SECTION 2- COLD WATER SUPPLY

SPECIFICATION

COLD WATER PLUMBING SERVICES1.0SCOPE OF WORK

The Section sets out required standard of workmanship and material for the supply, installation, testing and commissioning of all equipment and accessories, pipework and fittings, to complete the Water Supply System as shown in the accompanying drawings and as specified hereafter to the satisfaction of the Local Water Authority and the Superintending Officer and all relevant authorities.

The Contractor shall provide all labor, materials tools and equipment required to complete the Water Supply Installation. All pipes materials, fittings, hangers and clamps supplied shall be new and unused, be of best quality of their respective kind, sound free from defects and meet specification, approved for uses by the Local Water Authority and Superintending Officer and all relevant authoritiesAll the required excavation work, trenches, back filling, etc. for laying the buried pipework shall be done by this Contractor. After the buried section of the pipework has been tested and approved, the Contractor shall backfill all the trenches and dispose the remaining material from the work site as directed by the Superintending Officer (S.O).2.0RULES, REGULATION AND STANDARDSAll the workmanship and material for the supply, installation, testing & commissioning of all equipment and accessories shall be comply with the following rules and regulation requirements:

i) State Water Authorityii) Local Authorityiii) Superintending Officer (S.O).iv) JKR Malaysia or The Malaysian Water Association.

v) Other relevant Malaysian and British StandardAll fittings supplied and installed shall have the same working pressure as the pipes on which they are used.

3.0 WATER PIPE MATERIALS3.1 Internal Piping

All materials used in internal plumbing system shall be Stainless Steel or Acrylonitrile Butadience Styrene (ABS) or approved pipes by Local Water Authority, Jabatan Kerja Raya, the S.O and all other relevant Authority. Stainless Steel shall comply with ASTM A312, Schedule 40S. ABS shall comply to BS5391 and BS5392.

3.2 External / Underground Pipes

All external piping connecting from the JBA main to external water lines and to storage tank shall be HDPE Class PN 12.5 to MS 1058 : 1994 or approved pipes manufactured by Local Water Authority, Jabatan Kerja Raya, the S.O and all other relevant Authority.All pipes shall be buried in trench and laid according to the trench specification.4.0 PIPE INSTALLATION4.1 Internal Piping

All installation shall be done according to the drawings. Special care shall be taken in the arrangement of piping to ensure a neat finishing and alignment.

All pipes and fittings shall be thoroughly cleaned and free from burrs, scale and obstructions before erection. Clean sharp pipe cutters not hacksaws, shall be used to cut metal pipes. Threads shall be cut with clean sharp die.

Connection shall be as direct and as few as possible. Valves and fittings shall be grouped where this will not effect their operation, to reduce the number of joints to a minimum.

All necessary isolating valves, check valves and other fittings as required and as shown on the drawings for proper valving of the installation. Every section of major branch supply piping shall be controlled by a stop valve at the point of connection to the supply

All internal pipes shall be chased and concealed in wall, ceilings, boxed up or laid within the common trench, services ducts, etc provided where possible.Minimum diameter for internal plumbing system shall be 15mm except for flush valve system where minimum diameter shall be 25mm.The pipes shall be adequately against damage during transit. Each delivery of pipes shall be accompanied by the manufacturers test certificate.

4.2Underground / Buried Pipe

4.2.1Excavation and Trenching for Piping :

The Contractor shall perform all excavation to the depths indicated on the drawings or as specified in conformance with local relevant authority requirements. All excess excavation materials shall be removed from the site. Grading spaces be done as necessary to prevent surface water from flowing into trenches or the excavations and any water accumulating therein shall be removed by pumping or by other approved methods.

Sheeting and shoring shall be as necessary for the protection of the water and for the safety of personnel.

Excavation shall be by open-cut method, except that short sections of a trench may be tunnelled if, in the opinion of the S.O., the pipework be safely and properly installed and backfill can be properly tamped.

4.2.2Trench Excavation

Trenches shall be of necessary width for the proper laying of the pipe, and the banks shall be as nearly vertical as practicable. The bottoms of the trenches shall be accurately graded to provide uniform bearing and supports for each section of the pipe on undisturbed soil at every point along its entire length, or may be overexcavated 100mm below depth indicated and filled with well tamped salt free coarse sand or other approved materials. Layers or brick, concrete base and angle blocks shall be used support for the laying of piping.

4.2.3Depth of Cover

Trenches for utilities shall be of a depth that will provide 450mm minimum depth of cover from top of pipe to finished ground level where there is reinforced concrete slabs above. For other areas where there is no reinforced concrete slab above, the minimum depth of cover shall be 750mm.

4.2.4Protection of Existing Utilities

Existing utility lines or other completed utility lines if damaged by the Contractor shall be repaired by the Contractor at his own expense.

When connecting to existing utility lines, no section of the existing piping shall be abandoned unless it is specifically indicated on the drawings.

4.2.5Backfilling of Trenches

Trenches shall not be backfilled until all required pressure and other tests have been performed. Backfill trenches shall be well tampered and well watered with a 150mm layer of coarse salt-free sand under the pipes and 300mm minimum over the top of the pipes, to 90 % compaction. Backfill remaining trench and compact with soil to match surrounding soil except under paved areas, roads and R.C slabs, etc. Where backfill and compaction is to match Structural Engineers requirements.5.0PIPE JOINTSThe number of demountable joints, eg. flanges, unions, etc. shall be kept to a minimum.

5.1ABS Pipesa. Fittings

All ABS fittings used shall comply with AS 3518 or equivalent standard.

Where ABS spigot and socket joints required, only factory formed socket

may be used. Such material shall approved by the S.O prior to installation

b. Threaded JointsThreaded end connections for ABS pipes shall have tapered thread forms complying with AS 1722.1 or equivalent approved standard in accordance with manufacturers instruction. Where threaded joint is to be made between ABS pipes and metal, the ABS pipes should be the male component of the joint. All screwed joints shall be made by using Teflon tape or approved jointing compoundc. Solvent Cement Joints

Solvent cement used for ABS spigot and socket joints as well as saddle joints shall comply with AS 3691 or equivalent approved standard and shall be in accordance with manufacturers instruction.Drying time for ABS solvent cements joint shall be strictly followed the manufacturers instruction.

Full working pressure shall not apply until at least 24 hours has elapsed.

d.Flanged jointsFlanging or other suitable methods used shall be in accordance with the manufacturers instructions and comply with the Jabatan Bekalan Air Negeri.

5.2 Galvanized IronAll fittings for galvanized iron pipes shall be galvanized steel fittings conforming to BS 1740.

All screwed joints shall be made by using Teflon tape or approved jointing compound. Machined flanges shall be used for flanged joints.Pipe connections of 65mm and above connected to equipment shall be flanged joints and pipe connections below 65mm diameter shall be screwed unions to permit removal for maintenance without disturbing other pipes.

5.3 BendsBends of all piping shall have a radius of not less than 5 times the diameter and shall be of standard type

6.0PIPE SUPPORTSThe Sub-Contractor shall supply and install all necessary pipe supports, hangers, anchors, guides required for proper support.

Vertical riser shall be supported at each floor with mild steel riser clamps.Horizontal pipe runs shall be supported on hangers of split ring adjusted type or clevis type. Where pipelines run along walls, columns or ceilings, brackets or clamps may be used.All vertical and horizontal pipes shall be graded in the direction of flow in accordance with the accepted standard practice.

Piping at all equipment, valve positions and at main junctions, shall be adequately supported to prevent any distortion or transmission of strain to connected equipment or valves.

Where pipe lines run in a common group, they shall be supported from a common hanger bar fabricated from mild steel sections.

Pipe supports and hangers shall be spaced at intervals not exceeding the following:-a. Galvanized Iron PipesPipe Size

(mm)Support Horizontal

(m)

15

20-32

40-75

75 and above

1.8

2.4

3.0

3.7

b.ABS PipesNominalRecommended Maximum Spacing of Supports

(m)

SizeHorizontal or Graded Pipes

(mm)Temperature, CVertical Pipes

205070

1015

20

25

32

40

50

80

100

150

200

0.7

0.9

1.0

1.0

1.2

1.2

1.3

1.6

1.9

2.1

2.40.6

0.7

0.85

0.9

1.0

1.0

1.0

13

1.5

1.8

1.90.4

0.4

0.6

0.7

0.7

0.7

0.7

0.9

1.0

1.0

1.20.7

0.9

1.0

1.0

1.2

1.2

1.3

1.6

1.9

2.1

2.4

Vertical pipes shall be supported at least at the top and bottom of each riser, at each floor level, and at each isolating valve. In addition, a further support shall be provided between floor levels for pipes smaller than 32mm.

7.0PIPE SLEEVE AND COVER PLATEWhere pipes are required to be laid through structural beams or slabs, mild steel/G.I pipe sleeves shall be provided for such puncturing. All pipes shall be properly secured in place with brackets.

All exposed piping within occupied rooms shall be heavily chrome plated. Cover flanges shall be installed at the point of penetration by pipes or fittings at walls or ceiling where exposed to view.

8.0VALVES AND FITTINGAll valves and fittings necessary for the correct control, operation and maintenance of all services shall be provided and installed to the satisfaction of the S.O. Samples shall be submitted for S.O approval before installation. Valves shall be installed where they are easily accessible for maintenance and operating purposes.

Each valve shall be of the same nominal size as the line in which it is installed, except for control, pressure reducing and similar valves which shall be correctly sized for the duty concerned. Connecting between each valve and adjacent piping or equipment shall be made either flange or treaded joints may be applicable.Before installation, every valve shall be blown out with air to remove such foreign matter lodged in the valve.

All valves shall be of JBA approved manufacture and generally constructed in accordance with relevant British Standard specifications. All valves shall be suitable for operating pressure of 16 bar.

(a) Gate Valves

Gate valve 50mm and below shall be all bronze one piece screwed ends. Copper alloy gate valve shall comply with BS 5154:1991.

Gate valves of 65mm and above shall be cast iron body, bronze mounted double disc, taper seat outside screw and toke with rising spindle and flanged ends. Cast iron gate valve shall comply with BS 5150:1990.

Gate valves shall be used at connection to pumps, water mains, tank risers etc. where indicated on the drawings.

(b) Globe ValvesGlobe valve 50mm and below shall be all bronze renewable composition disc, slip on disc holder, screwed union bonnet and screwed ends. Copper alloy gate valve shall comply with BS 5154:1991.

Globe valves of 65mm and above shall be cast iron body, bronze mounted, renewable beveled bronze disc and seat ring, outside screw and toke with rising spindle and flanged ends. Cast iron globe valve shall comply with BS 5152:1974(1991).

(c) Strainers

Y-Type with removable stainless steel or bronze mesh basket strainer shall be supplied and installed where shown in the drawings.

(d) Pressure Gauges

Dial type with 3-way gauge cock shall be supplied and installed where indicated in the drawings.

(e) Float Valve

Float operated valves shall be globe or butterfly valves, operated by means of rust proof parallel bar linkages and chromium plated steel floats. Float shall conform to BS 1968 : 1953 and valve to BS 1212 : Part 2&3 :1990 and to JBA approved manufacture.

(f) Isolation Valve

Isolation valve shall be gate valve as specified. They shall be provided for every branch from main run or dropper so that every outlet or a series of outlets can be serviced without disrupting the general supply.(g) Water Meter

Suitable water meter approved by JBA shall be supplied and installed as required.

9.0TESTING AND COMMISSIONINGThe inspection, testing and approval of the plumbing system by Local Authorities shall be the responsibility of the Sub-Contractor. Any fee in respect of testing and approval shall be borne by the Sub-Contractor.

The Sub-Contractor shall allow for the cost of all tests to the plumbing system to the satisfaction of the S.O. The completed sanitary system shall be tested for water and gas tightness and the plumbing system shall be tested for hydraulic performance.

The cost for providing all testing and measuring equipment, all materials and consumables such as fuel, electricity, water etc. shall be borne by the Sub-Contractor.

All pipework which is to be encased or concealed shall be tested and approved before it is finally enclosed.

The Sub-Contractor shall give the S.O a full seven days notice of his readiness to carry out acceptance tests and shall submit for his approval a complete and detailed schedule of the tests to be carried out.

Before the commencement of acceptance tests the Sub-Contractor shall have brought the installation to a state of practical completion and shall have completed all of his preliminary testing and adjusted the equipment to its proper running order.During the testing period no modification, adjustment or other work on the installation shall be carried out without the permission of the S.O. Should there be any contravention of this requirement the results of all tests completed may be rejected and a retest carried out.

No acceptance test shall be carried out except in the presence of the S.O the Local Authoritys representative and the Sub-Contractor or their respective representative appointed for the purpose.

Should the installation fail to perform in accordance with the requirements of the Specification the S.O may reject the whole or any part of it.

9.1Pressure Test

After each section of pipework has been completed, the joints shall be sealed and the section subjected to a hydrostatic test at a pressure of 1 times the operating pressure (min. 2 bar). The pressure shall be held for a period not less than 24 hours and should leads become apparent, effective repair and testing are required. After correction for ambient temperature the pressure drop shall not exceed 5% of the test pressure.No pipework shall be covered or concealed until it has been tested to the satisfaction of the S.O. Where arrangement of work makes necessary, the piping system shall be tested by sections but final overall test shall be carried out to prove joints between section and all equipment not designed to withstand test pressure shall be disconnected during test.9.2Flow TestUpon completion of pressure tests on all risers, all pumps shall be run with all valves fully open. During test running, the following data shall be recorded :-a. Flow at outlet into tank to which water is pumped

b. Head at pump discharge outlet

c. Current consumed, and

d. Voltage

The permanently installed pumps shall not be used for pressure testing of the water system.9.3Flushing/Sterilization of Cold Water SystemAfter completion of the pressure tests to the satisfaction of the S.O and the local Authority, the whole system shall be thoroughly flushed with clean mains water to remove any dirty to debris within the system.

The Sub-Contractor, at his own expense, shall use public water supply for cleaning and flushing out of all the plumbing system that he had installed in this Contract.

Control valves and all equipment liable to damage, shall be disconnected before cleaning out. All strainers shall be thoroughly cleaned out during and at the completion of the cleaning out operation.

9.4Balancing

Prior to balancing, all isolation/gate valves shall be checked to be in the fully open position.

The balancing shall be carried out on a floor by floor basic. All water appliances on the floor to be balanced shall be turn on.

9.5 Records

All pressure, flow and balancing tests shall be recorded and certified by Contractor and S.O.

The S.O reserves the right to order a re-test should the Contractor fail to produce authentic test record.

10.CLEANING, PAINTING AND IDENTIFICATION10.1Cleaning of pipework

All pipes, fittings, etc. shall be kept closed against moisture and foreign matters when stored on site.

All pipes, fittings, valves and accessories shall be thoroughly cleaned internally and externally before their installation and again where necessary before closing up.

After installation and before putting into service all pipeworks including fittings, valves shall be thoroughly cleaned internally.

10.2 Painting and IdentificationThe whole of equipment and materials installed in this contract shall be paint in accordance to the specification.

All paints used shall be of the first and to the approval of the S.O. Paints shall be generally prepared by the manufacturer for use without thinning or reducing unless other wise specifiedAll surfaces to be painted shall be first thoroughly cleaned by wire brushing, scrubbing and scrapping to remove scales, grease spots etc. from surfaces.

Surface shall be completely dry before painting is applied.

All surfaces shall have one priming coat applied. Steel and iron shall be primed with rust inhibiting primer and galvanized surfaces shall be prime with an etching primer. A second priming coat shall be applied to all surfaces which will be cover by insulation or attached equipment and to all other surfaces where the S.O considers the first primer has proved inadequate.For surfaces not covered by insulation or attached equipment, after priming, one undercoat and two high gloss finish coat shall be applied.

All pipework, equipment, valve, etc shall be clearly identified as specified below and subject to the approval of the S.O.

(a) Pipework

All piping installed under this Contract shall be identified in accordance with the following table and requirements of Jabatan Bekalan Air.Nature of Pipes

Distribution Pipe

(from tank flow)

Hot Water

Toilets and Air Conditioning

Treated Cold Water Services from Public Supply

Fire Protection ServicesColour

Green BS 6-074

Brown BS 3-045

Yellow

French Blues BS 0-012

Red

(b)Labels for Valves and Controls

All control valves, relays, switches and instrumentation shall be identified by black or white engraved laminated plastic labels, securely attached to the item of equipment, or when such equipment is installed on or within panels or cubicle, the labels shall be located immediately below the equipment. Where valves are normally opened, the hand-wheels shall be painted green and if normally closed, the hand-wheels shall be painted red.

Directional arrows shall be painted on the pipework in the plant rooms, tank room and vertical risers.

11.Water Storage Tank

All water tanks shown in the tender drawings shall be supplied and installed by the Sub-Contractor.

All water tanks shall be supplied complete with :-

(a) Inlet pipes complete with isolation valve, ball float or cut-in/cut-out level switches as specified in the drawing.(b) Outlet pipe complete with gate valves(c) Warning, overflow and scour pipes complete with gate valves to sizes shown on drawings.(d) Covers and insect proof vent pipe to be fixed to the tank(e) Internal access ladder suitably constructed from aluminium and placed adjacent to the manhole.(f) When the tanks are over 1.23m in height external access ladder shall be similarly provided.

(g) Mechanical level indicator.

The water tank material shall be as indicated in the tender drawing and/of the following specification.

11.1FRP Water Storage Tank

a.General

The tanks shall be scribbled down and flushed out with clean water and sterilized with chemical containing chlorine before being put into use.

Water tank design will comply with the specification for glassfibre reinforced polyester sectional water tank SS245 : 1981 and be approved by the JBA and SIRIM.Materials for the construction of panels will be unsaturated polyester resin to conform to an appropriate standard in JIS 6919 and glassfibre used will be non-alkali type conforming to JIS R3411 to 3417 as specified in SS245 : 1981.

The manufacturing process of panel will be hot press moulding system of SMC method. The tank will be fabricated from glassfibre reinforced plastic (GRP) panels of dimension 1M x 1M square with maximum tolerance of 1.5mm. Each GRP panel will be manufactured with flanges at a right angle of 90 to all sides of each panel. The thickness of the flange for the side wall and base plates will not be less than 10mm and the landed width of each flange will not be less than 70mm for base and side panels.

b.Jointing Material

The jointing material shall be synthetic rubber as sealant with stainless steel nuts and bolts.

The holes for the bolts will be 12mm+ 1.5 to 2.0mm in diameter, suitable for M12 bolts and nuts.

c.Connections

All holes and pipe connection made in wall, top and bottom of tanks shall be factory fabricated before delivery of tank to site. The positions and type pipe connections shall be carried out strictly in accordance with the manufacturers recommendations.

d.ReinforcementThe interior supports for the panels will be resistant to the qualify of water stored. They will be GRP, PVC or stainless steel SUS 304.

All exterior supports and metal parts will be made of hot dipped galvanized mild steel.e.Plinths/Steel Beam

Plinths support for the storage tanks shall be provided by the contractor. Steel beam (hot dipped galvanized) shall be provided on top of and long the full length of each plinth by the contractor accordance with the suppliers recommendation

f.PaintingThe internal face of the water tank shall be given 2 coats of non-toxic non corrosive paint and external one coat primer and two coats of non-corrosive paint to S.O approval.

11.2Pressed Steel Water Storage Tank

a.General

The pressed steel construction storage tanks shall fully comply with the requirements of BS 1564 :1949 and its latest amendments and be approved by the JKR, SIRIM and JBA.

The tank shall be construction of not less than 6.35mm thickness and shall have internal flanges and be complete with all internal bracings, pipe pads, cleats, bolts, nuts, washers, jointing compound, cover, stiffening and everything else necessary for the complete installation of the tanks.b.Jointing Material

The jointing material used shall be bituminous putty, chemical resistant and insoluble in water. It shall not flow or deteriorate at an ambient temperature of 77C.c.Connections

All holes and pipe connection made in wall, top and bottom of tanks shall be factory fabricated before delivery of tank to site. The positions and type pipe connections shall be carried out strictly in accordance with BS 4504 and the manufacturers recommendations.

d.Hot Dipped GalvanizingAll pressed steel tanks shall be hot dipped galvanized.e.Plinths/Steel Beam

Plinths support for the storage tanks shall be provided by the contractor. The capacity and location of the storage tank shall be indicated in the tender Drawings.f. PaintingThe internal face of the water tank shall be given 2 coats of non-toxic non corrosive paint.

The external surface shall be painted with one coat of zinc chromate and finished with two coats of weather proof, mildew resistant paint of the required colour as instructed by S.O

11.3HDPE Tank

a.General

High Density Polyethylene (HDPE) tanks shall be manufactured with built-in stabilizer against embrittlement due to ultra-violet radiation. The material must be inert, non-toxic, odourless and physiologically safe and approved by FDA (Food & Drugs Authority in America) and Local Authorities.b. ConstructionThe tank shall be factory produced as a complete build-up tank body and cover is fully moulded in one single piece of material without welding, joint or seam

11.5 Mechanical Level IndicatorsEach tank compartment shall be fitted with a float and cable operated mechanical level indicator, located at the front of the tank. The floats guides cable and pulleys shall be constructed durable, corrosion resisting materials. The scales shall be fixed to the front of the tank shall be of metal construction with a hard durable paint finish. The scale board shall be sprayed painted in yellow and black marked in 150mm and 300mm intervals. The scale shall be positioned so that the level indicating pointers corresponds as closely as possible actual levels in the tank behind.

S4.1.11

CONTENT

A.COLD WATER SERVICES

General

S4.1.1

Pipe and Fitting Materials

S4.1.1

Pipe Installation

S4.1.2

Pipe Joints

S4.1.3

Pipe Support

S4.1.3

Sleave & Cover Plate

S4.1.4

Valves & Fittings

S4.1.4

Installation of Underground/Buried Pipe

S4.1.5-S4.1.6

Testing of Pipes

S4.1.7

Pressure Test

S4.1.7

Painting & Identification

S4.1.8

Cleaning Out the System

S4.1.8

Water Storage Tanks

S4.1.9-S4.1.10

B.SANITARY PLUMBING SERVICES

Scope of Works

S4.2.1

Regulation Code and Standard

S4.2.1

Excavation, Trenching and Making Good

S4.2.1

Testing

S4.2.2

Acceptance

S4.2.2

Sewer Connections

S4.2.2

Underground Sewers

S4.2.3

Internal Pipework

S4.2.3- S4.2.8

Pipe Installation

S4.2.8

Anti Syphonage Pipes

S4.2.8

S4.0

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