Document 5 Technical Specifications for HVAC

8/19/2019 Document 5 Technical Specifications for HVAC

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Issued by:

Special Officer & Director of Ports

Kerala Maritime Society

4th

& 5th

floorDirectorate of Ports

New Corporation Building

Palayam

Thiruvananthapuram-33

Consultant:

M/s. Ajit Associates

IIIrd floor, Puthuran PlazaKPCC Junction, M.G.Road

Kochi

Phone: 0484-4072000, Fax: 0484-4032517


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Technical Specification for HVAC Page 2 of 71

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1.2

• High pressure switch

• Low pressure switch

• Fan motor safety thermostat

• Fan driver overload protector

• Over current relay

• Inverter Overload Protector

• Fusible Plug

• Crank case heater

• Fuses

• Over current protector

• Unit shall be supplied with

•

Installation manual

• Operation Manual

• Connection Pipes

• Clamps

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The Entire Condensing unit and Evaporating unit should be Factory assembled and tested .The units

should come with an initial charge of refrigerant R410A or eco-friendly gas from the factory.

Refrigerant Piping Distance Limits

To be capable of refrigerant piping runs up to 150m between the condensing unit and fan coil units with

50m level differences without any oil traps or double risers. The Oil Equalizing line should be inside the

Condensing unit, to avoid ‘inverted’ oil traps at site. The level difference between fan coil units

connected to the same refrigerant circuit can be extended to 15m.


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1.10

The Indoor units shall be Hi-Wall / Cassette / Ducted type as per the aesthetic requirements of the client.

All indoor units should be provided with Cordless Remote controllers for ease of operation.

Minimum static required for IDUS:

HI-static-14mm-19mm

Medium static-5-7mm

Lowstatic-5mm

Electronic Expansion Valve:

Each indoor unit should be fitted with a pre filter, electronic expansion valve, which controls the

refrigerant flow in response to the load variations in the room. The electronic expansion valve is to be

controlled via a computerized control sensing the return air temperature, refrigerant inlet and outlet

temperatures. During the cooling operation the electronic expansion valve controls the refrigerant

superheat degree at the evaporator.

Direct driven of the DIDW multi-blade type, statically and dynamically balanced to ensure low noise and

vibration free operation.

To be direct expansion, constructed from copper tubes expanded into aluminium fins to form a

mechanical bond.

The indoor units should be provided with auto swing of the supply air louvers for cassette and under

ceiling type fan coil units. The louvers should be capable of providing continuous swing operation or to

be fixed in any direction required.

Include in the fan coil unit a printed circuit board complete with, address switches for a variety of

operation controls, emergency operation switch and fault/operation indication LED’s. Thermally protect

fan motors.

The fan coil unit casing (ceiling mounted units) to be fully insulated and sealed to prevent condensation.


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1.11 :

The Drain connection of each Fan coil unit to the main Header should be of 25mm Dia. The Header Pipe

should be of 40mm Dia. The Drain Pipe should be of Hard PVC, whereas the connection of the Fan coil

unit to the Hard PVC Pipe should be with flexible braided pipe. The Drain piping should be insulatedwith 13 mm thick tubular Nitrile Rubber Electrometric insulation.

1.12 :In case of individual and group control, set the addresses of each fan coil unit to minimize commissioning

time. In case of centralized control, set the addresses by the remote controller.

1.13

To be fully weatherproofed, factory assembled and pre-wired with all necessary electronic and refrigerant

controls. Construct the casing from mild steel panels coated with a baked enamel finish. Provide thecondenser coil fins with a corrosion resistant finish.

Larger Condensing Units: Incorporate 2 compressors in condensing units above 5HP with at least one

Rotary inverter / Inverter scroll type. The condensing unit preferably shall be of 3Rows condenser coils

for higher capacities.

Modular design: Allow for side-by-side installation, by the modular design of the condensing units.

Fan Motor Speed Control: The condensing unit fan motors to have at least two-speed operation to

maintain constant head pressure control in all ambient temperatures and modes of operation. The

condenser fan louvers shall be of self adjusting type for smooth air flow.

1.14

Provide highly efficient inverter rotary / inverter scroll type compressors with electronic controls, capable

of loading and unloading to follow the variations on cooling or heating loads, using the latest axial

compliant sealing technology. The microprocessor panel should incorporate control for precise

monitoring of status of the system. The system should not with electromagnetic interference & conversion

losses. Suitable resonance filters shall be incorporated to prevent electromagnetic interferences &

conversion loses. Each module should have variable speed compressors to ensure precise operation at

lower loads.

1.15

Construct the heat exchanger from seamless copper tubes mechanically bonded to aluminium fins to form

a cross fin coil. Treat the aluminium fins with an anti-corrosion film.


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1.16

Complete the refrigeration circuit of the condensing unit with refrigeration compressors, motors, fans,

condenser coils, electronic expansion valve, sight glass, solenoid valves, 4 way valve, distribution

headers, capillaries, filters, shut down valves, service ports, receivers and accumulators and all othercomponents which are essential for safe and satisfactory operation. The unit should have arrangement for

adjusting the condenser area as per indoor load requirement.

1.17 Equip the unit with an oil recovery system to ensure stable operation for systems with long refrigerant

piping. Operate the oil recovery system after the first hour of operation and then every consecutive 4

hours of operation. Also fit high efficiency oil separators to the discharge side of the compressor together

with factory fitted oil equalization system.

1.18 Fit the condensing unit printed circuit board (PCB) with selection switches, emergency operation

switches and service mode switches, together with LED indications for operation / fault indication.

1.19 Use computerized control to maintain a correct form of temperature. For the fan coil units incorporate an

on/off switch, fan speed selector, thermostat setting and liquid crystal display which indicates temperature

setting; operational mode, malfunction codes etc.

Fan coil control:

Accomplish by the use of individual controllers for each fan coil unit.

Fault Diagnosis:

Equip the system with a diagnostic function for quick and easy maintenance and service.

1.20

i) Product Data: Submit manufacturer's technical data for air distribution equipment, including capacity

ratings, fan performance curves with operating point clearly indicated, gages and finishes of

materials, dimensions, weights, furnished accessories, and installation and instructions.

ii) Wiring Diagrams: Submit the manufacturer's electrical requirements for power supply wiring to theunits.

iii) Operation and Maintenance Data: Submit maintenance and lubrication instructions, motor and drive

replacement instructions, and spare parts list for each unit.


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1.21 ,

A.Transportation, handling and storage of materials shall be in accordance with manufacturer's

recommendations regarding transportation, handling and storage of materials.

B. Deliver materials to the site in manufacturer's original factory wrappings and containers, clearly

labeled for identification of manufacturer, brand name and contents. Store materials off ground in

original undamaged packages and containers, inside well-ventilated area protected from weather,

moisture, soiling, extreme temperatures, and humidity. Follow manufacturer's instructions regarding

transportation, handling and storage of materials.

1.22 Materials shall be provided of standard products of specialist manufacturers who have long experience

of manufacturing and installing control equipment specified in this section. The system shall be

installed by competent personnel, regularly employed by the Controls manufacturer with full

responsibility for proper operation of the Controls including debugging and proper calibration ofeach component in the entire system. Supplier shall have in-place support facility within 30 km of

the site with technical staff, spare parts inventory and all necessary test and diagnostic equipment.

Submit a written guarantee signed by manufacturer, contractor, and installer agreeing to replace

partitions which fail in material or workmanship within a period of 2 year from the date of substantial

handing over.

1.23 Upon completion of all work and all tests, the Suppliers shall furnish necessary operators, labor and

helpers for operating the entire installation for a period of fifteen (15) working days of twelve (12) hours

each, to enable the Owner’s staff to get acquainted with the operation of the system. During this period,

the contractor shall train the Owner’s personnel in the operation, adjustment and maintenance of all

equipment installed

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TECHNICAL SPECIFICATION FOR HVAC

CONSTRUCTION OF MARITIME SOCIETY AT NEENDAKARA,

KOLLAM

1 SCOPE

The scope of this section comprises the supply of VRF units and associated works conforming to

these specifications and in accordance with the Schedule of Quantities and detailed BOQ.

LIST OF BUREAU OF INDIAN STANDARDS CODES

IS: 277-1992 galvanized steel sheet (Plain & Corrugated wire for fencing.

IS: 554 – 1985 (Reaffirmed 1996) Dimensions for pipe threads where pressure tight joints are

required on the threads.

IS: 655-1963 (Reaffirmed 1991) Metal air ducts

IS: 659-1964 (Reaffirmed 1991) Air Conditioning (Safety Code)

IS: 660-1963 (Reaffirmed 1991) Mechanical Refrigeration (Safety Code)

IS: 732-1989 Code of practice for electrical wiring

IS: 1239 (Part – I) – 1990 Mild steel tube

IS: 1239 (Part –II) – 1992 Mild steel Tubular and other wrought steel pipe fittings

IS: 1255-1983 Code of Practice for installation and maintenance of Power Cables up to and

including 33KV rating (Second Revision)

IS : 1554 – 1988 (Part – I) PVC insulated (Heavy Duty) electric cables for working voltages up to

and including 1100 volts

IS: 2379 – 1990 Colour code for the identification of pipelines.

IS: 2551 – 1982 Danger notice plate

IS: 3043 – 1987 Code of practice for earthing

IS: 3103 – 1975 (Reaffirmed 1999) Code of practice for Industrial Ventilation

IS: 3837 – 1976 (Reaffirmed 1990) Accessories for rigid steel conduit for electrical wiring

IS: 4736-1986 (Reaffirmed 1998) Hot-dip zinc coatings on steel tubes


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IS: 4894 – 1987 Centrifugal Fan.

IS: 5133-1969 (Part-I) (Reaffirmed 1990) Boxes for the enclosure of electrical accessories.

IS: 5312 (Part–I)–1984 (Reaffirmed 1990) Swing-check type reflux non return valves for water

works

IS: 5424-1989 (Reaffirmed 1994) Rubber mats for electrical purposes.

IS: 5578 & 11353-1985 Marking and identification of conductors

IS: 6392-1971 (Reaffirmed 1988) Steel pipe flanges.

IS: 13947-1993 (Part – V) Control Circuit Devices

BS: EN: 779-1993 Filters

ASHRAE Hand Books American Society of Heating

Refrigeration & Air conditioning

ASHRAE Indoor air quality Standard 62-1982

Submittals

i) Product Data: Submit manufacturer's technical data for air distribution equipment, including capacity

ratings, fan performance curves with operating point clearly indicated, gages and finishes of

materials, dimensions, weights, furnished accessories, and installation and instructions.

ii) Wiring Diagrams: Submit the manufacturer's electrical requirements for power supply wiring to the

units.

iii) Operation and Maintenance Data: Submit maintenance and lubrication instructions, motor and drive

replacement instructions, and spare parts list for each unit.

Transportation, Handling and Storage

A.Transportation, handling and storage of materials shall be in accordance with manufacturer's

recommendations regarding transportation, handling and storage of materials.

B. Deliver materials to the site in manufacturer's original factory wrappings and containers, clearly

labeled for identification of manufacturer, brand name and contents. Store materials off ground in

original undamaged packages and containers, inside well-ventilated area protected from weather,

moisture, soiling, extreme temperatures, and humidity. Follow manufacturer's instructions regarding

transportation, handling and storage of materials.


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C. The material should not damage before doing the commissioning and handing over and any damage

will lead to the replacement of the same.

Warranty

Materials shall be provided of standard products of specialist manufacturers who have long experience of

manufacturing and installing control equipment specified in this section. The system shall be installed by

competent personnel, regularly employed by the Controls manufacturer with full responsibility for proper

operation of the Controls including debugging and proper calibration of each component in the entire

system. Supplier shall have in-place support facility within 30 km of the site with technical staff, spare

parts inventory and all necessary test and diagnostic equipment. Submit a written guarantee signed by

manufacturer, contractor, and installer agreeing to replace partitions which fail in material or workmanship

within a period of 2 year from the date of substantial handing over.

On site training

Upon completion of all work and all tests, the Suppliers shall furnish necessary operators, labor and

helpers for operating the entire installation for a period of fifteen (15) working days of twelve (12) hourseach, to enable the Owner’s staff to get acquainted with the operation of the system. During this period,

the contractor shall train the Owner’s personnel in the operation, adjustment and maintenance of all

equipment installed

2 Design Conditions and Criteria

2.1 General

The Engineering Services for this project shall be installed in accordance with this specification

and the tender drawings.

2.2 Environmental Conditions

The mechanical installations within the building shall be designed to maintain the internal

conditions detailed below with a range of external conditions varying as per the Kerala climate.

All selected equipment shall be suitable for installation in coastal locations and shall have a

minimum life expectancy of 50 years. All services and equipment shall be designed to operate in

the ambient temperature.

Internal Conditions:

Summer ºC db – 23, Max RH – 60, NC - 30Winter ºC db – 21, Min RH – 50, NC - 30

3. Mechanical Engineering Specification (Material, Equipment andWorkmanship)


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3.1 Standards & Methods of Fixing

3.1.1 Generally

Materials, products and systems shall comply with the following:

This Specification;

1 Government Rules;2 EEC Regulations and Directives;3 Local Authority's Byelaws and Regulations;

4 Water Supply Authority's requirements;5 Model Water Byelaws;6 Electricity Supply Authority's requirements;7 Gas Supply Authority's requirements;

8 Building Control Officer's requirements;9 Fire Prevention Officer's requirements;10 Any other Special Licensing Authority's requirements;11 Appropriate British Standard Specification and Codes of Practice;

12 IEE Regulations for Electrical Installations 16th Edition;13 The Electricity at Work Regulations (1989).14 The Health & Safety at Work Regulations (1992).

15 The Fire Precautions (Places of Work) Regulations (1992).16 Appropriate Health & Safety Executive Guidance Notes;17 Ministry of Housing, Electricity and Water (MHEW)18 Loss Prevention Council (FOC) Rules 29th Edition;

19 CIBSE Guides and associated technical documents;20 American Society of Heating, Refrigerating and Air conditioning(ASHRAE)

21 Plumbing Engineering Services Design Guide (PESDG)22 Any other relevant document or regulation;

Revisions or alterations to the above standards and regulations that are published during theinstallation of the work shall be brought to the attention of the approval authority. Theappropriate instruction may then be issued.

All costs associated with charges made by any authority approving any part of the Contract

Works shall be included.

3.1.2 Suitability of Materials and Products

Materials and products shall be supplied to suit the temperatures and other condition normally

expected to apply during transit, storage and installation periods and after the installation is

completed, and also to withstand any test specified herein or in any document referred to herein.

Materials and products shall not support bacterial life and be proof against attack by insects and

vermin. Animal hair must not be used in acoustic or sound deadening materials.


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3.1.3 Standardisation

Equipment shall be standardised throughout the installation where possible.

3.1.4 Labels

All identification labels, duty labels, instruction and safety labels for electrical equipment and cables

shall be in English and other languages where specified.

3.1.5 Electrical Interference

All equipment offered for use anywhere on the project shall comply with BS EN 55014:1993

3.1.6 Minimum LP Rating Yet to be drafted.

3.1.7 Methods of Fixing

General

The size of bolt or screw used must be the largest permitted by the diameter of the hole in theequipment to be fixed.

All bolt or screw holes provided in equipment shall be used and each fixing must be secure.

All screws and bolts shall be sheradised. For fixing in block and concrete, holes of correct size

for screws or bolts shall be neatly drilled with tungsten carbide tipped twist drills to a depth

(excluding plaster thickness) equal to the length of plug to be used. The plug length must be

correct for the screw. Fixings shall not be made between joints in block work.

Unless otherwise specified all fixing screws in block work and concrete shall be 38mm long.

Conduit boxes shall be fixed by two roundhead screws. Countersunk screws shall only be used

where countersunk holes are provided, otherwise the wood screws shall be roundhead and set

screws shall be cheese head. Where holes have to be drilled for fixing, No 10 wood screws shall

be the minimum size used.

3.1.8 Lightweight and Heavyweight

Dependent upon size of fixing holes provided in the equipment, all fixings in block work and

concrete shall be by woodscrews and suitable plugs or mild steel bolts of the grouted type or by

one of the various type of expanding raw bolts. Fixing to timber shall be by means of

woodscrews or coach screws.

3.1.9 Fixing of Metalwork

Fixings to light gauge metal inaccessible at the back shall be by means of shake proof self


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tapping screws or raw plug spring or gravity toggles. Fixings to supporting metalwork shall

generally be made via proprietary fixings with clamp connections. Drilling of metalwork shall

be avoided wherever possible and shall only be carried out following approval. No fixings shall

be made to structural steelwork without approval.

4.1 Pipe work Installations

4.1.1 Standards

The pipe work installations shall conform to the following British Standard Specifications:

BS EN 12540:2000

Electroplated coatings of nickel and chromium.

BS 1710: 1984

Identification of pipelines and services.

BS 5306

Fire extinguishing installations and equipment on premises.

BS 6700 : 1997 BS EN 8062:2005

Design, installation, testing and maintenance of services supplying water for domestic use within

buildings and their cartilages.

4.1.2 General

The pipe work installations shall follow the detail set out on the tender drawings making due

allowance for the diagrammatic nature of the drawings and taking account of their requirements

of this specification. Pipe runs shall be installed in accordance with best accepted practice and

shall be arranged to present a neat appearance and shall be parallel with each other and with the

building structure except where falls are required to facilitate draining or venting.

4.1.3 Spacing of Pipes

Pipes shall be spaced, in relation to one another and to the building structure, to allow for the

required thickness of thermal insulation as specified elsewhere. The combined insulation of two

or more pipes in one composite casing will in no case be permitted.

4.1.4 Sleeves and Plates


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Where pipes pass through elements of the building structure, i.e. walls, floors, partitions, false

ceilings etc, they shall in all cases be enclosed concentrically within purpose made sleeves cut

from pipe of the same material one or two sizes larger as may be required to provide reasonable

clearance. Such sleeves shall be cut square at the ends, clean and flush with the finished wall

surfaces and extending 6mm above and below floor and ceiling surfaces. Sleeves shall in nocase be used as pipe supports, a free annular space being always provided for. The annular space

is to be packed with approved mineral fibre where it is necessary to maintain a fire stop.

Where pipes and tubes pass through the finishes of walls, floors, ceilings, partitions and false

ceilings of occupied rooms, they shall be fitted with a heavy chromium plated gunmetal masking

plate. Such plates shall be split on the diameter, be a snug fit to the pipe concerned and be

provided with counter sunk holes for wood screws. The fixing of such plates shall include

drilling and plugging to the wall and finally screwing on with substantial wood screws having

chromium plated raised counter sunk heads. Pipe joints shall not be made within the thickness of

walls, floors and other elements of the building structure.

4.1.5 Gradients

All pipe work shall be installed to gradients to allow for drainage and/or release of air, according

to the service concerned. Gradients shall be, generally, as follows:

(a) Refrigerant circulating pipes shall rise in direction of flow to predetermined high points.

(b) Condensate drains shall fall at a rate of not less than 1:120.

(c) Drains from tundishes shall fall to vertical drops at a rate of not less than 1: 250.

(d) Gas piping shall be laid to drain to low points where pockets with plugged ends shall be

fitted.

4.1.6 Cleanliness

Care shall be taken to avoid dirt entering pipe work during erection and all open ends must be

protected before and during installation with proprietary plastic or metal caps or plugs. Piping

shall be thoroughly cleaned prior to erection.

4.1.7 Chromium Plating

Copper pipe work for chromium plating shall be fully fabricated with all bends, soldered joints,

etc completed, clean and free from blemishes and then plated in accordance with the British

Standard.


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4.1.8 Electrolytic Action

A fitting of nonconductive, inert material is to be inserted to separate copper pipe work from any

galvanised or zinc coated steel.

4.1.9 Pipeline Identification

Identification of pipeline services and direction of flow shall be provided in accordance with the

British Standard and shall be applied after protective and/or decorative painting is complete.

Additionally in plant rooms, tank rooms, services and roof voids, pipe work shall be Colour

banded within 200mm of all connections to equipment.

Colour coding shall be provided as follows:

At 8m intervals on straight runs;

At all changes of direction;

Within 300mm of all valves;Within 300mm of all equipment items;At all junction points and branch (unless end of branch is visible from junction) and;

All lines passing through walls and floors where lines are accessible and not visible from an

identified main.

Direction of flow arrows and graphical symbols (where applicable) shall be stencilled in black on

a regular white background.

Closed circuit pipes shall be labelled 'FLOW' and 'RETURN' as applicable.

Letters and symbols shall be pipe nominal bore or 50mm in height whichever is the lesser.

Symbols shall conform to the legend on the record drawings and plant room charts.

The banding shall be achieved by use of purpose design plastic tapes.

The width of bands shall be at least 76mm wide and be placed at 3 meter intervals for voids,

ducts and false ceilings and in plant rooms around the whole circumference of the service and at

all other points where the service cannot be readily identified.

4.1.10 Pipes Passing through Walls EtcWhere pipe work passes through external walls, roofs and basement walls into the ground or into

trenches or ducts, the supply and fixing of weathering collars, sealing rings or frames and puddle

flanges as applicable shall be included to approved details. This is in addition to sleeving

requirements. The contractor shall provide and locate all sleeves and inserts required before the

floors and walls are built, or shall be responsible for the cost of cutting and patching required

where sleeves and inserts were not installed, or where incorrectly located.


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Sleeves shall be provided for all mechanical piping passing through concrete floor slabs and concretewalls, masonry, tiles and gypsum wall construction.

Sleeves shall not be provided for piping running imbedded in concrete slabs or insulatingconcrete slabs on grade. Where pipe motion due to expansion and contractor will occur, makesleeves of sufficient diameter to permit free movement of pipe. Where sleeves pass insulatedpipes, the sleeves shall be large enough to pass the pipe and insulation. Check floor and wallconstruction finished to determine proper length of sleeves for various locations make actuallength to suit the following:

(a) Terminate sleeves flush with walls, partitions, and ceilings

(b) In areas where pipes are concealed, as in shaft, terminate sleeves flush with floor© In areas where pipes are exposed extend sleeves 6mm above finished floor, except inrooms having floor drains. Sleeves shall be extended 18mm above floor.

All sleeves shall be constructed of galvanised steel pipes unless otherwise indicated in the

drawings.

4.1.11 Excavation and Backfilling

Underground Refrigerant supply piping shall be installed with the crown not less than 0.75m

below ground level. Excavations for pipe trenches shall be to straight lines and to correct depths

for the pipe and beds. The trench bottom shall be only of sufficient width to allow adequate

working space for pipe installers and where necessary, timbering to trenches shall be provided.

Excavated trenches shall not be opened too far in advance of pipe laying and shall not cause any

unnecessary obstruction of the site.

All pipes, cables, ducts, drains, mains and other services exposed by the excavations shall be

effectively supported and protected from damage. Should rock outcrops be discovered during the

course of excavation the Engineer shall be advised as soon as possible and work shall cease at

the location until the Engineer advises any modification which may be required to the pipe runs.

Backfilling with granular material shall be carried out over the barrels and between joints, prior

to pressure testing. After pressure testing, joints shall be covered with granular material to 50mm

above the crown of the pipe. The granular material shall be broken stone or gravel to pass 10mm

sieve and be retained on 5mm sieve well tamped.

As soon as possible after the position of pipe and granular material the trench shall be filled and

the next 300mm hand tamped with selected stone free excavated material placed in two equal

layers, fill in over to ground level with machine compacted excavated material and remove

surplus soil. Where pipes pass below roads and other asphalted or paved areas subject to motor

vehicle passage, cement pipe ducts with polypropylene sockets shall be provided.


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5.1 Piping and Joints

5.1.1 Standards

The piping and joints shall conform to the following British Standard Specifications:

BS 864 –2 : 1987 BS EN 1254 1998

Capillary and compression fittings for copper tubes.

BS 1724 : 1990

Bronze welding by gas.

BS 1044 : 1999

Specification for filler metals for brazing.

BS en 1057 : 1996

Copper tubes for gas.

5.1.2 General

All piping and tubing used in the construction of the various plants described in this specification

shall be straight, cleanly finished, round in cross section without cracks, surface flaws,

laminations/ and other defects and shall be free from scale in the case of ferrous material. Wherepipes are cut they shall be reamed to remove burrs.

5.1.3 Copper Tubes Half Hard Temper

(i) Light gauge copper tubes shall be half hard temper.

The tube shall be cleaned to remove any film or carbonised layer and must be acceptable to the

local Authority. Table Z tube may be used only in straight lengths.

(ii) Tubes shall have ends cut square to the axis and be suitable for connection by means of

compression or capillary fittings or welding.5.1.4 Copper Tubes Capillary Joints

Light gauge copper tubes, jointed with capillary type fittings shall be cut to the required length

with a purpose made copper tube cutter, the cut end then being filed true and smooth and the

outer periphery of the tube adjacent to the end cleaned with fine steel wool or fine sandpaper.

The fitting shall have an integral solder ring and the joint shall be made up by the application of

the correct flux and the flow of solder by capillary action along the annular space between the


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outside of the tube end and the inside of the socket of the fitting.

5.1.5 Copper Tubes Manipulative Compression Joints

Compression fittings may only be used where specified or following the engineer's approval.

Light gauge copper tubes jointed with manipulative compression fittings shall be cut to the

required length with a purpose made copper tube cutter, the cut end then being filed true and

smooth and all swarf, filings and dross then being carefully removed. The clean end shall then be

carefully expanded to the correct included angle with a drift provided by the manufacturer of the

fitting used, care being taken that the coned end so formed is not hardened. The joint shall be

made up by compressing the expanded portion of tube between the loose friction ring and loose

ferrule provided as part of the fitting.

5.1.6 Copper Tubes Non-Manipulative Compression Joints

Compression Fittings may only be used where specified or Following the Engineer's Approval.

Light gauge copper tubes jointed with no manipulative compression fittings shall be cut to the

required length with a purpose made copper tube cutter, The cut end then being filed true and

smooth, all swarf, filings and dross removed and the end cleaned with fine steel wool. The joint

shall be made by ensuring that the end is inserted into the threaded ring and olive and then

inserted fully into the fitting and tightened in accordance with the manufacturers' instructions.

5.1.7 Copper Tubes Welded Joints

Copper pipe work up to 200mm diameter with wall thickness up to 4.5mm shall be brazed in

accordance with the recommendations in HVCA Code of Practice TR/3, as modified below.

Joint designs, brazing procedures, brazer certification and production joint quality shall comply

with the requirements as interpreted by an approved testing body.

Brazing procedures shall include auxiliary heating for pipe diameters 75mm and larger, for solid

copper flanges, and in other circumstances where exposure, weather, wall thickness, etc, indicate sound

joints will not be otherwise assured.

Brazers shall hold a valid certificate of competency issued by an approved testing body. The

HVCA TR/3 standard test piece will be the accepted test of competency. Brazers without valid

certificates and those without relevant brazing work experience within the proceeding 3 months

shall undertake the TR/3 test, witnessed and certified by an approved body before commencing

work.

Brazers shall permanently identify each of their joints with their own marker, which will

withstand site conditions without damaging system or component performance. Methods of

marking shall be approved.


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A sample joint prepared by each brazer shall be subjected to visual and destructive testing, to the

satisfaction of the approved testing body. The sample joint shall be representative of the

thickness and diameter of the joints and the conditions of the site. 10% of production joints shall

be nondestructively tested by the approved test body in accordance with TR/3. Rectification

work on faulty joints shall be performed by different brazers. Brazers with failure ratesconsidered excessive by the approved test body shall be taken off the works.

.

5.2 Pipe Fittings

5.2.1 Standards

The piping fittings shall conform to the following British Standard Specifications:

BS EN 1057:1996

5.2.2 General

The equipment described in this section comprises all bends, springs, sweeps, elbows and other

changes in direction, all tees, oblique branches, swept branches and other junctions, all

reductions and enlargements in pipe bore, expansion loops, anchors etc.

The following general particulars shall apply to such fittings, irrespective of material and grade

as detailed in subsequent clauses, except where alternative particulars are specifically stated:

(a) Changes in Direction

All changes in direction shall be proportioned such that the ratio between the centre line radius of

the bend and the inside diameter of the pipe is not less than 1.5 to 1. Shorter radius bends shall

only be subject to specific approval where long radius bends will not fit or are not manufactured.

(b) Junctions

All branches from, and junctions to, a main pipe shall, except where otherwise detailed in the

drawings, be swept in with a radius or provided with an oblique approach in order to give a lead in thedirection of flow.

(c) Reductions and Enlargements

All reductions and enlargements in pipe bore shall be of the eccentric type where desirable for

venting or draining, and shall be proportioned to provide an easy transition. The included angle

shall be 10° where space permits and generally not in excess of 30°.


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5.2.3 Copper Capillary Fittings

Copper capillary type fittings shall be manufactured from copper or a suitable corrosion resisting

copper alloy as either castings, hot pressings or drawings, the material being non dezincifiable.

5.2.4 Copper Compression Fittings

Compression fittings may only be used where specified or following the engineer's approval.

Copper compression type fittings shall be manipulative fittings, type B. Such fittings shall be

manufactured from copper or a suitable corrosion resisting copper alloy as either castings, hot

pressings or drawings, the material being non dezincifiable. Each fitting shall consist of a body

having ends profiled to form a conical seating in the interior with threads or lugs on the exterior,

machined central ferrules having a double tape in cross section, machined conical friction rings

and coupling nuts or flanges.

5.2.5 Copper Pulled Bends

Where light gauge copper tubes are pulled on the site to form bends, springs, cranks and off sets,

the material used shall be as the piping standard. Tubes having nominal bores of up to 28mm

may be bent cold but larger sizes up to 42mm shall be annealed before manipulation.

Tubes shall be loaded prior to bending with springs. Where bending machines are used these

shall have smooth clean guides and formers, any scored or damaged tools being rejected. Bends

must not show any flattening, rippling or constriction of the tube bore.

5.2.6 Copper Junctions

Where junctions to copper mains are formed by autogenous or bronze welding on the site, such

work shall be carried out in accordance with the detail previously set down. Branches shall not

be welded into a main at any angle less than 60° and reinforcement by way of plates, collars or

shoes shall be provided. In general, branches shall take the form of a section of a pulled bend

welded into a hole cut in the main, the profile of both bend section and hole having been set out

to avoid excessive overlap and protrusion into main or branch. The main shall be cut and

swaged to form a raised cup and the spigot end of the bend section fitted thereto. Copper weld

junctions are to be used only with specific approval.

6 Pipe work Supports, Fixings and Anchors

6.1 General


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All supports, fixings, brackets, clips and accessories shall be included except where otherwise

stated.

6.2 Fixings

Fixings shall be of the type suitable for the structural member to which attachment is being made

and shall be approved.

Drilling for fixing to masonry and concrete utilising expanding bolts or self drilling fixing shall

be included. Where fixings are to be built in detailed drawings showing the necessary holes and

pockets shall be included. Alternatively where prior approval has been obtained the

requirements for holes and pockets can be marked up on site, and to be cut out. Use may be

made of tab or proprietary insert incorporated in the structure providing this is coordinated with

and not detrimental to the use of the fixings by others. The setting out of fixings shall be

included.

6.3 Brackets and Clips

The brackets and supports are to take the form of drop rods, cantilever Brackets, mild steel

channels supported by drop rods, ladder racks supported by drop rods, wall fixings or a

combination of these according to the number, size and location of the services to be supported.

Large scale detail drawings of brackets and shall be approved for approval before fabrication

commences.

The contact of dissimilar metals in brackets and piping is to be rigorously avoided. Drop rods

and bracket members will normally be of mild steel which shall be cleaned, degreased, primed

and painted with two coats of aluminium paint prior to erection. Pipe clips, rollers, U bolts, etc.

shall be a material appropriate to the pipe and shall, where necessary, be insulated from the

bracket and fixing bolts and nuts, by plastic linings and inserts.

Brackets shall provide for the specified gradients on all horizontal pipes and must carry the

provision for expansion, anchors, rollers etc. specified elsewhere.

Pipe brackets immediately above or below occupied spaces are to incorporate antivibration

isolation in the angle or channel supports or in the drop rods.

Drop rods shall normally be threaded at the lower end to allow for vertical adjustment and the

upper end shall be terminated to suit the structural fixing.

Pipes supported directly on mild sections shall be fixed with wrought iron ‘U’ bolts at each

support. The 'U' bolt shall be a clearance fit over the pipe, threaded at the end and secured to the

mild steel section with washers and locknuts on each side.


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Pipes which are thermally insulated with a vapour seal must be thermally isolated from the

bracket by inserting hardwood blocks or by Pipe support insert of Armaflex of the same outside

diameter as the overall diameter of the insulated pipe between the pipe and the bracket and under

the clamping 'U' bolt or mild steel strap.

6.4 Positions and Spacing of Brackets

Pipe work shall be supported on either side of changes of direction and pipeline mounted

equipment, and at centers not exceeding those shown in the following tables:

COPPER PIPES (TABLE X) PIPES

Pipe Dia Horizontal Vertical

(mm) (mm) (mm)

15 1200 1200

22 1500 2400

28 1800 240035 2100 300042 2400 300054 2700 3000

67 3000 360076 3000 3600108 3000 3600159 and over 3700 4200

UPVC PIPES (CLASSES D & E)

Pipe Bore Horizontal Vertical

(mm) (mm) (mm)

10 700 1500

13 900 180019 1000 210025 1000 210032 1200 2500

38 1200 250050 1300 2700

80 1600 2700

100 1800 2700150 and over 2200 3000


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Where two or more pipes are supported on a common bracket, the bracket spacing shall be that for the

smallest pipe concerned.

Vertical pipes shall be supported at the base or at anchor points to withstand the total weight of the riser.

Branches from risers shall not be used as means of support for the riser.

Supports in ducts, trenches and voids shall be so spaced to allow access to any pipe or joint without

disturbing the remainder.

7.0 Thermal Insulation

7.01 RELATED INSTRUCTIONS

1 Comply with requirements of Section 15010, Mechanical General Requirements.7.02 WORK INCLUDED

1 Work under this contract shall include but is not limited to the following.

2 The following services shall be provided with insulation as specified, Include other services

also if specifically stated elsewhere in the documents.

1 AC supply, return & Fresh air ducts.

2 Refrigeration piping.

3 Condensate water piping.

7.03 SUBMITTALS1 Submit detailed list of material for each service stating manufacture, ’K’ value, density, finish,

flame spread and smoke ratings, permeability, materials, finishes, cements and adhesives.

7.04 QUALITY ASSURANCE

1 Provide insulation of equipment, piping and ductwork as described or noted. Insulation, jackets

and adhesives shall be incombustible, in compliance with local Building Code; installed to

manufacturer’s standards, and to approval. Wheat pastes shall NOT be used. Products containing

asbestos shall not be used. Make suitable approved openings in insulation for inspection outletsand equipment nameplates.

2 Third Party Supervision Testing: Verification testing by a nationally recognized independent

testing organization that will conduct sampling of the product through to simulated end use

testing.

3 To allow for expansion and contraction of sheet and roll insulation, leave a ½. wide uncoated

border at the butt-edge seams on the surface to be insulated and the insulation surface. Overlap


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the insulation ¼. at the butt-edge and compress the edges into place. Apply adhesive to the butt-

edge of the insulation.

4 Consultant reserves right to demand test samples to composite insulation systems for fire

hazard test rating.

5 Where wire is specified to secure insulation, it shall be stainless steel wire, 1.3 mm gauge, deadsoft annealed type.

6 Material shall be delivered in non broken, factory furnished packaging and stored in a clean,

dry indoor space that provides protection against the weather.

7 Insulation shall be applied by qualified personnel skilled in this trade.

8 Progressive testing of the systems to be insulated shall have been completed, inspected and

approved by the Owner’s representative before the insulation is applied.

9 Insulation shall not be applied until all surfaces are clean, dry, and free of dirt, grease, frost,

moisture, and other extraneous elements.

10 Work shall be performed at the temperatures recommended by the product manufacturer.

7.05 MATERIALS

1 Acceptable Manufacturers: These specifications are based on products and data of Kaim - flex

and designate the type and quality of work intended under this section. Products of other

manufacturers, proposed as equivalent, must be submitted for written approval by the Engineer.

Supporting technical data, samples, published specifications and the like must be submitted for

comparison. The contractor should warrant that proposed substitutions, if accepted, shall provide

performance equal to the materials specified herein. Also refer section 1.11 for alternative

material as fiberglass or pre insulated ductwork. The contractor may propose manufacturer’s pre-

insulated copper pipes with internally profile to entrap air and provide a thermal barrier for hot

water piping.

2 Insulation materials shall be a flexible, closed-cell elastomeric insulation in tubular or sheet

form: AP Armaflex, AP Armaflex W, AP Armaflex SS, or kaim-flex. This product meets the

requirements as defined in ASTM C534, specification for preformed elastomeric cellular thermal

insulation in sheet and tubular form.

3 Materials shall have a flame spread rating of 25 or less and a smoke-developed rating of 50 or

less when tested in accordance with ASTM E84, latest revision. Sheet material with a thickness

greater than 1. shall have a flame spread rating of 25 or less and a smoke developed rating of 100

or less when tested in accordance with ASTM E84, latest revision. In addition, the product, when

tested, shall not melt or drip flaming particles, the flame shall not be progressive and all

materials shall pass simulated end-use fire tests.

4 Materials shall have a minimum thermal conductivity of 0.27 Btu-in/h-ft2 - ºF at a 75ºF mean

temperature when tested in accordance with ASTM C177 or ASTM C518.


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5 Materials shall have a minimum water vapor transmission of 0.08 perm-inches when tested in

accordance with ASTM E96, Procedure A, latest revision.

6 The material shall be manufactured under an independent third party supervision testing

program covering the properties of fire performance, thermal conductivity and water vapor

transmission.7 For high temperature and nonhalogen:

1. Insulation material shall be a flexible, closed-cell elastomeric insulation in tubular or sheet

form: HT Armaflex or NH Armaflex.

2. Materials shall have a flame spread rating of 30 or less and a smoke developed rating of 200 or

less when tested in accordance with ASTM E84, latest revision. In addition, the product, when

tested, shall not melt or drip flaming particles, and the flame shall not be progressive.

3. HT Armaflex shall have a minimum thermal conductivity of 0.30 Btu-in/h-ft2 - ºF at a 75ºF

mean temperature when tested in accordance with ASTM C177 or ASTM C518, latest revisions.

NH Armaflex shall have a minimum thermal conductivity of 0.275 Btu-in/ h-ft2 - ºF at a 75oF

temperature when tested in accordance with ASTM C177 or ASTM C518, latest revision.

4. HT Armaflex and NH Armaflex shall have a minimum water vapor transmission of 0.05

perm-inches when tested in accordance with ASTM E 96, Procedure A, latest revision.

8 Adhesive shall be the insulation manufacturer’s recommended contact adhesive. Armaflex 520

Adhesive or Armaflex HT 525 Adhesive.9 Insulation finish shall be the insulation manufacturer’s recommended finish: WP Armflex Finish.

10 Accessories such as adhesives, matches and cements shall have the same properties as listed

above and shall not detract from any of the system ratings as specified above.

7.06 PIPING

1 Install pipe insulation by slitting tubular sections and applying onto piping or tubing.

Alternately, whenever possible, slide unslit sections over the open ends of piping or tubing. All

seams and butt joints shall be adhered and sealed using Armaflex 520 Adhesive. When using AP

Armaflex SS, only the butt joints shall be adhered using Armaflex 520 Adhesive. When using

HT Armaflex for temperatures above 120ºC, Armaflex HT 525 Adhesive shall be used. The

complete insulation shall be covered with glass cloth & vapour barrier coating to avoid the

damages during installation phase.

2 Insulation shall be pushed onto the pipe, never pulled. Stretching of insulation may result in

open seams and joints.

3 All edges shall be clean cut. Rough or jagged edges of the insulation shall not be permitted.

Proper tools such as sharp knives must be used.


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4 On cold piping, insulation shall be adhered directly to the piping at the high end of the run

using a one-inch strip of Armaflex 520 Adhesive on insulation shall be coated with Armaflex

520 Adhesive.

5 Sheet insulation shall be used on all pipes larger than 150 mm insulation shall not be stretched

around the pipe. On pipes larger than 300 mm IPS, adhere insulation directly to the pipe on thelower 1/3 of the pipe.

6 Seams shall be staggered when applying multiple layers of insulation.

7.07 HANGERS

1 Standard and split hangers: Piping supported by ring hangers shall have hangers insulated with

the same insulation thickness as the adjacent pipe. All seams and butt joints shall be sealed with

Armaflex 520Adhesive. When using HT Armaflex above 120oC, Armaflex HT 525 Adhesiveshall be used. Ring hangers may be sleeved using oversized tubular insulation. ON cold piping,

insulation shall extend up the hanger rod a distance equal to four times the insulation thickness.

Insulation tape may be used to a thickness equal to the adjacent insulation thickness.

2 Clevis hangers or other pipe support systems - saddles shall be installed under all insulated

lines at unistrut clamps, clevis hangers, or locations where the insulation may be compressed due

to the weight of the pipe. Cold piping over 40 mm in diameter shall have wooden dowels or

blocks of thickness equal to the insulation and adhered to the insulation between the pipe and the

saddle.

7.08 OUTDOORS EXPOSED PIPING

1 All outdoor exposed piping shall be painted with two coats of WB Armaflex finish. Prior to

applying the finish, the insulation shall be wiped clean with denatured alcohol and finished with

0.6 mm aluminium cladding. The finish shall not be tinted.

2 All outdoor exposed piping shall have the seams located on the lower half of the pipe.

7.09 PIPING INSULATION THICKNESS SCHEDULE

2 Closed cell rubber insulation:

Refrigerant Pipe Insulation


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Condensates drain – Up to 50 mm – 12mmThickness.

Over 50 mm to 100 mm – 20 mm Thickness.

7.11 SQUARE AND RECTANGULAR DUCTWORK

1 Armaflex Sheet Insulation shall be adhered directly to clean, oil-free surfaces with a full

coverage of Armaflex 520 Adhesive. When using HT Armaflex for temperatures above 120oF,

Armaflex HT 525 Adhesive shall be used. AP Armaflex SA shall be adhered directly to clean,

oil-free surfaces. The complete insulation shall be covered with glass cloth & vapour barrier

coating to avoid the damages during installation phase.

2 The duct insulation shall be constructed from the bottom up, with the top insulation sized to

extend over the side insulation. This will form a watershed.

3 Butt-edge seams shall be adhered using Armaflex 520 adhesive or Armaflex HT 525 adhesive

by the compression fit method to allow for expansion/contraction. Leave a 12 mm wide uncoated

border at the butt edge seams on the duct surface and the insulation surface. Overlap the

insulation 8 mm at the butt-edges and compress the edges into place. Apply Armaflex 520

adhesive or Armaflex HT 525 adhesive to the butt-edges of the insulation.

4 Standing metal duct seams shall be insulated with the same insulation thickness as installed on

the duct surface. Seams may be covered using strips of Armaflex sheet insulation or half sections

of tubular pipe insulation with miter-cut ends. Standing seams shall be adhered using Armaflex

520 adhesive or Armaflex HT 525 adhesive.

5 Insulation seams shall be staggered when applying multiple layers of insulation.

6 In lieu of closed cell rubber insulation specified above contractor has option to provide

fiberglass rigid insulation for ducts, chilled water pipes or pre insulated ducts. The contractor to

qualify in tender response the option selected and in case same is not provided it shall be

considered that contractor has opted for closed cell insulation in the bid. The fiberglass insulation

shall be of fine, stable and uniformly textured inorganic glass fiber bonded to non water soluble

fire retardant thermosetting resin. The insulation shall be of rigid board type with foil reinforced

kraft laminate facing. The density of insulation shall be 48 kg/cu mtr and thermal conductivity

not to exceed 0.03W/m deg C at 0 deg C in accordance with ASTM C518. The vapour

permeability shall not exceed 0.02 perm and should confirm to Class 0 fire rating as per building

Piping System Up to

50 mm

Over 50 mm

to 100 mm

Over 100 mm

To 150 mm Over 150 mm

Above 25o F 20 mm 25 mm 25 mm 25 mm

10oF to 25oF 25 mm 25 mm 32 mm 32 mm

10oF to 25oF 25 mm32 mm

32 mm40 mm

40 mm32 mm

40 mm32 mm


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regulations section E15. The thickness of insulation shall be 25 mm for ducts in conditioned area

and 50 mm for ducts in non conditioned or exposed areas. The insulation thickness for chilled

water pipes in conditioned area shall be 25 mm for nominal pipe sizes up to 25 mm dia, 38 mm

for pipe sizes up to 40 mm dia and 50 mm for 50mm & above dia pipes. The thickness of

insulation shall be 50 mm for all pipes in unconditioned areas. The insulation shall be of rigidfiberglass pipe sections with density of insulation not less than 64 kg/ cu. Mtr. All other details

for insulation remains same as stated for duct board insulation. The duct applicable to be

insulated remains same as defined under section 1.15. All the fiber glass insulated ducts &

chilled water pipes are required to be provided with 10 x 10 glass cloth with 2 coats of

antifungal, flame retardant vapour barrier coating. The exposed to weather insulation shall be

provided 2 coats of weather proof anti fungal coating in addition to 0.6 mm aluminum cladding.

The vapour barrier shall be fire retardant and anti fungal type.

7 The contractor may propose pre insulated ducts with phenolic foam insulation but usage of

same shall be limited to FCU supply ducts and in accessible false ceiling areas.

7.12 EXPOSED OUTDOOR DUCT

1 All outdoor exposed ductwork shall be finished using 0.6 mm Aluminum cladding, stucco

finish.

7.13 W B ARMAFLEX FINISH

All outdoor ductwork & other insulated services as stated previously shall be finished with two

coats of WB Armaflex finish applied over a 10 x 10 Leno weave glass cloth 0.6 mm Aluminum

cladding:

1 The surface of the insulation must be clean and dry.

2 Allow adhesive seams on the insulation to set for two hours.

3 Apply thin uniform coat of Childers CHIL-SPRAY® WB CP-56 adhesive. Allow to become

tacky, and apply 10 x 10 Leno weave glass mesh. (CP-56 adhesive may take up to 20 minutes to

become tacky.)

4 Allow adhesive and mesh to dry four hours.

5 Apply WB Armaflex finish over the mesh at a rate of less than 400 square feet per gallon.

Allow to dry four hours.

6. Apply the second coat of WB Armaflex finish at a rate of less than 400 square feet per gallon.

7.14 MASTIC SYSTEM

1 The insulation shall be adhered to the material by using insulation manufacturers

recommended sealant. The contractor to consult the mastic manufacturer for any additional


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recommendations.

1 The surface of the insulation must be clean and dry.

2 Wipe the surface of the Armaflex insulation with a clean cloth.

3 Apply a tack coat of mastic with a uniform thickness at a rate of 50 square feet/gallon bytrowel, glove, large brush, or spray.

DO NOT THIN MASTIC!

4. Blend 10 x 10 Leno weave glass mesh into the first application of mastic, making sure to

overlap the seams of the glass cloth by 2 inches.

5. Apply a finish coat within one hour after the tack coat at a rate of 50 square feet/gallon. The

mastic will dry to the touch in two hours, but complete drying takes 24 to 36 hours.

7.15 DUCTWORK INSULATION THICKNESS SCHEDULE

1 Duct Systems:

Application Conditioned are Un Conditioned are Exposed

Supply air 13 mm 19 mm 25 mm

Return air except in

conditioned area

13 mm 19 mm 25 mm

Fresh air 13 mm 13 mm 25 mm

Exhaust air if used for

energy recovery

13 mm 19 mm 25 mm

7.16 EQUIPMENT INSULATION

1 Armaflex sheet insulation shall be adhered directly to clean, oil-free surfaces with a full

coverage of Armaflex 520 Adhesive or Armaflex HT 525 adhesive. AP Armaflex SA shall be

adhered directly to clean, oil-free surfaces. The make stated or equivalent is indicative of the

quality of insulation material expected.

2 All seams and butt-joints shall be adhered and sealed with Armaflex 520 Adhesive or

Armaflex HT 525 Adhesive.

3 On cold surfaces: All exposed end cuts of insulation shall be coated with Armaflex 520

adhesive or Armaflex HT 525 adhesive.

4 Seams shall be staggered when applying multiple layers of insulation.

7.17 EQUIPMENT INSULATION THICKNESS SCHEDULE


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System

Temperature

AP Armaflex

Thickness

HT Armaflex

Thickness

NH Armaflex

Thickne

Below 0oF 50 mm 50 mm 50 mm 0oF to 20oF 40 mm 40 mm 40 mm

20oF to 40oF 25 mm 25 mm 25 mm

40oF to 55oF 20 mm 20 mm 20 mm

55oF to 100oF 12 mm 12 mm 12 mm

100oF to 120oF 20 mm 20 mm 20 mm

120oF to 140oF 25 mm 25 mm 25 mm

140oF to 160oF 40 mm 40 mm 40 mm

160oF to 180oF 50 mm 50 mm 50 mm

180oF to 250oF-

63 mm -

250oF to 300oF-

75 mm -

7.18 REFRIGERATION PIPING INSULATION

1 All liquid and suction lines shall be insulated continuously from a point 150 mm inside the

display case to the suction service valve at the compressor.

2 All low temperature lines (-12oC and below) shall be insulated with a minimum of 25 mm

thickness.

3 All medium and high temperature lines (above -12oC) shall be insulated with a minimum of 25

mm thickness.

4 All medium and high temperature lines (above -12oC) shall be insulated with a minimum of 20

mm thickness.

5 Heat reclaim lines shall be insulated from the condensing unit to the heat reclaim units with 20

mm thickness.

6 All refrigerant copper lines must be free of extraneous chemicals such as corrosive cleaners or

building materials. Dust prior to the installation of the insulation.7 Refrigerant pipes shall be sealed while slipping on insulation to prevent foreign matter from

entering the tube.

8 Insulation is to be slid onto pipe; longitudinal slitting of the insulation is not allowed except on

mitered sections. Insulation shall be pushed onto pipe, not pulled.

9 Insulation shall be mitered; pre adhered and longitudinally slit to fit over all P-traps, tees and

elbows or bends over 90º.


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10 At the beginning, at every 4 to 6 m, and at the ends of ping runs, the insulation shall be

adhered directly to the copper using a 50 mm strip of adhesive. Insulation should not be adhered

to the pipe at the extreme low points in piping run.

11 Saddles shall be installed under all insulated lines at unistrut clamps, clevis hangers, or

locations where insulation may be compressed. Wood dowels or blocks, of a thickness equal tothe insulation, shall be inserted and completely sealed into the insulation if the excessive

compression of the insulation remains at the saddle locations.

12 Hangers clamped directly to the pipe shall be insulated over the hanger; insulation shall be

fully adhered to the hanger. In addition, hangers with double rods shall be insulated between the

rods. All seams of the insulation shall be sealed with adhesive.

13 All insulation exposed to sunlight or installed outdoors shall be protected with glass cloth &

two coats of WB Armaflex or equivalent finish (vapour barrier) & 0.6 mm Aluminum cladding.

All other piping shall have same finish as exposed except the aluminum cladding.

8.0 Low Velocity Ductwork

8.1 Standard Low Velocity Duct Works

The ductwork shall be manufactured and installed in accordance with Specifications DW 144,

DW 151 and DW 191 published by the Heating and Ventilating Contractors Association except

where amplified or amended below.

Continuously hot dip zinc coated and iron zinc alloy coated steel: wide strip, sheet/plate and slitwide strip.

BS 5588 : Part 9 : 1999

Fire precautions in the design and construction of buildings.

8.2 Specialist Installer

The ductwork and plant interconnections forming part of the air conditioning and ventilation systems

covered by this specification and shown on the drawings shall be manufactured and erected by

specialist workmen employed either directly in a specialist ductwork department by the Tenderer

or by a specialist ductwork firm. The Tenderer shall include the name of the selected ductwork

firm in the Tender details. Any subsequent change to the ducting firm shall be approved.

8.3 General Requirements and Erection

All ductwork shall be constructed and installed to present a rigid installation free from sway,


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drumming and movement. Ductwork shall be truetosize and accurately aligned.

Ductwork sizes indicated are clear internal airway dimensions. Allowance shall be made for

lining and coverings when required.

Takeoffs from the main ductwork shall be conical, bell mouth or shoe type. Duct size squaretakeoffs will not be allowed.

The use of self tapping screws shall be restricted to the completion of site joints in extremely

difficult locations only, with prior agreement of the Engineer.

8.4 Ductwork Drawings

Detailed layout drawings of all ductwork systems shall be prepared based upon the scheme

drawings and the Architect's and Structural Engineer's working drawings and incorporating such

variations as are advised subsequent to the issue of the scheme drawings. The layout drawingsshall clearly show the dimensional relationship between the ductwork and the building fabric and

shall be coordinated with and show space allowances for all other services to be installed.

The coordination shall make adequate allowance for the application of specified thermal

insulation on all surfaces of ducts by ensuring sufficient clearance from the building structure

and other adjacent services.

The drawings shall be at a scale of 1:20 except for extensive distribution systems which may be

at a scale of 1:50 with plant connections, connections to terminal devices and areas of potential

conflict with the building or other services shown at 1:20. The drawings shall be issued for

comment and, where necessary, amended and reissued for approval in accordance with

procedures detailed elsewhere. Ductwork manufacturing details (shop drawings, parts lists, etc)

shall also be submitted for comment before manufacture commences.

8.5 Air Leakage

Not withstanding any other leakage rates specified in this document the supply ductwork and

supply branches to terminal units shall be of the quality that limits the maximum permitted

leakage rate at a test pressure of 700 Pa to 0.21 liters/sec/m sq of surface area (Class C).

Leakage tests shall be carried out on site to demonstrate to the Engineer that the leakage rate

shall not be exceeded.

The Ductwork Leakage Testing Procedures shall be those set out in DW/142 and DW/143

published by the HVCA. Before the commencement of any testing the Contractor shall submit a

method statement including a schedule of the surface areas of each section of the ducting to be


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tested which shall be printed on the working drawing. Each section to be tested shall be clearly

defined on the drawings.

8.6 Ductwork Standards

All other ductwork systems shall be constructed to Class A, low pressure (up to 500 Pa) systemrequirements unless stated otherwise.

3.7 Ductwork Materials

Ductwork shall be manufactured from hot dip galvanized sheet to BS 2989 : 1982 Grade Z2

coating type G275 and mild steel section to the gauges and sections specified in DW 142 except

that ducts with longest side dimensions up to 600mm may be made from 0.5mm thickness sheet.

Cut edges of galvanized sheet and all mild steel sections used in joints, stiffeners or supports,

shall be free from rust and painted one coat of aluminium paint at work and again immediately

prior to erection.

8.8 Seams, Joints And Stiffeners

Longitudinal seams shall be as specified in DW 142 figures 1, 2 or 7. Lateral joints in ducts with

longest side dimension not exceeding 400mm shall be plain slip joints to figure 9 in DW 142.

Lateral joints in ducts with longest side dimension exceeding 400mm but not exceeding 1500mm

shall be angle reinforced slip joints to figure 12 in DW 142. Lateral joints in ducts with longest

side dimension exceeding 1500mm shall be angle flanged joints to figure 33 in DW 142 and

incorporating an approved gasket. Where the specified joint cannot be used due to the close

spacing of the building or other services, internally made joints will be permitted. Such internal

joints may be of the slip or butt strap pattern and where the DW 142 specification calls for

stiffening, this will take the form of internal mild steel flat bar. Such internal joints are to present

a smooth surface to the air flow with the maximum permissible reduction from nominal area

being 3%. The quality of ductwork construction shall be suitable for the particular application

and adequate stiffening shall be applied to prevent the vibration and flexing of ductwork in

operation and to ensure that air leakage is kept to a satisfactorily low level.

8.9 Bends, Tees, Tapers, Etc

Bends and tees are to be constructed with a throat radius equal to one half of the duct dimension

taken in the same plane. Tapers, change sections and offsets are to be constructed with their sideshaving an angle to the axis of the adjacent straight duct no greater than 22.5°. Where these

requirements cannot be achieved due to the constraints of the building structure or other services,

internal splitters are to be used to DW 142 figures 52(b) and 68. Where square bends are

necessary, aerofoil turning vanes shall be employed as DW 142 figure 55. Branches and twin

bends are to be as DW 142 figures 59 and 56 respectively.


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8.10 And Fixings

All ductwork and equipment supports and fixings to the building structure shall be included. The

fixing shall be suitable for the building member to which they are attached and shall be subject to

approval.

Supports are to be constructed and spaced in accordance with Specification DW 142. On all thermally

insulated ducts a thermal bridge between the ductwork and the support is to be avoided. On

circular ducts the supporting strap shall be separated from the ductwork material by a 6mm thick

self-extinguishing grade neoprene spacing gasket fixed to the strap with adhesive. On

rectangular ducts the separation is to be achieved by hardwood blocks between the supporting

member and the ductwork.

8.11 Cleanliness

Cleanliness of ductwork systems shall be carried out in accordance with the Intermediate

Standard of DM/TM2, 1991 "Guide to Good Practice Internal Cleanliness of New DuctworkInstallations" published by the HVCA. All plant and ductwork shall be cleaned thoroughly

internally before it becomes inaccessible due to the progress of building operations.

8.12 Regulating Dampers

Regulating dampers shall be provided where shown on the drawings and wherever necessary for

the proper regulation and balancing of the systems. They shall be 'Air shield' type with aerofoil

section, stainless steel blades in a galvanized double skin casing with totally enclosed gears and

control. In ducts where the air velocity is less than 4 meters/sec and the diameter is less than

300mm or the longest dimension is less than 450mm, single skin damper blades may be used. The

damper shall be capable of locking securely in the required position when system regulation has

been completed. The position of each damper when it is correctly set shall be recorded.

8.13 Non Return/Volume Dampers

Non return dampers shall be provided where shown on the drawings. Non return dampers shall

be of the balanced, tight closure, self operating type. Non return damper blades and frames shall

be fabricated from 2.65mm thick extruded aluminium; blades of reinforced double wall air foil

design with stainless steel side jambs.

8.14 Test Holes \25mm diameter test holes with 50mm diameter covers fixed with two self tapping screws shall

be fixed at suitable agreed test positions adjacent to plant and to all branches. The cover shall

have one hole slotted to allow the cover to hinge sideways. Two test holes will be provided on

ducts up to 225mm wide. On ducts more than 225mm wide they shall be at not more than

100mm centers and 50mm from the side of the duct.


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8.15 Plenum Boxes

Plenum boxes for terminal devices shall be constructed to the same standards as ductwork of

similar dimensions.

8.16 Flexible Plant Connections

Flexible plant connections shall be fitted to the inlet and discharge of all fans and air handling

plants. The flexible connections are to be minimum 75mm long and the duct openings are to be

correctly lined up. Each end of the connection shall be flanged and sandwiched between the

flange on the fan etc, and a substantial mild steel counter flange. All joints shall be sealed and

capable of withstanding the required working pressure.

8.17 Flexible Ducts

Flexible duct connections to terminal devices shall be fitted where indicated on the drawing and

shall comply with clause 25.2 of DW 142 and be fixed with sealant and worm drive clips.

Flexible ducts shall not be used to connect adjoining lengths of sheet metal ductwork. Supply air

flexible ducts shall be preinsulated with a nominal 25mm thickness of fiberglass with reinforced

metallized ylarNeoprene laminate to provide a vapour seal. Flexible ducts which are crushed,

deformed, split or have damaged insulation or vapour seal will be rejected by the Engineer. The

flexible ducts are to be mounted so as to give satisfactory radii on bends, etc and the terminal

devices and duct connections are to be so positioned as to permit this to be achieved to the

Engineers satisfaction. The maximum length of flexible duct shall be no more than 7500mm.

No combustible flexible duct or joint shall be installed in a false floor void or a false ceiling void

or any other void where the presence of combustible material would result in the installation of

smoke barriers over and above those otherwise necessary or which would result in such a void

requiring sprinkler protection which would not otherwise be installed.

Elsewhere Class 0 or Class 1 spread of flame shall apply as required by the Local Authority.

8.18 Of Ductwork

All ductwork shall be identified in accordance with the following clauses of appendix C of DW

142

8.19 Identification of Equipment

All equipment shall be identified in accordance with the reference system used in the "As

Installed" information, and be approved by the Engineer. Labels shall be white/black/white

traffolite and be rivetted or self adhesive fixed to equipment items.

8.20 Duct Mounted Sensors, Control Items, Damper Linkages, Etc

All duct mounted sensors, thermostats, damper linkages, damper actuators and associated duct


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mounted control items shall be fitted on site.

8.21 Ducts Passing Through Walls, Etc

Where ductwork passes through external walls, roofs and basement walls into the ground or into

trenches or ducts, the supply and fixing of weathering collars, sealing rings or frames and puddle

flanges as applicable shall be included. All details shall be approved prior to installation.

9.0 Refrigeration Equipment

9.1 Standards

The refrigeration equipment and cooling towers shall comply with the following British

Standards:

BS EN 60085: 2004

Method for determining the thermal classification of electrical insulation.

BS EN 12449: 1999

Tubes for general purposes.

BS EN 102442: 2001

Requirements for refrigeration safety.

BS 4485 : Part 3 : 1988

Code of practice for thermal and functional desk.

BS EN 15151: 2000

Flanges and their joints. Bolting

BS EN 1092 –2: 1997

Flanges and their joints

9.2 Refrigeration Machines

9.3 Split System Air Conditioning Units

General

The contractor shall supply, install, test and commission split system air conditioners, as shown

on drawings and as specified in the following section. Each split unit shall be guaranteed by the

manufacturer to produce a capacity not less than the specified capacity at specified conditions. The

Split Units shall be suitable for continuously operating at 520C ambient temperature.


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Condensing unit

Each condensing unit shall be complete with compressor and motor assembly, air cooled

condenser fan with motor, internal piping, control panel, switches, and internal wiring all

enclosed in a weatherproof enclosure suitable for prevailing ambient conditions. The unit shall

operate satisfactorily with a voltage variation of at least + 10% from the specified voltage.

The units shall be specially designed for Middle East High Ambient temperature and desert

conditions. The casing shall be constructed out of coated, galvanized sheet steel, protected by

stratashield special paint cycle to provide long term resistance to weather. The casing shall

comply with ASTMB117:1000 hour salt spray test.

The compressor shall be hermetic reciprocating type suitable for operation on R22 refrigerant

with high EER (Energy Efficiency Ratio).

The condenser coil shall be air cooled type with aluminium fins mechanically bonded to copper

tubes and necessary refrigerant connections. The copper tubes shall not be less than 12mm OD.

The condenser fans shall be propeller type vertical or horizontal discharge direct driven complete

with motor. The air quantity and area of condenser coil shall be adequate for satisfactory

operation up to ambient temperature of 520C. The condensing unit shall be equipped with HP &

LP switches as a standard.

Indoor Fan Coil Unit

The indoor unit shall be matched with the condensing unit. Unit shall comprise cooling coil, fansection, filter, outer casing and accessories. The cooling coil shall have copper tubes of not lessthan 10mm OD and continuous aluminium fins. The fins shall be mechanically bonded to the

tubes.

The fan section shall consist of forward curved fan complete with scroll, shaft and self aligning

bearings and fan motor mounted on flexible supports.

The unit shall have automatically controlled discharge air louvers with up and down swing

motion for uniform air distribution. Further, it shall be possible to set the louver’s position from

the remote control according to the user’s choice.

The unit shall have hinged front grille for easy access to filter and unit.

Filters shall be cleanable type low velocity design. The unit shall have provision of auto fan

s

Documents

Document 5 Technical Specifications for HVAC