and valve location.
2.
Anchor fixed Point Pipe Clamps : Where necessary and according to the thermal
study, use fixed point for a flexible and reliable fixing system against axial thermal
expansion forces. The anchor points should be used strictly in accordance with the
manufacturer recommendations and loading characteristics and in accordance with
the calculated expansion forces provided by the thermal study.
3.
Expansion compensators : For critical application and if expansion movement
cannot be taken up by free movement of the pipe bends, expansion compensators
or bellows of the axial and/or angular type should be used in conjunction with the
fixed anchor points and in accordance with the thermal study. Expansion
compensators should be used in accordance with manufacturer recommendations.
2.11 ACCESSORIES
A.
Safety or Relief Valves
1.
The relief valves shall be set to a maximum of 0.3 bar above the working pressure of
the line in which they are fitted or as indicated on drawings. Safety and relief valves
shall be suitable for the operating condition of the system.
2.
They shall be of the totally enclosed spring loaded type with padlock.
3.
Safety valves and relief valves shall have a full bore discharge connection. Where
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any law point occurs in the discharge run, it shall be fitted with a 22 mm size copper
waste pipe carried clear of the insulation for drainage. The discharge and waste
pipes shall be run to visible safe positions to be agreed..
4.
B.
Relief valves shall be ASME approved and labeled, size, capacity and setting as
indicated.
Temperature and Pressure Test Pugs
1.
Provide temperature and pressure test plugs as described in Chapter 15990.
PART 3 - EXECUTION
3.01
PIPING INSTALLATIONS
A.
General
1.
B.
Installation instructions contained in this Chapter pertain to most systems. For
specific requirements for installation of each system, refer to individual system
specification chapters.
Piping Installation Generally
1.
Conceal all pipe installations in walls, pipe chases, utility spaces, above ceilings, etc.
unless other wise indicated. Under slab piping shall be kept to the absolute
minimum.
2.
Install all piping free of sags or bends and with ample space between piping to
permit proper installation.
3.
Install piping at right angles or parallel to building walls. Diagonal or bent piping will
not be permitted.
4.
Install piping tight to slabs, beams, joints etc. where possible and such that any
removable ceiling panels may be removed for access above ceilings.
5.
Protect all piping from entrance of dirt or other foreign materials during the
construction period. At the completion of the project, all dirt and foreign matter in
piping shall be removed completely.
6.
Piping passing through exterior building walls shall be caulked whether tight.
7.
Provide drain lines from all relief valves and condensate pans and run drain line full
size to the nearest floor or equipment drain.
8.
All water piping shall have draining points at all low points. For mains, risers and
branch lines there shall be at least a 20 mm drain valve with a threaded hose
connection for other points a15 mm drain valve and hose and hose connection shall
be provided.
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9.
Water piping shall be securely anchored to insure proper direction of expansion and
contraction.
10.
Expansion loops or expansion joints shall be provided as indicated and required, and
shall be cold sprung.
11.
Verify existing grades, inverts, and topographic conditions prior to any trenching,
excavation, or installations.
12.
Horizontal piping shall slope uniformly without sags or humps to provide for
complete drainage of systems and elimination of air.
13.
High points in closed piping systems shall be vented by Automatic air vents.
Drainage piping shall slope as required by code or as indicated. Steam and
condensate shall slop down in direction of flow 12 mm per 500 mm unless
otherwise indicated. Slope water piping up in the direction of flow 12 mm per 500
mm.
14.
Piping shall be cut accurately to measurements established at the site, worked into
place without springing or forcing, and shall clear all windows, doors and other
openings. Cutting or other weakening or building structure to facilitate piping
installation is not permitted, install to permit free expansion and contraction
without damage.
15.
Swing joints at runouts to equipment and risers. Provide expansion loops at all
other points for flexible piping systems.
16.
Drain piping from pump glands, relief valves, condensate drain pan etc., to spell
over open sight drains, floor drains, or other acceptable discharge points
terminating drain line with plain end ( unthreaded ) pipe.
17.
Provide necessary temporary connections, valves, oversize flushing connections,
pumps, etc., as required to properly clean and test systems.
18.
Coordinate piping installations with ductwork, structure, lighting, electrical conduit
and all other materials and equipment.
19.
Use flexible pipe connectors for all inlet and discharge final connections to pumps (
except in line pumps ) and other vibration producing equipment.
20.
Provide flanges on all valves, apparatus, and equipment having 50 mm and larger
connections.
21.
Reduction in pipe sizes except in drainage pipe, shall be made using eccentric
reducer couplings installed with the level side up on water piping and level side
down on steam and condensate piping.
22.
Provide unions adjacent to each valve at the final connection to each piece of
equipment of plumbing fixture having 50 mm and smaller connections and where
otherwise indicated.
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C.
23.
Wherever wells are installed in piping for thermometers, pressure gages, probes,
etc., pipe size shall be increased by one pipe diameter to accommodate same.
24.
Provide air chambers at the top of all hot and cold domestic risers, at the end of
each water header in utility spaces, at the end of each branch line, and at the top of
all branches to fixtures. Provide shock absorbers at each solenoid valve or piece of
equipment that has a quick closing type valve. Air chambers shall be a minimum of
two pipe sizes larger than the terminating pipe and shall be equipped with an
accessible drain valve and air recharging petcock or installed at least 600 mm above
fixture to permit recharging by draining air chamber.
25.
Use fittings for all changes in direction and all branch connections and take - off
from mains. Changes in direction and branch connection in welded piping shall
conform to Chapter 15051 Welding.
26.
Connect dissimilar piping material using dielectric unions or insulating flanges.
Hangers & Supports
1.
Approved hangers and stiff leg supports shall be installed in quantity and size as
required to carry the weight of pipe, contents, and insulation and shall be arranged
to prevent vibration transmission to the building and allow for pipe movement.
2.
Support on pipework requiring a vapor barrier shall be installed on the outside of
the insulation. Approved material shall be provided between the pipe and the
support to give adequate support and thermal isolation. The vapor barrier will
cover the chock.
3.
Hangers spacing shall be as per clause 2.04 K of this chapter.
4.
Hangers shall be supplied with lock nuts in sufficient number and location to lock all
rod adjustments permanently at the adjusted height. Two lock nuts shall be used
unless the nut tightens against a threaded socket. Minimum rod diameters shall be
as follows :
NOMINAL PIPE SIZE
ROD DIAMETER
12 mm through 50 mm
60 mm and 75 mm
100 mm and 125 mm
150 mm
200 mm through 250 mm
300 mm
9 mm
12 mm
15 mm
19 mm
22 mm
25 mm
5.
Location of hangers shall be coordinated with light fixtures as shown on reflected
ceiling plans. Piping shall not be supported from ductwork, duct supports, or other
piping. Hanger rods shall not penetrate ductwork
6.
Provide all necessary supplementary steel for support and attachment of hangers,
and pipe , and duct supports in shafts and between building structural members.
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D.
E.
7.
Piping at pumps, tanks, etc., shall be supported independently so that pipe weight
will not be supported by equipment. Each piece of pipework system shall be
supported so that no stress shall be imposed on equipment connections or flexible
joints to equipment.
8.
Provide anchors, guides, and bracing as indicated to prevent lateral movement
9.
Where an excessive number of fittings or accessories are installed between
hangers, provide additional hangers or adequate support.
10.
Rods for trapeze hangers supporting several pipes shall be sized for the equivalent
load.
11.
Hangers rods shall be attached to structural members of the building.
12.
Provide additional hangers or anchoring devices necessary for support of piping at
corners, tops of risers, etc.
13.
Anchors shall consist of rigid members clamped or welded to the pipe to prevent
pipe movement at that point. Attach anchors to structural members of the building.
Joints
1.
Any leaking joints shall be completely disassembled and remade with new
materials.
2.
Caulked joints in drainage piping shall be made using spun oakum to within 25 mm
of hub and the remaining space filled with poured pure pig lead and swigged.
3.
Ends of all copper tubing and the interior of the cup of the fitting shall be
thoroughly cleaned and polished prior to the application of the flux and solder. The
flux shall not be used as a substitute for proper joint preparation.
4.
All pipe shall be carefully reamed. Threaded pipe shall have full length clean cut
threads.
5.
All sockets and pipe ends of PVC shall be cleaned and solvent cement applied for
full circumferential cover.
Pipework Expansion
1.
The contractor shall supply and fix expansion devices, anchors and guides to
adequately allow for the expansion and contraction of the pipework. The minimum
number considered necessary are shown on the contract drawings..
2.
Whenever possible, such as brunch take-offs , natural expansion shall be used
within the configuration of the pipework system.
2. Pipe work expansion shall be carefully controlled to prevent damage to the pipework system,
equipment, structure, etc.
3. All expansion devices shall be suitable insulated to prevent accident to personnel, but does not
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restrict the movement of the pipework
4. All expansion devices and natural expansion pipework systems shall be installed with 50 % cold
draw of the total movement.
5. Anchor points shall be provided as shown on the drawings. The anchor shall be capable of resisting
the maximum stresses that be applied. The contractor shall ensure that the structure, that the
anchor is attached to, shall also be capable of withstanding the same stresses.
3.02 VIBRATION CONTROL
A.
General
1.
B.
Noise Criteria
1.
C.
All vibrating equipment connected to the pipework system shall be isolated to
eliminate transmission of noise and vibration. All vibration control study shall be
done by a specialized company taking into consideration the Seismic condition of
the building, all to the approval of the Contracting authority.
Each piece of mechanical equipment selected shall be evaluated for quietness.
Particular care shall be taken to evaluate acoustical performance as well as
mechanical function. Sound pressure level within spaces shall not exceed the NC
curves indicated.
Piping Insulations
1.
2.
All piping 63 mm and larger specified with vibration isolation shall have anti vibration hangers . Static deflections as follows :
a.
First three hangers away from any spring isolated piece of equipment shall
have hangers with same static deflection as equipment isolators.
b.
All others shall have 25 mm static deflection.
All piping 50 mm and smaller shall have isolators as follows :
a.
First three hangers away from any spring isolated piece of equipment shall
have hangers with same static deflection as equipment isolators.
b.
For insulated piping outside equipment rooms isolators are not required.
3.
Install temporary anchors as required to permit readjustment of springs in risers
and to fix direction of pipe movement and final operating deflection of springs
4.
Provide permanent limit stops to prevent excessive vertical motion in risers in event
system is drained and to prevent excessive lateral motion.
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3.03 ACCESSIBILITY
A.
B.
C.
Locate all equipment that must be serviced, operated , or maintained, in fully accessible
positions. Minor deviations from the drawings may be allowed for better accessibility at
written approval.
Allow ample space for removal of parts that may require replacement or service in the
future.
Extend all grease fittings to an accessible location.
3.04 MECHANICAL CUTTING AND PATCHING
A.
Contractor shall be responsible for all cutting, fitting, or patching of his work which may be
required to make its several parts come together properly and fit it to receive, or be
received, by work of other trades. Cutting of structural members shall not be done without
written approval.
B.
Any cost caused by defective or ill-timed work shall be borne by the contractor, as
determined by the Contracting authority. Contractor shall not endanger any work, persons,
or construction by cutting, digging or otherwise.
C.
Place sleeves through all walls , floors, and ceilings during the initial construction where it is
necessary for piping to go through. When this is not done, do all cutting and patching
required for the installation of the work. Any damage caused to the building by this cutting
and patching, shall be corrected at no additional cost.
D.
Patching of all openings for new installations and all openings resulting from the removal or
relocation of any installations shall be done by craftsmen skilled in the particular trade
effected, with materials of like type adjoining openings.
END OF CHAPTER
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VALVES
PART 1 - GENERAL
1.01
SUMMARY
A.
Provide labor, materials, equipment and services, and perform operations required for
complete installation of Valves and related work as indicated on the drawings and specified
herein.
B.
Work Included: The work shall include, but not be limited to, the following:
1.
Types of valves specified in this chapter include the following:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
2.
C.
Valves furnished as part of factory-fabricated equipment, are specified as part of
equipment assembly in other Division 15 chapters.
Related Work Specified Elsewhere
1.
2.
1.02
Gate Valves.
Check Valves.
Globe Valves.
Float Valves.
Pressure Reducing Valves.
Double Regulating Valves.
Strainer.
Temperature and pressure relief valves.
Ball Valves.
Plug Valves.
Expansion Joints.
Flexible Connections.
Self balancing valve.
Air Separator.
Basic Mechanical Requirements - Chapter 15010.
Basic Mechanical Materials and Methods - Chapter 15050.
QUALITY ASSURANCE
A.
Materials and work shall conform to the latest edition of reference specifications, industry
standards listed below and specified herein and to applicable codes and requirements of local
authorities having jurisdiction, whichever is more stringent.
B.
Tests: Test valves in accordance with the appropriate chapter of the specification describing
each system.
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1.03
SUBMITTALS
A.
Submit the following in accordance with requirements specified under Submittals in Chapter
15010.
1.
1.04
Product Data: Submit copies of manufacturer's latest published literature for materials
and equipment specified herein for approval; obtain approval before ordering materials.
DELIVERY, STORAGE AND HANDLING
A.
Exercise proper care in the handling of work so as not to injure the finished surfaces, and take
proper precautions to protect the work from damage after it is in place.
PART 2 - PRODUCTS
2.01
GENERAL
A.
Provide valves of same type by one manufacturer.
B.
Provide valves with manufacturer's name (or trademark) and pressure rating clearly marked
on valve body.
C.
Valves up to 2” (50mm) diameter, threaded ends, to meet the followings:
-
D.
Body, bronze ASTM B62
Non rising stem – solid wedge disc, screwed in Bonnet, hand wheel operated.
Threaded ends to ANSI B1.20.1
Testing to be accordance with BS 5154 Series B.
Pressure rating PN20.
Valves from 2 ½” (65mm) diameter and up, flanged ends, raised face, in accordance with:
- Body, cast iron ASTM A126.
- Valves specified as non rising stem, inside screw, bronze facing disc, bronze trim, hand
wheel operated.
- Flanges to BS 4504.
- Testing to BS 5150 for gate valve,
- Pressure rating as specified for relevant system as noted in chapter 15010.
- BS 1552 for globe valve.
- BS 5153 for check valve.
E.
All valves (gate, globe, check, strainer), threaded or flanged to have the same connection size
with the pipe(except where mentioned).
F.
Taper thread, spherical seat union to be installed with all threaded valves.
G.
All valves shall be capable for repacked under pressure.
H.
A union shall be used with all gate, globe, regulating, check and float valves.
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2.02
GATE VALVES
Gate valves shall be designed for the indicated working pressure whether valves are opened or
closed.
a) Bronze gate valve on all equipment to be heavy duty type, heavy weight and meet ASTM B62,
non rising stem, PN20, Kitemark approved.
b) Cast iron gate valve for all equipment except fire fighting, shall be heavy duty type and in
accordance with ASTM A126, O.S & Y, rising stem, PN16, Kitemark approved for systems above
level 50 and class 150 for systems below level 50. valves in mechanical rooms or for airhandling
units and equipment shall be O.S&Y rising stem and stem. All others shall be non rising stem.
2.03
CHECK VALVES
Check valves shall be used on the discharge side of pumps and whenever shown on the drawings or
requested by the Contracting authority. Material & pressure to be as 2.01. Check valves shall be
swing type.
2.04
GLOBE VALVES
Globe valves shall be installed where shown on drawings for water flow control. For proper
throttling, globe valve, cast iron body flanged, PN16, to have a45° Mitre type disc.
Material and pressure to be as 2.01.
2.05
FLOAT VALVES
Float valves shall be of all bronze construction including levers and arms, with PVC float and suitable
for a cold water working pressure of 10 bars. Float valves shall have screwed inlets.
Float valves shall be of the full bore, equilibrium ball type, designed to close tight against maximum
pressure when half submerged. They shall have renewable synthetic rubber valve discs and balancing
piston buckets.
2.06
PRESSURE REDUCING VALVES
Pressure reducing valves to be of the self-contained, direct acting, spring loaded, diaphragm type,
with stainless steel filter mesh (0.16mm) around the seat. Replacement of any part must be done
without removing the valve body from the pipe. Pressure reducing valve station (PRV) shal be
duplicate type complete with valves as detailed on drawings.
- Pressure reducing valve size up to 2”, to be in accordance with:
- Brass body, threaded connections, steel adjustment spring not in contact with water NBR
diaphragm and seals, stainless steel or synthetic valve material, set pressure to appear on a
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set point scale, set pressure to maintain constant even when fluctuation on the inlet side
occurs.
Inlet pressure up to 25 bars.
Outlet pressure from 1.5 to 6 bars installed before and after the P.R.V.
- Pressure reducing valves size from 2 1/2” and larger in accordance with:
- Cast iron body, flanged, synthetic coating inside and outside (toxically safe) steel adjustment
spring not in contact with water, brass seat,EPDM diaphragm set pressure to maintain
constant even fluctuation on the inlet side occurs. Set pressure to appear on a scale.
Inlet pressure depend on application 16 or 25 bars.
Outlet pressure from 1.5 to 6 bars.
Pressure gage shall be installed before and after the P.R.V.
2.07
Double Regulating Valves
- Double regulating valve shall be of the Y-pattern bronze globe valves, it shall have a
characterized throttling disk with sufficient authority to regulate flow in a circuit incorporating a
Flow Measurement Valve. The valves shall have a unique device which enables the disk to be
locked in position to control flow at a pre-determined rate. An Allen key (3mm) shall be supplied
for lock adjustment. Tight closure of the valve shall be assured by use of a PTFE disc insert. The
valves shall be rendered 'tamper proof'. Even with hand wheel and test point is the vertical down
position.
- Pressure regulating valve, size up to 2” (50mm) diameter to be in accordance with:
Bronze body, screwed equal percentage fixed orifice or variable orifice. Accuracy of flow
measurement + 5% , with digital high strength melon, hand wheel with a gear operated gear
mechanism. Two different scales:
one for complete rotation (4rotations)
one for indicating the division of each turn in tenths from zero to nine.
Operating pressure 25 bars.
- Pressure regulating valve, size 2 1/2” and larger to be in accordance with:
- Ductile iron body, flanged, variable orifice. Accuracy of flow measurement + 5% , with
micrometer style hand wheel with a gear operated gear mechanism. Two different scales:
- one for complete rotation (4rotations)
- one for indicating the division of each turn in tenths from zero to nine.
Operating pressure 16 bars.
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2.08
Flanges and gaskets
Flanges to be forged carbon steel, material A105-98, fully machined.
For ANSI valves use:


ASA 150, R.F. ANSI B16.5, slip-on or welding neek.
ASA 300, R.F: ANSI B16.5, slip-on or welding neek.
For Metric Valves use:

PN 16, R.F. BS 4504 table 16/5, slip-on or welding neek.

PN 10, R.F. BS 4504 table 10/5, slip-on or welding neek.
Gaskets shall be non asbestos to ANSI B16.21 and dimensions to suit ANSI B16.5 class 125, flat
faced compressed sheeting 1.6 mm thick.
Stud bolts shall be to ASTM A193 grade B7, threaded full length complete with 2 nuts ASTM A194
grade 2H.
2.09
Strainers
-
Water strainer shall be supplied and installed at the suction connection of all pumps, and
ahead of all automatic flow control valves.
-
Strainers must have a large screening area assuring free flow of liquid with minimal pressure
loss. Stainless steel or copper perforated screen.
-
Bronze strainer, screwed up to 2” in accordance with:
- Screen perforation hole diameter 0.8mm body to have hexagonal end connection on
both side.
- Y type, screwed in cap.
- Pressure rating 25 bars.
-
Cast iron strainer, flanged, 2 ½” and larger in accordance with:
-
2.10
Screen perforated hole diameter 0.75 mm.
Y type, bolted cap.
Cap drilled & tapped.
Pressure rating 16 bars.
Flexible Pump Connectors
Shall have excellent ability to isolate sound and vibration, used to protect mechanical equipment by
relieving piping stresses caused by piping misalignment. Rubber material to be Neoprene for cover
and tube. Flexible connection to withstand indicated pressure below and 660 mm vacuum.
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Size up to 2” to have galvanized double union ends threaded, twin rubber sphere.
Size larger than 2” with floating flanges single sphere Class 150.
For fire pumps, use adequate pressure 300 PSI.
For all pumps in basement use adequate pressure 300 PSI.
For all pumps on roof use PN16 pressure rating.
2.11
Ball Valves
1.
Ball valves, 50mm and smaller: bronze body conform to ASTM B62, two piece end entry, full
bore, brass chrome plated polished ball, seat and packing PTFE, quarter turn bubble tight
shut off, blow out proof stem and vinyl-covered T handle.
2.
Screwed ends to ANSI B.1.20.1 pressure rating 25 bars, for use on steel water pipes.
3.
Compression ends to BS 864 to suit copper tube to BS 2871, part 1, table X, Y and Z.
Pressure rating 16 bars.
2.12
2.13
Plug Valves
1.
Plug valves, 50mm (2") and smaller: Rated at labour WOG; bronze body, with straightway
pattern, square head, and threaded ends PN20.
2.
Plug valves, 65mm (2½") and larger: MSS SP-78; Class 150, lubricated plug type, with semi
steel body, single gland, wrench operated and flanged ends.
Wall Mounted Water Taps
Wall taps installed outside the building shall be jet cock with isolating valve, non-return valve,
double service and finishing facade plate.
2.14
Chapter Valves and Specialties
a.
Combined Pressure/Temperature Relief Valves: diaphragm operated, cast-iron or brass body
valve, with low inlet pressure check valve, inlet strainer removable without system shut-down,
and non-corrosive valve seat and stem. Select valve size, capacity, and operating pressure to
suit system. Valve shall be factory-set at operating pressure and have the capability for field
adjustment. Valve shall be suitable for a pressure up to 300 psi with temperature relief set
100 ºC. Valve shall be AGA and ASME rated.
b.
Safety relief valve designed, manufactured, tested, and labeled in accordance with the
requirements of Chapter IV of the ASME Boiler and Pressure Vessel Code. Valve body shall be
cast-iron, with all wetted internal working parts made of brass and rubber, 860 kPa working
pressure and 121 °C maximum operating temperature. Select valve to suit actual system
pressure and kCal capacity. Provide with fast fill feature for filling hydronic system.
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2.16
Air separator
Air separator: welded black steel; ASME constructed and labeled for minimum 860 kPa water
working pressure and 190 °C operating temperature; perforated stainless steel air collector tube
designed to direct released air into compression tank; tangential inlet and outlet connections;
screwed connections up to and including 50 mm NPS; flanged connections for 40 mm NPS and
above; threaded blow down connection; sized as indicated for full system flow capacity.
2.17
Flexible expansion joints
Stainless steel expansion joints, to have stainless steel 321 corrugated metal sheets with welded
steel tube ends. An internal stainless steel 304 sleeve to protect bellows. Steel tube ends to be plain
ends or threaded for sizes up to 2”(50mm), and flanged with ties for sizes larger than 2”(50mm).
Calculation must be presented to the Contracting authority showing the number of joints used in
relation between the total length expanded and the axial movement of the joints.
Pressure rating 10 bars or 25 bars depending on application.
2.18
AUTOMATIC AIR VENT
Automatic air vents shall be installed as shown on the drawings, at all high points in the system and
where indicated by the Contracting authority.
Automatic air vents of the free floating mechanism type. They shall support a working pressure up
to 150psi, body and cap 250psi.
Mechanism of automatic air vent shall be interchangeable.
Each automatic air vent shall be completed as specified herein after:
a.
b.
c.
d.
e.
f.
2.19
Cast iron body, ASTM-278.
Stainless steel seat and valve, heat treated.
Interchangeable free floating mechanism.
Stainless steel float, heli arc welded.
Vent test cock.
Isolating valve, PN20.
Temperature and Pressure Relief Valve
-
This valve shall be used on domestic hot water lines wherever applicable.
-
Temperature and pressure relief valve shall be self-closing type with test lever and screwed
connections.
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2.20
-
Valve shall be suitable for a pressure of 16 bar service and shall be supplied with
temperature relief set at 210 oF (100 oC).
-
Valve shall be AGA and ASME rated.
BACKFLOW PREVENTERS
A.
Provide backflow preventers as indicated, of the reduced pressure principle type, consisting
of assembly including shutoff valves on inlet and outlet, and strainer on inlet.
B.
Backflow preventers to include test cocks and pressure- differential relief valve located
between two positive seating check valves.
C.
Construct backflow preventers in accordance with ASSE Standard 1013.
C.
Subject to compliance with requirements, provide backflow preventers
E.
Back flow preventer shall be suitable for a pressure of 16 bar.
END OF CHAPTER
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PIPE, FITTINGS AND VALVES - APPLICATION
PART 1 - GENERAL
1.01
SUMMARY
A.
Provide labor, materials, equipment and services, and perform operations required for
complete installation of pipe, fittings and valves application and related work as indicated on
the drawings and specified herein.
B.
Work Included: The work shall include, but not be limited to, the following:
1.
C.
1.02
This chapter of the specifications consists of the application of the various types of
Pipe, Fittings and Valves as described in Chapter 15060 "Pipe & Fittings" and Chapter
15100 "Valves."
Related Work Specified Elsewhere
1.
Basic Mechanical Requirements - Chapter 15010.
2.
Basic Mechanical Materials and Methods - Chapter 15050.
QUALITY ASSURANCE
A.
Materials and work shall conform to the latest edition of reference specifications and
industry standards specified herein and to applicable codes and requirements of local
authorities having jurisdiction, whichever is more stringent.
B.
Fittings shall have the same wall thickness and schedule as the pipe.
C.
Pressure rating of fittings and valves shall exceed highest specified service pressure of the
system in which installed.
D.
Materials, fittings and valves of any one type shall be from one manufacturer.
PART 2 - EXECUTION
2.01
EXAMINATION
A.
Examine conditions at the job site where work of this chapter is to be performed to insure
proper arrangement and fit of the work. Start of work implies acceptance of job site
conditions.
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2.02
2.03
PREPARATION
A.
Examine the Contract Drawings and specifications in order to insure the completeness of the
work required under this Chapter.
B.
Verify measurements and dimensions at the job site and cooperate in the coordination and
scheduling of the work of this Chapter with the work of related trades, so as not to delay job
progress.
INSTALLATION
A.
Pipe and Fittings
1.
Install pipes and pipe fittings, in accordance with recognized industry practices, which
will achieve permanently leakproof piping systems capable of performing each
indicated service without piping failure. Install each run with minimum joints and
couplings, but with adequate and accessible unions for disassembly and
maintenance/replacement of valves and equipment. Reduce sizes by use of reducing
fittings.
2.
Locate piping runs, except as otherwise indicated, vertically and horizontally; pitch to
drain and avoid diagonal runs wherever possible. Orient horizontal runs parallel with
walls and column lines. Locate runs as shown or described by diagrams, details and
notations or, if not otherwise indicated, run piping in shortest route which does not
obstruct usable space or block access for servicing building and its equipment. Hold
piping close to walls, overhead construction, columns and other structural and
permanent enclosure elements of building; limit clearance to 1/2 inch where furring is
shown for enclosure or concealment of piping, but allow for insulation thickness, if any.
3.
Provide domestic water connections to equipment requiring them from valved outlets
dedicated for this service.
4.
Cap or plug open ended valves for future connections, drains and vents.
5.
Electrical Equipment Spaces: Do not run piping through transformer vaults and other
electrical or electronic equipment spaces and enclosures unless unavoidable. Install
drip pan under piping that must be run through electrical spaces.
6.
Pipe Joints - Mechanical
a.
Make mechanical joints in strict accordance with the recommendation of the
manufacturer using jointing material provided with the pipe.
b.
7.
Clean jointing surfaces thoroughly by wire brushing before assembly. Center
spigot in bell, apply soapy water and slip the gasket over the spigot and into the
bell.
Arrangement and Alignment
a.
Install piping in straight parallel lines.
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8.
b.
Install pipe groups for plumbing and HVAC parallel with pipe of other trades.
c.
Space pipe supports, arrange reducers and pitch piping to allow air to be vented
to system high points and to allow the system to be drained at the low points.
Provide drain valves at the base of each riser, at low points and wherever
required to permit complete draining of lines.
d.
Provide automatic air vents at high points of water lines and wherever required
to allow air to vent from system. Each vent shall have a drain line piped to
nearest indirect waste.
e.
Configure piping with loops, swing joints, anchors, base elbows, etc. as required
and approved to assure proper expansion and contraction of elements of the
piping system without damage to equipment, structure, or piping.
f.
Provide runouts, risers and connections to coils, convectors and fan-coil units
with double swing joint connections to withstand expansion and contraction.
g.
Pipe and fittings furnished as part of factory fabricated equipment are specified
as part of equipment assembly in other chapters.
Fittings - General
a.
Make changes in size and direction of piping with fittings. Do not use miter
fittings, face or flush bushings, close nipples or street elbows.
b.
Make branch connections with tees as directed by the Contracting authority.
c.
Use eccentric reducing fittings or eccentric reducing couplings where required by
the contract documents or where required to prevent pocketing of liquid or
non-condensibles.
d.
Fittings shall be factory manufactured. Shop or field fabricated fittings are not
acceptable.
e.
A nipple shall be considered any piece of pipe 6 inches in length or less.
Threaded nipples shall be extra heavy. Do not use close nipples.
f.
9.
Screw threads shall be cut clean and true; make screw joints tight without
caulking. Caulking is not permitted; a non-hardening lubricant is acceptable.
Bushings shall not be used. Make reductions, otherwise causing objectionable
water or air pockets, with eccentric reducers or eccentric fittings. Ream out pipe
after cutting to remove burrs.
Connections to Equipment and Control Valves
a.
Provide flanges or unions at final connections to equipment and control valves to
facilitate dismantling. Offset connections to permit removal or servicing of
equipment being serviced without dismantling the piping.
b.
Provide automatic valves with a gate valve and a strainer on the inlet side.
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B.
c.
Install supply piping to coils, pumps and other equipment including gate valves
and strainers at line size. Make reductions in size only at the inlet to the control
valve or pump. Install the outlet piping from the control valve at the full size of
the tapping in the equipment served.
d.
Install piping and dirt pockets or mud legs in return lines the full size of the
tapping in the equipment served. Install piping, check valves and strainers in
these return lines beyond the dirt pockets the size of the tapping in the trap.
e.
Provide "quick-fill" connections from domestic water supply to circulating water
systems. Connections shall be 1-1/2 inches minimum and shall have removable
spool pieces or backflow devices in accordance with applicable codes.
Valves
1.
General Requirements
a.
Install valves with handwheels horizontally or vertically upward unless
specifically shown otherwise.
b.
Install valves in accessible locations to facilitate easy removal for repair or
replacement.
c.
Connect threaded end valves installed in copper tubing lines where joints are
ordinarily soldered or brazed to the tubing by means of adaptors screwed into
the valves and soldered or brazed into the tubing.
d.
Valves shall be full line size, unless otherwise indicated.
e.
Globe and check valve discs shall be in accordance with manufacturer's
recommendations for the service.
f.
Valves shall be capable of being repacked while wide open and operating at their
rated pressure.
g.
Where angle valves are indicated or required, use equivalent of specified globe
type.
h.
2.
3.
Provide 5 operating wrenches for each type of valve not equipped with
handwheels.
Except as otherwise indicated, install valves where required for proper operation of
piping and equipment, including valves in branch lines where necessary to isolate
chapters of piping. Locate valves to be accessible and so that separate support can be
provided when necessary. Install valves with stems pointed up, in vertical position
where possible, but in no case with stems pointed downward from horizontal plane
unless unavoidable. Install valve drains with hose-end adapter for each valve that
must be installed with stem below horizontal plane.
Insulation: Where insulation is indicated, install extended-stem valves; arrange in
proper manner to receive insulation.
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4.
Selection of Valve Ends (Pipe Connections): Except as otherwise indicated, select and
install valves with the following ends or types of pipe/tube connections:
a.
Tube Size 2" diameter and Smaller: Soldered-joint valves.
b.
Pipe Size 2" diameter and Smaller: One of the following, at Installer's option:
1)
2)
3)
4)
5)
c.
Pipe Size 2 1/2" diameter and Larger: One of the following, at Contractor's
option, as approved by Contracting authority:
1)
2)
3)
4)
5)
6)
7)
h.
Threaded valves
Grooved-end valves
Butt-welding valves
Socket-welding valves
Flanged valves
Grooved-end valves
Threaded valves
Butt-welding valves
Socket-welding valves
Flanged valves
Wafer valves
Mechanical joint end valves
Installation of Check Valves
1)
2)
3)
Swing Check Valves: Install in horizontal position with hinge pin
horizontally perpendicular to center line of pipe. Install for proper
direction of flow.
Wafer Check Valves: Install between 2 flanges in horizontal or vertical
position; position for proper direction of flow.
Lift Check Valve: Install in piping line only if approved by Contracting
authority with stem vertically upward; position for proper direction of
flow.
3.04
FIELD QUALITY CONTROL
A.
Material Tests and Identification
1.
In addition to the tests required for specific systems, the manufacturer shall test or
guarantee material specified prior to delivery.
2.
Inspect materials for defects. Identify materials with factory applied permanent
stampings or markings designating their conformance with specified requirements.
B.
Hydrostatic Pressure Tests
1.
Test piping including valves, fittings and joints at a pressure equal to at least 1-1/2
times the rated or system pressure, as indicated. Perform the test hydrostatically
unless directed otherwise. Minimum pressure shall be as indicated in Chapter 15110
"Pipe, Fittings and Valves - Application".
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C.
2.
Blank off or remove elements such as traps, instruments, automatic valves, diaphragm
valves, relief valves, pumps or any other equipment which may be damaged by test
pressure. Open, but do not back seat, valves.
3.
Fill the system with water and vent the system at high points to remove air.
4.
Maintain the required test pressure for a sufficient length of time to enable complete
inspection of joints and connections but no less than 24 hours.
5.
Repair leaks or defects uncovered by the tests and retest the system.
6.
After completion of tests, drain the system and blow out and clean it of rust and/or
foreign matter. Clean strainers, valves and fittings of dirt, filings and debris.
7.
Do not insulate or conceal piping until completion of tests and approval of the results.
8.
Perform tests in the presence of, and to the satisfaction of, the Contracting authority.
Testing of Piping - General
1.
Test piping, mains, and joints for leaks, before any piping is enclosed, insulated, or
concealed in any way. Follow specific procedures, if given, in the other specification
chapters.
2.
Refrigerant piping. Test for leaks with a halide torch. Recharge each system as
necessary after testing.
3.
Provide temporary equipment for testing, including pump and gauges. Test piping
system before insulation is installed, wherever feasible, and remove control devices
before testing. Test each natural chapter of each piping system independently, but do
not use piping system valves to isolate chapters where test pressure exceeds valve
pressure rating. Fill each chapter with water and pressurize for indicated pressure and
time.
6.
a.
Required minimum test period is 24 hours.
b.
Test runs at pressures listed except where fittings are lower Class or pressure
rating.
c.
Test each piping system at 150 percent minimum of operating pressure
indicated, but not less than 25 psi test pressure.
d.
Observe each test chapter for leakage at end of test period. Test fails if leakage
is observed or if pressure drop exceeds 5 percent of test pressure.
Repair piping system chapters which fail required piping test by disassembly and
reinstallation, using new materials to extent required to overcome leakage. Do not use
chemicals, stop-leak compounds, mastics, or other temporary repair methods.
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7.
3.05
Drain test water from piping systems after testing and repair work has been
completed.
CLEANING, FLUSHING, INSPECTING AND DISINFECTION
A.
Clean exterior surfaces of installed piping systems of superfluous materials, and prepare for
application of specified coatings, if any. Flush out piping systems with clean water before
proceeding with required tests. Inspect each run of each system for completion of joints,
supports and accessory items.
B.
Disinfect water mains and water service piping in accordance with AWWA C601.
C.
Cleaning - Piping Systems
D.
1.
Plug open ends of piping, valves and equipment except when actual work is being
performed, to minimize accumulation of dirt and debris.
2.
After installation is complete, place temporary screens at connections to equipment
and at automatic control valves where permanent strainers are not provided.
3.
Prior to the performance of tests, flush out piping that is to receive a hydrostatic test
with clean water. Blow out piping that is to be air or gas pressure tested with
compressed air.
4.
Remove dirt and debris collected at screens, strainers and other points from the
system.
5.
After hydrostatic testing, blow out fuel oil lines with compressed air until dry.
6.
Where noted, flush out fuel oil pipe lines with clean oil after lines are dry.
Supplemental Cleaning - Water
1.
After the piping system is installed, tested and flushed, completely clean the system to
remove organics, rust and other foreign matter and provide protection of the metal
surfaces in preparation for permanent water treatment.
2.
Use a cleansing agent which will not in any way interact with any of the materials in
the system to produce corrosion, form deposits, weaken, reduce the life or in any way
have a detrimental effect on any system components.
3.
Fill the system with clean water and add sufficient cleaning preparation to provide a
concentration adequate to perform complete cleaning. Add the cleaning preparation
at a point which will assure good mixing and complete dispersal throughout the
system.
4.
Provide temporary receivers or drums to accommodate any foam that may form.
5.
Circulate the mixture of cleanser and water for a sufficient length of time to complete
the cleaning.
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6.
E.
Drain the system, flush with clean water, clean strainers and screens and refill the
system.
Disinfection-Potable Water Systems
1.
Disinfect new or repaired potable water systems prior to use whenever samples from
the system show any contamination after making a bacteriological examination. Take
samples as required by the Department of Health. Follow the method as prescribed by
the Department of Health, or where no method is prescribed by the Department of
Health, by the following:
a.
Flush the pipe system with clean potable water until no dirty water appears at
the outlets.
b.
Fill the system or part thereof with a water-chlorine solution containing at least
50 ppm of chlorine and valve off the system or part thereof and allow to stand
for 24 hours or, fill the system or part thereof with a water-chlorine solution
containing at least 200 ppm of chlorine and allow to stand for 3 hours.
c.
Following the prescribed standing time, flush the system with clean potable
water until no excess chlorine remains in the water coming from the system.
d.
Repeat the procedure if it is shown that contamination still persists in the
system.
F.
Valve Adjustment: After testing and putting piping systems into service, but before final
testing, adjusting, and balancing, inspect each valve for possible leaks. Adjust or replace
packing to stop leaks; replace valve if leak persists.
G.
Cleaning: Clean factory-finished surfaces. Repair any marred or scratched surfaces with
manufacturer's touchup paint.
I.
Gaskets: Gaskets for HVAC system shall be as directed by the Contracting authority.
END OF CHAPTER
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R.O. WATER TREATMENT PLANT
1.01 Scope of Work
The contractor shall supply and install a complete Water Reverse Osmosis Water Treatment
Plant including all required equipment, pipe work and controls to have a complete and operable
system to the approval of the Contracting authority FOR 4 SCRUBBLERS.
1.02 Drawings
The drawings are essentially diagrammatic and include general layouts and typical details of
various systems to be installed. The contractor shall prepare all the Contracting authoritying
drawings, calculations and shop drawings and submit for approval. The contractor shall provide
the following:
- Process flow + PID Diagrams
- General Arrangement Drawings
- Single Line Electric Diagrams
- Catalogue cuts of all purposed equipment
- Operation and maintenance manuals in 3 sets
1.03 Tests
Contractor shall carry out as necessary and as directed by the Contracting authority to
determine the quality of treated water and to demonstrate that equipment meets the design
requirement noted on drawing and a specified here in with. Contractor shall test all equipment
and controls to the satisfaction of the Contracting authority.
1.04 Installation and Commissioning
Contractor shall provide Specialized Contracting authority from equipment manufacturer to
supervise installation and start-up, make necessary adjustments, calibrations and tests and
instruct and train the Employer´s personnel for a period of two weeks from the preliminary
handover date.
1.05 Scope of Supply
Mechanical contractor shall design, supply, deliver and install the Brackish Water R.O. Water
Treatment Plant all in accordance with this specifications and to the approval of the Contracting
authority. R.O. plant shall be manufactured in USA by an approved specialized company.
The Brackish Water R.O. Water Treatment Plant will consist but not limited to the following
equipment:
-
Hypochlorite Dosing Set
Coagulant Dosing Set
Static Mixer
Booster/Backwash Pumps
Multimedia Filtration
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-
Activated Carbon Filtration
Bisulfite Dosing Set
Acid Dosing Set
Antiscalant Dosing Set
Cartridge Filtration
High Pressure Pumps
R.O. Train
pH Adjustment Dosing Set
Post Chlorination Dosing Set
Instruments
Motor Controller
Cleaning System
Contractor to provide all additional equipment and chemicals to have a complete and operational
system.
Contractor to provide 3 years maintenance of the R.O. Plant included in the price of the R.O. plant.
END OF CHAPTER
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SUPPORTS AND ANCHORS
PART 1 - GENERAL
1.01
SUMMARY
A.
Provide labor, materials, equipment and services, and perform operations required for
complete installation of Piping and Fittings and related work as indicated on the drawings
and specified herein.
B.
Work Included: The work shall include, but not be limited to, the following:
C.
1.02
1.
Extent of supports and anchors required by this chapter is indicated on drawings
and/or specified in other Division 15 chapters.
2.
Supports and anchors shall be of approved type, selected from an approved
manufacture. No field fabrication is acceptable unless otherwise advised by the
Contracting authority.
3.
Supports and anchors furnished as part of factory-fabricated equipment, are specified
as part of equipment assembly in other Division 15 chapters.
Related Work Specified Elsewhere
1.
Basic Mechanical Requirements - Chapter 15010
2.
Basic Mechanical Materials and Methods - Chapter 15050
QUALITY ASSURANCE
A.
Materials and work shall conform to the latest edition of reference specifications and
industry standards listed below and specified herein and to applicable codes and
requirements of local authorities having jurisdiction, whichever is more stringent.
1.
Code Compliance: Comply with applicable plumbing codes pertaining to product
materials and installation of supports and anchors.
-
1.03
Welding Process
NFPA Compliance
EN Compliance
AWS D1.1 Structural Welding Code-Steel
SUBMITTALS
A.
Submit the following :
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1.
Shop Drawings: Submit shop drawings for work specified herein for approval. Shop
drawings shall show manufacturer's assembly-type shop drawings for each type of
support and anchor, indicating dimensions, weights, required clearances, and
methods of assembly or components.
2.
Product Data
a.
b.
1.04
Submit copies of manufacturer's latest published literature for materials
specified herein for approval; obtain approval before ordering materials.
Data shall include manufacturer's technical product data, including installation
instructions for each type of support and anchor. Submit pipe hanger and
support schedule showing Manufacturer's figure number, size, location, and
features for each required pipe hanger and support.
DELIVERY, STORAGE AND HANDLING
A.
Exercise proper care in the handling of work so as not to injure the finished surfaces, and
protect the work from damage after it is in place.
PART 2 - PRODUCTS
2.01
GENERAL
Material shall be product of approved manufacture. No field fabrication is acceptable. Design of
support system shall be done by the approved support manufacturer including submittal of all
necessary calculations for the Contracting authority approval.
2.02
MANUFACTURED UNITS
A.
Hangers, Supports and Components: factory fabricated according to MSS SP-58.
1. Components include galvanized coating where installed for piping and equipment that
will not have a field applied finish.
2. Pipe attachments include nonmetallic coating for electrolytic protection where
attachments are in direct contact with copper tubing.
B.
Thermal Hanger Shield Inserts : (690 kPa) average compressive strength, waterproofed
calcium silicate, encased with sheet metal shield. Insert and shield cover entire
circumference of pipe and are of length indicated by manufacturer for pipe size and
thickness of insulation.
C.
Powder Actuated Drive Pin Fasteners: Powder actuated type, drive pin attachments with
pull out and shear capacities appropriate for supported loads and building materials where
used. Fasteners for fire protection systems include UL listing and FM approval.
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D.
2.03
Mechanical Anchor Fasteners: Insert type attachments with pull out and shear capacities
appropriate for supported loads and building materials where used. Fasteners for fire
protection systems include UL listing and FM approval.
MISCELLANEOUS MATERIALS
A.
B.
C.
D.
Structural Steel : (ASTM A 36M), steel plates, shapes, and bars, black and galvanized.
Bolts and Nuts : ASME B18.10 or ASTM A 183, steel, hex head, track bolts and nuts.
Washers : ASTM F 844, steel, plain, flat washers.
Grout : ASTM C 1107, Grade B, nonshrink, nonmetallic.
1. Characteristics include post hardening, volume adjusting, dry, hydraulic cement type
grout that is nonstaining, noncorrosive, nongaseous and is recommended for both
interior and exterior applications.
2. Design Mix : (34.5 Mpa), 28 day compressive strength.
3. Water : Potable.
4. Packaging : Premixed and factory packaged.
PART 3 - EXECUTION
3.01
EXAMINATION
A.
3.02
Examine conditions at the job site where work of this chapter is to be performed to insure
proper arrangement and fit of the work. Start of work implies acceptance of job site
conditions.
PREPARATION
A.
Examine the Contract Drawings and specifications in order to insure the completeness of
the work required under this Chapter. Provide supplementary parts necessary to complete
work, though not specifically indicated on Drawings or specified herein.
B.
Verify measurements and dimensions at the jobsite and cooperate in the coordination and
scheduling of the work of this Chapter with the work of related trades, so as not to delay job
progress.
C.
Proceed with installation of hangers, supports and anchors only after required building
structural work has been completed in areas where the work is to be installed. Correct
inadequacies including (but not limited to) proper placement of inserts, anchors and other
building structural attachments.
D.
Prior to installation of hangers, supports, anchors and associated work, Contractor shall
meet at project site with installer of each component of associated work, inspection and
testing agency representatives (if any), installers of other work requiring coordination with
work of this chapter and Contracting authority for purpose of reviewing material selections
and procedures to be followed in performing the work in compliance with requirements
specified.
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3.03
INSTALLATION
A.
3.04
Installation of Hangers and Supports
1.
Comply with MSS SP-69 and SP-89 for the installation of hangers, supports, clamps
and attachments.
2.
Install hangers, supports, clamps and attachments to support piping properly from
building structure. Arrange for grouping of parallel runs of horizontal piping to
support together on trapeze type hangers where possible. Install supports as directed
by the Contracting authority. Where supporting piping of various sizes together by
trapeze hangers, space hangers for smallest pipe size or install intermediate supports
for smaller diameter pipe. Do not use wire or perforated metal to support piping, and
do not support piping from other piping.
3.
Install hangers and supports complete with necessary inserts, bolts, rods, nuts,
washers and other accessories. Except as otherwise indicated for exposed continuous
pipe runs, install hangers and supports of same type and style as installed for adjacent
similar piping.
4.
Install support for fire protection system independent from other piping.
ADJUSTING AND CLEANING
A.
Hanger Adjustment: Adjust hangers so as to distribute loads equally on attachments.
B.
Support Adjustment: Provide grout under supports so as to bring piping and equipment to
proper level and elevations.
C.
Cleaning: Clean factory-finished surfaces. Repair any marred or scratched surfaces with
manufacturer's touchup paint.
END OF CHAPTER
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SUBMERSIBLE PUMPS
PART 1 - GENERAL
1.01
A.
B.
DESCRIPTION OF WORK
Extent of work: The extent of pump work is indicated on drawings and in schedules, and by
requirements of this chapter.
The application of general use centrifugal type pumps required include:
1.
1.02
A.
Submersible pumps.
QUALITY ASSURANCE
Electrical Standards: Provide electric motors and products which have been listed and labeled
by Underwriters Laboratories and comply with National Electrical Manufacturers Association
(NEMA) standards.
B.
Certification, Pump Performance, Provide pumps whose performance under specified
conditions, is certified by the manufacturer. Contractor to submit certificate of origin with
shipment certificate to the Contracting authority.
C.
All pumps shall be assembled in country of origin. Local assembly is not acceptable.
D.
All pumping units shall be designed and built for twenty-four hour continuous service at any and
all points within the specified range of operation, without overheating, without cavitation,
without excessive vibration or strain and requiring only that degree of maintenance generally
accepted as normal for the specific type of pump required. All parts and components of all
pumping units shall be designed and built for interchange ability so that replacement parts may
be installed without any additional fitting or machining. Upon request, or if hereafter specified,
the manufacturer shall submit evidence that the tolerances and finishes on the detail drawings
so permit, and the manufacturer's shop is equipped with the necessary machinery, jigs, fixtures
and gauges to assure such interchange ability.
E.
Failure to successfully comply with the requirements of the previous paragraphs will constitute
grounds for disqualification of the pump manufacturer. Poor performance of similar pumping
equipment now in operation under the specified conditions of service and pump rating
constitute grounds for disqualification of the pump manufacturer, supplier or both, unless such
poor performance has been corrected.
1.03
A.
B.
SUBMITTALS
Manufacturer's Data: Submit manufacturer's data on pumps, including but not limited to, pump
characteristics and performance curves.
Pump Characteristics Curves:
1.
Submit for each pump specified, copies of the characteristic curves of the proposed pump.
For each pump (or pumping unit where overall efficiency is specified) the following
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characteristic curves shall be shown as ordinates plotted against the rate of flow of the
pump:
2.
C.
1.04
A.
B.
a)
Total Dynamic Head.
b)
Pump Efficiency.
c)
Brake Horsepower.
d)
Net Positive Suction Head.
e)
Power Input to Electric Drive Motor.
f)
Overall Efficiency of Pumping Unit.
g)
Total Inertia.
Indicate the limits of the range of rate of flow at which the pump can successfully operate
on such curve when the operable range differs from the complete range shown. Approval
of the characteristic pump curve shall in no way be construed to be permissive to proceed
with the manufacture of the pump. Upon receipt of an approved pump curve, the
Contractor shall submit, if he has not previously done so, all other drawings, material lists
and other information specified, requested and/or necessary to coordinate the pumping
installation with the balance of the work and to show complete compliance with all details
of the Contract Documents.
Shop Drawings:
1.
Submit drawings and information necessary for final design of foundations, structural
supports, connected piping and valves, pump drip and drainage piping, electrical
connections, starting and protective equipment and auxiliary equipment.
2.
Submit for all pumping units, a dimensioned and scaled assembly outline drawing or
drawings of the complete pump, drive and all associated equipment furnished. Such
drawing or drawings shall show plan, elevation and any other view or chapter requested.
3.
For all pumping units a scaled cross-chapteral drawing of the assembled pump showing
full details and materials of construction shall be submitted for approval. For pumping
units powered by motors rated at 20 horsepower or less, catalog cuts may be submitted
to supplement the outline and cross furnished with steel base plates, sub-bases and
similar components, detailed dimensioned drawings giving full information thereon shall
be submitted for approval. Steel components shall be at least 9.5 mm thick and no
undrained pockets will be permitted.
PRODUCT DELIVERY, STORAGE AND HANDLING
Deliver and store pump products in factory-wrapped packaged which properly protect pumps
against weather, dirt and damage.
Handle pumps carefully to avoid damage to motors, components, enclosures and finish. Do not
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install damaged units, replace and return damaged units to pump manufacturer.
PART 2 - PRODUCTS
2.01
Submersible SEWAGE Pumps
Supply and install submersible sewage pumps one duty and one stand by complete with level
control switches & accessories as shown on the Drawings and of indicated capacities and heads.
The pump and motor housing shall form a compact integral unit and shall be of the completely
submersible type.
END OF CHAPTER
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MECHANICAL IDENTIFICATION
PART 1 - GENERAL
1.01
SUMMARY
A.
Provide labor, materials, equipment and services, and perform operations required for
complete installation of Mechanical Identification and related work as indicated on the
drawings and specified herein.
B.
Work Included: The work shall include, but not be limited to, the following:
1.
C.
1.02
Related Work Specified Elsewhere
1.
Basic Mechanical Requirements - Chapter 15010
2.
Basic Mechanical Materials and Methods - Chapter 15050
3.
Mechanical identification furnished as part of factory-fabricated equipment, is
specified as part of equipment assembly in other Division 15 chapters.
4.
Refer to other Division 15 chapters for identification requirements at central station
mechanical control center; not work of this chapter.
5.
Refer to Division 16 chapters for identification requirements of electrical work; not
work of this chapter.
QUALITY ASSURANCE
A.
1.03
Extent of mechanical identification work required by this chapter is indicated on
drawings and/or specified in other Division 15 chapters.
Materials and work shall conform to the latest edition of reference specifications and
industry standards listed below and specified herein and to applicable codes and
requirements of local authorities having jurisdiction, whichever is more stringent.
SUBMITTALS
A.
Submit the following in accordance with the requirements specified under Submittals in
Chapter 15010.
1.
Samples: Submit samples of materials specified herein for approval; obtain approval
before ordering materials. Sample shall include samples of each color, lettering style
and other graphic representation required for each identification material or system.
Provide mockup type sample installation for review and approval by Contracting
authority.
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2.
Product Data: Submit copies of manufacturer's latest published literature for
materials specified herein for approval; obtain approval before materials are
delivered to the site. Data shall include manufacturer's technical product data and
installation instructions for each identification material and device required.
3.
Maintenance Data: Along with product data and schedules, submit manufacturers in
maintenance manuals for maintaining identification work specified herein.
PART 2 - PRODUCTS
2.01
MATERIALS
A.
Mechanical Identification Materials: Provide manufacturer's standard products of
categories and types required for each application as referenced in other Division 15
chapters. Where more than single type is specified for application, selection is Contracting
authority's option, but provide single selection for each product category.
B.
Plastic Pipe Markers
1.
Snap-On Type: Provide manufacturer's standard preprinted, semi-rigid snap-on,
color-coded pipe markers as directed by the Contracting authority
2.
Pressure-Sensitive Type: Provide manufacturer's standard preprinted, permanent
adhesive, color-coded, pressure-sensitive vinyl pipe markers with arrow tape banding
both ends to indicate flow direction as directed by the Contracting authority
3.
Insulation: Furnish 1" thick molded fiberglass insulation with jacket for each plastic
pipe marker to be installed on uninsulated pipes subject to fluid temperatures of 125
degrees F or greater. Cut length to extend 2" beyond each end of plastic pipe marker.
4.
Small Pipes: For external diameters less than 6" (including insulation if any), provide
full-band pipe markers, extending 360 degrees around pipe at each location; fasten by
one of the following methods:
5.
a.
Snap-on application of pretensioned semi-rigid plastic pipe marker.
b.
Taped to pipe (or insulation) with color-coded plastic adhesive arrow tape, not
less than 3/4" wide; full circle at both ends of pipe marker, lap tape 1-1/2".
Large Pipes: For external diameters of 6" and larger (including insulation if any),
provide either full-band or strip-type pipe markers, but not narrower than 3 times
letter height (and of required length); fasten by one of the following methods:
a.
Laminated or bonded application of pipe marker to pipe (or insulation).
b.
Tape to pipe (or insulation) with color-coded plastic adhesive arrow tape, not
less than 1-1/2" wide; full circle at both ends of pipe marker, lap tape 3".
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c.
6.
Lettering: Manufacturer's standard preprinted nomenclature which best describes
piping system in each instance, as selected by Contracting authority in cases of
variance with name as shown or specified.
7.
Lettering
1.
a.
Comply with piping system nomenclature as specified, scheduled or shown, and
abbreviate only as necessary for each application length.
b.
Arrows: Print each pipe marker with arrows indicating direction of flow, either
integrally with piping system service lettering (to accommodate both
directions), or as separate unit of plastic.
C.
Plastic Duct Markers
Provide manufacturer's standard laminated plastic, color coded duct markers.
Conform to the following color code:
a.
b.
c.
d.
e.
2.
E.
Green: Cold air.
Yellow: Hot air.
Yellow/Green: Supply air.
Blue: Exhaust, outside, return, and mixed air.
For hazardous exhausts, use colors and designs recommended by ANSI A13.1.
Nomenclature: Include the following:
a.
b.
c.
d.
e.
D.
Strapped-to-pipe (or insulation) application of semi-rigid type, with
manufacturer straps or powerlock.
Direction of air flow.
Duct service (supply, return, exhaust, etc.)
Duct origin (from).
Duct destination (to).
Design cfm.
Plastic Tape
1.
Provide manufacturer's standard color-coded pressure-sensitive (self-adhesive) vinyl
tape, not less than 3 mils thick.
2.
Width: Provide 1-1/2" wide tape markers on pipes with outside diameters (including
insulation, if any) of less than 6", 2-1/2" wide tape for larger pipes.
3.
Color: As directed by the Contracting authority
Valve Tags
1.
Brass Valve Tags: Provide (19) gauge polished brass valve tags with black filled,
stamp-engraved piping system abbreviation in (1/4") high letters and sequenced valve
numbers (1/2") high, and with (5/32") hole for fastener.
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a.
b.
c.
d.
Provide (1-1/2") diameter tags, except as otherwise indicated.
Fill tag engraving with black enamel.
Provide plain stamped tags.
Provide color anodized and engraved aluminum tags.
2.
Etched Aluminum Valve Tags: Provide manufacturer's standard .04" thick etched
aluminum valve tags, with piping system abbreviation in (1/4") high letters and
sequenced valve numbers (1/2") high, and with (5/32") hole for fastener. Provide
(1-1/2") square black tags with white lettering, except as otherwise indicated.
3.
Plastic Valve Tags: Provide manufacturer's standard solid plastic valve tags with
printed enamel lettering, with piping system abbreviation in approximately (3/16")
high letters and sequenced valve numbers approximately (3/8") high, and with
(5/32") hole for fastener. Provide (1-1/8") square white tags with black lettering.
4.
Valve Tag Fasteners: Provide manufacturer's standard solid brass (plated steel) chain
(wire link or beaded type), or solid brass S-hooks of the sizes required for proper
attachment of tags to valves; manufacture specifically for that purpose.
5.
Access Panel Markers: Provide manufacturer's standard 1/16" thick engraved plastic
laminate access panel markers, with abbreviations and numbers corresponding to
concealed valve. Include 1/8" center hole to allow attachment.
F.
Valve Schedule Frames: For each page of valve schedule, provide glazed display frame, with
screws for removable mounting on masonry walls. Provide frames of extruded aluminum,
with SSB-grade sheet glass.
G.
Engraved Plastic-Laminate Signs
1.
2.
H.
Provide engraving stock melamine plastic laminate in the sizes and thicknesses
indicated, engraved with engraver's standard letter style of the sizes and wording
indicated, black with white core (letter color) except as otherwise indicated; punch for
mechanical fastening except where adhesive mounting is necessary because of
substrate.
a.
Thickness: 1/16", except as otherwise indicated.
b.
Thickness: 1/8", except as otherwise indicated.
c.
Thickness: 1/16" for units up to 20 square" or 8" length; 1/8" for larger units.
Fasteners: Self-tapping stainless steel screws, except contact-type permanent
adhesive where screws cannot or should not penetrate the substrate.
Lettering and Graphics
1.
Coordinate names, abbreviations and other designations used in mechanical
identification work, with corresponding designations shown, specified or scheduled.
Provide numbers, lettering and wording as indicated or, if not otherwise indicated, as
recommended by manufacturers or as required for proper identification and
operation/maintenance of mechanical systems and equipment.
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PART 3 - EXECUTION
3.01
EXAMINATION
A.
3.02
3.03
Examine conditions at the job site where work of this chapter is to be performed to insure
proper arrangement and fit of the work. Start of work implies acceptance of job site
conditions.
PREPARATION
A.
Examine the Contract Drawings and specifications in order to insure the completeness of
the work required under this Chapter.
B.
Cooperate in the coordination and scheduling of the work of this Chapter with the work of
related trades, so as not to delay job progress.
C.
Where applying identification to surfaces which require insulation, painting or other
covering or finish, including valve tags in finished mechanical spaces, install identification
after completion of covering and painting. Install identification prior to installation of
acoustical ceilings and similar removable concealment.
INSTALLATION/APPLICATION
A.
B.
Ductwork Identification
1.
Identify air supply, return, exhaust, intake and relief ductwork with duct markers; or
provide stenciled signs and arrows, showing ductwork service and direction of flow, in
black or white (whichever provides most contrast with ductwork color).
2.
In each space where ductwork is exposed, or concealed only by removable ceiling
system, locate signs near points where ductwork originates or continues into
concealed enclosures (shaft, underground or similar concealment), and at 30 feet
spacings along exposed runs.
3.
Provide duct markers or stenciled signs on each access door in ductwork and
housings, indicating purpose of access (to what equipment) and other maintenance
and operating instructions, and appropriate safety and procedural information.
4.
Where access doors are concealed above acoustical ceilings or similar concealment,
install plasticized tags for identification in lieu of specified signs, at Contracting
authority's option.
Piping System Identification
1.
Install pipe markers of one of the following types on each system indicated to receive
identification, and include arrows to show normal direction of flow:
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2.
a.
Plastic pipe markers, with application system as indicated under"Materials" in
this chapter. Install on pipe insulation segment where required for hot
non-insulated pipes.
b.
Stenciled markers, black or white for best contrast, wherever continuous
color-coded painting of piping is provided.
Locate pipe markers and color bands as follows wherever piping is exposed to view in
occupied spaces, machine rooms, accessible maintenance spaces (shafts, tunnels,
plenums) and exterior non-concealed locations.
a.
Near each valve and control device.
b.
Near each branch, excluding short takeoffs for fixtures and terminal units; mark
each pipe at branch, where there could be question of flow pattern.
c.
Near locations where pipes pass through walls or floors/ceilings, or enter
non-accessible enclosures.
d.
At access doors, manholes and similar access points which permit view of
concealed piping.
e.
Near major equipment items and other points of origination and termination.
f.
Space intermediately at maximum spacing of 50 feet along each piping run,
except reduce spacing to 25 feet or less in congested areas of piping and
equipment.
g.
C.
D.
On piping above removable acoustical ceilings, except omit intermediately
spaced markers.
Valve Identification
1.
Provide valve tag on every valve, cock and control device in each piping system;
exclude check valves, valves within factory-fabricated equipment units, plumbing
fixture faucets, convenience and lawn-watering hose bibs, and shutoff valves at
plumbing fixtures, HVAC terminal devices and similar rough-in connections of end-use
fixtures and units. List each tagged valve in valve schedule for each piping system.
Prepare and mount valve tagging schedules for the following systems:
2.
Mount valve schedule frames and schedules in machine rooms where indicated or, if
not otherwise indicated, where directed by Contracting authority. Where more than
one major machine room is shown for project, install mounted valve schedule in each
major machine room, and repeat only main valves which are to be operated in
conjunction with operations of more than single machine room.
Mechanical Equipment Identification
1.
Install engraved plastic laminate sign or plastic equipment marker on or near each
major item of mechanical equipment and each operational device, as specified herein
if not otherwise specified for each item or device. Provide signs for the following
general categories of equipment and operational devices:
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3.04
a.
Main control and operating valves, including safety devices and hazardous units
such as gas outlets.
b.
Meters, gauges, thermometers and similar units.
c.
Pumps, compressors, condensers and similar motor-driven units.
d.
Heat exchangers, coils, evaporators and similar equipment.
e.
Fans, blowers, primary balancing dampers and mixing boxes.
f.
Packaged HVAC central-station and zone-type units.
g.
Tanks and pressure vessels.
h.
Strainers, filters, water treatment systems and similar equipment.
2.
Optional Sign Types: Where lettering larger than 1" height is needed for proper
identification, because of distance from normal location of required identification,
stenciled signs may be provided in lieu of engraved plastic, at Contracting authority's
option.
3.
Lettering Size: Minimum 1/4" high lettering for name of unit where viewing distance
is less than 2 feet, 1/2" high for distances up to 6 feet, and proportionately larger
lettering for greater distances. Provide secondary lettering 2/3 to 3/4 of size of
principal lettering.
4.
Text of Signs: In addition to name of identified unit, provide lettering to distinguish
between multiple units, inform operator of operational requirements, indicate safety
and emergency precautions, and warn of hazards and improper operations.
5.
Optional Use of Plasticized Tags: At Contracting authority's option, where equipment
to be identified is concealed above acoustical ceiling or similar concealment,
plasticized tags may be installed within concealed space to reduce amount of text in
exposed sign (outside concealment).
ADJUSTING AND CLEANING
A.
Relocate any mechanical identification device which has become visually blocked by work of
this division or other divisions.
B.
Clean face of identification devices, and glass frames of valve charts.
END OF CHAPTER
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NOISE, VIBRATION & SEISMIC CONTROLS
PART 1 - GENERAL
1.01
WORK INCLUDED
A.
1.02
Sound Noise Levels
Attenuators
Vibration Control
Machinery Bases
RELATED WORK
A.
Division 15 Mechanical.
1.03
SYSTEM DESCRIPTION
A.
General
1.
Acoustic and vibration transmission control shall be applied on all work to obtain
the limits specified.
2.
Work included :
a.
All duct systems and associated equipment will be attenuated to prevent
both transmission noise and breakout from the equipment at any part of
the system.
b.
All rotating plant will be adequately isolated from the main structure of
the building to prevent the transmission of vibration.
c.
All pipework will be suitably installed to prevent undue strain upon
equipment it is connected to and isolation of rotating equipment is also
required to prevent the transmission of vibration.
3.
All systems and equipment shall be selected and installed to meet the required
noise criteria specified herein. Where items are not covered then ASHRE Guide
shall be taken as the reference.
4.
Noise and vibration control study and installation shall be done by a specialized
company . All Contracting authoritying studies and material selection shall be
submitted to the Contracting authority for approval.
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B.
Noise Control Generally
1.
2.
System Description
a.
Systems shall be installed on the basis of noise control to produce the
results set out in the schedule below.
b.
The equipment provided by the Contractor shall be designed and
arranged to maintain these criteria.
c.
Where sound characteristics of selected equipment gives excessive noise
then attenuation treatment shall be applied to achieve the desired
criteria. Where silencers are scheduled on the drawings the Contractor
shall be responsible for any adjustment in size required the meet the
desired criteria, based on equipment finally selected.
Noise Criteria (NC) level
The maximum acceptable noise level for the various areas is as follows:
Location
Lobby & Public Areas
Fittness Center
Bed Rooms
Kitchen & Laundry
Offices
Toilets, Utility Rooms
Parking
Specified Level
NC 30
NC 30
NC 30
NC 35
NC 30
NC 35
NC 40
3.
4.
In-Duct Attenuation
a.
C.
Purpose made attenuators shall be provided in the positions indicated on
the drawings. The attenuators shall reduce the sound level produced by
the fan to an acceptable level in the occupied spaces. The attenuator shall
have adequate strength and cohesion to resist erosion by the air flow and
shall not produce dust. The acoustic infill shall be free from odour and
proof against rot, damp, vermin. Adhesive shall be compatible with the
sound absorbent material and shall be non - flammable.
Vibration Control Generally
1.
System Description
a.
All equipment and plant shall be so designed that it does not, in itself,
vibrate excessively, particularly if its natural frequency is below 20 Hz. The
apparatus shall be mounted upon resilient mountings such as cork, rubber
or springs, loaded close to the maximum and designed to transmit the
least energy to the base without permitting excessive oscillation of
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machines.
1.04
b.
Select equipment with minimum out-of-balance forces, use control
devices to isolate equipment, piping and ducting as necessary.
c.
All rotating parts of equipment shall be balanced to best commercial
tolerances before leaving the factory.
REFERENCES
A.
The latest editions of the following standards shall apply :
1.
American Society for Testing and Materials (ASTM )
a.
2.
1.05
SUBMITTALS
A.
Product Data
1.
ASHRAE Handbook : Systems - Chapter 35 Sound and Vibration Control. This shall
be referred to for items not specifically covered in this chapter.
Description literature for each of the actual proposed equipment to be used
including:
a.
b.
c.
d.
e.
f.
g.
h.
B.
ASTM E477 : Testing Duct Liner Materials and prefabricated Silencers for
Acoustical and Airflow performance.
Capacity.
Insertion Losses.
Pressure Losses.
Fluid Flows.
Test Reports.
Certificates of approval.
Deflection curves.
Type, styles, material and finishes of each isolator.
Shop Drawings
1.
Shop drawing for each of the actual proposed equipment shall include the
following:
a.
b.
c.
d.
e.
f.
Working or manufacturing drawings.
Design Calculations.
Installation details.
Accessories available indicating those included.
Pictures.
Seismic restraint detail.
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g.
1.06
Vibration isolation base detailed.
QUALITY ASSURANCE
A. Professional Contracting authority Qualifications : A professional Contracting authority who is
legally qualified to practice in the Jurisdiction where the Project is located and who is experienced in
providing Contracting authoritying services of the kind indicated. Contracting authoritying services are
defined as those performed for installations of vibration isolation bases and seismic restraints that are
similar to those indicated for this Project in material, design, and extent.
1.07
PROJECT CONDITION
A.
B.
Project seismic Zone 2B with a zone factor of 0.20G.
Building importance factor 1.
PART 2 - PRODUCTS
2.01
ATTENUATORS
A.
Construction
The Contractor shall supply and fix acoustic insulation and noise attenuator units where
necessary to reduce the air borne noise transmission through the distribution duct system, so
that the specified noise criteria levels are satisfied.
-
Attenuator Units
The attenuator units shall be inserted in the ducts where they pass through the mechanical
room walls, the gap between the wall and attenuator being packed with felt to form an air
tight seal. However where this is not possible, the attenuator shall be fitted in the duct
between the fan and the mechanical room wall with the duct between the silencer and the
wall acoustically lagged to prevent noise re-entry. Attenuators shall consist of attenuator
splitters which are assembled in one attenuator casing. Splitter case shall be made from
galvanized sheet steel: absorption material moisture repellent and abrasion proof up to
approx. 3600 fpm. (18 m/s) air velocity density 65 kg/m3 mineral wool, with absorption
degree at 250 Hz, Alpha 1, control plates on surface of splitters is made from galvanized steel
sheet.
Sound attenuator casing shall be made from galvanized sheet steel, with pre-drilled angle
flanges.
Attenuators or splitters of large cross chapter or length can be manufactured in modular
chapter as required for ease of site handling.
-
Internal Acoustic Lining of Ducts
-
Furnish and install duct lining wherever shown on Drawings.
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-
Where it is possible to achieve the required attenuation by lining the interior of duct runs,
this may be accomplished by applying one inch thick lining to the inside of the ducts.
-
Lining for rectangular ducts shall be semi-rigid fibrous glass blanket and for round ducts shall
be flexible fibrous glass blanket, both with special surface treatment and for apparatus
casings, large plenums, and masonary air shafts shall be rigid coated fibrous glass board.
-
Acoustic insulation shall be suited to the atmosphere in which it is to operate, and shall be
incombustible or self-extinguishing nonflame spread grade, vermin proof and adequately
fixed to ducting or mechanical room walls. Liner density shall be 3 lbs. per cu. ft and shall
comply with NFPA requirements.
-
Duct liners shall be applied with both mechanical fasteners and an adhesive. Adhesives
must be both water and fire resistant.
Mechanical fasteners could be either of the welded pin or impact pin types. The length of each
pin shall be enough to accommodate the specified liner thickness. Washers on top of the pins
shall retain the liner.
-
B.
Sound Compressor Enclosure Units
Each enclosure is made of:
-
Galvanized steel sheets of 1.25mm thickness.
-
Needed access door for maintenance.
-
On the interior walls of the compressors, sound insulation rebounded PUR foam,
PO60 in 40mm thickness is placed.
-
The enclosure comes also with a sound absorption PUR foam in 40mm thickness
covered with a polyester non-woven covering for good mechanical surface protection.
This covering is petrol - and - oil resistant, waterproof impregnated and UV-resistant.
This sound absorption is placed on the floor of the enclosure. Degree of absorption αs
at 250Hz = 0.88
Performances
1.
Internal lining of ductwork shall be applied where necessary to achieve the required level.
The lining shall be 25 mm thick and 32kg/m3 density otherwise as described for attenuators
above with minimum thermal conductivity of 0.055 W/mC.
2.
Where internal duct lining is to be applied the duct sheet metal sizes shall be increased to
compensate and thus maintain the net free airway sizes noted on the drawings as duct sizes.
3.
Internal duct lining shall have a factory bonded PVC coating fixed to the insulation with a
synthetic rubber base adhesive which is flame retardant when dry.
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2.02
MANUFACTURERS
A.
2.03
Available manufacturers : subject to compliance with requirements, manufacturers
offering products that may be incorporated into the work
VIBRATION ISOLATORS
A.
Isolator Pads: Oil and water resistant and factory cut to sizes that match requirements of
the equipment supported.
- Rubber Isolator Pads: Elastometer (neoprene or silicone) arranged in single or multiple
layers and molded with a nonslip pattern and steel baseplates of sufficient stiffness to
provide uniform loading over the pad area.
- Fiberglass or Cork Isolator Pads: Molded cork or glass fiber not less than (25mm) thick
and precompressed through 10 compression cycles at 3 times the rated loaded.
- Load Range: From (689 to 345 kPa) and a deflection not less than (2mm per 25 mm) of
thickness. Do not exceed a loading of (345 kPa).
D.
Rubber Isolator Mounts: Double deflection type, with molded, oil resistant rubber or
neoprene isolator elements, with encapsulated top and baseplates. Factory drilled and
tapped top plate for bolted equipment mounting. Factory drilled baseplate for bolted
connection to structure. Color code to indicate capacity range.
E.
Spring Isolators: Freestanding, laterally stable, open spring type isolators.
- Outside Spring Diameter: Not less than 80 percent of the compressed height of the
spring rated load.
- Minimum Additional Travel: 50 percent of the required deflection or rated load.
- Lateral Stiffness: More than 1.2 times the rated vertical stiffness.
- Overload Capacity: Support 200 percent of rated loaded, fully compressed, without
deformation or failure.
- Baseplates: Factory drilled for bolting to structure and bonded to a (6 mm) thick,
rubber isolator pad attached to the baseplate underside. Size baseplates to limit floor
loading to (690 kPa).
- Top Plates: Provide threaded studs for fastening and leveling equipment.
- Finishes: Manufacturer’s standard corrosive resistant finish.
F.
Restrained Spring Isolators: Vertically restrained, freestanding, laterally stable, steel open
spring type isolator.
- Housing: Welded steel with resilient vertical limit stops to prevent spring extension due
to wind loads or when weight is removed. Factory drilled baseplate for bolting to
structure and bonded to a (6mm) thick, rubber isolator pad attached to the baseplate
underside. Provide adjustable equipment mounting and leveling bolts.
- Outside Spring Diameter: Not less than 80 percent of the compressed height of the
spring rated load.
- Minimum Additional Travel: 50 percent of the required deflection at rated load.
- lateral Stiffness: More than 0.8 times the rated vertical stiffness.
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- overload capacity: Support 200 percent of rate load, fully compressed, without
deformation or failure.
- Finishes: Baked enamel for metal components on isolators for interior use. Hot dip
galvanized for metal components on isolators for exterior use.
G.
Rubber Hangers: Double deflection type, with molded, oil resistant rubber or neoprene
isolator elements bonded to formed steel housings with threaded connections for hanger
rods. Color code to indicate capacity range.
H.
Spring Hangers: Combination spring and elastomeric hanger with coil spring and
elastomeric insert in compression.
- Frame: Formed steel, fabricated for connection to threaded rods and to allow for 30
degrees of angular hanger rod misalignment without binding or reducing isolation
efficiency.
- Outside Spring diameter: Not less than 80 percent of the compressed height of the
spring rated load.
- Minimum Additional Travel: 50 percent of the required deflection at rated load.
- Elastometric Element: Molded, oil resistant rubber or neoprene.
- Finishes: Baked enamel for metal components. Color code to indicate capacity range.
2.04
SEISMIC CONTROLS
A. Thrust Restraints: Combination spring and elastomeric restraints with coil spring and
elastomeric insert in compression. Factory set for thrust.
1. Frame: Formed steel, fabricated for connection to threaded rods and to allow for 30
degrees of angular hanger rod misalignment without binding or reducing isolation
efficiency.
2. Outside Spring Diameter: Not less than 80 percent of the compressed height of the spring
at rated load.
3. Minimum Additional Travel: 50 percent of the required deflection at rated load.
4. Elastomeric Elements: Molded, oil resistant rubber or neoprene.
5. Finishes: Baked enamel for metal components. Color code to indicate capacity range.
B. Manufactured Seismic Snubbers: All directional, double acting snubbers.
1. Construction: Interlocking steel members restrained by a (19mm) thick, replaceable, shock
absorbing neoprene insert. Maintain (3mm) clearance in all directions between rigid and
resilient surfaces.
C. Fabricated Seismic Snubbers : Welded structural steel shapes designed and fabricated to
restrain equipment or vibration isolation bases from excessive movement during a seismic
events. Design to resist gravity forces identified by authorities having jurisdiction.
1. Construction: Welded steel shapes conforming to (ASTM A 36 M).
2. Resilient Components: (19mm) thick, replaceable, shock absorbing neoprene insert.
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2.05
VIBRATION ISOLATION BASES
A. Fabricated Steel Bases: Structural steel bases and rails designed and fabricated by the isolation
equipment manufacturer. Include equipment static loadings, power transmission, component
misalignment, and cantilever loading.
1. Fabricate bases to shapes required, with welded structural steel shapes, plates, and bars
conforming to (ASTM A 36 M). Include support brackets to anchor base to isolation units.
Include prelocated equipment anchors bolts and auxiliary motor slide bases or rails.
2. Design and fabricate bases to result in the lowest possible mounting height with not less
than (25mm) clearance above the floor.
3. Concrete Filled Inertia Bases: Weld reinforcing bars to the structural frame. Pour concrete
into base relocated equipment anchor bolts.
4. Weld steel angles on frame for outrigger isolation mountings, and provide for anchor bolts
and equipment support.
5. Configure inertia bases to accommodate equipment supported.
6. Pump Bases: Size to support pump and piping elbows.
7. Factory Finish: Manufacturer’s standard corrosive resistant finish.
2.06
VIBRATION ISOLATION ROOF CURBS
A. Description: Factory assembled, fully enclosed, insulated, air and watertight curb designed to
resiliency support roof mounted equipment and to withstand (56m/s) wind impinging laterally
against the side of the equipment. Design restraints to meet seismic requirements of
authorities having jurisdiction.
B. Components: Upper support frame, lower support assembly, freestanding, unhoused, laterally
stable steel springs, vertical and horizontal restraints.
1. Lower Support Assembly: Provide a means of attachment to the building structure and
include a wood nailer stripe for attachment of roof material and (50mm) of rigid
insulation on the inside of the assembly..
2. Spring Isolators: As indicated or scheduled. Include adjustment bolt to permit leveling of
equipment after installation. Attach to lower assembly with a rubber isolation pad. Locate
spring isolators so they are accessible for adjustment at any time during the life of the
installation without interfering with the integrity of the roof.
3. Water Seal: Elastomeric seal conforming to UL Class A roofing materials, attached to the
upper support frame, extending down past the wood nailer of the lower support
assembly, and counterflashed over the roof materials.
PART 3 - EXECUTION
3.01
INSTALLATION
A. Install and anchor vibration, sound and seismic control products according to manufacturer’s
written instructions and authorities having jurisdiction.
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3.02
3.03
3.04
B.
Anchor interior mounts, isolators, hangers, and snubbers to vibration isolation bases. Bolt
isolator baseplates to structural floors as required by authorities having jurisdiction.
C.
Anchor exterior mounts, isolators, hangers, and snubbers to vibration isolation bases. Bolt
isolator baseplates to structural supports as required by authorities having jurisdiction.
D.
Fill concrete inertia bases, after installing base frame, with (20.7 Mpa) concrete, and
trowel to a smooth, hard finish. Cast in place concrete is specified in Division 3.
E.
Install pipe connectors at connections for equipment supported on vibration isolators.
SEISMIC CONTROL
A.
Vibration Isolation Bases: Mount equipment on structural steel bases or concrete
inertia bases.
B.
Snubbers: Install the required number of seismic snubbers on each spring mounted
piece of equipment. Locate snubbers as close as possible to the vibration isolators and
bolt to supporting structure.
ADJUSTING AND CLEANING
A.
Adjust limit stops or restrained spring isolators to mount equipment at normal operating
height. After equipment installation is complete, adjust limit stops so they are out of
contact during normal operations.
B.
Adjust thrust restraints for maximum of (6mm) of movement at start and stop.
EQUIPMENT CONSIDERATION
A.
B.
Fans
1.
2.
3.
Flexible collar connections between fans and ductwork shall be correctly aligned.
Centrifugal fans and motor assemblies shall be mounted on a rigid common
inertia base, the whole mounted on spring and rubber vibration isolation mounts.
For all fans having motor size 7.5 kw or larger, bases shall be of steel and concrete
weighing as much as the fan motor assembly. Bases shall be sufficiently rigid to
resist any twisting or bending forces, and any dynamic forces, without creating
vibration of the base of any other member of the assembly.
4.
All holding down bolts shall be installed so as to avoid bridging of isolation.
Pumps
1.
All pumps shall be selected for the highest efficiency consistent with the specified
duty, but it is generally desirable that the pump impeller diameter should not
exceed 0.90 of the maximum impeller diameter capacity of the pump housing to
reduce the possibility of tonal effects. Departure from this to be made only with
the approval of the Contracting authority. The motor and pump assembly shall be
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mounted on a rigid steel and concrete inertia base of equivalent weight to the
pump-motor assembly, the whole mounted on spring isolation mount selected for
at least 90% isolation efficiency but in any case having a minimum deflection of
25mm.
2.
C.
3.07
Pump bases shall be designed to support the weight of elbows, valves and other
fittings without creating undue stress on the pump assembly.
Condensing Units
1.
Condensing units incorporating compressors shall include bases, frames, etc., to
provide proper alignment of the various components.
2.
Equipment shall be installed on an inertia base; dimensions and thickness will be
determinate by calculations.
3.
Insulation system should be mass-spring-mass-damper to reach maximum
efficiency of vibration insulation, e.m. 90-95%.
Static deflection of the spring between equipment and floating base should be
25mm.
INDOOR UNIT
Suspended on special elastic suspensions to isolate vibration form the structure
3.08
VIBRATION ISOLATOR SCHEDULE
Equipment
Isolator Type
Supply and return air centrifugal
Fans and exhaust Fans
Inertia base plus Elastomer mounts 4th basement
floor.
RPM ≥ 1400
RPM ≤ 1000
Isolation Efficiency
%
87-90
Inertia base plus Elastomer mounts all other floors.
95-97
Inertia base plus spring mounts 4th basement floor
87-90
Inertia base plus spring mounts all other floors.
95-97
END OF CHAPTER
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EQUIPMENT & PIPE INSULATION
PART 1 - GENERAL
1.01
SUMMARY
A.
Provide labor, materials, equipment and services, and perform operations required for
complete installation of Insulation and related work as indicated on the drawings and
specified herein.
B.
Work Included: The work shall include, but not be limited to, the following:
1.
2.
C.
Related Work Specified Elsewhere
1.
2.
1.02
Materials shall conform to the latest edition of industry standards and reference
specifications specified herein and to applicable codes and requirements of local authorities
having jurisdiction, whichever is more stringent.
SUBMITTALS
A.
1.04
Basic Mechanical Requirements.
Basic Mechanical Materials and Methods
QUALITY ASSURANCE
A.
1.03
Pipe Insulation
Equipment Insulation
Submit the following in accordance with the requirements specified under Submittals in
Chapter 15010.
1.
Product Data: Submit names of manufacturer and copies of latest published
literature including types, applications and thermal characteristics for materials
specified herein for approval; obtain written approval before ordering materials.
2.
Samples: Submit samples of materials specified herein for approval; obtain approval
before ordering materials.
DELIVERY, STORAGE AND HANDLING
A.
Deliver materials specified herein in manufacturer's unopened containers, with
manufacturer's name and point of origin on each container.
B.
Deliver materials and handle to prevent the inclusion of foreign materials and the damage
of materials by water or breakage.
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C.
1.05
Store materials and equipment where designated and within the manufacturer's
recommended temperature range. Assume responsibility and security for materials and
equipment and take precautions for protection from detrimental conditions.
GENERAL REQUIREMENTS
-
-
General

All insulation shall have a smooth, homogenous and lineable finished surface. All rigid
chapters shall be concentric and be accurately matched for thickness.

All surface to be insulated shall be dry and free from loose scale, dirt, oil or water
when insulation is applied.

Insulation shall be applied in such a manner that air circulation within the insulation
or between the insulation and the pipe shall be avoided.

No surface imperfections in the insulation such as damaged edges, or ends, cracks and
small voids or holes shall be accepted.

Insulation materials shall be stored and protected from weather moisture,
accumulations of foreign matter, or possible damage in a dry and clean store.

Canvas jacket, where used, and all insulating materials shall be non-combustible, or
self-extinguishing non-flame spread grade.

Surface finishes and lagging adhesives shall not be diluted and shall be applied in
accordance with the manufacturer's instructions.

Apply insulation to permit expansion or contraction of metal without causing damage
to insulation or surface finish.
Piping Insulation - General Provisions

All pipe covering 2 1/2" (65 mm) or less in thickness shall be applied in single layer
with joints tightly butted together.

All pipe covering 3" (80 mm) and larger in thickness shall be double layer with lateral
and longitudinal joints of the second layer staggered with those of the first layer. No
canvas is to be used between the layers.

All pipe covering shall fit snugly on the pipe to which it is applied. Inside
circumference of pipe covering when applied shall not vary from the outside
circumference of the pipe by more than 3mm. undersize.

Pipe insulation shall have factory applied jackets and secured with plastic bands at
each joint at center of each chapter and where chapters abut upon fittings, except
where otherwise specified.

Insulation shall only be applied to piping after all testing has been accomplished and
after all the coats of paint have been applied.
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
Pipe covering shall be terminated at a sufficient distance from all flanges to permit
easy removal of bolts.

Sufficient time shall be allowed to permit complete dry out of insulation at flanges or
openings in insulation as well as of all cement before sealing them up.
Insulation on flanges and flanged fittings shall consist of a layer or layers of pipe
covering or block insulation extending across and overlapping the adjacent pipe
covering at least 50mm. The outside of the insulation shall be given a trowelled coat
of finish cement to present a smooth surface.
 Where insulated piping is subject to movement and supported on roller hangers,
steel protection saddles shall be provided and welded to the pipe. Saddles shall be
filled with asbestos cement.
-

All insulated piping not supported on roller hangers and subject to movement, shall
be provided with protection shields at all hanger locations. Shields shall be of 3mm.
galvanized iron extending on each side of the hanger for a distance equal to the
diameter of the insulation and shall extend up the sides of the insulation to the
center of the pipe and shall be provided with cork pad support.

Special care shall be exercised in insulating refrigerant lines to revent sweat leaks at
piping hanger locations.

Where standard insulation shapes are not available, cut, score or miter segmental or
flat block to fit contour of pipe, stagger joints of adjoining segments. Fit insulation
carefully and secure with wire. Smooth with insulating cement.

Insulate valves, strainers, fittings and flanges with identical material, density,
thickness and finish as the piping insulation. Use premolded insulation material where
available, otherwise use shaped block segments wire on with all edges filled with
insulation cement or filler.

Insulate strainers to permit removal of the basket without disturbing the insulation of
the strainer body.
Equipment Insulation - General Provision

Curved or cylindrical equipment shall be insulated with blocks or curved segments in
one layer for thicknesses of 65 mm or less and two layers for thicknesses of 76 mm or
more. The insulation shall be applied with joints staggered and tightly butted together
and held in place with bands. Square cornered equipment such as boilers, ducts
casings etc. shall be insulated with block insulation protected at corners by metal
shields and held in place by bands, carried around the unit over the insulation and
fastened tight.

Metal anchoring clips shall be welded to the equipment surface so that the band will
pass over them and may be wired to them after insulation is in place.

For outdoor installation, and as a protection against mechanical damage and weather
the finish coat over insulation shall consist of 25 mm hexagonal metal mesh
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equipment tightly stretched over the insulation and secured to clips, bands or tie
wires, 13 mm thick rough coat of insulating cement and 1/4" 6 mm thick coat of
finishing cement trowelled smooth and applied after the rough coat is dry and a coat
of weather resistant mastic.

Any part of equipment that is normally removable for service such as heads of heat
exchangers, shall be insulated separately from the equipment.

No insulation shall be applied over nameplates.
PART 2 - PRODUCTS
MATERIALS/EQUIPMENT
All outdoor insulated pipework shall have Foster Vapor Safe Coating below aluminium jacketing
applied on Canvas.
All aluminium jacketing indoor and outdoor shall have Foster Elastolar sealant 95-44 applied on
laps to prevent entrance of the moisture.
2.01
2.02
PIPE INSULATION - Type A
-
This type of insulation shall apply to domestic hot water pipes.
-
Pipe insulation shall be performed rigid chapter fiberous glass molded in cylindrical form
to fit snuggly, chapteral one piece construction with a min. density of 4 lbs/ft3(65 kg/m3)
for indoor pipes and 96 kg/m3 for outdoor pipes and a max. K factor of 0.25 Btu.in/ft2.
hr. oF (0.036 W/m.deg.K) at a mean temperature of 75 oF (24 oC). The insulation shall
have a factory applied high density white kraft bonded to aluminium foil, reinforced with
fiber glass yarn. The kraft paper shall be chemically treated to assure fire and smoke
safety and to prevent corrosion of foil. The insulation shall be applied to the pipe with
longitudinal joints staggered. Laps and sealing strips shall be sealed applying fire resistant
adhesive or circumferential joints.
-
The surface finish shall be secured with aluminium bands, using a minimum of three
bands per block.
-
Insulated Pipes in shafts and above false ceiling shall be covered with 8 ounce canvas with
adhesive plaster.
PIPE INSULATION - Type B
This type of insulation shall apply to refrigerant pipes, condensate drain pipes, cold water pipes
on roof and to domestic hot water system under tiles or in walls.
Pipes shall be insulated with rubber type insulation Armaflex 12 mm thick. Insulation shall be
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closed sell tubing with finished skin, chemical and oil resistant with minimum water absorption.
Insulation shall stand extremes temperatures ranging from 40ºC to 120ºC. Inner tubing
insulation diameter shall be equal to outer utility pipe diameter. Insulation shall be wrapped
with 2 layers of PVC tape.
Insulation density shall be 0.111 Gms/m3 with thermal conductivity K value at 40ºC mean
temperature 0.041 W/M-K insulation shall be self extinguishing.
Insulation shall be ASTM approved.
2.03
PIPE INSULATION - Type C
This type of insulation shall apply to boiler breeching and chimney generator exhaust pipe.
Insulation shall be of rock wool ( 150kg/m3) 100 mm thick with galvanized jacket 0.6 mm thick.
Outdoor chimney shall have stainless steel jacket 316L.
2.04
RANGE HOOD EXHAUST DUCT - INSULATION
Insulation shall be 50mm hick mineral wool, 90kg/m3 density, wrapped with aluminum mesh,
8ounce canvas with adhesive plaster.
2.05
EQUIPMENT INSULATION
-
This type of insulation shall apply to boilers, heat exchangers, water heaters, pumps and
domestic hot water tanks.
Insulation shall be semi-rigid fibrous glass with organic binder up in board form with a
minimum density of 3 lbs/ft3 (50 kg/m3) and a maximum K-factor of 0.42 Btu-in/ft2.hr.oF
(0.06 W/m.deg.K) at a mean temperature of 200 oF (94 oC). Insulation shall be applied
over pins welded to the vessel on 300 mm centers. All joints shall be staggered and
tightly butted. The insulation shall be covered with gauge 18 aluminium jacket.
2.06
SCHEDULE OF INSULATION THICKNESS
The thickness of the insulation applied to pipes and equipment shall be as stated hereinafter.
Insulation
Pipe Diamete
Thickness
Service
Location
inches (mm)
inches (mm)
-
Domestic hot water
up to 2 inch diameter (indoor)
---
1" (25)
-
Domestic hot water pipes
2 inch diameter and larger (indoor)
---
1 ¼" (32)
-
Domestic hot water pipes
---
2" (50)
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on roof
-
A/C condensate drain pipes
---
---
19 mm
-
Domestic hot water pipes in walls
---
---
19 mm
---
---
19 mm
or under tile
-
Refrigerant suction line
END OF CHAPTER
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FIRE SYSTEM
PART 1 - GENERAL
1.01
SUMMARY
A.
B.
Provide labor, materials, equipment and services, and perform operations required for
complete installation of Plumbing Equipment and related work as indicated on the drawings
and specified herein.
Work Included: The work shall include, but not be limited to, the following:
1. Portable Fire Extinguishers.
2. Automatic fire protection system.
1.02
SUBMITTALS
A.
Submit the following in accordance with Chapter 15010.
1. Product Data
a.
Submit copies of manufacturer's latest published literature for materials
specified herein for approval; obtain approval before ordering materials.
2.
Shop Drawings: Submit shop drawings for work specified herein for approval.
1.03
DELIVERY, STORAGE AND HANDLING
A.
Deliver materials and handle so as to prevent the inclusion of foreign materials and the
damage of materials.
B.
Store materials where designated and assume responsibility and security for materials and
equipment. Take precautions for protection from detrimental conditions.
PART 2 - PRODUCTS
2.01
GENERAL DESCRIPTION
Supply and install, wherever shown on the Drawings, complete fire fighting systems of the
following types:
 Dry chemical portable fire extinguishers in all areas .
 Automatic sprinkler system for chemicals and gases storage areas.
PORTABLE FIRE EXTINGUISHERS
Supply and install wherever shown on the drawings portable fire extinguishers of the
capacities and ratings indicated on the drawings.
Each extinguisher shall be complete with a frame for hanging, a cabinet, 36cm. long hose,
discharge valve and pressure gauge.
Heavy duty drawn steel cylinder with hard scratch resistant enamel finish with color as
per international fire regulations.
Extinguisher shall be rechargeable dry chemical type or carbon dioxide as shown on the
drawings with the following minimum capacities:
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-
FE-1, 4.5 kg multi purpose dry chemical.
FE-2, 9 kg multi purpose dry chemical.
Extinguisher shall be UL listed & FM approved.
END OF CHAPTER
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DUCT INSULATION
PART 1 - GENERAL
1.01
SUMMARY
A.
Provide labor, materials, equipment and services, and perform operations required for
complete installation of Insulation and related work as indicated on the drawings and
specified herein.
B.
Work Included: The work shall include, but not be limited to Duct Insulation
C.
Related Work Specified Elsewhere
1.
2.
1.02
QUALITY ASSURANCE
A.
1.03
Materials shall conform to the latest edition of industry standards and reference
specifications specified herein and to applicable codes and requirements of local authorities
having jurisdiction, whichever is more stringent.
SUBMITTALS
A.
1.04
Basic Mechanical Requirements - Chapter 15010.
Basic Mechanical Materials and Methods - Chapter 15050.
Submit the following in accordance with the requirements specified under Submittals in
Chapter 15010.
1.
Product Data: Submit names of manufacturer and copies of latest published
literature including types, applications and thermal characteristics for materials
specified herein for approval; obtain written approval before ordering materials.
2.
Samples: Submit samples of materials specified herein for approval; obtain approval
before ordering materials.
DELIVERY, STORAGE AND HANDLING
A.
Deliver materials and handle to prevent the inclusion of foreign materials and the damage
of materials by water or breakage.
B.
Store materials and equipment where designated and within the manufacturer's
recommended temperature range. Assume responsibility and security for materials and
equipment and take precautions for protection from detrimental conditions.
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PART 2 - PRODUCTS
2.01
MATERIALS/EQUIPMENT
A.
Duct Insulation
All air conditioned rectangular supply and return air ducts shall be insulated with blanket
fiber glass to ASTM C 553 Type II, Class F-1 having a thermal coefficient of :
K = 0,3 BTU/Hr/F/Ft² and density = 24 kg/m3
Insulation shall have aluminum foil vapor barrier flame retardant. Exposed insulated
ductwork shall have aluminum jacketing gauge 18.
B.
Outdoor Insulation
Supply and return air ducts located outdoor shall be semi rigid jacketed board to ASTM C
612, Class 2
K = 0,3 BTU/Hr/F/Ft² and density = 48 kg/m3
Insulation shall have aluminum foil vapor barrier flame retardant.
Insulation shall be protected with aluminum jacketing gauge 18.
All outdoor insulated ductwork shall have Foster Vapor Safe Coating below aluminum
jacketing applied on Canvas.
All aluminum jacketing indoor and outdoor shall have Foster Elastolar sealant 95-44 applied
on laps to prevent entrance of the moisture.
C.
Cellular Glass
a. Material: Inorganic, formed or cellulated glass, annealed, rigid, hermetically sealed
cells, incombustible.
b. Facing: ASTM C 921 Type 1, factory applied, laminated foil, flame retardant, vinyl facing
or equivalent.
c. Form: the following as indicated:
1.
2.
3.
Blocks: ASTM C 552, Type I
Boards : ASTM C 552, Type IV
Special Shapes: ASTM C 552, Type III, in shapes and thicknesses as indicated.
d. Thermal Conductivity: (0.055 W x m/sq.mx K) average maximum at (24°C) mean
temperature.
e. Minimum Density: (112 kg/cu.m)
f. Maximum Density: (152 kg/cu.m)
D.
Jackets
a) General: ASTM C 921, Type 1, except as otherwise indicated.
b) Foil and paper Jacket: Laminated glass fiber reinforced, flame retardant kraft paper and
aluminum foil.
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1. Water Vapor Permeance: (1.2ng/Pa x s x sq.m) maximum, when tested according to
ASTM E 96.
2. Puncture Resistance:50 beach units minimum, when tested according to ASTM D
781.
E.
Accessories And Attachments
a. Glass Cloth and Tape: Woven glass fiber fabrics, plain weave presized a minimum of
(271 g per sq.m).
1. Tape width: (102 mm).
2. Cloth Standard: MIL-C-20079H, Type I.
3. Tape Standard: MIL-C-20079H, Type II.
b. Bands: (19mm) wide, in one of the following materials compatible with jacket:
1.
2.
3.
4.
5.
Stainless Steel: Type 304, (0.5 mm) thick.
Galvanized Steel: (0.13mm) thick.
Aluminum: (0.18 mm) thick.
Brass: (0.25mm) thick.
Nickel Copper Alloy: (0.13mm) thick
c. Wire: (1.6 mm) nickel copper alloy, (1.6 mm), soft annealed stainless steel, or (1.6 mm),
soft annealed galvanized steel.
d. Corner Angles: (0.3 mm), (25mm by 25mm) aluminum, adhered to (51 mm by 51 mm)
kraft paper.
e. Anchor Pins: Capable of supporting (9kg) each. Provide anchor pins and speed washers
of sizes and diameters as recommended by the manufacturer for insulation type and
thickness.
F.
Sealing Compounds
1. Vapor Barrier Compound: Water based, fire resistive composition
i)
Water Vapor Permeance: (4.6 ng/Pa x s x sq.m) maximum.
ii)
Temperature Range: (Minus 29 to 82 °C)
2. Weatherproof Sealant: Flexible- elastomer based, vapor barrier sealant designed to seal
metal joints.
i)
ii)
iii)
G.
Water Vapor Permeans: (1.2ng/Pa x s x sq.m) maximum.
Temperature Range: (Minus 46 to 121 °C)
Color: Aluminum
Duct Fire Protection
Air ducts when specified to be fire rated shall be protected by a fire proof product made
of light fiber, UL Listed having a minimum density equal to 350 Kg/m3 with two hours
rating.
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PART 3 - EXECUTION
3.01
INSTALLATION
Install all duct insulation in accordance with the following requirements :
No insulation shall be applied until ducts have been tested and found correct.
All insulation shall be applied by skilled laborers of a specialized sub-contractor in accordance with
the best pipe covering practice.
Insulation to be applied so as to give smooth homogeneous and fine surface. All flat surfaces truly
plane and parallel and all edges straight.
Insulation shall fit tight to the surfaces to be covered and any surface irregularities left shall be
repaired.
All air conditioned rectangular duct shall be insulated with blanket type fiber glass panel having a
thermal coefficient of :
K = 0,3 BTU/Hr/F/Ft²
Insulation to be rigidly fixed on duct by an approved method and recovered by aluminum foil to
be approved.
The minimum insulation thickness for duct work to be 40 mm.
All insulation materials shall be properly stored in a suitable manner so as to protect them from
damage or deterioration before installation.
END OF CHAPTER
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DOMESTIC WATER PIPING SYSTEM
PART 1 – GENERAL
1.01
SCOPE
A.
1.02
1.03
1.04
The work described in this chapter of the specification is related to the hot , cold, and
soft water distribution systems.
RELATED WORK
A.
Basic Mechanical Requirement.
B.
Basic Materials and Methods.
C.
Pipe and Pipe Fittings.
D.
Valves.
E.
Insulation.
F.
Testing and Commissioning.
REFERENCES
A.
Refer to Individual Materials for Specified Reference Standards .
B.
Uniform Plumbing Code ( UPC ) .
C.
American Society of Plumbing Contracting authoritys ( ASPE ) Manual.
D.
American Water Works Association ( AWWA ) Standards as specified in the chapter.
SYSTEMS DESCRIPTION
A.
The hot, cold and well water systems comprise of a system of pipework, valves fittings
and appurtenances providing hot & cold water for ablutionary purposes to the various
plumbing fixtures situated throughout the buildings. The work includes recirculation hot
water and specialties.
B.
The soft water system comprises of a system of pipework, valves, fittings and
appurtenances providing soft water for cooling and heating plants and where indicated
on drawings.
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PART 2 - PRODUCTS
2.01
WATER SERVICES.
A.
2.02
See chapter Pipe and Pipe Fittings for Water Service Piping Materials and Installation.
MATERIALS
A.
Copper Piping
Refer to Chapter “PIPING”
B.
Galvanized Steel Piping
Refer to Chapter “PIPING”
C.
Black Steel Piping.
Refer to Chapter “PIPING”
D.
UPVC Pressure Piping
Refer to Chapter “PIPING”
E.
I.
Accessories
1.
Flexible pipe connectors shall have a stainless steel bellows with a woven flexible
bronze wire reinforcing protective jacket. Connectors shall be minimum of 300
mm in length with thread male or flanged ends as required for proper
installations. Sweat end connections re not acceptable. Connectors shall be rated
for 1 MPa water working pressure, 120C operating temperature and suitable for
up to maximum 20 mm misalignment.
2.
Shock absorbers shall be elastomer bellows type, with stainless steel shell,
glycerin hydraulic displacement fluid and pressurized argon pneumatic
displacement cushion. Shock absorbers shall be individually sized as required for
equipment served.
Electric Water Heater
Supply and install electric water heaters wherever shown on the drawings of capacities as
indicated on the drawings.
Each electric water heater shall be of the cylindrical storage type constructed of heavy
gauge steel with white enamel finish and glass lining from inside.
Heater shall have polyurethane foam insulation wall between the outer casing and the
glass lining all around top and bottom of cylinder. Heater shall be suitable for a working
pressure of 100 psi (690 Kpa) and shall be certified by UL or equivalent European Norm.
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Each electric water heater shall be complete with the following:
- Fast acting surface mounted thermostat for automatic temperature control.
- Factory installed sensitive high limit energy cut-off (for safety to prevent overheating)
present at 210 oF (99 oC ) and shall be listed and labeled by UL, AGA or CE.
- Electric element of 3000 watt capacity and smaller as indicated on the drawings.
Element shall be constructed of highest quality resistance wire sheathed in mineral
filling and the whole encased in a copper tube and subjected to a high voltage test.
- Removable heating water seamless copper coil, U bend heating chapter with 3 way
motorized valve and all valves and accessories as detailed on drawings.
- A nonreturn valve at the cold water inlet to the heater.
- Pressure relief valve installed between heater and non return valve and shall be listed
by AGA and shall be labeled by AGA, ASME or CE.
- Removable access panel to the heating element and thermostat.
- Factory installed nipples.
- Gate valves on cold and hot water connections.
- Wall fixing brackets and support.
PART 3 - EXECUTION
3.01
INSTALLATIONS
A.
AS PER Basic Materials and Methods, for general piping installation instructions.
B.
Supplies and Trim
1.
C.
Vacuum Breakers
1.
D.
All supplies, hardware, trim, traps, etc. to fixtures and equipment shall be
chrome plated brass if exposed to view.
Vacuum breakers shall be furnished and installed on all faucets and valves which
have provisions for hose connections and water supplies to equipment or devices
that have inlets below the overflow rim.
Underground Piping
1.
No underground or underslab water piping within building shall be permitted
unless specifically shown otherwise on the drawings.
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E.
Joints
1.
F.
Joints shall be made using 95-5 Tin- Antimony solder ASTM B-32. Joints for
underground ( if any ) shall be made using a brazing compound containing silver
alloys having a melting point of 520C or higher. Wrought copper and bronze
fittings shall be to ANSI B16.22.
Flushing of pipework Systems
Prior to the chemical cleaning or treatment of any pipework system, the entire system,
chapterally or as whole, shall be subjected to a full bore rapid flush to ensure the
complete removal of any loose foreign material. This shall also apply to pipework systems
where chemical cleaning is not called for. Flushing shall be carried out without circulating
water through any filter, pump, coil, heat exchanger etc., and the Contractor shall be
responsible for providing temporary by-pass connections where necessary to enable this
to be achieved. The Contractor shall also be responsible for providing temporary fill and
drain points on each system and for making whatever temporary arrangements that may
be necessary to have adequate raw water available at the fill points and for the removal
of flushing water from the drain points.
Temporary drain points for flushing shall not be less than 65 mm diameter in pipework of
65 mm nominal bore or larger and pipeline size in pipework of less than 65 mm nominal
bore.
If flushing of a system is carried out on a Chapteral basis, it shall be done in such a
manner that foreign material cannot be introduced into a chapter of pipework already
flushed.
The contractors proposals and timing for flushing out of pipework should be submitted to
the Contracting authority.
G.
The entire flushing operation of a system shall e carried out of the satisfaction of the
Contracting authority, and in accordance with the AwwA No. B300 recommendation.
Chemical Cleaning of LTHW
All pipe systems shall be chemically cleaned internally prior to commissioning and to the
Contracting authority agreed programme. The systems shall first be treated to remove
corrosion products, followed by a further treatment to inhibit corrosion.
The Contractor shall provide suitable tapping points for chemical introduction and all
necessary drainage/flushing connections etc.
The Contractor shall allow in his tender for discharging the effluent including diluting the
discharge to meet the local Authority’s requirements and all charges levied by the local
Authority.
The Contractor shall ensure tat the pipework system installed under this Contract is
totally isolated from any other or existing systems before chemically cleaning out.
The Contractor shall also include for the full duty to be treated such that sufficient
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protection remains to prevent corrosion occurring for a period of 6 months from the date
of handover.
Any equipment liable to deterioration due to the cleaning operation shall be removed
from the pipeline and the necessary temporary make-up pieces installed.
The Contractor shall also include for providing water heaters, circulator and bypass lines
etc., where necessary.
B-
Disinfecting of Hot and Cold Water Systems
Disinfecting shall be carried out following satisfactory flushing pressure testing and
setting to work prior to handover.
The whole of each system including systems, vessels, pipework, shall be disinfected with
chlorine by a specialist organization certified to BS 5750 Part 1 for this type of work or
the Water Undertaking as agreed with the Contracting authority.
The producers shall follow DOH Code of Practice “ The Control of Legionella in Health
Care Premises “ and BS 6700 chapter 13.9 as outlined in the following clauses.
Flushing and disinfection shall not be a substitute for a high degree of cleanliness during
installation.
C-
Distribution Pipework Chlorination
Chlorination shall be generally to the Department of Health Code of Practice “ The
Control of Legionella in Health Care Premises”.
The mains supply to storage cisterns shall have been satisfactory chlorinated as
necessary, and all cisterns cleared of all visible contaminants before services within
buildings are treated.
The capacities of the systems shall be calculated to determine amounts of chlorine to be
added.
All water shall be drained off and all draw off points closed and all isolating valves
opened except on cistern outflow.
After flushing, the system shall be filled with water and the servicing valve on the supply
to the cistern shall be closed.
Following this the capacity of the system shall be assessed and a calculated quantity of
sodium hypochlorite of known strength shall be added to the cistern to give a free
residual chlorine concentration of 50 ppm to the cistern water content. The chlorinated
water shall be drawn around the system by successively opening each draw-off fitting.
Working away from the cistern, and closing it when chlorinated water at 40-50 ppm is
discharged, the concentration being determined by calorimetric methods. The cistern
shall be refilled and chlorinated as above during these operations, to maintain a residual
chlorine level of 50ppm in the cistern at all times. The contact time shall commence
when the entire system is filled with chlorinated water, together with the cistern to
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overflow level.
It is essential that the internal coatings of cisterns are thoroughly cured before
disinfection take place and care must be taken not to exceed 5 ppm chlorine
concentration.
The above procedures shall apply to cold water services and to the secondary circuits of
hot water systems before heat is applies and with the water cold. Care shall be taken not
to use excessive amounts of chlorine which may effect pipework or other materials.
Records shall be kept of all procedures, checks, tests and witnessing.
D-
Prevention of Water Stagnation
Regular draining off of water and re-filling with potable water shall be allowed for after
chlorination.
Draining down and re-filling shall be on a routine basis twice weekly until handover.
E-
Water Quality Tests
The Contractor shall allow for all systems to have been satisfactory set to work and
disinfected before water samples are taken.
Analysis of both hot and cold water supplies shall be allowed for taken from
representative sampling points at draw off and storage positions with the system at
working temperatures .
Water quality tests shall include for all samples to be tested in accordance with the
DoH/DoE Report No.71 - The Bacteriological Examination of Water Supplies, or any
method approved and employed by the Public Analyst.
All the samples shall be tested for E.Coli and chemical analysis including copper and lead
content. The quality of potable water at outlets, (as sampled) and as supplied by the
Water Authority, to be generally to EC Directive, 15th July 1980, 80/778/EEC “ Quality of
Water intended for Human Consumption “. Potable water from a borehole supply must
comply with DoE Circular 25/84 and EC Directive 80/778/EEC.
The Contractor shall provide for samples to be taken and analysed initially as a reference
point as agreed with the Contracting authority.
Samples shall be taken from :
Main supply on site
Storage cisterns ( Hot/Cold )
Selected hot and cold outlets ( to be agreed with the Contracting authority ) in each
department
The Contractor shall allow for the tests to be carried out by the Public Health Authority
Laboratory Service or the local Water Undertaking as agreed with the Contracting
authority.
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Two sets of tests shall be included, the first after setting-to-work and disinfecting and the
second in conjunction with the handover date and the date for occupation of the
premises.
F-
Legionnaires Diseases Precaution
Legionnaires Disease precautions shall be in accordance with the requirements of the
Department of Health Code of Practice - The control of Legionellae in Health Care
Premises ( HMSO) - Clause 2210 - 2207, Commissioning and Testing.
The length of HWS system dead legs shall be revised to 5.0 metre’s.
The Contractor shall include for taking water samples for Legionellae bacteria normal hot
and cold water systems. The method for taking samples shall be in accordance with the
Public Health Laboratory Service requirements.
The Contractor shall provide for the tests to be carried out by the Public Health
Laboratories &/or other certified laboratories on samples taken from representative
sampling points when the systems are at working temperatures and conditions.
Temperature of the water ( hot or cold ) at the sampling points shall be recorded at the
time of taking each sample.
Water samples for analysis shall be taken from three hot and three cold outlets, the
location of the outlets to be determined by the Contracting authority.
The Contractor shall provide for the samples and their analysis to be carried out prior to
Practical Completion and the Contracting authority notified of the results.
G-
Analysis Reports
All test reports shall be discussed with the Contracting authority and the Medical Officer
for Infection Control and where results are not satisfactory, suitable remedial action shall
be agreed upon and undertaken by the Controller.
If the results are found to be unsatisfactory due to poor workmanship and/or use of
unacceptable components , all remedial work shall be carried out at the Contractors
expense.
END OF CHAPTER
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SOIL, WASTE,& ROOF DRAINAGE PIPING SYSTEMS
PART 1 - GENERAL
1.01
SCOPE
A.
1.02
1.03
1.04
The work described in this chapter of the specification is related to the soil, waste and
ventilating pipework installation and the storm drainage system.
REFERENCES
A.
Refer to individual materials for reference standards.
B.
Uniform Plumbing Code ( UPC ) .
C.
American Society of Plumbing Contracting authoritys ( ASPE ) Standard as specified in this
chapter.
SYSTEM DESCRIPTION
A.
Building shall have a comprehensive system of soil, waste, anti-syphon ventilation and
rainwater pipework so designed as to convey all soil, waste and rainwater to the main,
city sewage and rainwater networks.
B.
Drainage system for basement floor shall be drained to lift station and then pumped to
city networks.
QUALITY ASSURANCE
A.
Comply with the provisions of ASME B31.9 " Building Services Piping " for materials,
products and installations.
B.
Provide listing / approval stamp, label or other marking on piping made to specified
standards.
PART 2 - PRODUCTS
a.
Vent Pipe Terminations
1.
Vent pipe terminations through roofs formed with asphalt shall be spigot and
socket medium grade cast iron connectors having turned down luting flange
homogeneously cast around the base of the socket.
2.
Vent pipe terminations through roofs with materials other than asphalt are to be
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b.
weathered with lead slates formed from 2.24 mm lead sheet. The upstand
around the pipe shall be of the equivalent diameter and be of sufficient length to
provide a minimum height of upstand of 225 mm from roof level at any point. The
base of the slate shall be of sufficient size to enable a water-tight joint to be made
with the roofing material. Lead burnt seams to upstand and base chapter shall be
double loaded and formed in a sound workmanlike manner to the satisfaction of
the Contracting authority.
Roof Vents and Vent Caps
All vent pipes located above roof level shall be of cast iron with adaptor connection to
PVC pipes located indoor.
Supply and install all roof vents and vent caps on cast iron pipes wherever shown on the
drawings and as specified herein.
Each vent cap shall be of cast iron Vandal proof type, full size of vent pipe, caulked base
connection for cast iron pipes.
2.01
UPVC Pressure Piping
A.
2.02
Pressure UPVC pipes shall be as described in chapter 15060 Paragraph 2.02E for water
piping system suitable for pressure pipes up to 15 bars.
UPVC Drainage and Vent Pipes & SUNDRIES
A.
UPVC drainage pipes type 2 shall be extruded unplasticized polyvinyl chloride conforming
to the following European Standards for non pressure drainage pipes:
-
Pipes 32 mm, 40 mm, 50 mm & 75mm installed above ground to EN 1329.
-
Pipes 110 mm & above installed above ground to EN1401-SN4.
-
Pipes 110 mm and above installed underground to EN1401-SN4.
-
Pipes 110 mm and above installed underground deeper than 7 m to EN1401-SN8.
-
Pipes shall be European make suitable for rubber ring pressure joint. Sealing rings
to be rubber to EN681.
-
Fire stop jackets shall be installed on all PVC pipes penetrating floor slabs or fire
rated walls similar to HILTI model CP642 /CP643.
-
Pipe fittings shall be UPVC of the same weight and quality as the pipe. Lubricant
shall be as recommended by pipe manufacturer.
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Contractor to provide all accessories and supports of UPVC system to suite high rise
building applications and to provide all accessories to protect installation from the seismic
action defined for this project.
B.
Floor Drains - Type FD
Supply and install all floor drains wherever shown on the drawings and as specified herein
where floor drains are connected to PVC pipes.
Each floor drain shall be constructed of heavy duty UPVC and shall conform with the
following requirements:
2.03
a)
Integral trap with cleaning plug.
b)
Adjustable level, heavy duty, large grate area, stainless steel model FERPLAST
strainer,
200 x 200 mm fixed onto the drain body with stainless steel cover.
Cleanouts
The cleanouts shall be of the same material and dimensions as the pipes to be cleaned and shall
be placed under the floor slabs or extended through to terminate flush with the finished floor.
Cleanouts on concealed piping shall be extended through and terminate flush with the finished
floor.
Cleanouts shall be installed at each change of direction greater than 45°.
They shall be also provided at or near the foot of each vertical soil and waste stack.
Cleanouts shall be installed such that the cleanout opens in a direction opposite to the flow of the
drainage line or at right angles thereto.
Floor cleanouts with covers shall be formed with a "Y", "F" or 45 elbow fitting of the same
material and size as the pipe accommodated and provided with an adapter and a threaded brass
plug.
Cover plate and frame shall be 200 x 200 mm stainless steel model FERPLAST as requested and
approved by the Contracting authority. The cover shall be threaded to the frame to ensure an air
tight closure. Cover and frame finish as approved by the Contracting authority.
2.04
Balcony Drain - type BD
Each balcony drain shall be constructed of UPVC and shall conform to the following requirements:
a)
b)
c)
Large grate area body
Adjustable level, heavy duty stainless steel flat strainer Model FER PLAST 200 x 200 mm
fixed onto the drain body.
Side or bottom outlet to suit installation in shallow finish height.
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d)
Integral flashing guard.
Balcony drain shall be similar to Nicolle with grating finish as approved by the Contracting
authority.
2.05
CONNECTION TO CITY MAINS
Contractor shall supply, install and connect sewage and rain water pipes to existing city manholes
where indicated on drawings including all necessary excavation and back filling, all to the approval
of the Contracting authority.
PART 3 - EXECUTION
3.01
GENERAL
B.
Provide all necessary devices, supports, hangers and other accessories to withstand
seismic action as classified for this project.
C.
Soil and waste stacks shall be carried up full bore 460 mm above roof level and in any case
not less than 915 mm above the head of any window within a horizontal distance of 3 m
from the pipe and shall be provided with wire balloon guards and roof connectors.
D.
Branch ventilating pipes shall be connected within the limits of 75 mm and 450 mm from
the crown of the trap. From WC’s they shall be connected to the cast iron/steel
connectors or to branches immediately following thimbles from “P” traps.
E.
Main branch ventilating pipes shall be run above spill-over level of fitments except where
shown, and if connected to main soil, soil-waste or waste pipes, the connections shall be
at a point above spill-over level of the highest fitment connected to the main soil, soilwaste pipe.
F.
Single Stack ( i.e. Unventilated One-Pipe) Systems shall have branch pipes fixed accurately
and to the correct gradients and heights. The connection to the main soil-waste pipes
shall be made by means of approved fittings fixed accurately.
G.
The connection of galvanized steel branch soils and wastes from sanitary fittings to cast
iron stacks shall be made using screwed iron .
H.
Joints of length to length for galvanized steel pipework will be by means of fittings
threaded only standard pipe fittings shall be used. Bending of pipes is prohibited.
I.
Where galvanized steel pipes are in contact with concrete or cement mortar, or clinker
type blockwork they must be wrapped with self adhesive cellulose tape or coated
externally to resist chemical attach.
J.
Pipework shall be installed to the routes and diameters indicated on the drawings and
where exposed shall run in parallel lines when grouped together to obtain a neat and
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satisfactory appearance.
3.02
K.
Open ends of pipework left during the progress of work shall be blanked off with a
temporary plug or cap to prevent the entry of any foreign matter.
L.
Make changes in direction for drainage and vent piping using appropriate Y - branches , Y branched with 1/8 bends, and long sweep 1/4 ,1/5, 1/6, 1/8, and 1/16 bends. Use long
turn double - Y branch and 1/8 - bend fittings where 2 fixtures are installed back to back
or side by side and have a common drain. Where different sizes of drainage pipes and
fittings are connected use standards increases and reducers.
M.
Branches on waste and soil pipe work must be swept in with the direction of flow.
N.
Pipes shall be spaced in ducts in a manner which will permit subsequent access to any
pipe for maintenance or removal without disturbance to the remaining pipes.
O.
Long radius bends shall be provided at the connection of all soil and rain water stacks to
the underground drain, with an access pipe above floor level.
GENERAL REQUIREMENTS FOR PIPE INSTALLATION
-
All pipes shall be installed in straight parallel lines.
-
Pipes shall be spaced to permit their installation, maintenance and insulation.
-
Concealed pipes shall be installed in such a way as to permit their maintenance and
inspection.
-
All pipes shall be so installed as to ensure easy and even flow of the water to and from all
equipment and fixtures.
-
Pipelines shall be installed in a manner to allow for easy air escape and system draining.
It shall be endeavored to obtain this naturally by gravity.
-
However, where this cannot be met, provision should be made to ensure quick and
positive drainage and noiseless air discharge.
-
Drain pipes shall be joined together in a manner satisfying perfect running condition.
-
Vent pipes shall not be trapped and shall be graded to drip back to waste or soil line.
-
All vents for waste and soil stacks shall extend above the highest point of the roof and
shall be equipped with a vent head and cap as specified.
-
Free discharge outlets of rain water drains shall be done in 45° or 90° combination of
bends as found necessary by the Contracting authority.
-
Sleeves shall be supplied and installed wherever pipes cross slabs, walls, partitions, etc.
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3.03
3.04
-
Connection of plastic underground pipes to manholes shall be made by means of a
suitable manhole lining to ensure adequate bonding to the concrete.
-
Cleanouts shall be placed at all changes in direction whether shown on the drawings or
not.
-
In case of welding work to be done in proximity of plastic pipes, special care shall be taken
to avoid damaging the pipes.
CONDITIONS FOR PIPE ASSEMBLY
-
Before installation, all pipes shall be cleaned of all foreign matter and shall be reamed
smooth after cutting. All trenches shall be cleaned up.
-
Pipes shall be carefully cut by hacksaw or by special pipe cutting machine.
-
Steel pipe ends shall be cleaned and smoothed on edge to avoid all roughness and
unevenness before welding or threading.
-
Threading shall be done for the total length of joint or accessory with a reliable threading
machine.
-
PVC pipes when cut, shall be debarred and chamfered according to the instructions of the
manufacturer to ensure a proper and easy assembly.
-
All changes in pipe size shall be made with fittings. Eccentric reducing fittings shall be used
to prevent pocketing.
-
Change in direction of piping shall be made with long radius fittings.
-
The exposed ends of incomplete or unconnected work shall be plugged. Plugging shall be
perfect with gate valves, counter flange plugs or thread plugs.
-
All piping subject to expansion and contraction shall be installed with expansion bends,
swing joints made up of fittings or other approved methods or devices. Branch lines from
lines subject to expansion and contraction shall have a swing joint at the point of
connection with the main. Expansion joints shall be installed even if not shown on the
drawings or count for in the bill of quantities.
JOINTING
C
PLASTIC PIPES
-
Solvent weld joints shall be made with the proper solvent cement furnished by
the manufacturer for that purpose. Both, the inside of the socket and the outside
of the spigot end of the pipe shall be roughened using sand paper. All grease and
dirt shall be removed from the surface with a special cleaning fluid supplied by the
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-
-
3.05
CONNECTIONS TO SANITARY FITTINGS
A.
General
1.
B.
D
Connection shall be made to the 35 mm BSPT male thread waste connector by
means of a 35 mm diameter two piece copper compression outlet 75 mm water
seal “ P” trap.
Connections To Sinks.
1.
F.
The following connections to sanitary fittings are to be provided where
arrangements to the contrary are not indicated on the drawings.
Connections To Basins
1.
Unless otherwise stated connections to sinks shall be made with a 42 mm two
piece, deep seal copper trap.
Connections to W.C. ‘s and slop Sinks
1.
3.06
manufacturer. Immediately after cleaning, solvent cement shall be applied and
pipe pushed into the socket up to the shoulder without turning.
Rubber ring joints shall be made with the proper sealing ring furnished by the
manufacturer for that purpose. After the spigot end has been lubricated, it shall
be pushed fully into the socket and then pulled out by about 3mm per meter of
pipe length (but in no case less than 1cm) to allow for longitudinal thermal
expansion.
Cleaning and lubrication shall be as recommended by the manufacturer. No oil or
grease should be used.
Connections to W.C.’s and slop sinks shall be made by means of a flexible push fit
connector manufactured from Ethol Vynel Acitate ( E.V.A.) and so constructed as
to be self sealing. The connector being fitted strictly in accordance with the
manufacturer’s instructions.
FIXING
A.
The contractor shall be responsible for determining the nature of the materials to be fixed
to and for marking out positions of fixing for the cutting of cavities where required. Where
cast iron, galvanized steel and PVC pipes are fixed in a vertical plane they shall be plumb
or in alignment with the structure, and provided with sufficient fixing to ensure a rigid
installation on completion . Spacing of fixtures shall be in accordance with the Uniform
Plumbing Code. At changes of direction in the vertical plane, fixings shall be located on the
sockets of the bends. Where pipes are located against walls they shall be provided with
sufficient clearance from same to permit maintenance and painting. Pipes laid horizontally
or to gradients shall be fixed as shown as on the spacing chart and around the socket of
pipe. All pipework shall be symmetrical and correctly aligned as required. The pipes shall
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be installed to true gradients free from high spots or depressions. Failure to comply with
this requirements shall render the contractor liable at his own expense to any alteration,
removal or replacement that is required.
B.
Spacing
1.
C.
The contractor shall provide supports at the spacing outlined in the following
table.
Material Pipe size
mm
Interval for Horizontal
Pipes m.
Interval for Vertical
Pipes m.
CI
Plastic
Plastic
1.5
1.2
1.8
1.5
2.4
3.0
All
65/50/40
75 & above
2.
At changes in direction in the pipe run additional supports shall be provided
adjacent to each side of the change of direction, On pipe runs that extend from
floor to ceiling a minimum of one additional mid-way support shall be provided
irrespective of greater distances specified in the table.
3.
Hangers on Plastic pipes shall be design which does not clamp the pipe tightly but
permits axial movement.
4.
Support but do not rigidly restrain Plastic pipes at end of branches and at change
of direction or elevation. Vertical piping shall be maintained in the straight
alignment. Support trap arms in excess of 900 mm in length as close as possible to
the trap.
Brick or Blockwork Walls.
1.
Where pipes are to be fixed against brick or blockwork walls they shall be secured
thereto by bituminous coated 25 mm wide by 4.7 mm thick cast iron two piece
brackets for securing to the socket of the pipe with tails for building into
structure. The bracket band around the socket of the pipe shall be secured
together by means of 8 mm hexagonal headed brass bolts, nuts and washers. The
bracket tails shall be set into the structure of a depth to give clearance behind the
pipes barrel when fixed 40 mm from the face of the finished wall. Where pipes are
to be fixed against walls where building in is not permitted they shall be secured
thereto by brackets of mild steel. The tails of the brackets shall be turned out at
right angles and drilled to receive bolt or screw fixings plugged into wall.
2.
Where pipes 50 mm and under are to be fixed to walls and partitions fixing shall
be by means of two piece brass clip split pattern bracket of the appropriate size.
The walls shall be drilled and plugged and the clip secured with dome headed
black japanned screws of the required size.
3.
Where pipes 50 mm are to be fixed to walls and partitions fixing shall comprise
mild steel trice drilled and counter sunk back plate for screw fixing to structure
incorporating female boss short extension rod and two piece brass ring clip of the
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appropriate diameter with securing brass screws and boss for extension rod. The
walls shall be drilled and plugged as required and the ring dip backplate secured
thereto by means of black japanned screws. On completion the pipe shall be fixed
so that a clearance of 25 mm is provided to future finished surfaces.
D.
E.
Duct Fixing
1.
Where pipes are to be fixed in ducts in conjunction with other pipes, the
contractor shall provide angle iron bearers of approved size to bridge the duct
cavity. The pipes shall be fixed to the angle bearers by means of brackets as
before described but having welded boss on the back face to receive screwed
extension rod tail. The angle bearer shall be drilled to the correct size to pass the
extension rod which shall then be double bolted thereto. The burring out of holes
in the angle bearers will not be permitted.
2.
Where pipes are to be fixed in ducts to angle iron bearers the pipe shall be fixed
by means of two piece ring pattern brass clip with threaded boss. The angle iron
support shall be drilled to the correct size to receive the extension rod which shall
be a maximum of 150mm long of the appropriate diameter for the pipe brackets,
threaded both ends and secured to the angle support with nut and luck nut. The
pipe fixing ring shall be threaded onto the extension rod and on completion the
extension rod bracket shall be square to the pipe.
Suspended Pipes Concrete Floors
1.
Where pipes are to be suspended below slabs where floor screeds are to be
formed they shall be supported by means of hangers comprising 100 x 100 x 6
mm mild steel plate set at structural slab level with 9.5 mm extension rods double
bolted or welded thereto of the required length for suspension. The rod shall be
complete with adjusting and locking nuts for adjustment of gradient and
threaded end for insertion into the welded boss of the pipe bracket.
2.
Where pipes are to be suspended from ceilings and soffits the pipes shall be fixed
by a bracket comprising ring clip, extension rod and backplate.
3.
The backplate shall be of the screw fixing pattern with A.S.P.T. female boss for
extension rod. The structure shall be drilled and plugged and required and bracket
secured with dome headed black japanned screws of suitable size. The extension
rod shall be of sufficient diameter for the duty and of the required length for the
application, with threaded end s to receive backplate ring clip. The ring clip shall
be two piece pattern.
4.
Where more than one pipe is required to be supported from one extension rod,
Approval of the Contracting authority to the method proposed is to be obtained.
5
Where pipes are to be suspended below slabs where screeds are to be formed
they shall be supported by means of hangers comprising 100 x 100 x 5 mm mild
steel plate set at structural slab level with extension rod double bolted thereto or
welded to the required length for suspension.
6.
The extension rod shall have threaded end to receive two piece pattern ring clip.
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3.07
3.08
CUTS IN PIPES
A.
Cut length to tubes shall be made by means of wheel type cutters or sharp hacksaws to
give a clean true square face to the pipe . Irregularities to cut faces are to be filed smooth
and the internal burr removed by means of a burring reamer. Reductions to the true bore
of the pipe are to be made good by the insertion of a metal turn - pin.
B.
Cut lengths to cast iron pipes shall be made by means of wheel type cutting tools to give a
clean true square face to the axis of the pipe. Exposed metal shall be coated to the axis of
the pipe. Exposed metal shall be coated with tar based solution applied before installation
of the pipe.
SOUND INSULATION
A.
3.09
PAINTING
A.
3.10
3.11
Where pipework due to its location is required to be insulated against sound transmission
a 0.25 mm thick strip of rubber shall be inserted between the inner face of the pipe clip
and the galvanized steel pipe. 50 mm thick mineral wool 50kg/m3 shall be wrapped
around the pipe with cartoon and coton canvas on top not less than 272g/m2 and painted
with two coats of heat resistant water paint. A coat of primary paint shall be applied of
the color requested by the Contracting authority. The strip shall be trimmed in a
workmanlike manner.
The contractor shall paint all pipe supports of mild steel to prevent corrosion with one
coat of red oxide primer.
CO - ORDINATION
A.
In areas such as false ceilings, builders work ducts, floor ducts, trenches and where
different services are run in close proximity, the contractor shall ensure that his services
do not prevent the installation of other services.
B.
In this respect the contractor will be deemed to have consulted other trades and all
relevant drawings issued by the consultant and sub - contractors. The contractor shall not
install any services in these areas until routing has been agreed with other trades.
PROVISION OF ACCESS.
A.
Access points as before described are to be provided at the base of the soil pipes
immediately prior to connection with the drainage system and elsewhere as required to
be in such position that all times the location is accessible to ensure necessary clearance
of the system. Where working is in confined ducts the contractor shall be responsible for
determining this position in relation to any other service .
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3.12
3.13
PROTECTION OF WORKS
A.
Both during and on completion of the works the contractor is to be held responsible for
the full protection of his works and freedom from blockages and obstructions.
B.
Prior to commissioning tests, grease felt washers to access doors shall be regreased and
the whole installation presented as new for testing.
PIPE SLEEVES
-
Provide all pipe openings through walls, partitions and slabs with sleeves having an
internal diameter at least 2" larger than the outside diameter of the pipe for uninsulated
lines or of the insulation for insulated pipes.
-
Install sleeves through interior walls and partitions flush with finished surfaces; sleeves
through outside walls to project 15 mm. on each side of the finished wall; and floor
sleeves to project 50mm. above finished floors.
-
Set sleeves in place before pouring concrete or securely fasten and grout in with cement.
-
Sleeve construction :


-
-
3.14
Interior Partitions - galvanized sheet iron.
Interior & Exterior Masonry Walls and Floors-galvanized steel pipe.
Fill the space between outside of pipe or insulation and the inside of the sleeve or framed
opening with fibrous asbestos in interior walls and floors and pack with oakum, seal with
lead and watertight mastic or asphalt in exterior walls.
Sleeves in fire rated wall shall be of galvanized steel pipe 2 sizes bigger with fire resistant
seal as wall rating.
PIPE ACCESSORIES AND FITTINGS
A.
General
The accessories shall be of the same standard as the pipes on which they are fitted, they
shall be flanged, threaded or welded depending on the type and the diameter of the pipe
and the location in which the pipes are installed.
For PVC pipes, all fittings shall be made of PVC from the same series and by the same
manufacturer of the pipes.
B.
Clamps for Plastic Pipes
Plastic pipes shall be supported with galvanized steel clamps with rubber pad as
recommended by the pipes manufacturer.
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Anchorage of the Plastic pipe work shall be provided by using clamps with an in-laid
plastic strip to ensure a firm hold after each group of fittings immediately following the
last coupling, and using loose clamps between the fittings.
Horizontal lines shall be supported at intervals of 10 times the outside pipe diameter.
Vertical lines shall be supported at no more than 2 meters interval.
C.
D.
Connection to Equipment and Control Valves
-
Provide flanges or unions at all final connections to equipment and control valves
to facilitate dismantling. Arrange connections so that the equipment being served
may be removed without disturbing the piping.
-
Install all supply piping, pumps and other equipment including gate valves and
strainers therein, at line size with the reduction in size being made only at the
outlet piping from the control valve at the full size of the tapping in the
equipment served.
Hangers, Supports, Anchors and Guides - General
-
Support, anchor and guide all piping to preclude failure or deformation. Construct
and install hangers, supports, anchors, guides and accessories to the approval of
the Contracting authority. Do not use wire, tape or metal bands. Supports shall
be designed to support weight of pipe, weight of fluid and weight of pipe
insulation.
-
Fasten piping securely to the structure without overstressing any portion of the
supports or the structure itself. Secure pipe supports, anchors and guides to
concrete by means of inserts or if greater load carrying capacity is required by
means of steel fishplates embedded in the concrete.
-
Arrange hanger to prevent transmission of vibration from piping to building and
supports.
-
Uninsulated copper or brass pipe and/or tubing shall be isolated from ferrous
hangers or supports
-
Support piping and tubing at intervals indicated in the schedule hereinafter and at
all changes in direction. Maximum deflection shall not exceed 3 mm.
-
Clearance for application of specified Vapor sealed insulation without cutting
pipeline covering or fitting covering in installation of pipe hangers and fittings
shall be provided.
-
Furnish pipe hangers and supports complete with rods, bolts, lock nuts, swivels,
couplings, brackets and all other components and accessories, to allow
installation to freely expand and contract.
-
Hangers shall be formed steel clevis type, unless otherwise specified, with
adjustable attachment to hanger rod. For copper or brass pipe, use plastic
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sheathed hangers. Pipe hangers shall fit over vapor sealed insulated piping.
-
Where pipe exceeds maximum loading recommended for clevis type hanger,
provide steel pipe clamps.
-
Provide trapeze hangers where several pipes can be installed parallel and at the
same level. Trapeze shall be of steel channel sized to support load and drilled for
rod hanger at each end. Provision should be made to keep the lines in their
relative position to each other by the use of either clamps or clips.
-
Use roller supports, where provision for expansion is required. Rollers shall have
cast iron adjustable bases.
-
For hanger rods on piping 10 mm thru 50 mm inclusive use 10 mm rods, and for
piping 65 mm thru 125 mm use 16 mm rods, and for piping 150 mm thru 300 mm
use 22 mm rods.
-
Provide additional steel members required for hanging piping systems in areas
with special conditions, or where vertical or horizontal structural steel supports
are required other than those provided in the structure.
-
C-type hangers on sprinkler piping shall have lock nuts.
-
Provide lateral bracing for supporting rods over 450mm. long braced at every
fourth hanger with diagonal bracing attached to slab or beam.
-
Floor supports - provide for supporting horizontal piping from floors with castiron rests, with pipe nipples to suit. Fasten to floor. Where provision for
expansion is required, provide pipe roll stands, without vertical adjustment.
Provide concrete or steel pipe piers, fasten stands to piers.
-
Wall supports - provide for supporting horizontal piping from wall with steel JHook for pipe located close to wall and not larger than 80 mm pipe. For greater
loads, up to 680 Kg maximum loading provide welded steel bracket.
-
Vertical piping supports - support cast-iron soil pipe at every floor and at base of
stack, other pipes at every floor unless shown otherwise. Use steel extension pipe
clamps. Refer to manufacturer's rated maximum loading for each size pipe. Bolt
clamps securely to pipe, rest clamp-end extension on building structure. Place
pipe clamps at ceiling below, support clamp and extension from inserts where
pipe sleeves extend above floor.
-
Pipe-covering (insulation) protection saddles.

Provide hanger shields to protect vapor sealed pipe insulation within
mechanical equipment rooms at each support point by a 360o insert of high
density, 100 psi, waterproofed calcium silicate encased in a 120o sheet metal
shield. Insert thickness shall be same as insulation. Shield length shall equal
nominal pipe diameter, minimum but shall not be shorter than 100mm. and
need not be longer than 300mm. if bearing load causes no discernible
deformation. Insert shall extend 25mm. beyond sheet metal shield. 100mm.
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shields shall be 26 gauge minimum. Shields 130 to 230mm. long shall be 20
gauge minimum. Shields longer than 230mm. shall be 16 gauge.
-

Provide penetration shields to encase insulated pipes penetrating fire walls or
floors in a 360o, 24 gauge minimum sheet metal hanger shield with insert of
high density, 100 psi. waterproofed calcium silicate the same thickness as
insulation and further enclosed within the sleeve, sized for maximum 25mm.
spacing between sleeve and insulation shield, pack annular space between
sleeve and shield on both ends with double neoprene coated asbestos
rope. Install an escutcheon plate to completely cover the wall penetration
opening and fit snugly over the pipe insulation shield. Insert shall extend at
least 25mm. beyond penetrated surface and escutcheon.

Provide oversize hangers with blocking the same thickness as the insulation to
pitch vapor sealed insulated pipes accurately at time of insulation.
Except for fire protection systems, maximum horizontal spacing for pipe hangers
are as follows:






3/4" -4" (20 and 100 mm) steel pipe
5" & above (125 and above) steel pipe
Up to 1 1/4" (32 mm) copper pipe
1 1/2" (40 mm) and over copper pipe
2 1/2" (65 mm) and smaller PVC pipe
3" (80 mm) and over PVC pipe
2.5 meter
4.0 meter
2.0 meter
3.0 meter
1.2 meter
1.8 meter
vertical spacing - Plastic pipe twice as those of hor. spacing.- other pipes - at
every floor level.
E.
-
Hangers on Plastic pipes shall be of design which does not clamp the pipe tightly
but permits axial movement.
-
Support but do not rigidly restrain Plastic pipes at end of branches and at change
of direction or elevation. Vertical piping shall be maintained in the straight
alignment. Support trap arms in excess of 900mm in length as close as possible to
the trap.
Cleaning of Piping Systems
-
Plug all opening ends of piping, valves and equipment except when actual work is
being performed to minimize accumulation of dirt and debris.
-
After installation is complete, place temporary screens at connections to all
equipment and at automatic control valves where permanent strainers are not
provided.
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3.15.
-
Prior to the performance of tests, flush out all piping that is to receive a
hydrostatic test with clean water.
-
Remove dirt and debris collected at screens, strainers and other points from the
system.
-
The Contractor shall disinfect water piping before it is placed in service. The
Contractor shall furnish all equipment and materials necessary to do the work of
disinfecting and shall perform the work in accordance with the procedure
outlined in AWWA Standard for Disinfecting Water Mains Designation C 601-68.
The dosage shall be such as to produce a chlorine residual for not less than 10
ppm after a contact period of not less than 24 hours. After treatment, the piping
shall be flushed with clean water until the residual chlorine content does not
exceed 0.2 ppm. During the disinfecting period, care shall be exercised to prevent
contamination of water in steel main.
MANHOLE
A.
Manhole Construction
Manholes shall be constructed of class "B" concrete as shown on the drawings.
The base (where required) shall be of precast class "B" reinforced concrete.
The shaft shall be constructed of poured reinforced concrete to suit the required depth.
The top shall be of class "B" reinforced concrete. An opening suitable for the cover shall
be left in the top around which the radial concrete bricks or concrete ring are built for
proper adjustment of levels. Bricks shall be fully bedded in mortar and the inside surface
of joints finished flush and clean.
The benching shall be formed in the bottom of manholes in class "B" concrete. "U"
channels shall be formed with bottom flush with inside surfaces of pipes and sides
extending the full height of the largest pipe and then sloped back at a minimum fall of
10%. The benching and channels shall be finished with 2 cm thick rendering composed of
1/2 cement/sand mortar, and surface hardened with two coats of sodium silicate solution
brushed on. The finished diameter of channels shall be the same as the diameter of pipes
entering or leaving the manhole.
B.
The paint for the manhole interior shall be coal tar epoxy resin.
Frames, Covers & Gratings
The Contractor shall furnish and set level and to the proper grade, a ductile frame and
cover or frame and grating of the form and dimensions shown on the Drawings. The
concrete masonry shall be neatly and accurately brought to the dimensions of the base
of the frame. The frames shall be thoroughly embedded in mortar. All covers and frames
shall be heavy duty quality.
All castings for frames, covers, and gratings shall be of ductile iron. All castings shall be
made accurately to dimensions and shall be machined to provide even bearing surfaces.
Covers and gratings must fit the frames in any position and if found to rattle under traffic,
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shall be replaced. Filling to obtain tight covers will not be permitted. No plugging, burningin or filling will be allowed. All castings shall be carefully coated inside and out with coal
tar pitch varnish of approved quality.
3.16
DUCTILE IRON TRENCH GRATE & FRAME
Supply and install wherever shown on drawings trench grates and frames as hereinafter
specified.
Grate shall be ductile iron, heavy rectangular, chapteral bar pattern, suitable for car parking.
Grate openings shall be laid in wide dimensions in a steel frame with flat bar anchors and
nailing clips. Grating and frame shall be Saint Gobain Model RE 40D3HD, 400 mm wide with
frame.
Grating in R/O room shall be of UPVC 300 x 300 similar with stainless steel 316L frame.
3.17
TESTING OF THE WORK
A.
On completion of the soil and waste pipe works or chapter of the work as may be required
the contractor shall arrange the testing of the works and witnessing of the tests.
B.
The tests shall comprise an air test as set out in the Uniform Plumbing Code, and
described below.
C.
Where the testing is to be carried out in chapters the contractor shall retain on site a
drawing indicating chapters tested and recording dates on which the tests took place duly
witnessed.
D.
The contractor shall be responsible for providing all skilled and unskilled labor necessary
to carry out tests and ensure that all supplies and instruments are available.
E.
Water Test
F.
a.
Apply the water tests to every part of each drainage system. Test each system in
its entirety or in chapters. Tightly close openings in the piping.
b.
If testing the system in chapters, tightly plug each opening, except the highest
opening of the chapter being tested, and fill each chapter with water. Test every
chapter with a head of water equivalent to the greatest floor-to-floor distance
between floors with a minimum of at least a 10 foot head of water.
c.
Keep the water in the system, or in the portion under test, for at least 15 minutes
before inspection starts.
d.
There shall be no leakage.
Smoke Test
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G.
3.18
a.
After connecting fixtures, perform a smoke test on the sanitary and laboratory
drainage systems.
b.
Fill traps with water, then produce a thick, penetrating smoke with one or more
approved smoke machines and inject into the entire system. As the smoke
appears at the stack openings on the roof, tightly close such openings and apply a
pressure equivalent to a 1 inch water column.
c.
Maintain pressure of 1 inch water column for at least 15 minutes before
inspection starts.
d.
Inspect traps. There shall be no leakage.
Correct defects detected by any test and retest.
PROTECTION
A.
The Contractor shall be responsible for repairing and replacing plumbing materials and
equipment, whether or not installed, which are damaged due to freezeups, until the
systems are approved by the Contracting authority and turned over to the Employer.
END OF CHAPTER
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WATER DISTRIBUTION SYSTEM
PART 1 - GENERAL
1.01
SUMMARY
A.
Provide labor, materials, equipment and services, and perform operations required for
complete installation of the Water Distribution System and related work as indicated on the
drawings and specified herein.
B.
Work Included: The work shall include, but not be limited to, the following:
1.
2.
3.
4.
5.
C.
Related Work Specified Elsewhere
1.
2.
3.
4.
1.02
Basic Mechanical Requirements - Chapter 15010.
Basic Mechanical Materials and Methods - Chapter 15050.
Pipes and fittings - Chapter 15060.
Valves - Chapter 15100.
QUALITY ASSURANCE
A.
1.03
Air vents.
Backflow preventer.
Water hammer arrestor.
Valve box.
Vaccum breaker.
Materials and work shall conform to the latest edition of industry standards, reference
specifications listed below and specified herein and to applicable codes and requirements of
local authorities having jurisdiction, whichever is more stringent.
SUBMITTALS
A.
Submit the following in accordance with the requirements specified under Submittals in
Chapter 15010.
1.
Product Data
a.
Submit copies of manufacturer's latest published literature for materials
specified herein for approval. Obtain approval before ordering materials.
b.
Data shall include manufacturer's technical product data, including installation
instructions, and dimensioned drawings for each type of manufactured piping
specialty. Include pressure drop curve or chart for each type and size of
pipeline specialty. Submit schedule showing manufacturer's figure number,
size, location, and features for each required piping specialty.
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1.04
DELIVERY, STORAGE AND HANDLING
A.
Deliver materials and handle so as to prevent the inclusion of foreign materials and the
damage of materials.
B.
Store materials and equipment where designated. Contractor shall assume responsibility
and security for materials and equipment. Take precautions for protection from
detrimental conditions.
PART 2 - PRODUCTS
2.01
MATERIALS/EQUIPMENT
See specifications in chapter “valves”
I
PART 3 - EXECUTION
3.01
EXAMINATION
A.
3.02
3.03
Examine conditions at the job site where work of this chapter is to be performed to insure
proper arrangement and fit of the work. Start of work implies acceptance of job site
conditions.
PREPARATION
A.
Examine the Contract Drawings and specifications in order to insure the completeness of
the work required under this Chapter.
B.
Verify measurements and dimensions at the job site and cooperate in the coordination and
scheduling of the work of this Chapter with the work of related trades, so as not to delay job
progress.
INSTALLATION
A.
Connections to fixtures and equipment shall conform to local applicable code requirements.
B.
Provide automatic air vent valves at high points in water systems; pipe drain lines to nearest
indirect waste. In general, pitch piping up in direction of water flow.
END OF CHAPTER
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PLUMBING FIXTURES
PART 1 - GENERAL
1.01
SUMMARY
A.
Provide labor, materials, equipment and services, and perform operations required for
complete installation of Plumbing Fixtures and related work as indicated on the drawings
and specified herein.
B.
Work Included: The work shall include, but not be limited to, the following:
1.
2.
Lavatories
Water closets and seats
PART 2 - PRODUCTS
2.01
MATERIALS/EQUIPMENT
GENERAL
a.
Plumbing fixtures, trim and accessories to be obtained from one approved manufacturer
unless otherwise specified.
b.
Vitreous china : heavy duty first quality, of specified colour, with smooth glazed surfaces
free from warps, cracks, checks, flaws, discolouration or other imperfections.
c.
Vitreous china accessories: to match fixtures and of same manufacture and colour.
d.
Exposed piping and metal trim : chrome plated brass with polished finish guaranteed not
to strip or peel off.
e.
List of all proposed plumbing fixtures, trim and accessories, indicating manufacturer, type
and model number and catalogues shall be submitted for approval.
f.
Samples for fixtures, trim and accessories shall be submitted for approval.
g.
Plumbing fixtures shall be stored under cover and kept dry.
h.
Mortar: as per architectural specifications.
j.
Black bitumen coating solution for cold application to BS 3416 Type 1.
k.
Waterproof jointing compound for wastes: type recommended by waste manufacturer.
A.
Lavatories
1)
Wall Hung Lavatory
Vitreous china, wall hung type, with size & model as shown in the attached list. Color as
approved by the Contracting authority, complete with following trim and accessories
manufactured by the same fixture manufacturer and as shown in ARCHITECTURE list:
1/2" mixer with spout with pull-knob 1 1/4" diameter pop-up waste.
1 1/4" chrome plated P-trap with wall tube and wall flange, adjustable type.
Trap cover.
Two 1/2" chrome plated angle valves with 300 mm long tubes and wall flanges.
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2)
Counter Lavatory
Vitreous china, with overflow for fitting in a counter top, with size & model as shown in the
attached list, color as approved by the Contracting authority, complete with following trim
and accessories manufactured by the same fixture manufacturer and as shown in the
attached list:
1/2" single hole chrome plated monobloc mixer with fixed cast spout projection 118
mm with pull-knob, 1 1/4" diameter pop-up waste.
1 1/4" chrome plated P-trap with wall tube and wall flange, adjustable type.
Two 1/2" chrome plated angle valves with 300 mm long tubes and wall flanges.
B.
Water Closet
Vitreous china, European type, wall hung, coupled to flush tank and all accessories, with
wall support, with size & model as shown in the attached list. Color as approved by the
Contracting authority, complete with the following trim and accessories manufactured by
the same fixture manufacturer and as shown in the attached list:
½” chrome plated angle valve with copper tubing.
white solid plastic seat and cover with metal hinge, rubber washers and plastic screws
and nuts.
Concealed flush tank with all accessories.
Spray assembly unit where shown on drawings with flexible hose, nozzle with aerator,
mounting bracket, exposed vacuum breaker and self closing push button valve.
3.01
INSTALLATION
The installation and connection of all sanitary fixtures shown on the drawings or provided later
shall satisfy the following specifications:
- Ample application of petroleum jelly shall be applied to all surfaces of exposed chrome plated
piping, valves and fittings and stainless steel fixtures immediately after installation.
- Concealed brackets, hangers and plates shall have a shop coat of paint.
- All exposed piping and trim shall be chrome plated and fully protected during installation.
Strap or padded wrenches shall be used on chrome pipe fittings and valves.
- All exposed metal parts in the sanitary blocks shall be chrome plated.
- All exposed valves in the sanitary blocks shall be chrome plated of the recessed type.
- Plumbing fixtures shall be complete with all required trimmings, including faucets, waste
plugs, traps, supplies, stop valves, escutcheons and casings and all necessary hangers, plates,
brackets, anchors and supports.
- All fixtures shall be individually trapped.
- All fixtures shall be equipped with chrome plated angle valves, whether specified, shown on
drawings or not.
- Fixtures shall be set in a neat, finished and uniform manner making the connection to all
fixtures at right angles with the walls, unless otherwise directed by the Contracting authority.
- Roughing for this work must be accurately laid out so as to conform with the finished wall
material.
- Fixtures are not to be set until so directed by the Contracting authority.
- The location and disposition of all items shall be as indicated on the relevant drawings.
- It is to be noted that all fixtures mentioned below shall be approved for shapes and colors
before ordering.
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Laboratory Workbenches Technical specifications
Consist of the following:
1. Working surface (Qty :14):
 Dimensions (4000 Lx 700mm D)
 Thickness 13 mm minimum
 Backsplash: 6 cm
 Downturn: 3 cm
 Working surface molded as a single piece
 Chemical resistance: resistance to acids, alkalis, salts and organic solvents
 anti-scratch
2. Base unit: Dimensions: Length 4000cm x Depth 700cm x Height 90cm, Wood with steel
support (wood: moisture resistant, fire retardant / steel (minimum 4*4 cm) epoxy coated
3. Under bench cupboards and drawers
 18 mm thick
 wood :moisture resistant, fire retardant
 PVC lipping for all exposes edges (cabinet edges, doors and drawers front)
 Cupboards :- Dimensions: approximately length 4000cm, depth 60cm, height 60 cm,
a with one shelf in each cupboard, Cupboard doors are hinged.
 Drawers Case box: (70 cm depth,60 cm width ): 16Nr. approximately 15 cm high
drawers ,Conforms with EN14727 (Laboratory furniture - Storage units for
laboratories –Requirements)
4. Sinks( Qty : 4), Dimensions : approximately 50 X 50 cm, Chemical resistance: resistance to
acids, alkalis, salts and organic solvents with Water Taps (Qty: 4), Single hole mixer fitting
with swivel swan neck and fixed nozzle.
 Sinks connection to drainage
 Taps connection
 Main valves to exiting pipe outlet under bench
END OF CHAPTER
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AIR DISTRIBUTION UNITS
PART 1 - GENERAL
Work incorporated in this chapter includes :
1.
2.
3.
A.
FANS.
MINISPLIT SYSTEM
VRV SYSTEM
General Requirements
a.
Equipment to have factory applied finish coat of machinery enamel unless otherwise
specified.
b.
Warranty: equipment is to carry manufacturer's warranty against defects in materials and
workmanship for a period of Three years after handing over
c.
Furnish equipment supplier with all necessary data such as available electric current
characteristics, maximum and minimum ambient temperatures and humidities, altitude,
water quality and other particular site conditions so that manufacturer will supply equipment to
specifically suit Site conditions particularly for necessary derating in capacity for altitude and
temperature, necessary class of insulation for electric motors, special construction for
water quality, high temperatures and humidities, sandy environment etc.
d.
Electric motors are to conform to the specification for electric motors given under "Motors"
Chapter and with requirements given under equipment specifications for particular motor
driving that equipment.
e.
safe
f.
to be
g.
of
Equipment is to be supplied from factory complete with all necessary accessories and
components that are standard items of manufacturer or as recommended by him for good,
and efficient operation of equipment irrespective of whether these are specified or not.
Construct ductwork in a sturdy, neat, tight manner in accordance with ASHRAE
Standards. Make casing and plenum joints square and remove sharp edges. Seams are
double lap. Slip joints to have smooth interior surface, made in direction of airflow and
continuous around four sides. Slips to be at least one gauge heavier than ducts.
Brace and stiffen ductwork so that it does not vibrate, rattle, 'breathe' or sag.
Bracing to be on outside of ducts and to consist of standing seams, angles and cross-breaking
duct panels.
h.
Reinforce and stiffen ductwork at damper locations, at access door locations and at other
locations as required.
j.
Uninsulated ducts larger than 460 mm are to be cross- broken.
k.
of
Joints and seams: make airtight with sealing compound during fabrication and after erection
ductwork.
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l.
Changes in direction and shape: make with as long a taper as possible.
m.
Curves, bends and offsets: make with large radii, with average centreline radius not less
than one and a half (1 1/2) times width of duct.
n.
Turning vanes: provide inside elbows where conditions necessitate elbows with radii less
than 1 1/2 times width of duct. Space turning vanes in accordance with ASHRAE
Standards.
p.
Splitter vanes: provide at all branches in duct for adjusting and balancing air flows to
different
branches. Fit in duct in an approved manner to prevent rattling and vibration.
q.
Joints between dissimilar metals: make with angle iron companion flanges separated by
compressed asbestos composition gasket.
r.
Screws: do not use sheet metal screws in construction of ductwork.
s.
Acoustic lined ducts: make larger to accommodate specified thickness of lining while
retaining internal dimensions of duct indicated on the drawings.
t.
For payment purposes to be based on length of ducts installed. Rates to be calculated
taking into consideration losses, joints, seams etc.
u.
HVAC systems more than 2,000 cfm in size should include smoke detectors in the discharge
air
duct (Refer to detail drawings). Designs of systems for more than 15,000 cfm require
additional
placement of smoke detectors and dampers in the HVAC discharge and return air
paths.
Centrifugal In-Line Fans
Supply and install all centrifugal in-line fans wherever shown on the drawings and as specified herein.
a.
Fan shall be in line centrifugal, silent duct fan type, with radial impeller statically and
dynamically balanced. Motor shall be totally enclosed, permanently lubricated type with built-in
overload protection.
b.
Housing shall be galvanized steel. Fan shall be supplied complete with fan controller with
indicating light and necessary supports.
c.
Fans used for smoke exhaust shall be suitable for operation at 400°C for one hour.
VRV SYSTEM
Supply and install VRV system as shown on the drawings and as specified herein. The system shall be
of the inverter driven VRV type with components as follows.
GENERAL
The Air Conditioning Contractor shall supply, deliver, install, set to work and commission the systems
and equipment as detailed in this chapter of the specification, as shown on the Tender drawings and
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listed in the Schedule .
DESCRIPTION OF WORKS
Heating and Cooling is to be provided by utilising the VRV R410A series (Inverter, Heat
recovery) modular systems comprising a number of external condensing units connected via
refrigerant pipework to internal direct expansion fan coil units
FEATURES
The VRV system will control flow of refrigerant through the fan coil unit, by means of an electronic
expansion valve fitted in each indoor unit.
The system will be capable of cooling with external ambient temperatures down to –5oC and
providing heating with ambient temperatures down to –20oC.
The equipment manufacturer shall be responsible for the manufacture of the compressor, refrigerant
oil and refrigerant used within the system to maintain integrity of design and optimise efficiency and
reliability of equipment.
The VRV system will have the ability to sustain refrigerant piping lengths of up to 165m with a level
difference of 90m between fan coil units and condensing unit if the outdoor unit is located below the
highest level indoor unit. An option shall be
available to increase the level difference of the pipe work to 90m between fan coil units and
condensing unit if the outdoor unit is located above the lowest level indoor unit.
The system shall be capable of having up to 1,000m of refrigerant pipe work installed.
The VRV system shall operate with Refrigerant R410A, the refrigerant shall be a zeotropic blend
constituted of a maximum of two different refrigerants providing a maximum temperature glide
of less than 0.17K to avoid fractionation problems.
The equipment manufacturer shall be fully certified and registered to comply in the areas of CE,
Eurovent, ISO9001 and ISO14001.
A Certificate of Conformity shall be supplied with each machine.
All equipment shall be run tested in accordance with the following procedures prior to leaving place
of manufacture.
•
A choke test carried out on the refrigerant piping to detect obstacles
•
The pipework shall be tested to 38bar.
•
Electronic leak testing shall be carried out to ensure maximum system refrigerant
containment.
•
System vacuum test to 2 Torr
•
Refrigerant test to within 0.3%
•
Electrical tests shall include flash testing at 1440V AC to ensure that current leaks above 5mA
are detected, megger test at 500V DC to ensure resistance levels are above 10 mega Ohm and earth
continuity tests.
OUTDOOR UNITS
The units shall be air-cooled type incorporating heat exchanger coils manufactured from copper
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tubes and aluminium fins, factory treated to reduce the effect of atmospheric corrosion. The unit
casing shall be manufactured from (70µ) polyester powder coated baked enamel finish sheet
steel in order to have a high corrosion resistance and to protect against salt laden environment close
to where the units may be installed. The colour shall be manufacturer’s standard. The air outlet
shall have plastic coated wire guards.
The outdoor units shall have inverter driven compressor, electronically controlled and capable of
changing speed linearly to follow the variation in cooling or heating requirements.
The compressor shall be scroll type with fixed and orbiting scrolls. The low pressure refrigerant
shall be fed directly into the scroll and the discharge refrigerant shall cool the motor windings
and place the compressor shell under discharge pressure.
The lubrication oil of the compressor shall be fed through the centre of the crankshaft and then
across the complete area of the scrolls from the centre outwards to ensure the complete
contact area is positively lubricated maximising compressor efficiency and minimising wear and tear.
The size 10 to size 18 outdoor unit shall contain both and inverter driven compressor and
fixed speed compressor(s). This combination shall allow the maximum efficiency of the system at
part load conditions by realising the precise steps of a smaller inverter compressor.
The fixed speed compressor(s) shall allow a rapid warm up to be realised during the heating cycle.
The outdoor unit shall be capable of proving emergency operation should one of the compressor(s)
fail.
The outdoor units will be inverter and shall be determined electronically by sensing
operational temperatures, pressures and ambient temperature and monitoring the dictates of the
indoor units.
The units shall be complete with electronic expansion valve(s), oil separator(s), suction accumulator,
high pressure switches, inverter driven fan motors, safety thermostat, over current relay, inverter
overload protection, fuses, necessary solenoid valves, liquid shutoff valves, gas line shut off valves,
short re-cycling guard timer and all necessary sensors for optimized, safe and trouble free
operation.
The access to the internal components for maintenance purposes shall be by removable panels.
The unit shall be capable of operating with reduced operational sound pressure levels which can
be selected at 45dbA or 50dbA. This feature is provided via an optional adapter which can accept
an external signal for a timeclock or other external source.
The unit shall be available with the option of a digital display of operational pressures
permanently mounted on the electrical panel of the unit.
All refrigerant connections both internal within the unit and the external connections
to the indoor units shall be brazed. Flared or mechanical connections will not be acceptable on
the outdoor unit.
The unit shall be capable of carrying out automatically the calculated required additional refrigerant
charge necessary to operate the system within its optimum efficiency. This cycle shall be completely
automatic and provide a warning to the service technician to indicate when charging has been
completed or the charging cylinder is empty.
The refrigerant cycle shall not rely upon float valves, level switches or weighed input of the
refrigerant.
The calculated refrigerant charge shall be retained within the memory of the outdoor
unit as a reference for a refrigerant containment check which can be carried out as required to verify
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the correct refrigerant charge remains within the system.
The automatic refrigerant charging and containment check facilities shall be capable of being
used at any time during the life of the system for any alterations or service operations which may be
required.
INDOOR UNITS
Ducted Concealed Type
The unit casing shall be manufactured from galvanised steel plate and shall be fully insulated. The
use of a polystyrene only construction for the outer casing will not be acceptable. Facility shall be
provided for duct connection for introduction of the fresh air in the unit and branch ductwork from
the unit. The return air to the unit shall be through the rear of the unit as standard. A facility shall
be provided for alternative return air position through the underside of the unit.
The fan shall be of the dual suction multi blade type, statically and dynamically balanced to
ensure low noise and vibration free operation.
The heat exchanger coils will be manufactured from copper tubes and aluminium fins. It shall have
electronic expansion valve to control refrigerant flow rate in response to the load variation in the
conditioned space. The expansion valve shall be controlled by an integral computerised PID control
system to maintain correct room temperature.
A condensate lift pump shall be provided within the unit and shall be capable of discharging above
the drain outlet.
The condensate shall be drained from the unit using suitable tube and run directly to a main drainage
point.
Wall Mounted Type
The unit casing shall be manufactured from heat resistant plastic. The casing colour shall be
standard manufacturer colour. The back plate and the support frames shall be manufactured from
galvanised steel plate.
The fan shall be multi blade cross flow type, statically and dynamically balanced to ensure low noise
and vibration free operation.
The heat exchanger coils will be manufactured from copper tubes and aluminium fins. It shall have
electronic expansion valve to control refrigerant flow rate in response to the load variation in the
conditioned space. The expansion valve shall be controlled by an integral computerised PID control
system to maintain correct room temperature.
The condensate shall be drained from the unit using suitable tube and run directly to a main drainage
point.
The air filters shall be incorporated within the unit and shall be washable resin net type.
ANCILLARY ITEMS
Proprietary joints and headers shall be used throughout the installation to reduce imbalance in
refrigerant flow between indoor units.
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CONTROLS
Mains Power Wiring shall be the responsibility of the Electrical Contractor who shall be provide a 3phase 400V mains isolators mounted on the VRV Condensing Units and a
1-phase 230V fused spur located within 1m of fan coil units.
Controls wiring shall be the responsibility of the Air Conditioning Contractor who shall provide
system control wiring in accordance with the manufacturer’s recommendations.
Cabling shall be two core flex to BS6500 and 0.75-1.25mm2.
The minimum separation from mains power cabling shall be as follows:
Current Capacity of Power Cable
(>100V)
Minimum separation (mm)
Based upon 100M Run of Parallel Cables
0 – 10A
300
11-50A
500
51 – 100A
1000
>100A
1500
Remote Controller
Local control will be provided via remote controllers mounted within the occupied space,
providing individual start/stop, run/fail indication, set point adjustment and fault code diagnosis.
Time Clock control shall be flexible with seven independent day settings, five actions per day of
ON or OFF which can be can be configured in any desired pattern. The controller shall contain an
internal temperature sensor, which can be used for system control or Fabric Protection control.
Fabric protection shall be
configurable with a start temperature of between 5 – 150C and adjustable differential
for the off temperature of between 1 – 50C higher. The controller shall have the ability to be locked
down without the need of any other external adapter PCB or Centralised device to leave only the
following functions operable:
LEVEL 1 ACCESS
•
All buttons operational
LEVEL 2 ACCESSES
•
On/off button
•
schedule timer on/off button
•
Temperature adjust button
•
Operation adjust button
•
Fan speed button
•
Air direction adjust button
LEVEL 3 ACCESSES
•
On/off button
•
Temperature adjust button
•
Fan speed button
Intelligent Touch Controller
Intelligent Touch Controller System will be provided with a true touch active screen with colour
Liquid Crystal Display with Icon displays to provide simple user friendly operation:
•
Have no physical buttons, all commands via Touch Screen
•
Operate with easy to understand “Windows” operating system
•
Have the capacity to control up to 64 Addressable Groups in standard format and be capable
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of
the
•
controlling up to 128 Addressable Groups with optional expansion adapter DCS601A52 using
one touch screen display
Be capable of Remote Access and Open Protocol control (DOMOTICS etc) via a LAN or WEB
connection via the inbuilt Ethernet port
•
Proportional power consumption to make the controller capable of providing energy
monitoring
& client billing requests
Controller Display
On/Off selection
Set Point adjustment (Range 16-32oC)
Fan speed adjustment
Heat/cool/auto changeover mode selection
Frost protection set point
Timer settings
Holiday period settings
Priority settings for restriction of local access for start/stop, heat/cool mode and set point
adjustment range limitation
Reset ability for malfunction codes and filter maintenance warnings
Indoor Units Monitoring Display
Room set point
Room Temperature Display
Operation mode; Heating or Cooling
Display of number of devices operating within system
•
Start/stop operation, set point control, cool/heat mode selection, air volume setting, air flow
direction setting and enabling/disabling operation of the remote controllers by group, zone
or
collectively.
•
Monitoring of operation status of the indoor units, filter change indication and error
code of the
group or the zone.
•
Comprehensive schedule set up to start/stop the air conditioning systems. This can be set
for
year
, month, weekday, hour and minute. This will enable normal day-to-day time clock functions
as
well as yearly holiday set up. Up to 8 settings can be
configured up to 13 months in advance and
allocated to various groups/zones.
•
Volt free forced stop input possible such as fire shut down.
•
Flexible Group/ Zone selection Remote monitoring of common operation/fault.
•
Running cost per indoor unit via software licence.
•
To be connectable to the newly developed Daikin, Hitachi preventative
maintenance system.
•
Possibility to perform monitor operation/fault for 8 separate systems with optional
control board.
•
Possibility to perform on/off control and monitor operation/fault for 4 separate systems
with optional control board.
•
Password protection for zone, group and schedule set-up functions.
•
The controller shall have wide touch screen control colour display and can be wired by a
non-polar 2-wire transmission cable to a distance of 1 km away from the outdoor
units.
•
The controller shall contain an internal power supply system WITHOUT the need for
any
external power supply, the controller shall accept a direct connection of a 230V AC power supply.
REFRIGERANT PIPEWORK
The interconnecting refrigerant piping shall be manufactured from seamless quality phosphorous
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dioxide soft/medium drawn copper to BS2781 Part II ASTM, DIN
1754/8905, fully tested by the eddy current method, dehydrated and capped.
The copper tubing shall be of a suitable thickness to be capable of withstanding pressure test
as detailed in the current revision of BS/EN378.
The copper tubing shall be suitably selected with a wall thickness capable of withstanding the
system operating pressures on Refrigerant R410A, all as described within the outdoor unit’s
installation manual.
Pipework shall be supported and not secured at regular intervals not exceeding 1.5m. Preferably to
create a method of adequate support ant containment, piping should be laid on suitably supported
galvanised cable tray, insulated and held in position with plastic coated steel banding. Due care and
attention shall be taken at all times to allow pipework to freely expand and contract naturally.
Insulation
All Refrigerant pipe work to be insulated with slip-on close cell elastomeric pipe insulation,
with a fire performance rating class “O” of the 1985 Building Regulations, having a wall thickness of
not less than 13mm. After commissioning, all joints to be properly sealed to provide and
adequate seal and clearly marked for ease of identification.
Where required external insulation shall be protected with a suitable enclosure to encase the piping,
as to reduce the effects of Bird, Environmental attack.
REFRIGERANT PIPEWORK INSTALLATION
Pipework shall be installed by a Daikin, Hitachi Approved Installer in accordance with the current
revision of BS/EN378 and in accordance with Design and Installation Instructions and the unit’s
installation manual.
Brazing shall be carried out by skilled operatives, in accordance with the HVCA Code of Practice –
Brazing and Bronze Welding of Copper Pipe and Sheet.
During brazing, oxygen free nitrogen shall be passed through the pipework to displace oxygen and
ensure that oxidisation does not occur.
Longest possible lengths of copper pipe shall be utilised to minimise joints on site.
Appropriate refrigerant tools shall be utilised at all times. The use of hacksaw or any tool that
creates filings is prohibited.
Pipework shall remain capped at all times other than when actually being installed to prevent the
ingress of moisture and contaminants.
CONDENSATE PIPEWORK
Condensate pipework shall be installed by the Daikin, Hitachi Approved Installer in accordance with
Design and Installation Instructions and the unit’s installation manual.
COMMISSIONING & TESTING
Commissioning shall be carried out by a Daikin, Hitachi trained Contracting authority with the
optional assistance of Daikin, Hitachi.
The entire refrigeration system shall be pressurised with Nitrogen to 38 bar for a period of 24hours.
Leak testing shall be carried out with a calibrated electronic leak detector, or similar if the system
fails to hold pressure within testing period.
Upon completion of pressure test the pressure shall be released and vacuum pump installed on
the system to remove air and moisture from the system. The system shall be evacuated to –101.1kPa
(-758mmHg, 2 torr) and held for a period of 2 hours with the vacuum pump switched off.
Refrigerant should be charged to the liquid pipe in its liquid state to ensure that the refrigerant
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composition is assured. The refrigerant charge shall be calculated to the system requirements and
in accordance with Design and Installation Instruction booklet.
QUALITY ASSURANCE
The VRV installation shall be subject to supervised visits by the specialist representative .
The Supervisor will ensure correct system installation takes place in accordance with the
manufacturer’s instructions, relating to refrigerant piping, drainage piping, control wiring, power
wiring and equipment location/positioning.
The vital areas of the installation, including brazing, pressure testing and evacuation shall be checked
by the Daikin, Hitachi Supervisor, prior to commissioning.
Upon Contracting authoritys Instructions, up to two brazed joints per pipework system may be
removed, at the contractor’s expense, for inspection.
Should carbonisation be evident on these joints, the above should be repeated and if further
evidence of carbonisation is evident, then the entire pipework system will be removed and refitted at
no expense to the contract.
The system will be commissioned in the presence of the Daikin, Hitachi Supervisor who will utilise the
Service Checker to confirm correct system operation and to produce a printout of all operational
data relating to each individual system
A log of all system settings, serial numbers, configuration and wiring diagrams shall be compiled and
be presented to the Client as an independent and impartial As Fitted Quality manual for the
complete VRV installation
WARRANTY Standard Terms
Equipment is subject to a three-year warranty, provided that the system complies with the
manufacturers recommendations, and is installed and maintained (throughout the 3-year period
after handing over)
END OF CHAPTER
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DUCTWORK
PART 1 - GENERAL
1.01
SUMMARY
A.
Provide labor, materials, equipment and services, and perform operations required for
complete installation of the Ductwork and Casings and related work as indicated on the
drawings and specified herein.
B.
Work Included: The work shall include, but not be limited to Duct work
C.
Related Work Specified Elsewhere
1.
2.
1.02
QUALITY ASSURANCE
A.
Materials shall conform to the latest edition of industry standards and reference
specifications specified herein and to applicable codes and requirements of local authorities
having jurisdiction, whichever is more stringent.
1.
2.
3.
4.
5.
B.
1.03
Basic Mechanical Requirements - Chapter 15010.
Basic Mechanical Materials and Methods - Chapter 15050.
Fabrication and installation shall comply with Sheet Metal and Air Conditioning
Contractors National Association, Inc. (SMACNA) construction and testing manuals,
latest editions.
Applicable codes and regulations.
NFPA 90 A, Insulation of Air conditioning and Ventilation Systems.
NFPA 90 B, Insulation of Warm Air Heating And Air conditioning Systems.
NFPA 93, Ventilation Control & Fire Protection of Commercial Cooking Operations.
System Performance: The system has been designed for optimum performance. Any
subsequent alterations to the design must be accompanied by a computer analysis or hand
calculations showing that the proposed alterations will still provide the original design
volume without increasing the system total pressure. Any unavoidable field changes to the
original design (offsets, etc.) shall be reported to the Contracting authority so that accurate
"as built" operating parameters may be established.
SUBMITTALS
A.
Submit the following in accordance with the requirements specified under Submittals in
Chapter 15010.
1.
Product Data: Submit manufacturer's technical product data, including performance
data for each size and type of equipment schedule showing drawing designation,
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room location, number furnished, model number, size, and accessories furnished, and
installation instructions.
2. Shop Drawings: Submit shop drawings indicating dimensions, layout, required
clearances, capacities, and methods of assembly of components. Obtain approval of
duct fabrication standards proposed before making any duct layout or fabricating any
ductwork. Indicate deviations from specification requirements and document
Contractor's fabrication standards with SMACNA standards.
3. Submit hangers and supports including methods for building attachment, vibration
isolation and seismic restraints.
4.
Maintenance Data: Submit maintenance data and parts list for each type of air
terminal including "trouble shooting" maintenance guide. Include this data, product
data, shop drawings, and maintenance data in maintenance manual in accordance
with requirements
PART 2 - PRODUCTS
2.01
MATERIALS/EQUIPMENT
A.
General
1.
The Contractor shall supply and erect ductwork of the dimensions and in the
positions indicated on the drawings. The Contractor shall be deemed to have
checked building dimensions on site before the preparation of the ductwork
manufacturing drawings and shall submit these drawings for approval before
commencement of manufacture. The Contractor shall also be required to erect
ductwork in such an order to maintain an overall continuity of work for all trades.
2.
All ductwork shall be manufactured and installed in accordance with SMACNA
Standards and this Specification.
3.
All access opening shall be rigidly framed and fitted speedily removed and refixed. Multiple set screws or self tapping screws are not acceptable as a method
of fixing, unless otherwise stated.
4.
Access doors and other openings in the duct work shall be provided for the
purpose given below.
a.
Access for personal for maintenance and replacement of equipment.
b.
Access for routine maintenance , lubrication and adjustment of items not
requiring full man access.
c.
Access for cleaning.
d.
Access for inspection of items concealed in ductwork ( e.g. dampers,
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fusible links, thermostats ).
5.
e.
Hand holes required to permit proper jointing of ductwork chapters in
awkward location ( these should be kept to a minimum and as small as
possible ). To be sealed after use.
f.
Test holes to permit entry of pilot tubes and other test equipment.
Pressure- Velocity Classification.
Duct Class
Static Pressure Rating
Pressure
Seal Class
Velocity
High Pressure Duct Standard
High Pressure
2.5 Kpa Pos.
A
10 m/s Up
Medium pressure
1.5 Kpa Pos.
A
10 m/s Up
Medium Pressure
1.0 Kpa Pos.
A
10 m/s Up
Medium Pressure
0.75 Kpa Pos.or Neg.
A
20 m/s Dn.
Low Pressure Duct Standard
B.
Low Pressure
0.50 Kpa Pos. or Neg.
B
12.5 m/s Dn.
Low Pressure
0.25 Kpa Pos. or Neg.
C
12.5 m/s Dn.
Low Pressure
0.125 Kpa Pos. or Neg.
D
10 m/s Dn.
Sheet Metal Materials
1. galvanized sheet steel: lock forming quality ASTMA 653/A 653 M,, (G90 or Z275).
2. coating designation : mill-phosphatized finish for surfaces of ducts exposed to view.
3. carbon Steel Sheets: ASTM A366/ A366 M, cold rolled sheets, commercial quality,
with oiled, exposed matte finish.
4. Stainless steel : ASTM A 480/ A 480 M, type 316, sheet form with 4 finish for surfaces
of ducts exposed to view and type 304 sheet form No 1 finish for concealed ducts.
C.
Kitchen Hood Ducts
Exposed kitchen hoods shall be stainless steel 304, 1.2mm thick installed in accordance with NFPA96.
Concealed ducts shall be black steel 1.5 mm thick painted with fire resistive paint and insulated as
specified.
2.08
HIGH VELOCITY DUCTWORK
A.
General
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B.
1.
Ductwork shall be manufactured from strip mill cold reduced sheet , for
rectangular and straight seamed or straight welded circular ductwork, and coil for
spirally wound circular or flat oval ductwork, continuously hot dip galvanized to
G90-ASTM A525-64T, or a similar approved international standard. The galvanized
sheet or coil shall be of lock-forming quality to ASTM A527 capable of being bent
flat upon itself without fracture of the base metal , and shall have zinc coating
weight of at least 275 to 428 g/m, on both sides.
2.
The thickness of metal, angle joints and tie rods shall be as specified below and
the length of the longest side in rectangular and flat oval ductwork shall
determine the thickness of material for straight duct chapters and fittings.
Rectangular Ductwork : High Velocity
1.
Chapters of straight ductwork shall be formed from, where practicable, a single
sheet of sheet steel of thickness as specified below, and shall be jointed
longitudinally by a grooved seam, continue to the extreme ends of the duct and
sealed during manufacture with a jointing compound to prevent air leakage.
2.
The maximum distance between joints or intermediate stiffeners are given in the
SMANCA standard. The size of angle used for the intermediate stiffeners shall be
as specified in the SMANCA Standard. Stiffeners shall be fitted to the outside of
the duct. Tie rods shall be provided on ductwork above 1500 mm wide and shall
be located at each stiffener and joint and shall be of the size and fitted at the
centers. The tie rods shall link oppositely-located stiffeners or angle flanged joints
by means of mild steel rod threaded at two ends secured to each flange by a nut
and lock nut. The tie rod shall pass through a length of mild steel pipe within the
duct , equal to the duct depth and shall be held rigidly by a compressible washer
and the action of the tightening of the nut and lock nut. The mild steel pipe shall
be of the minimum diameter capable of having the tie rod passed through it.
3.
High Velocity Rectangular Duct
a.
Up to 750 Pa - Ductwork may be made in the following thickness without
stiffing :
Up to 250 mm ( longest side )
0.6 mm
251 to 300 mm ( longest side )
0.8 mm
301 to 350 mm ( longest side )
1.0 mm
351 to 450 mm ( longest side )
1.2 mm
450 to 600 mm ( longest side )
1.6 mm
601 and over shall be made with stiffeners.
b.
751 to 1000 Pa - Ductwork may be made in the following thickness without
stiffening:
Up to 200 mm ( longest side )
0.6 mm
201 to 250 mm ( longest side )
251 to 300 mm ( longest side )
0.8 mm
1.0 mm
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301 to 400 mm ( longest side )
401 to 450 mm ( longest side )
1.2 mm
1.6 mm
451 and over shall be made with stiffeners.
c.
1001 to 1500 Pa - Ductwork may be made in the following thickness without
stiffening :
Up to 200 mm ( longest side )
0.6 mm
201 to 250 mm ( longest side )
1.0 mm
251 to 350 mm ( longest side )
1.2 mm
351 to 400 mm ( longest side )
1.6 mm
401 and over shall be made with stiffeners.
d.
1501 to 2500 Pa - Ductwork may be made in the following thickness without stiffening :
Up to 200 mm ( longest side )
0.8 mm
201 to 250 mm ( longest side )
1.2 mm
251 to 300 mm ( longest side )
1.6 mm
301 and over shall be made with stiffeners.
C.
Circular Straight Seamed and Welded Ductwork : High Velocity
1.
D.
Straight chapters of ductwork shall be formed from, where practicable, a single
sheet of sheet steel of thickness as specified previously and shall be jointed
longitudinally by a grooved seam, continued to the extreme ends of the duct,
sealed with jointing compound, for straight seamed ductwork and by continuous
butt or lap welded joint for straight welded ductwork .
Duct Fittings High Velocity
1.
All duct fittings except where stated otherwise, shall be made from the same
material and specification of material as the adjoining ductwork. The specification
with regards to stiffeners, joints, seams and maximum distance between joints
and stiffeners for straight ductwork shall also apply to the duct fittings. The
distance between joints stiffeners of bends shall be taken around the centerline
of the fitting, and stiffeners shall be, when required, arranged in a radial pattern.
The larger dimension in all fittings shall determine the sheet thickness and
stiffening.
2.
Rectangular Fittings
a.
The inside radius of bends shall be 100 mm or equal to the width of the duct,
viewed on the bend, whichever is the greatest.
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b.
Alternatively square bends with turning vanes shall be used. The turning
vanes shall be provided at a maximum spacing of 60 mm across the angle of
the bend, and may be of the single skin or double skin aerofoil type. The
recommended ratio between spacing and the distance between the leading
and trailing edges of the vane, measured in a straight line, is 0.3 for single
skin vanes and 0.5 for double skin vanes. The vanes shall be securely
fastened at each end, to internal runners and the runners attached to the
duct by mechanically closed rivets , bolts or welds, at 150 mm maximum
spacing. Intermediate spacing shall be provided if the length of the vanes
exceed 450 mm for single skin and 750 mm for double skin vanes.
c.
In all cases of change chapters the larger dimension shall determine the
sheet thickness and stiffening. Where expansions and constructions are
required, an expansion shall be made up stream of a branch connection. The
slope of either an expansion or construction shall not exceed 22 1/2 on any
side.
d.
Change of shapes, used to avoid obstructions or to suit available space,
shall, where the cross chapteral area remains unchanged, have a maximum
slope of 22 1/2 on each side of the obstruction. Where the cross chapteral
area changes temporarily, the percentage area reduction shall not exceed
20% and the a maximum contraction slope shall be 22 1/2 and the
expansion slope shall not exceed 15.
Connections to equipment shall have a maximum slope of 30 on expansions
and 45 on contractions on any side.
e.
f.
3.
Circular Fittings : High Velocity
a.
E.
The maximum slopes may be exceeded where space prevents the specified
slope from being used, provided that splitters are fitted such that the angle
of slope and the center line of the duct are divided into chapters, and the
angle between the splitter and the center line of the duct and the angle
between splitters does not exceed the maximum specified. The splitters shall
be securely fixed to the duct in a similar manner to mid-feathers on bend.
The nominal diameter is the size used for design and ordering. Where joints
are socket and spigot, care shall be taken to ensure that the dimensions of
fittings are correctly related to the dimensions of fittings of the ducts.
Fastenings : High Velocity
1.
General
a.
Tables below give the a maximum centers for fastenings for each application.
Only fastenings shown in the tables as being permitted, shall be used for the
application shown. Manufacturers recommendations as to use, size and drill
size are to be followed for solid and mechanically closed rivets. Perforated
rivets shall not be used.
b.
When galvanized material is welded, the areas, where the galvanizing has
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been destroyed, shall be suitably prepared and painted internally and
externally with zinc rich paint plus suitable finishing coat. Welding shall not
be used for sheet less than 1.0 mm thick. In all cases, welded joints shall
provide a smooth internal surface and shall be free from porosity. Distortion
shall be kept to a minimum .
c.
Chapter to chapter fastening shall be performed by 8 mm bolts and nuts at
150 mm maximum centers for both rectangular and circular ductwork. Other
forms of fixing shall not be permitted.
d.
Maximum Centers of Sheet to Sheet Fastenings
Fastening
Rectangular Duct
Split Joints Butt or
Joints
Circular Duct
Lap
Slip Joint
Butt or
Joints
RIVETS
Solid
Mechanically closed
NP
60 MM
NP
NP
NP
3 No. min.
NP
NP
SCREW & BOLTS
Self tapping bolts
6 mm lockbolts
8 mm lockbolts
60 mm
NP
NP
NP
NP
NP
3 No. min.
NP
NP
NP
NP
NP
WELDS
Spot
Plug
Tack
Continuous
NP
NP
NP
NP
NP
NP
NP
Continuous
NP
NP
NP
NP
NP
NP
NP
Continuous
Note: NP = NOT PERMITTED
Maximum Centers of Sheet to Chapter Fastening
Fastening
Rectangular Duct
Circular Duct
Flanged Joint Intermediate Straight Seamed
Spirally
Stiffeners
Wound
RIVETS
Solid
Mechanically closed
150 mm
100 mm
300 mm
150 mm
300 mm
150 mm
NP
NP
SCREW & BOLTS
6 mm lockbolts
8 mm bolt & nut
150 mm
150 mm
300 mm
300 mm
300 mm
300 mm
NP
NP
WELDS
Spot
Plug
Tack
Continuous
75 mm
150 mm
150 mm
Continuous
150 mm
300 mm*
300 mm*
NP
150 mm
300 mm
300 mm
Continuous
NP
NP
300
NP
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*
The welds shall be staggered and a minimum of three shall be used per side.
F.
Supports and Hangers : high Velocity
1.
Where there is a possibility of the transmission of vibration care shall be taken to
isolate the duct from the structure.
2.
Hangers required for the support of horizontal ductwork and its associated
insulation are specified below. Where heavy equipment, mechanical services
ceilings or any other additional load is to be applied, further support may be
required, to suit the greatest load. For large ducts, supports shall be designed to
suit the loading.
3.
Support for Horizontal Rectangular Ductwork
Length of longer side mmDrop rod or hanger
M.S. rod mm
10
10
10
10
10
….
Up to 300
300 – 600
601 – 1000
1001 – 1250
1251 – 1500
1501 & above
Minimum
member mm
M.S. flat mm
25 x 3
25 x 3 flat
25 x 3
40x40x4 angle
25 x 3
50x50x5 angle
25x 3
50x50x5 angle
15 x 3
50x50x5 angle
Design to suit loadings
bearing
Maximum spacing mm
3000
3000
2500
2000
1800
…
The bearing members shall not be required where the hanger is fixed to an angle joint or stiffener.
4.
Support for Horizontal Circular Ductwork
Duct diameter or longest
Drop rod or hanger
Maximum Bearing member mm
side
M.S. rod mm
M.S. flat mm
Straight seamed mm Spirally wound mm
Up to 200
8
20 x 3
1800
3000
201 – 600
8
25 x 3
2500
3500
601 - 1200
10
40 x 4
2500
3500
1201 & above
…
Designed to suit loadings
…
The mild steel flat strip bearer shall not be required if hanger is fixed directly to angle
stiffeners or flanges.
5.
2.09
The design of supports for vertical ducts is directed by site conditions, and
spacings may be greater than for horizontal ducts. Vertical ducts shall be
supported by the stiffening angles or the angle flanges, but where this is
impracticable, supporting angles shall be fixed to the duct.
LOW VELOCITY DUCTWORK
A.
General
1.
Materials shall be as specified in clauses 2.1 and 2.2 except that thickness
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stiffening and joints shall be as specified below.
Supply and install sheet metal ductwork for the air conditioning and the
ventilating systems as shown on the drawings and as detailed below.
The Contractor shall check the building dimensions and the dimensions and
positions of plant on site before the fabrication of ductwork are started. All
seems, joints and connections to plant shall be made so as to reduce air leakage
to a minimum. Internal roughness and obstructions to airflow (other than
dampers, vanes, etc.) will not be accepted. Sharp edges or corners on the outside
of ductwork, flanges, supports, etc. will not be accepted. Any part of galvanized
ductwork where the galvanizing is damaged during manufacture or erection shall
be painted with two coats of aluminum, zinc rich or other corrosion resisting
paint.
B.
Ductwork
Provide all ductwork, plenums, fittings and related sheet metal work shown,
noted and/or specified for the air conditioning and ventilating systems.
Provide wood frames for air outlets fixing and duct passage through no fire rated
walls and slabs.
Conform accurately to the layout indicated on the drawings, and construct to be
straight and smooth on the inside with all joints neatly finished.
Securely anchored to the building construction in an approved manner, and
installation to be completely free from vibration and pulsing under all operating
conditions.
Contractor shall be fully responsible for all off-sets, up-slopes, down-slopes, etc.
necessary to avoid conflict with lighting fixtures, sanitary piping, etc.
Bends and offsets shall have a minimum throat radius equal to the width of the
duct. Where short radius elbows are indicated or are agreed by the Contracting
authority as necessary due to site limitations the dimensions and internal vane(s)
shall be in accordance with duct detail drawings.
Low pressure flat ducts over 450 mm wide shall be stiffened by cross breaking.
All exposed ductwork shall be painted with one coat of primer suitable to
galvanized steel and two coats of finishing paint of type and color as approved by
the Contracting authority.
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C.
Rectangular Ductwork : Low Velocity
1.
The ductwork construction shall be used on the Duct Construction Standards as
laid by The Sheet Metal and Air Conditioning Contractors National Association (
SMACNA )
2.
Material thickness is to be based upon a pressure velocity classification as
indicated below . Thickness is dependent upon the relationship between the
pressure class as depicted in this table and the frequency/type of supports.
3.
Up to 125 Pa - Ductwork any be made in the following minimum thickness with no
additional stiffening :
Up to 400 mm
( Longest side )
401 to 600 mm
( Longest side )
601 to 650 mm
( Longest side )
651 to 750 mm
( Longest side )
751 to 900 mm
( Longest side )
901 mm and over shall be made with stiffeners.
4.
126 Pa to 250 Pa - Ductwork may be made in the following minimum thickness
with additional stiffening.
Up to 350 mm
( Longest side )
351 to 450 mm
( Longest side )
451 to 500 mm
( Longest side )
501 to 650 mm
( Longest side )
651 to 750 mm
( Longest side )
751 mm and over shall be made with stiffeners.
5.
0.6 mm
0.8 mm
1.0 mm
1.2 mm
1.6 mm
250 Pa to 500 Pa - Ductwork may be made in the following minimum thickness
with no additional stiffening.
Up to 300 mm
( Longest side )
301 to 350 mm
( Longest side )
351 to 450 mm
( Longest side )
451 to 500 mm
( Longest side )
501 to 600 mm
( Longest side )
601 mm and over shall be made with stiffeners.
6.
0.6 mm
0.8 mm
1.0 mm
1.2 mm
1.6 mm
0.6 mm
0.8 mm
1.0 mm
1.2 mm
1.6 mm
Thinner materials may be used but stiffening must be added to comply with tables
1-3 through 1-9 of the SMACNA Standards. Proposed thickness are :
Largest duct size
Sheet Metal Thickness
0 – 300 mm
310 – 750 mm
760 – 1500 mm
1510 – 2200 mm
0.6 mm
0.7 mm
0.9 mm
1.0 mm
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D.
Duct Fittings : Low Velocity
1.
All duct fittings except where stated otherwise, shall be made from the same
material and specification of material as the adjoining ductwork. The
specifications with regards to stiffeners, joints, seams and maximum distance
between joints and stiffeners for straight ductwork shall also apply to the duct
fittings. The distance between joints stiffeners of bends shall be taken around the
centerline of the fitting, and stiffeners shall be , when required, arranged in a
radial pattern. The larger dimension in all fittings shall determine the sheet
thickness and stiffening.
2.
Rectangular Fittings
a.
The inside radius of bends shall be 100 mm or equal to the width of the
duct, viewed on the bend, whichever is the greatest.
b.
Alternatively square bends with turning vanes shall be used. The turning
vanes shall be provided at a maximum spacing of 300 mm across the
angle of the bend, and shall be double skin aerofoil type. The
recommended ratio between spacing and the distance between the
leading and trailing edges of the vane, measured in a straight line, is 0.5.
The vanes shall be securely fastened at each end, to internal runners and
the runners attached to the duct by mechanically closed rivets, bolts or
welds, at 150 mm maximum spacing.
c.
Branch piece shall conform to the standards American take-off that
incorporates an aerofoil splitter damper pivoted at one end. The throat
dimensions for branch ducts emanating from the side of the duct run shall
be calculated from the equation 1.
t = v1 . W ------- 1
v2
Throat dimensions for small branch ducts which maintain the depth of the
branch duct on connection to the main duct shall be calculated from
equation 2.
t = v1 . W.D2 ------- 2
v2 D1
Where t
V1
V2
=
=
=
D1
D2
W
=
=
=
Throat dimension
Air volume in branch
Air volume in main duct before branch take
off.
Depth of branch duct.
Depth of main duct before branch take off.
Width of main duct before branch take off.
The splitter damper shall be capable, in the case of a full depth branch, of
isolating either branch of main. The splitter damper rod shall extend
outside the ductwork to a hand control lever with a locking device.
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d.
e.
E.
In all cases of change chapters the larger dimensions shall determine the
sheet thickness and stiffening . Where expansions and contractions are
required, an expansion shall be made up stream of a branch connection
and a contraction downstream of a branch connection. The slope of either
an expansion or contraction shall not exceed 22 1/2 on any side.
Change of shapes, used to avoid obstructions or to suit available space,
shall , where the cross chapteral area remains unchanged, have a
maximum slope of 22 1/2 on each side of the obstruction. Where the
cross chapteral area changes temporarily, the percentage area reduction
shall not exceed 15.
f.
Connections to equipment shall have a maximum slope of 30 on
expansions and 45 on contractions on any side.
g.
The maximum slopes may be exceeded where space prevents the
specified slope from being used, provided that splitters are fitted such
that the angle of slope and the center line of the duct are divided into
chapters, and the angle between the splitter and the center line of the
duct and the angle between splitters does not exceed the maximum
specified. The splitters shall be securely fixed to the duct in a similar
manner to turning vanes on bends.
Fastening : Low Velocity
1.
Permitted Sheet to Sheet Fastening
Fastening mm
RIVETS
Solid
Mechanically closed
WELDS
Spot
Plug
Continuous
2.
Maximum Spacing mm
60
60
30
60
Continuous
Permitted Sheet to Chapter Fastening s
Fastening
Maximum
spacing
for cross joints mm
Maximum spacing
for intermediate
stiffeners
RIVETS
Solid
Mechanically closed
150
100
300
150
LOCK BOLTS
150
300
BOLTS & NUTS
150
300
WELDS
Spot
Plug
Tack
75
150
150
150
300
300
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The minimum number of fastening per side or per stiffener relating to table shall be three.
3.
Permitted Chapter to Chapter Fastening.
Fastening mm
Maximum Spacing mm
LOCK BOLTS
BOLTS & NUTS
150
150
The minimum number of fastening per side relating to Table above shall be two .
F.
Supports and Hangers : Low Velocity.
1.
Length of longer side mm Drop rod or hanger
Minimum
member mm
bearing
Maximum
spacing mm
M.S. rod mm
M.S. flat mm
Up to 500
10
25 x 3
25x25x3 angle
3000
501 - 800
10
25 x 3
40x40x4 angle
3000
801 - 1000
10
25 x 3
40x40x4 angle
2500
1001 - 1500
10
25x 3
50x50x5 angle
2500
1501 – 2250
12.5
40 x 3
100x50 channel
2000
Above 2250 to suit loading -----------------------------------------------------------------------
G.
2.
The bearing member shall not be required on ductwork above 1500mm where the hanger
supports are fixed to the duct joints, due to the provision of the angle flanges.
3.
No screws, bolts or other fittings for brackets or supports shall penetrate the air duct.
4.
The design of supports for vertical ducts is dictated by the site conditions and spacing may
be greater than that of horizontal ducts . Vertical ducts shall be supported by the
stiffening angles, or angle flanges, but where this is impractical, supporting angles shall be
fixed to the duct. Fastenings shall be in accordance with the table for cross joints.
Sealants
1.
H.
Sealants shall be of the liquid/mastic type which permanently retain adhesion and
elastically throughout a temperature range of 0°C to 70C . The sealant shall be applied
with a brush or gun and shall completely seal the joints. Sealant shall be applied on all
duct joints and seams.
Duct Protection
The Contractor shall by means of polyethylene or similar sheeting protects all openings in
ductwork during erection to prevent the collection of dust and dirt during the building
construction.
He shall be responsible for removing all these sealers from the systems prior to the plan being
commissioned.
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He shall nevertheless be responsible for cleaning all ducts internally before the plant is
commissioned, the provision of the seals being a precaution aimed at reducing the amount of
cleaning necessary.
I.
Duct Leak Test & Sealing
The Contractor, shall when the main fans are operable, test all flanged joints, access doors or
panels, hand holes and test points with soap and water. Any joints failing the test shall be remade.
Insulation shall not be applied until this test has been made.
J.
Silencing & Acoustic
The Contractor shall be responsible for the quietness of the equipment in respect of vibration and
sound transmission to the structure and occupied spaces.
Where it is necessary to provide silencing equipment, anti vibration inserts mountings and other
acoustic devices, the Contractor shall include them in his tender.
K.
Duct Lining- Internal Insulation
Where ducts are to be provided with internal absorbent linings to meet the Contractor's
requirements in respect of silence, the Contractor shall provide 25 mm thick non-inflammable
resin bonded mats of glass fiber 48 kg/m3 that have a strong film of PVC sheet on the air flow
side. Such mats shall be secured to ducts with synthetic resin or other suitable adhesives and
aluminum strips. See Chapter 15200. Material and adhesive shall comply with NFPA 90 A or 90 B
and ASTM C916.
The type of external insulation required will be specified under normal insulation.
L.
Plenum Boxes
Plenum boxes construction and installation shall be similar to ductwork with internal duct lining as
specified above.
2.10
FLEXIBLE DUCTWORK
A.
General
1.
Where flexible connections are indicated or required between rigid ductwork and
particular component or items of equipment the internal diameter of the flexible duct
shall be equal to the external diameter of the rigid duct. The use of flexible ductwork
between rigid chapters of sheet metal ductwork to change direction or plane will not be
permitted except where indicated.
2.
The flexible duct shall have a liner and a cover of rough heat-resistant fabric equal in
durability and flexibility to glass fiber fabric and shall be impregnated and coated with
plastic. It shall be reinforced with a bonded galvanized spring steel wire helix between the
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liner and the cover and an outer helix to glass fiber cord, or equal shall be bonded to the
cover to ensure regular convolutions. Insulation shall be as specified for rigid steel.
2.11
3.
Alternatively, where indicated on drawings the flexible duct shall consist of flexible
corrugated metal tubing of aluminum. The metal may be lined on the inside or the outside
or both with plastic material. The joints to rigid spigots shall be sealed with a brush coat of
pipe jointing paste or mastic compound. Ducts up to 150 mm diameter shall be secured
with a worm drive type hose clip complying with BS 3628. Ducts over 150 mm diameter
shall be secured with a band clip. Insulation shall comply with regulator rigid duct.
4.
The frictional resistance to the air flow per unit length of the flexible duct shall not exceed
50% more than the frictional resistance per unit length of the galvanized steel ducts of
equivalent diameter. The radius ratio R/D for bends shall not be less than 2. Where R is
the centre line radius and D is the diameter of the flexible duct.
5.
The leakage from any chapter of flexible air duct shall not exceed 1% of the design air flow
rate at the static operating pressure.
6.
Flexible ducts shall be suitable for an operating temperature range of -18C to -120C and
shall comply with BS 476 Part 1, Chapter 2, Clause 7 ( class 1 : surface of very low flame
spread).
7.
Flexible ducts shall be supported at 1 meter centers.
DAMPERS
All dampers shall be fabricated by an approved Manufacturer and not by the Mechanical
Subcontractor duct-man .
A.
B.
Regulating Dampers
1.
Sufficient dampers shall be provided to regulate and balance the system. Dampers on
grilles or diffusers shall be used for fine or secondary control. All dampers shall be
sufficiently rigid to prevent fluttering. The air leakage past dampers in the fully closed
position shall not exceed 5% of the maximum design air flow in the duct. All duct dampers
except fire dampers and self-closing dampers, shall be fitted with locking devices and
position indicators.
2.
Each primary control damper shall be fitted with a non-corrodible label stating the actual
air flow in m/s and the cross chapteral area; alternatively, these figures shall be painted in
a visible position on the adjoining ductwork or insulation. The position of a damper as set
after final regulation and balancing shall be indelibly marked on the damper quadrant.
3.
Motorized dampers shall be fitted with a Electric actuator as described in Chapter 15900
of the specification.
Multileaf Dampers
1.
Multileaf dampers shall be used in rectangular ducts having a short side dimension in
excess of 300 mm. All multileaf dampers shall be constructed on demountable ductwork
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chapters, which shall extend beyond the swing of the blades. The blades of the damper
shall operate on the opposed blade principle unless required solely for isolation, in which
case they may be arranged for parallel operation.
C.
D.
2.
No damper blade shall exceed 150 mm in width and where dampers are required for
greater widths, the damper chapters shall be constructed in multiple frames. Individual
dampers blades shall not exceed 225 mm in height. Each leaf of a multileaf damper shall
consist of two plates of material of the same thickness as the associated duct and rigidly
fixed to each side of an operating spindle, the ends of which shall be housed in brass,
nylon, oil impregnated sintered metal, PTFE impregnated or ball bearings. The ends of the
spindles shall be linked so that one movement of the operating handle shall move each
leaf an equal amount. An inspection door shall be provided adjacent to each multileaf
damper.
3.
On low velocity systems only, multileaf damper blades may be of a single plate, at least
1.6 mm thick and suitably stiffened and the blade linkages may be within the duct. These
dampers shall have bearings and inspection doors as specified above.
4.
Quadrants and operating handles shall be of die-cast aluminum with the words “OPEN”
and “CLOSED” cast on the quadrant. Quadrants shall be securely fixed and the damper
spindles shall be close fitting in the quadrant hubs to prevent any damper movement
when the damper levers are locked.
Single Blade Dampers
1.
In ductwork 300 mm or less, single blade dampers may be used. The blade shall be made
from a single plate, at least 1.6 mm thick and suitably stiffened. One end of the damper
spindle shall be housed in brass, nylon, oil impregnated sintered metal, PTFE impregnated
or ball bearings. The other end shall extend beyond the damper casing with an operating
handle and quadrant.
2.
Quadrants and operating handles shall be of die-cast aluminum with the words “ Open” &
“Closed ” cast on the quadrant. Quadrants shall be securely fixed and the damper spindles
shall be close fitting in the quadrant tubes to prevent any damper movement when the
damper levers are locked.
Pressure Relief Dampers
Pressure relief dampers shall be combination of weather resistant louvers and multileaf pressure
relief dampers with masonry sub-frames .
Masonry sub-frames and pressure relief dampers casing shall be of galvanized sheet steel with
weather resistant louver of extruded aluminum chapters. Pressure relief dampers blades shall be
of anodized extruded aluminum. All other accessories shall be of stainless steel.
Relief damper shall be fitted with pressure deferential regulator to maintain specified pressure
with stairwells.
Relief damper installated on roof slab shall be mounted in a louvered pent house. Louvered pent
house shall be made of 4 louvered sides and one cover. The sides are joined at the four corners by
sheet metal screws in each louver. The cover is securely fastened to the unit by stainless steel
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sheet metal screws.
The louvered pent house shall be designed for low pressure drop and shall be constructed of
aluminum. The removable cover shall be lined with fiber glass to prevent condensate. Louvered
pent house shall include bird screen and relief damper with pressure differential as described
before louvered penthouse.
E.
Back Draft Dampers
Supply and install gravity dampers wherever shown on the Drawings and with the airflow
direction indicated therein.
Gravity dampers shall consist of:
-
Galvanized sheet steel frame.
Aluminum blades.
Stainless steel bearing shafts and brass bearings.
Neoprene seal to withstand 120 deg.C. air temperature.
Aluminum blade travel stop.
All blades shall be coupled together by means of an aluminum bar.
2.13
A.
FLEXIBLE JOINTS
General
1.
Flexible joints shall be provided on the fan inlet and outlet connections and elsewhere on
the ductwork where indicated. They shall be of the full cross chapteral area of the mating
fan inlet, outlet or duct chapter. The ends of the ducts or the duct and the fan connection
shall be in line.
2.
Flexible joints shall consists of , or be protected by material having a fire penetration time
of at least fifteen minute when tested in accordance with the BS 476 Part 1, Chapter 3.
The material shall be of the glass fibre cloth type; canvas will not be accepted. The width
of joints from metal edge to metal edge shall not be less than 80 mm and not more than
250 mm.
3.
All flexible joints other than fan inlet connections shall be between flanged ends. The
flexible material flange shall be backed by an angle or flat iron flange and the flexible joint
shall be securely held between the metal flanges. Flat iron bands used with fan inlets shall
be not less than 5 mm thick.
PART 3 - EXECUTION
3.01
GENERAL
A.
Air- handling units, fans and equipment generally shall be floor mounted on 100 mm raised
concrete housekeeping pads and supported from building structural frame using vibration
isolators. Provide all supporting steel, anchors etc. required to properly support the unit.
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B.
Replace throwaway filters just prior to building acceptance and after the system has been
balanced.
3.02
CONNECTIONS TO BUILDER’S WORK
A.
Where metal ducts and fan inlets and outlets connect to builder’s work, connections shall be by
either built-in timber frames or built-in companion rings or flanges. Built-in timber frames shall be
used except where the connection is to be made in fire barrier walls or in the fixing of fire
dampers. Timber frames shall be constructed in hardwood of 50 mm minimum thickness.
Companion rings or flanges shall be provided with an adequate number of suitably sized rag bolts
or similar fixing devices.
B.
In all cases the duct end shall be finished with a mating flange and where this is fixed to a timber
frame the flange shall be wide enough to overlap the joint between timber and masonry by least
15 mm.
C.
The material of the duct shall be extended in the form of a spigot, beyond the flanged connection
and into the builder’s work cavity.
D.
Joints between mating flanges and companion rings or hardwood frames shall be fitted with a
sealing gasket as specified previously.
3.03
DUCTWORK INSTALLATION
A.
General
B.
1.
All external ductwork shall be galvanized after manufacture. Ducting passes through the
roof, it is to be fitted with angle flanges and a weather cravat welded to the ducting or
other approved method. External ductwork shall be protected by one coat of calcium
phumbate primer followed by two coats of zinc chromate paint.
2.
Where ductwork is to be galvanized after manufacture in order to restrict the distortion
encountered in galvanizing such ductwork it shall be manufactured from thick sheet.
3.
Where a continuous vapor barrier is required, supports shall not be connected directly to
the duct stiffening or flanges. The insulation and vapor barrier should be abutted to an
insulator incorporated with the duct support. The insulator shall be incompressible and
made from hardwood, rot-proofed soft wood or other approved material
4.
Support drop rods and bolts shall be bright steel, nuts and washers shall be sheradized.
Access Doors and Panels, Test Holes
1.
Hinged access doors should not be larger than 600 mm high by 600 mm wide unless
necessary for equipment handling. Doors should preferably open against the air pressure.
Both the opening in the duct and the access door itself should be adequately reinforced to
prevent distortion. A suitable sealing gasket shall be provided together with sufficient
clamping type latches to ensure an air-tight and water-tight seal between the door and
the duct. The latches shall have handles to operate from both the inside and outside of
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the door.
C.
2.
Removable access covers shall not be larger than 375 mm wide by 300 mm high, unless
essential for access to equipment, in which case the size shall be agreed. The opening in
the sufficiently rigid shall be provided distortion. A suitable sealing gasket shall be
provided with sufficient fastenings to ensure an air-tight seal.
3.
Access openings in insulated ducts shall have door frames extended beyond the face of
the duct by a measurement equal to the thickness of the insulation and be so arranged
that the insulation and finish can be ‘dressed’ into the frame, thereby ensuring that the
opening is not concealed and that the edges of the insulation are protected from
accidental damage. The access door shall be dished to contain the insulation.
4.
Test holes for instruments shall be provided at regular intervals along the ductwork and to
enable fan duties to be tested and the performance of regulating dampers to be accessed.
All holes shall be 25 mm diameter and provided with an effective seal.
Flexible Joints
1.
Flexible joints shall be of full cross-chapteral area of the mating equipment connections
and duct chapter and the ends of the duct and equipment connection shall be in line.
2.
The flexible joints shall be manufactured from fire rated reinforced Neoprene or glass
fibre cloth and not be less than 75 mm wide ( metal edge to metal edge) and not more
than 250 mm wide.
3.
Flexible joints shall be normally fitted to suction and delivery connections of all fans and
at expansion joints in buildings. Any other requirements shall be indicated on the
drawings.
4.
On rectangular connections, the flexible material shall be held in place by a mating flange
with a backing plate. If proprietory material is used, the metal edge shall be held in
position by a backing plate or angle flange. Backing plates shall be not less than 3 mm
thick.
5.
On spirally wound circular ducts, a coupling shall be attached to duct ends to provide a
smooth surface and ends carefully cleaned with a suitable solvent over a length of 100
mm.
6.
On all circular spigots, the flexible material is to be secured by a clipband with adjustable
screw or toggle fittings. Unless a proprietry metal edged material is used when screws and
sealant may be used.
7.
Flexible ducts may be used to overcome difficult connections between rigid components
but the minimum amount shall be used to prevent excess pressure drop. In normal
circumstances, connections should not exceed six diameters. Adequate support must be
installed to prevent the ductwork sagging. The Contractor shall ensure that the properties
of the flexible duct comply with the fire regulations applying to the building.
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D.
E.
F.
G.
Sealants and Gaskets
1.
The sealant shall be applied with a brush or gun and shall completely seal the joint. The
ductwork must not be pressurized until the sealant has cured. The jointing between
angles shall be suitable gaskets or mastic sealant.
2.
The gasket shall not be less than 3mm thick for ducts of up to 1mm sheet thickness or not
less than 4mm for ducts of up to 1.2mm sheet thickness. Before application of the sealant,
all surfaces shall be thoroughly cleaned.
Connections
1.
Ends of chapters where connecting to grilles and diffusers shall be flanged or shaped
according to the connection required. Sharp edges or corners on ducts, associated
equipment, supports, angle stiffeners etc., shall not be permitted. All duct edges shall be
painted with zinc chromate paint. Ductwork where the galvanized protection is damaged
during manufacture or erection, shall only be accepted, by applying two coats of zinc
chromate paint and a final coat of aluminum paint.
2.
Exposed ductwork shall have 75 mm clearance from walls and ceilings for cleaning
purposes.
Supports
1.
Supports and brackets for ductwork shall be purpose made and adjustable, fixed to the
building structure with special brackets and cantilevers and spaced to ensure adequate
support and where practicable, should be fitted at each joint of the ductwork.
2.
Vertical ducts shall be supported by the stiffening angles or angle flanges but where this is
impractical, supporting angles should be fixed to the duct. Spacing of supports for vertical
ducts may be at greater intervals than for horizontal ducts.
Air Leakage Tests
1.
For testing of ductwork and equipment see Chapter 15050.
3.04
INSTALLATION OF KITCHEN HOOD DISHWASHER DUCTWORK
A.
Ductwork for the kitchen hoods and dishwasher shall be fabricated and installed in accordance
with the Uniform Mechanical Code, Chapter 20. Exposed ducts shall be of stainless steel. Hidden
ducts shall be of black steel painted and insulated as specified. All duct connections shall be flange
type with fire rated gasket. Access doors shall be provided at each change of direction.
3.05
INSTALLATION OF AIR GRILLES
A.
Install air outlets and inlets in accordance with manufacturers written instructions and in
accordance with recognized industry practices to insure that products serve intended functions.
B.
Coordinate with other work, including ductwork and duct accessories, lighting, structural and
Architectural elements, as necessary to interface installation of air outlets and inlets with other
work.
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C.
Locate ceiling air diffusers, registers, and grilles, as indicated on general construction "Reflected
Ceiling Plans" or as approved by Contracting authority. Unless otherwise indicated, locate units in
center of acoustical ceiling modules.
D.
Diffuse supply air to assure air velocities not in excess of (50 fpm) 0.017 m/s at 1.8m or less above
the floor line. Mix room air with the primary air by induction to effect subsequent equalization of
the room temperature without stratification. Install all outlets in accordance with manufacturer's
recommendations.
E.
For outlets used with under-the-window or wall units, coordinate the outlet dimensions,
arrangement and pressure drop with the units and enclosure to assure compatibility.
F.
Outlets shall comply with applicable noise criteria specifications.
3.06
FIELD QUALITY CONTROL
A.
Tests During Construction
1.
During construction of the duct systems and before the application of insulation, one or
more designated duct chapters shall be tested for each Duct Construction Class and for
each Leakage Class for each system as designated by and in accordance with the
SMACNA"HVAC Air Duct Leakage Test Manual", including casings and flexible runouts in
the presence of the Contracting authority. The Contracting authority shall establish the
sizes and locations of test chapters. The designated duet chapter shall represent a
minimum of 25% of each system. If any chapter has three (3) chapter failures, the entire
system shall be tested.
2.
The testing shall be performed by the Mechanical Subcontractor and supervised by
Contracting authority familiar with testing procedures. See Chapter "Testing and
Balancing of Mechanical Systems."
3.
The size of the test chapter may vary from a complete supply or exhaust system to a
portion of a system, depending on its complexity and size. The Contracting authority shall
use Appendix F in the aforementioned SMACNA Manual as a guide in determining test
chapter sizes and locations.
4.
Refer to Chapter 15991 for Testing & Commissioning.
END OF CHAPTER
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AIR OUTLETS AND INLETS
PART 1 - GENERAL
1.01
SUMMARY
A.
Provide all labor, materials, equipment and services, and perform all operations required for
complete installation of the Air Outlets and Inlets and related work as indicated and
specified herein.
B.
Work Included: The work shall include, but not be limited to, the following:
1.
2.
C.
Related Work Specified Elsewhere
1.
2.
1.02
Basic Mechanical Requirements
Basic Mechanical Materials and Methods
QUALITY ASSURANCE
A.
1.03
Diffusers
Grilles
Codes and Standards
1.
ARI compliance - Test and rate air outlets and inlets in accordance with ARI 650
"Standard for Air Outlets and Inlets".
2.
ASHRAE Compliance - Test and rate air outlets and inlets in accordance with ASHRAE
70 "Method of Testing for Rating the Air Flow Performance of Outlets and Inlets".
SUBMITTALS
Submit the following in accordance with the requirements specified
1.
Product Data: Submit manufacturer's technical product data for air outlets and inlets
including:
a.
2.
Data sheet for each type of air outlet and inlet, and accessories furnished,
indicate materials of construction, finish, mounting details and method of
assembly of components. Mark data with specification type.
Shop Drawings:
a.
Shop drawings of diffusers, registers and grilles must include complete schedule
for each diffuser outlet type indicating drawing designation, room location,
number furnished, model number, size and accessories furnished. Mark data
with specification type.
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3.
1.04
b.
In all cases, prepare and submit a schedule of grilles, diffusers and registers to
the Contracting authority for approval of size and design of outlets before
ordering for installation.
c.
Submit samples for approval where required by Contracting authority and three
samples of each type of finish furnished.
Maintenance Data: Submit maintenance data including cleaning instructions for
finishes, and spare parts lists. Include this data, product data, and shop drawings in
maintenance manual in accordance with requirements.
DELIVERY, STORAGE AND HANDLING
A.
Deliver air outlets and inlets wrapped in factory-fabricated containers. Identify on outside
of container type of outlet or inlet and installation location. Avoid crushing or bending and
prevent dirt and debris from entering and settling in devices.
B.
Store air outlets and inlets in original cartons and protect from weather and construction
work traffic. Where possible, store indoors. When necessary to store outdoors, store
above grade and enclose with waterproof wrapping.
PART 2 - PRODUCTS
2.01
GENERAL
Provide all grilles, diffusers, ceiling return inlets, bar grilles, etc., as shown and noted on the
drawings. Models shall be approved by the Contracting authority and shall be selected carefully so
as to permit good air distribution inside the air conditioned space and keep air motion and noise
within acceptable limit.
The fixing of grilles and diffusers to the ductwork shall be by means of spring. External screws will
not be accepted.
All grilles and diffusers shall have suitable colour finish as approved by the Contracting authority.
2.02
GRILLES AND REGISTERS
Supply, return or exhaust air grilles shall have two sets of separately adjustable louvers, one set
horizontal and one set vertical, and shall be complete with an opposed blade multy-leaf damper.
This air controller shall control both the volume of air passing and the distribution of air across the
grille face. The louvers and the damper shall be adjustable from the front of the grille.
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2.03
CEILING DIFFUSERS
Ceiling diffusers shall be of heavy gauge extruded aluminum construction mechanically assembled
and anodized.
Diffusers shall be provided with volume control dampers and equalizing deflector that shall be
adjustable from the front of the diffuser.
2.04
EXTERNAL LOUVERS
All louvers for fresh air and exhaust air shall be fabricated from heavy duty aluminum extrusions.
The horizontal blades shall be angle down towards the front of the louvers and each blade shall
have a down turn at the front and up turn at the back edges in such a manner that the ingress of
rain is prevented. Each blade shall be securely fixed to the surrounding frame.
All louvers shall be fitted with an aluminum bird wire screen on the inside face.
2.09
DOOR LOUVERS
Supply and deliver door louvers to the door manufacturer for installation.
The door louvers shall be sized so that the face velocity does not exceed 250 fpm (1.3
m/s) unless otherwise indicated on the Drawings.
The louver shall be extruded aluminium completely lightproof V-Chapter with double
frame.
PART 3 - EXECUTION
3.01
EXAMINATION
A.
3.02
Examine conditions at the job site where work of this chapter is to be performed to insure
proper arrangement and fit of the work. Start of work implies acceptance of job site
conditions.
PREPARATION
A.
Examine the Contract Drawings and specifications in order to insure the completeness of
the work required under this Chapter.
B.
Verify all measurements and dimensions at the job site and cooperate in the coordination
and scheduling of the work of this chapter with the work of related trades, so as not to
delay job progress.
C.
Provide all templates as required to related trade for location of all support and anchorage
items.
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3.03
INSTALLATION
A.
Install air outlets and inlets in accordance with manufacturers written instructions and in
accordance with recognized industry practices to insure that products serve intended
functions.
B.
Coordinate with other work, including ductwork and duct accessories, lighting, structural
and Architectural elements, as necessary to interface installation of air outlets and inlets
with other work.
C.
Locate ceiling air diffusers, registers, and grilles, as indicated on general construction
"Reflected Ceiling Plans" or as approved by Contracting authority. Unless otherwise
indicated, locate units in center of acoustical ceiling modules.
D.
Diffuse supply air to assure air velocities not in excess of 50 fpm at 6 feet or less above the
floor line. Mix room air with the primary air by induction to effect subsequent equalization
of the room temperature without stratification. Install all outlets in accordance with
manufacturer's recommendations.
E.
For outlets used with under-the-window or wall units, coordinate the outlet dimensions,
arrangement and pressure drop with the units and enclosure to assure compatibility.
Outlets shall comply with applicable noise criteria specifications.
END OF CHAPTER
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TESTING, ADJUSTING AND BALANCING OF MECHANICAL SYSTEMS
PART 1 - GENERAL
1.01
RELATED WORK
A.
1.02
SYSTEM DESCRIPTION
A.
1.03
Division 15 - Mechanical
This Chapter covers the testing and commissioning requirements for air handling, piping
controls and mechanical systems generally. The Contractor to comply with the
requirement of this chapter and to follow the procedure set for testing, commissioning and
balancing. irrespective of the presence of the specialized company selected by the
Contracting authority to supervise or execute the works described in this chapter.
QUALITY ASSURANCE
Testing & commissioning shall be executed by a specialist independent company for
commissioning, testing & balancing. The independent testing, balancing and commissioning
company is to have no vested interest in the project and not belong wholly or partly to a company
related to the supply or design of HVAC equipment or systems. Not depending on the Specialist
assigned by the Contracting authority. The Contractor shall execute his own testing, commissioning
and shall provide all the necessary tools, material, consumables and labour to execute this tank to
the approval of the Contracting authority. The Contractor shall submit all the necessary manuals
and shall comply fully with the requirements of this chapter.
The independent company must have been established and carried out commissioning works on at
least five similar projects in Lebanon. The Contracting authoritys employed by the independent
Commissioning Company shall have at least 5 years proven experience within commissioning.
Testing and balancing.
All Contracting authoritying services systems are to be thoroughly commissioned and tested to
prove that they are capable of achieving the specified performance, to prove the correct and stable
operation of all control systems and are safe to operate and maintain.
Specialized companies shall have international testing and commissioning certificates such as NEBB
or equivalent international instituted.
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1.04
SUBMITTALS
A.
Testing and Balancing
1.
2.
3.
4.
Certificate
a.
Submit Warning Certificate.
b.
Fully detailed method statements are to be provided in advance for
approval for each system to indicate the methods to be employed.
Tests are to be carried out in accordance with agreed recognized standards
such as those produced by C.I.B.S.E / B.S.R.I.A or NEBB.
Data Sheets
a.
Submit typewritten data sheets on each item of testing equipment to be
used.
b.
Include name of device, manufacturer’s name, model number, latest data
of calibration, calibration due data and correction factors.
c.
All products and instrumentation used shall be subject to approval.
Report Forms
a.
Submit specimen copies of report forms, for approval for their use on this
project.
b.
Forms shall be quarto paper for loose leaf binding, with blanks for listing of
the required test ratings and for certification of report.
Testing & Operational Manuals
Including all test results, operation procedure of systems, spare parts' lists,
maintenance procedure catalogue cuts and all other information requested by the
Contracting authority for proper handover of system and operation by
maintenance staff.
Provision Of Test Point And accessories.
All required test points, although not mentioned in the BOQ, are deemed
to be included in the pipework and ductwork installations and included in
the unit rate of these systems. The contractor shall allow sufficient points
and where required by the Contracting authority for the correct and
complete regulation, testing and commissioning. All test points shall be
indicated on the working and record drawings. Test points shall be fitted
with removable plugs, flanges or other approved devices appropriate to
the service concerned .
Balancing valves and dampers shall be included on every main branch and
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subcircuit to facilitate system commissioning. All such devices shall be
identified on the working drawings and submitted for approval.
Each volume control damper and fire damper shall be complete with
adjacent access panel.
Balancing valves shall be propriety commissioning sets consisting of double
regulating valve and close coupled orifice plate.
The Contractor shall prepare system loading diagrams for each system including
control dampers, regulating valves and test points and shall indicate their physical
location in pipework or ductwork.
Environmental tests are to include, where necessary, the provision of artificial
loads to simulate the full range of operating conditions. The correct operation of
each system is to be demonstrated on completion of the commissioning and
testing.
Recording of Test Results :
The Contractor shall give 7 days notice, to the Contracting authority in writing, prior
to any regulation, testing and balancing being undertaken to enable he Contracting
authority to witness the work.
The Contractor shall formulate and provide all test sheets to a format agreed by the
Contracting authority. Each sheet shall contain the project title, the logos of the
Employer and the Contracting authority . Each sheet shall have witnessing signatory
space specific to the Contractor’s Contracting authority, and the Contracting
authority’s designed representative.
The test result sheets shall be fully cross-referenced to the system loading diagrams
which shall be updated to include the actual test results.
Duplicate signed test certificates shall be provided after each test, which will be
countersigned by the Contracting authority who witnesses the test. The test
certificate shall give the following particulars :
Apparatus or Chapter under test
Makers number ( if any )
Nature, duration and conditions of test
Result of test
No test shall be valid until the test certificate is provided.
Duplicate copies of test certificates carried out at manufacturer works shall be
forwarded to the Contracting authority for approval prior to dispatch of the
article to site.
No Chapter of the works shall be insulated or in any other way concealed prior to
testing and inspection and subsequent concealment where applicable shall only
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take place following written authority from the Contracting authority.
All necessary facilities, measuring and recording instruments including test pumps
and gauges for inspection/testing and commissioning requirements shall be
provided and shall be checked or calibrated as necessary before use. The
Contracting authority reserves the right to call for a demonstration of the
accuracy of any instruments provided.
Testing Instruments :
The Contractor shall submit with his Tender a full list of instruments, together
with relevant standards, which he intends to use in the regulation, testing and
balancing of the Contract Works. The Contractor shall include the full cost of
regular calibration test to be carried out on all instruments used and the cost of
any necessary recalibration. Certified documentation confirming current
certificate calibration shall be available for examination by the Contracting
authority at all times. Instruments not supported by up-to-date calibration
certificates shall not be used.
All instruments necessary for conducting the test shall be provided including the
following minimum range :
Tube type velometer ( Range 1.5 to 13 m/sec).
Sloping tube manometers.
Pitot tubes of various length to suit duct sizes.
Mercury in glass thermometers.
Weekly recording thermometers.
Weekly recording R.H. meters.
Specially mounted anemometers fixed in a conical sheet metalwork hood for
measuring accurately air flow from diffusers.
Ammeters.
Tachometers.
Surface contact dial indicating pyrometer.
Hot wire digital anemometers.
Sound meters.
Digital touch thermometers.
Multi-channel digital thermometers ( where necessary).
“U” tube manometers.
Commissioning set electronic flow meters.
Brass cased certified thermometers.
The Contractor shall prepare and submit with his Tender a schedule of
recommended test equipment suitable for Technician Grade maintenance
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staff to assess whether the commissioned standards are being maintained.
Whilst the level of equipment need not be comparable to the Specialist
Commissioning Contractors own test equipment it should meet the
following requirements :
a)
b)
c)
4.
Measurement of air and water temperatures including all test
probes.
Air flow measurement, both in duct and at diffuser discharge.
Water flow measurement using commissioning valves sets
provided under the Mechanical Services Contract.
Final Report
a.
Upon completion, all information shall be neatly typed accompanying
schematic diagrams of systems tested.
b.
All test reports shall be assembled, indexed, and submitted to the
Contracting authority.
PART 2 - PRODUCTS
2.01
O&M MANUALS RECOMMENDED TECHNICAL SPECIFICATIONS
The Operation and Maintenance manuals shall be prepared by a specialised, independent (third
party) firm, with a minimum of fifteen (15) years experience in this field, and on similar projects.
This firm shall have on its technical staff, full-time, specialised Technical Writers with several
years experience on equivalent project. The Operation and Maintenance (O&M) Manuals shall be
constructed to include the items listed below. These specifications are applicable for all the
relevant plant systems and equipment, especially the mechanical and electrical disciplines.
A.
GENERAL FORMAT REQUIREMENTS
1.
GENERAL FORMAT
a- Language: Simple, direct, universally accepted terminology and nomenclature shall be used to facilitate
comprehension.
b- Units of Measure: Units of measure shall be in Systems International d'Unites (SI units), except pipe
sizes which shall be in inches and electric motor sizes in horsepower.
2.
HEADING LEVELS
The following format for numbered headings identifying chapters and subchapters shall be
observed:
a- First Order: Centred below the chapter number and in all capital letters.
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b- Second Order: The subchapter number shall be flush left, head shall be in all capital letters
beginning four spaces after the number. Text shall begin as a new paragraph.
c- Third Order: The subchapter number shall be flush left, the head shall be in initial capital letters
followed by lower case letters beginning two spaces after the number. Text shall begin as a new
paragraph.
d- Fourth Order: No number shall be used at this level. Head shall be flush left with initial capital
letters and underlined. Text shall begin as a new paragraph.
e- Fifth Order: No number shall be used at this level. Head shall be flush
left with initial
capital letters, underlined, and followed by a period. Text shall begin two spaces after the period.
If a list, or stepped or sequenced instruction is necessary, a numeric identifier may be used
for each item of the list or for each sequence of the instruction.
There shall be a maximum of fifth order head for chapters and subchapters.
3.
PARAGRAPH NUMBERING
Unless otherwise specified. paragraph numbering shall be decimal and sequential, with a
maximum of a fifth order head for chapters and subchapters.
4.
PAGE NUMBERING
Pages shall be numbered consecutively for each chapter. Arabic style numbers shall be used. The
chapter number shall be used as a preface for each page number, Example: 1-1. 1-2. . . .., 2-1, 2-2.
.. ., etc. Page numbers shall be centred at the bottom of the page except for foldouts where page
numbers shall be placed on the right side in order, to be visible after the folds have been made.
5.
TABLE AND FIGURE NUMBERS
Tables and figures shall be numbered consecutively by chapter. Example: Figure 3-1. Table 3-1.
6.
ILLUSTRATIONS, TABLES. AND DRAWINGS
a- Illustrations, tables, and drawings necessary for clarity shall be included. All illustrations, tables,
and drawings-shall be mentioned in the text.
b-
Illustrations, tables, and drawings shall be independent units whenever possible and, unless
otherwise specified. shall not. require explanation within the text. . .They shall be numbered
consecutively within each chapter in the order mentioned 'in the text.' Each illustration, table,. and
drawing shall be placed as close as possible to the page of the text on which it is first mentioned
or shall be placed at the end of the applicable chapter, if appropriate to facilitate use.
c- Illustrations, tables and drawings contained in the body of the manual shall be black and white.
7.
BINDERS
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Binders shall be rigid, white in colour and of heat resistant, loose leaf type, with four rings. Rings
shall be round or D shaped and not exceed 64 mm. Each binder shall be provided with sheet
lifters installed and not contain more than 64 mm (2-1/2 inches) of material. Each binder shall be
equipped with full-sized durable clear plastic insert pockets on the front and spine portions of the
binder.
8.
INSERT SHEET (FRONT LOGOS) AND SPINE INSERT
The insert sheet for the front pocket of the binder shall be of 160g/m2 stock minimum. The spine
insert shall be of the same quality and-colour as the. front insert sheet. All printing shall be
horizontal.
9.
PAGE SIZE AND IMAGE AREAS
The size of the standard pages shall be ISO A4. Foldouts shall not exceed ISO A3. Unless otherwise
specified all material typed or drawn, shall be positioned on the page so that there is at least a
25mm (1 inch) margin of unused white space on all four sides.
Each page shall have the applicable revision number and date printed
10.
CHAPTER DIVIDERS AND TABS
Major chapters of the manual shall be-separated by dividers, 300g/m2, with tabs which shall be
laminated and printed on two sides with binding edge reinforced. Tabs shall be specifically
printed with chapter number and title.
11.
PRINTING
All documents shall be printed clearly, without smudges, in black ink.
12.
PAPER STOCK
Text shall be printed on 100g/m2 stock. Paper shall be sufficiently opaque that printing does not
show through the back side. Paper shall absorb ink in a manner that produces clear, crisp print.
Paper used for chapteral dividers shall be 300g/m2 stock.
13.
ELECTRONIC VERSION
Electronic Versions: Upon notification from the Consultant that the final review is complete and
that the draft O&M Manuals are completely satisfactory the Contractor shall prepare and submit
to the Consultant the revised Manuals in a standard CD-Rom (CD) format minimum performance
1x-6x and capacity 650MB. The Contractor shall submit two copies of each CD, one marked
“Master” the other marked “Back-up”. Drawing files shall not be compressed. Each CD shall
carry a manufacturers lifetime warranty and be virus checked before submission.
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The Manuals in CD contents format shall be prepared as a “Portable Document Format” (PDF)
using Adobe Software. Non electronic documents shall be scanned and converted to PDF image
files. The CD shall be self executing and the software for the operation of the CD is Adobe
Acrobat Reader which shall be delivered as part of the CD operating system. The Adobe Acrobat
Reader shall allow the PDF files to be viewed, printed and navigated.
A table of contents shall be incorporated on the CD and shall open automatically upon the
insertion of the CD and this shall be the key documents for the structure of the CD. All volumes,
chapters and chapters of the Manuals shall be addressed from this document and every entry in
the table of contents shall contain hypertext links to the corresponding volume, chapter or
chapter of the Manuals. The user shall be able by one keystroke to return to the table of
contents from any page of the Manuals. The index system shall be based on the list of contents
and its sub-division and link to a master index and search facility.
The electronic Manuals on CD shall be an exact copy of the hard copy version and once a chapter
is opened it must be capable of being read or printed page by page. Each CD shall include an
electronic database index listing all the files. The Contractor shall also submit a hard copy of the
database index with the CD’s.
B.
STRUCTURE AND CONTENTS
1. HOW TO USE THE MANUAL
This initial chapter is a guide to the contents, structure and layout of the manual. It enables the reader
to comprehend the scope and purpose of the document and to identify readily where specific
information can be obtained.
2. CONTRACTUAL AND LEGAL GUIDES
The contractual and legal records of the installation should include:
-
the name and address of the installation;
details of ownership etc;
details of local and public authority consent;
details of
the design teams, consultants, installation contractors and associated
subcontractors;
dates for the start of the installation, for hand over (practical completion) and for the expiry of
the defects liability period;
information on all guarantees affecting components, systems and plant items, together with
expiry dates and names, addresses and telephone numbers of relevant contacts
For each item of plant and equipment installed within the building and contained in the list of
services covered by O&M manual, copies of the following documents should also be provided,
where applicable:
-
test certificates
manufacturers’ guarantees and warranties;
insurance inspection reports;
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-
safety and fire certificates
A clear statement should be made in this chapter concerning those hazards and safety
precautions of which the operators and maintainers of the installations need to be made aware.
This should include the following:
-
any known feature or operational characteristic of the equipment or systems installed which
may produce a hazard;
any known hazards against which protection can be provided;
any mandatory requirements relating to safety;
any other safety precautions which should be observed;
any other relevant warnings
3. OVERALL PURPOSE
This chapter provides a general overview of the original design intent. It should include a
summary for each Contracting authoritying system installed giving:
-
the parameters and conditions within which it has been designed to operate, including known
hazards;
the type of each service (gas, electricity, water) required to operate the system:
the intended method of control
The chapter should be kept as brief as possible.
4. DESCRIPTION
This chapter provides a detailed description of each Contracting authoritying system installed. It
should include:
-
the system type (eg cold water supply)
system location and what it serves;
what the system depends upon in order to function;
design data, basic design parameters, basic assumptions made during design;
reasons for selecting particular plant;
expected service life (where available)
planned operational efficiency
5. EQUIPMENT SCHEDULE
The type, model number and serial number of all component items within the system should be
listed, together with the names of their respective manufacturers or suppliers.
PARTS IDENTIFICATION AND RECOMMENDED SPARES
This should comprise a parts identification list detailing and identifying replaceable assemblies, subassemblies and components. It should include suppliers’ recommendations for both spares and
‘running spares’ (ie parts required for scheduled replacement due to wear or deterioration).
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which is acceptable. It should also take into account suppliers’ recommendations as given above.
6. COMMISSIONING DATA
The results of all commissioning work and associated tests should be given. This should include:
-
measured data;
measurement points
test equipment used;
calibration certificate details;
a statement of whether design requirements were achieved.
7. OPERATION
Instructions must be given for the safe and efficient operation, under both normal and emergency
conditions, of each Contracting authoritying system installed. These will be in addition to
manufacturers’ literature for plant items and should include:
-
a recommended strategy for operation and control;
an outline of the general operating mode;
control data (location, effect, object, sequence, limits of capability, modes, set points);
procedures and sequences for start-up, running and shut-down, under both normal and
emergency conditions;
interlocks between plant items;
operating procedures for stand-by plant;
precautions necessary to overcome known hazards;
the means by which any potentially hazardous plant may be made safe;
forms for recording plant running hours, energy consumption and energy costs.
8. MAINTENANCE
8.1
Maintenance instructions
The recommendations and instructions for maintenance must be detailed for each item of plant and
equipment installed. Clear distinction should be made between planned tasks ( preventive
maintenance) and work done on a corrective basis. Instructions should be given on each of the
following, as appropriate:
-
8.2
the isolation and return to service of plant and equipment;
adjustments, calibration and testing;
dismantling and re-assembly;
the exchange of components and assemblies;
dealing with hazards which may arise during maintenance;
the nature of deterioration and the defects to be looked for;
special tools, test equipment and ancillary services.
Maintenance schedules
Maintenance schedules should be provided for all the preventive maintenance tasks identified above
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in. These should be based on both manufacturers’ recommendations and other authoritative sources.
-
inspections;
examinations
tests
adjustments
calibration
lubrication
periodic overhaul
The frequency of each task may be expressed as specific time intervals, running hours or completed
operations, as appropriate. Collectively, the schedules will form a complete maintenance cycle,
repeated throughout the working life of the installations.
8.3
Fault finding
Procedures for the logical diagnosis and correction of faults should be provided.
9.4 Lubrication
A schedule of all plant requiring lubrication should be provided together with manufacturers’
recommendations on the type of lubricant and the method and frequency of application. Where the
type of lubricant is identified by product name, a generic reference (eg British Standard) should also
be given. Information must also be provided on special requirements for the handling and storage of
lubricants.
9. DISPOSAL INSTRUCTIONS
Where relevant, information should be provided detailing:
-
any known dangers likely to arise during the disposal of specific items of plant or equipment
together with the necessary precautions and safety measures;
methods for safety disposing of or destroying the equipment or any parts thereof, including
packaging, insulation and fluids;
sources from which further advice can be obtained
10. NAMES AND ADDRESSES OF MANUFACTURERS
Details of all manufacturers and suppliers of equipment listed in the manual should be provided under
this heading giving name, address, telephone number and telex/fax number and e-mail.
INDEX OF PLANS AND DRAWINGS
An inde should be provided of all ‘ as fitted’ drawings supplied during the course of the installation
work, identified by number and title.
The index should also include a schedule of all drawings issued by manufacturers and suppliers during
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the course of the installation work, eg control panel wiring diagrams.
11. EMERGENCY INFORMATION
An important feature of any manual is the emergency information. Located, for ease of reference, at
the end of the document, this should include names, addresses, telephone and telex/fax numbers of
the appropriate contacts in the event of fire, theft or burglary, and gas, electricity or water
failure/leaks. It should also list those firms or staff to contact in the event of the failure or break down
of such plant as lifts, boilers or pumps.
Where applicable, the location of fire-fighting equipment, hydrants and rising mains should be
described.
Special attention should be given to hazards particular to the building.
12. MANUFACTURERS’ LITERATURE
A complete set of all manufacturers’ literature should be provided for the plant and equipment
installed and assembled for each building services system.
PART 3 - EXECUTION
3.01
OPERATIONS OF EQUIPMENT & SYSTEMS.
A.
3.02
The Contractor shall make the necessary adjustments for each system and piece of
apparatus installed, using factory-trained technicians wherever practicable, and shall
thoroughly instruct the client appointed representatives in the roper operation of the
apparatus. Printed instructions written in both Arabic and English, shall be permanently
attached to the relevant equipment.
TESTING GENERALLY
A.
Where an individual inspection or test takes place at a sub-contractor’s work, a
representative of the client will be required to be present.
B.
Unless otherwise indicated, the Contract shall include the cost of all tests, necessary
instruments, equipment, supervision and labor both at the manufacturer’s plant and on
site. The accuracy of the test instruments shall be demonstrated where so directed.
C.
The site test shall be of at least six hours duration. On large installations, the site test may
last several days and shall be long enough to allow the taking of all the measurements
required in subsequent clauses of this Chapter and to demonstrate the performance of the
installation. Any defects of workmanship materials and performance, maladjustments or
other irregularities which become apparent during the tests shall be rectified by the
Contractor at his expense and the tests shall be repeated at the Contractor’s expense to
the satisfaction.
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D.
3.03
The Contractor’s representative present at the site tests shall be fully conversant with the
operation of the thermostatic controls, the control panel and the refrigeration system,
representatives of the manufacturers of the equipment shall be present,
TESTS AT MANUFACTURERS WORKS
A.
Unless otherwise indicated, tests shall be carried out in accordance with the appropriate
Standard or Code or Practice. Test certificates for works tests shall be submitted
induplicate.
B.
Test certificates shall be submitted :
C.
I.
For Fans : Type test certificates showing fan characteristic curves and type test
certificates for sound levels.
2.
For Pumps : Type test certificates for head, discharge, speed and power input.
3.
For Electrical Motors : Type test certificates for motors of 40 KW output and above,
routine ( individual ) test certificate.
4.
For Starters and Control Gear : Type test certificates for control panels as a whole,
routine ( individual ) high voltage test.
5.
For Other Electrical Equipment : Such as air heaters ( but excluding thermostatic
control equipment ) test certificates.
6.
For Hydraulic Equipment : Test certificates for hydraulic and air pressure testing at
works.
Testing is to include as a minimum.
Pipework
Cleanliness, internal and external
Flow rate/balancing
System component pressure drops
Pressure reducing valve settings
Safety relief valve setting and operation
Operation of all components
Performance-temperature/noise
Purity of Fluid
Earth bonding
Ductwork
Leakage
Cleanless, internal and external
Damper Operation
Fire & smoke operation
Flow rate balancing
System component performances-heating/cooling
batteries filter
C.V/V.V box operation / calibration
Performance-temperature/noise air change
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Operation of all components
Purity
Earth bonding
The
Services
shall
setting to
Plant Equipment
as fitted
Room
manuals
provision
charts to
by a
chapter 3
Control
Operation-normal, abnormal, safety devices, interlocks Mechanical
Performance duty / speed / pressure / efficiency / noiseContractor
Standby
include for the
Component performance- heat / cool / batteries / filterwork of the
installation,
Cleanliness, internal and external
preparation of
Vibration
drawings and
Electrical safety / security / bonding
operating and
maintenance
Environmental –temp, humidity, air change, noise
and the
Air flow direction, distribution, draughts
of labels and
be undertaken
Component operation
Commissioning
Settings
Control action – limits, response time, alarms, interlocksSpecialist, as
identified in
Electrical safety/security/bonding
of the
specification.
The Commissioning Specialist must be appointed and identified to the Professional Team within 4 weeks of
the Contractor receiving an order to proceed or before any working program is agreed, whichever is the
sooner.
3.04
PRESSURE TESTING OF PIPEWORK SYSTEMS
A.
Upon the completion of each length or chapter of the pipework the Contractor shall
subject the length or chapter to a hydraulic test and demonstrate to the satisfaction of the
Contracting authority that the length of the chapter is sound and watertight. The test
pressure shall be one and a half times the maximum working pressure or 700 KPa,
whichever is the greater, for a period of two consecutive hours. Items of equipment, e.g.
safety valves, bursting discs, set to operate at or below this pressure shall be isolated or
removed prior to applying this test.
B.
All faults discovered during such-test- shall be remedied by the Contractor at his own
expense and the test re-applied until the Contracting authority is satisfied that the chapter
is sound and watertight.
C.
Installations chapters thereof which will be embedded in the structure or concealed in
permanently sealed ducts, trenches etc., shall be individually tested as they are laid and
before being embedded or concealed.
D.
All pressure tests shall be carried out before the application of thermal insulation.
E.
On completion of the test, the water is to be released and drained completely away as
rapidly as possible, the chapter then being thoroughly sluiced through to ensure the
removal of as much dirt and foreign matter as possible before being refilled and put into
service.
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3.05
AIR LEAK TESTING OF DUCTWORK SYSTEMS
A.
B.
General
1.
All ductwork and equipment items shall be checked for air leakage. This shall be
completed before installation or enclosure of ductwork and before any terminal
units are fixed.
2.
The air leakage tests shall be based on the measurement of air leakage at constant
pressure. The test pressure shall be the design static pressure of the chapter to be
tested plus 250 pa. The aggregate of air leakage shall not exceed 1% of the system
design air flow rate, and leaks shall not be audible. The air leakage rate for any
chapter shall not be in excess of the permissible rate, in m3/s per meter, for the
whole system.
3.
Sufficient time shall be allowed, before testing, for the sealant to cure. The
ductwork system, or chapter to be tasted shall be sealed by the incorporation of,
blanking plates fitted at flanged joints, for main ducts and for small open ends,
polythene bags may be used. The polythene bags may be retained to aid in
preventing the ingress of dirt into the system.
4.
Care shall be exercised in jointing tested chapters of the ductwork system
together, as it will generally be impracticable to test such joints.
Test Apparatus and Method
1.
Portable test apparatus shall be provided by the Contractor and shall comprise the
following equipment: Electrically driven fan capable of delivering not less than
0.03m3/s against a duct pressure of 2.5 Kpa, a static pressure gage suitable for
recording the duct static pressure test, an inclined pressure gage, a variable speed
type, and a flow measuring device complete with test cocks. The accuracy of the
measuring device shall be +/-5% of the permitted air leakage rate.
2.
The apparatus shall be connected to the blanking plate inserted in the chapter of
ductwork to be tested. With the bleed valve fully open or the variable speed motor
set to minimum speed, start-up fan, and adjust fan speed or close bleed valve until
static pressure reading on static pressure gage reaches desired value. If pressure
cannot be obtained, the ductwork shall be checked for obvious leaks and rectified.
With the duct chapter maintained at the test pressure, the ductwork shall be
checked for major and audible leaks. The leakage rate, as indicated on the inclined
pressure gage, connected across the flow measuring device, shall be recorded and
checked that it is within the permitted limits. This leakage rate shall be maintained
for at least 15 consecutive minutes without increasing.
3.
The fan shall then be turned off and the pressure in the test chapter of duct
returned to zero before starting the fan again and establish that the air leakage
rate has not increased from the previous reading.
4.
Any results not within the permitted limits shall require that the ductwork be
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examined and any leaks rectified. Time shall be allowed for the sealant to cure
before the test is restarted.
5.
3.06
3.07
Readings of the test for each chapter of ductwork shall be recorded and presented
to the Contracting authority before any further work is carried out on the chapter
of ductwork tested.
TESTING OF SOIL, WASTE AND ROOF DRAINAGE PIPING SYSTEMS
A.
On completion of the soil and waste pipe works or chapter of the work as may be required
the plumbing contractor shall arrange the testing of the works.
B.
The tests shall comprise an air test as set out in the Uniform Plumbing Code, and described
in chapter 15405, and a performance discharge test as required. Should the Contracting
authority deem the test unsatisfactory his visit shall at his desecration be considered
abortive and all costs incurred in respect of time, travel and expenses shall be recoverable
from the contractor who shall then rectify the works and arrange for a further test to be
witnessed at his own expense.
C.
Where the testing is to be carried out in chapters the Contractor shall retain on site a
drawing indicating chapters tested and recording dates on which the tests took place duly
witnessed.
D.
The Contractor shall be responsible for providing all skilled and unskilled labor necessary to
carry out tests and ensure that all supplies and instruments are available.
COMMISSIONING GENERALLY
A.
B.
General
1.
Each installation shall be fully commissioned. Commissioning shall include the
balancing and regulation of air and water distribution systems and the final
adjustment of control system.
2.
Particular attention shall be paid to :
a)
The maintenance of cleanliness of all equipment and distribution and
distribution systems during construction and ensuring that distribution
systems are cleared through as part of commissioning.
b)
The protection of equipment, particularly sensitive of fragile items, from
the activities of other trades during construction and from dirt and
maloperation during commissioning.
c)
The protection of Electrical equipment from damp during construction and
commissioning.
Adjustments
1.
Adjustments shall be made to the following items :
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3.08
a)
Adjust blowers, fans and ducts to deliver or exhaust design air flow rate.
b)
Adjust diffusers, register, and grilles to deliver or exhaust design air flow
rate.
c)
Adjust relief dampers and vents.
d)
Adjust diffusers, registers, and grilles to minimize drafts.
e)
Adjust all zones for design supply and return air flow rates.
f)
Adjust blowers and fans to design revolutions.
g)
Balance cooling water systems to achieve design flow characteristics.
h)
Balance domestic hot water return loop.
COMMISSIONING AIR SYSTEMS
A.
Preparation :
Prior to system testing and balancing.
B.
1.
Systems shall be fully operational.
2.
All filters shall be clean.
3.
Temperature and system controls shall be checked for proper operation.
4.
Fan rotation shall be checked.
Air handling System
1.
Fan air handling quantities and other major air flow quantities where required,
shall be measured by pitot tube and inclined manometer using multi-point
traversing techniques.
2.
The following items shall be specifically checked and/or adjusted and recorded on
the Site Test Certificate for each air handling unit.
a)
External air dry bulb temperature and relative humidity.
b)
Air dry bulb temperature and relative humidity in each space.
c)
Air dry bulb temperature and relative humidity in each main return duct.
d)
Air dry bulb temperature and relative humidity before and after each air
heater.
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3.
C.
e)
Air dry bulb temperature and relative humidity before and after each air
cooler.
f)
Air dry bulb temperature and relative humidity before and after
humidifying equipment.
g)
Air dry bulb temperature and relative humidity before and after a fresh
and return air mixing chamber.
h)
Air dry bulb temperature and relative humidity in each main supply air
duct.
j)
Fresh air quantity ( m3/s).
k)
Air flow ( m3/s) and resistance ( Pa or mm of water ) across a main fan .
l)
Air flow ( m3/s) and resistance ( Pa or mm of water ) across each heater.
m)
Air flow ( m3/s) and resistance ( Pa or mm of water ) across each cooler.
n)
Air flow ( m3/s) and resistance ( Pa or mm of water ) across each
humidifying equipment.
a
Perform the following minimum air system tests balancing.
a)
Air flow (m3/s) in each main supply, return a grille and diffuser.
b)
Air flow (m3/s) at each supply grille and diffuser.
c)
Fan and ,motor speeds, air quantity and dry bulb temperature and relative
humidity, both on and off the cooling coil, for at least two of each size fan
of the cooler unit.
d)
Main fan and motor speeds.
e)
Current taken under running conditions for each fan above 4 KW and each
electric air heater, and maximum current for each electric air heater.
f)
In cooperation with the temperature control system installer, set
adjustments of automatically operated dampers to operate as specified,
indicated and noted.
Record Data
Record the following minimum data :
1.
Air flow rate delivery and rpm of blowers and fans.
2.
Static pressure at inlet and outlet of blowers and fans.
3.
All equipment nameplate data.
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3.09
4.
Actual running current and voltage of fan motors.
5.
Air flow rate, delivery or exhaust at each diffuser, register and grille.
COMMISSION WATER SYSTEMS
A.
Preparation :
Prior to system testing and balancing
B.
1.
Open all valves to full open position. Close coil bypass stop valves. Set mixing
valves to full coil flow.
2.
Remove and clean all strainers.
3.
Examine water in system and determine if water has been treated and cleaned.
4.
Check pump rotation.
5.
Clean and set automatic fill valves for required system pressure.
6.
Check expansion tanks to determine that they are not air bound and the system is
completely full of water.
7.
Check air vents at high points of water systems and determine if all are installed
and operating freely.
8.
Set all temperature controls of all coils calling for full cooling. Same procedure
when balancing hot water coils : set for full heating.
9.
Check operating of automatic bypass valve, if furnished.
10.
11.
A complete air balance must be accomplished before beginning the water
system test and balance.
Water Handling Systems
1.
General
a.
2.
The satisfactory operation of all make-up, drain and overflow arrangement
shall be checked. Where water treatment is included initial commissioning
shall be carried out and then rates of flow, dosing quantities etc., shall be
calibrated and set for routine operation.
Perform the following minimum water system test and balance :
1.
Set water pumps to proper flow rate.
2.
Adjust water flow through equipment.
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C.
3.10
3.
Check leaving water temperatures and return water temperature. Reset to
correct design temperatures.
4.
Check water temperatures at inlet side of coils. Note rise or drop of
temperatures from sources.
5.
Proceed to balance each water coil.
6.
Upon completion of flow readings and adjustments at coils, mark all
settings and record data.
7.
After adjustments to coils are made, recheck settings at pumps and
readjust if required.
8.
Install pressure gages in gage fittings provided on coil, read pressure drop
through coil at set flow rate for full cooling and on full heating. Set
pressure drop across bypass valve to match coil full flow pressure drop.
Record Data
Record the following minimum data at each cooling element :
1.
Inlet water temperature.
2.
Leaving water temperatures.
3.
Pressure drop of each coil.
4.
Pressure drop across bypass valve.
5.
Pump operating suction and discharge pressures.
6.
List all mechanical specifications of pumps. Check and record starter size, heater
sizes, etc.
7.
Rated and actual running amperage of pump motor.
8.
Water balance device readings and settings.
COMMISSIONING OF REFRIGERATION SYSTEM
A.
During erection, commissioning and at the end of commissioning particular attention shall
be paid to competent workmanship adequate sealing of valves and fittings and
comprehensive leak testing, to minimize future leakage of refrigerant.
1.
The following items shall be checked and/or tested and entered on the Site Test
Certificate:
a.
b.
Refrigerant suction and discharge pressure and temperatures.
c.
Compressor and motor speeds.
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3.11
Compressor oil pressure.
e.
The satisfactory operation and set operating pressures of high pressure,
low pressure and oil pressure failure cut-outs.
f.
Current taken by each compressor at full load and at each step of capacity
reduction.
CONTROL SYSTEMS
A.
B.
3.12
d.
Particular attention shall be paid to the following features :
1.
Satisfactory operation of any automatic or manually operated sequences to be
used in the event of fire.
2.
Safety in the event of failure and of sudden resumption of electric supply.
The following items shall be checked and/or tested and recorded on the Site Test
Certificate :
1.
Set desired value of all control devices.
2.
Satisfactory operation of equipment protection devices.
3.
Satisfactory operation of all sequencing operations and alternate working
selections, and automatic or manual change-over or duplicate equipment.
NOISE AND SOUND CONTROL
A.
B.
Sound level readings shall be taken with a simple sound level meter using the ‘A’ scale
weighting network. The spaces in which readings shall be taken as agreed but will in
general, be the following :
1.
Equipment rooms.
2.
Occupied rooms adjacent to equipment rooms.
3.
Outside equipment rooms facing air intakes and exhausts and condensing
discharge, to assess possible nuisance to adjacent accommodation, if the adjacent
accommodation is private residential building tests may be required at night.
4.
In the space served by the first grille or diffuser after a fan outlet.
5.
In at least two of the spaces served by fan coil units.
Alternatively, sound level readings shall be taken using a sound analyses to give an octave
band analysis of the sound spectrum and to pinpoint the frequency values of peak sound
levels.
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3.13
COMMISSIONING BOILER EQUIPMENT
A.
B.
Maximum Continuous Rating Test
1.
During the commissioning period a maximum continuous rating test shall be
carried out on each of the boilers.
2.
The test shall be for a period of 4 consecutive hours exclusive of the time required
for preparation, attaining test conditions and running down. During this test it shall
only be necessary to measure the evaporation of the boiler, the amount of fuel
fired and the exit flue gas temperature.
Acceptance Tests
1.
On completion of the installation the Contractor shall carry out thermal efficiency
tests on all the boilers. These tests shall take place during periods of maximum
loads and the Contractor shall allow for adequate visits to satisfactorily test the
thermal efficiency of the boilers and performance of ancillary equipment.
2.
Test and record flue gas exit velocity, temperature and CO2 content by volume,
fuel consumption.
3.
The following shall be checked and /or tested and recorded on the Site Test
Certificate :
a.
3.14
The boiler relief valves and any other relief valves in the steam system shall
be tested and proved to lift at their required pressure using live steam.
SETTING TO WORK
The work shall be considered to consist of three separate chapters of activity, namely PreCommissioning, Commissioning and Post-Commissioning.
A.
Pre-Commissioning
The Mechanical Services Contractor and their specialists as specified elsewhere and as follows
shall generally carry out pre-Commissioning:
Hydraulic Pipeline Testing
The Mechanical Services Contractor shall test all pipework
installations.
Flushing
All pipework installation, except compressed air systems, shall
be flushed by the mechanical services contractor.
The commissioning specialist shall be in attendance and
witness the flushing exercises and the subsequent cleaning of
the strainers.
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Sterilization and chlorination
All domestic hot and cold water systems shall be sterilized and
chlorinated by the mechanical services contractor.
The commissioning specialist shall be in attendance and
witness the sterilization and chlorinating exercises.
Water Supplies
The commissioning specialist shall confirm the presence of
water supplies to all tanks and outlets.
Plant and Ductwork cleaning
The Mechanical services contractor shall thoroughly clean all
internal and external surfaces of ductwork and plant.
Electrical Supplies
The mechanical Services contractors controls specialist shall
commission the whole controls installation.
The commissioning specialist shall establish that all electrical
connections have been made during pre-commissioning and
that power is available to all equipment.
Rotating Equipment
The commissioning specialist shall check for free rotation of
equipment and correct alignment, security and tension of
belt drives and operate fans and pumps to check direction
of rotation.
Test certificates
The Mechanical Services Contractor shall provide copies
of all tests undertaken at manufacturers work and
pre-commissioning tests.
B.
Commissioning
The commissioning specialist shall commission the whole of the Mechanical Services installations,
working in conjunction with the commissioning Contracting authoritys of equipment
manufactures and systems specialists.
Where manufacturers offer a commissioning service this must be used in preference to other
methods. All manufacturers reports shall be included in the final documentation.
The commissioning specialist shall regulate and adjust valves, apparatus, plant and equipment
such that the whole of the works shall be left in a satisfactory working order to the requirements
of the professional team.
Before commencing final balancing of water circulation systems the mechanical services
contractor shall remove, clean and replace all strainers.
Where appropriate the systems shall be commissioned in accordance with the latest edition of
the C.I.B.S.E/B.I.S.R.A commissioning codes.
Upon completion of all tests and balancing of the systems, the whole of the works shall be
operated under normal working conditions and fine tuning of controls undertaken to achieve
stable operating conditions of the plant and within the building.
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The commissioning Specialist shall be required to work closely in conjunction with the control
specialist to fine-tune the systems.
This operation of the installations under normal working conditions and fine tuning shall be
undertaken during the commissioning period and shall not be considered as post commission
proving.
The commissioning Specialist shall maintain a diary on site and record all activities of other
specialist and manufactures commissioning Contracting authoritys. The diary shall be available for
inspection by the Professional Team at all times.
The commissioning Specialist shall provide all necessary instrumentation and measurement
devices along with current calibration certificates for commissioning of the works.
C.
Post Commissioning
The commissioning Specialist shall demonstrate and prove to the Professional Team that the
system operates correctly, with stability and the commissioning Specialist shall undertake tests as
directed by the Professional Team.
The commissioning Specialist shall be resident on site full time throughout the postcommissioning period.
The commissioning Specialist shall, in conjunction with the Mechanical Services Sub-Contractor
and his other specialists, instruct the employer in the operation, inspection, inspection and
general maintenance of the whole of the Mechanical Services Installations.
The commissioning Specialist shall supply and place in position and maintain operation of and
calibrate a number of 7 day/24 hr temperature and humidity recorders for a minimum period of
seven consecutive days or otherwise as specified. The records shall be positioned and re-located
as directed by the professional Team.
D.
Commissioning Report
The commissioning Specialist shall prepare a Commissioning Report for submission to the
Professional Team and ultimately for inclusion in the O&M Manual. The report shall contain the
following:
Plant run times during tests
Air flow volumes for each system, including duct traverse record sheets.
Terminal grille and diffuser volume flow records for all systems, including hood factor tests etc.
Central plant test data including filter and coil pressure drops, etc.
Fan performances including fan curves and plotted performance on high and low volumes where
applicable.
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Pump performance including Pump curves and plotted performance on high and low volumes
where applicable.
Water distribution systems water flow balance, control valve duties including valve performance
data charts.
Refrigeration plant commissioning data
Control settings for all plant.
Control setting programmed into Building Management System.
Control Panel fuse ratings and overload settings.
Record of all temperature and pressure point tests.
Equipment running current for all three phases.
Noise level recordings, including sketch plan of positions where readings were taken.
Pressure test certificates.
Clean water/system certificates for domestic water systems.
Sketch diagrams of systems indicating all equipment, controls and control and regulating valves
all referenced.
Provision shall be made in the report for recording alterations made to control set points during
post-commissioning and the first twelve months of plant operation
Provision shall be made in the report of recording test data during any re-commissioning exercise.
3.15
SCOPE OF WORK
A.
Pre-Commissioning
The Independent Commissioning Specialist Company shall provide a part/full time Contracting
authority/s to evaluate the systems prior to installations being complete. The Contracting authority
shall review the systems being installed and provide a detailed report to the Consultant
Contracting authority.
B.
Commissioning
The Independent Commissioning Specialist Company shall provide a full time Contracting
authority/s to carry out the commissioning of the installations. The Contracting authority shall
provide the Consultant Contracting authority with a weekly report.
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C.
Post Commissioning
The Independent Commissioning Specialist Company shall demonstrate and prove to the
Consultant Contracting authority that the system operates correctly and meet the performance
criteria.
D.
Duct Work Insulation Testing
The Independent Commissioning Company shall use a Thermographic techniques to inspect all
finished duct work to prove the insulation integrity. The temperature surrounding the duct work
shall be recorded on a area by area basis. Any leakage shall be digitally photographed and recorded
together with the Thermographic image. This report shall be given to the contractor to rectify and
leakages or break down of insulation. The Independent Commissioning Company shall then resurvey these area and confirm that these works have been completed satisfactorily.
E.
Electrical Testing
The Independent Commissioning Company shall use a Thermographic techniques to inspect all the
electrical systems including the following HV through to LV.
The refrigeration systems shall be inspected
F.
Testing & Balancing – Air Systems
The Independent Commissioning Specialist Company shall provide for Testing of the air systems
based upon but not limited to the following information.
Number of VRV
Number of Fans
Number of Fan Coil Units
Number of Volume Control Dampers
Number of Outlet Grilles
Number of Inlet Grilles
Number of Spigots
Number of Traverse Checks
G.
Testing & Balancing – Water Systems
The Independent Commissioning Specialist Company shall Provide Testing of the water systems but
not limited to the following information:
Number of Pumps
Number of Commissioning Sets
H.
Electrical Testing
The Independent Commissioning Specialist Company shall provide Testing of the following systems
but not limited to:
Number of Main Cables
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Number of MDB
Number of SMDB
Number of Final DB’s
Number of Fire Alarm Panels
Number of UPS’s
Number of VRV
Number of Fan Coil Units
Number of Fans
END OF CHAPTER
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