JD 007 Part 5 Mechanical Specifications R02

REPORT NO 007
1 CENTRAL - PHASE 1 A6
PART 5 - MECHANICAL STANDARDS
SPECIFICATIONS
CONFIDENTIAL 18 SEPTEMBER 2016

1 CENTRAL - PHASE 1 A6
PART 5 - MECHANICAL STANDARDS
SPECIFICATIONS
DWTC
Confidential
Project no: 37452030

Date: 18 September 2016
WSP | Parsons Brinckerhoff

P.O. Box 1924
Sharjah
UAE
Tel: +971 6 598 1777
Fax: +971 6 598 1666
www.wspgroup.com
www.pbworld.com
QUALITY MANAGEMENT
ISSUE/REVISIO FIRST ISSUE REVISION 1 REVISION 2 REVISIO
N N3
Remarks Tender Issue Detailed Design issue Tender issue
Date 05 June 2016 28 August 2016 18 September 2016
Prepared by James Devassy / Giovani James Devassy / Giovani James Devassy / Giovani
Tauckoor Tauckoor Tauckoor
Signature
Checked by Stuart Moodie Stuart Moodie Stuart Moodie
Signature
Authorised by Stuart Moodie Stuart Moodie Stuart Moodie
Signature
Project number 37452030 37452030 37452030
File reference 37452030-SM-007 37452030-SM-007-R01 37452030-SM-007-R02

ii
PRODUCTION TEAM
WSP I PARSONS BRINCKERHOFF
Senior Mechanical Engineer James Devassy
Principal Engineer Public Giovani Tauckoor

Health
Associate Electrical Stuart Moodie
1 Central - Phase 1 A6 WSP | Parsons Brinckerhoff

DWTC Project No 37452030
18 September 2016 Confidential
iii
TABLE OF CONTENTS
MECHANICAL STANDARD SPECIFICATIONS .........................................1

Confidential 18 September 2016
1
MECHANICAL STANDARD
SPECIFICATIONS

Confidential 18 September 2016
Part 5 Mechanical Services
Section 1 Pipework and Fittings
Contents
Part 5 Mechanical Services 1
Section 1 Pipework and Fittings 1
1.1 General requirements 1

1.2 Protection during construction 2
1.3 Pipework spacing 2
1.4 Steel pipework 3
1.5 Pre-insulated steel pipework laid in ground 4
1.6 ABS pipework (chilled water alternative) 6
1.7 GRP pipework (condenser water) 9
1.8 Copper pipework (Above ground) 10
1.9 Copper pipework (Laid in ground) 11
1.10 Copper pipework (Installed within screed) 11
1.11 Stainless steel pipework 11
1.12 Polyethylene pipe (Laid in ground) 12
1.13 Galvanised mild steel pipework 12
1.14 Press-fit pipework systems 13
1.15 Victaulic jointing systems 14
1.16 Cast iron pipework 15
1.17 Cast iron water main 16
1.18 Plastic soil and waste pipework 16
1.19 Refrigerant pipework 16
1.20 Brazing and bronze welding 17
1.21 Copper capillary fittings 18
1.22 Expansion of pipeworks 18
1.23 Expansion loops 19
1.24 Anchors and guides 19
1.25 Sets and pulled bends 20
1.26 Pipe sleeves and plates 20
1.27 Pipe sleeves through fire barriers 21
1.28 Pipe sleeves through acoustic barriers, enclosures and plant rooms 21
1.29 Puddle flange assemblies 21
1.30 Pipe supports 21
1.31 Pipework brackets 23
1.32 Venting and draining 24
1.33 Air bottles 24
1.34 Automatic air vents 25
1.35 Dirt pockets 25
1.36 Overflows and condensate drains 25
1.37 Fan coil connections 25
1.38 Flushing bypasses 26
1.39 Positioning of control components 26
1.40 Referred documents 26
Section 1 Pipework and Fittings
1.1 GENERAL REQUIREMENTS

Supply, deliver and install all pipework materials and fittings for the pipework services
installation.
Pipework shall follow the routes and approximate positions indicated on the drawings. However
it should be noted co-ordination with other services, architecture, structure and any furniture or
equipment in the served areas is the Contractors responsibility. Fully co-ordinated shop
drawings including builders work drawings shall be submitted by the Contractor to the CA for
approval.
Pipework, ancillaries, valves and demountable joints shall be installed for convenient and safe
routine maintenance and renewals.
All pipework shall be installed with adequate gradients to facilitate draining and venting.
Pipework shall be run in a neat manner and installed plumb, straight, symmetrical and at right
angles to or parallel to adjacent walls.
No joints shall be formed inside wall constructions or floor slabs.
All pipework, fittings and valves shall be free from corrosion, scale and internal obstructions.
Pipework ends shall be cut square, reamed, free from burrs and finished full bore.
Sufficient unions and flanged joints shall be provided to allow for installation and dismantling
sections of pipework, wherever difficulties may occur and on straight runs of more than 25m.
Unions or flanges shall be provided at all valves and equipment to allow for easy dismantling.
Connections to coils, pumps, and other equipment shall be made in such a manner as to
eliminate undue strains on piping and equipment. Necessary fittings and bends shall be
furnished to avoid springing of pipes during assembly.
Care shall be taken in placing unions to allow the freedom to spring apart. Unions and flanges
shall not be placed in inaccessible positions. Where pipework is installed in inaccessible
locations, a union or flange shall be installed prior to the pipe passing into the wall or floor.
Unions shall have two bronze conical seats ground-in. Long screw connections will not be
acceptable.
Piping shall be installed to allow for expansion. The Contractor shall demonstrate adequate
allowance for expansion and contraction based on the final pipework routing indicated on the
shop drawings. The Contractor is responsible for co-ordination of pipework services with all
other services and shall where requested provide calculations to demonstrate the adequacy of
expansion provisions and support systems. The routing on the design drawings is indicative.
The Contractor shall make due allowance in his tender for full co-ordination of services and
pipework routing, supporting, expansion and contraction of pipework, venting, draining, flushing,
cleaning etc. as required.
Universal movement joints shall be installed where pipework traverses building joints.
Where installations are in a recognised earthquake zone and as defined in the particular
specification spring hangers and mountings and movement joints shall be installed to maintain
system integrity.
Part 5
Section 1 - Page 1
All black mild steel pipework in wall chases shall be welded throughout with flanged joints at 16
m maximum intervals if applicable.
Manufacturers standard fittings shall be used and fabricated fittings will not be accepted without
approval.
Bends and tees shall be of the easy sweep type, except at air vents, drain points and dead legs
where square tees shall be used.
Changes in the diameter of horizontal pipework shall be formed eccentrically.
Prior to any work being "covered up", the installer shall request the CAs approval for that part of
the installation in question.
Pre-fabricated pipework shall be in accordance with the relevant clauses.
Appropriate means must be taken to prevent galvanic action where dissimilar metals are
connected.
The Contractor shall obtain approval from the relevant Local Authority for materials used in
water supplies.
1.2 PROTECTION DURING CONSTRUCTION

Adequate storage facilities shall be provided to ensure that pipe tubes does not suffer any
deterioration from the as new delivered condition.
During construction work care shall be taken to prevent any foreign matter entering the pipework
either in storage or during installation.
Open ends shall be capped with appropriate pipework fittings. Wooden plugs and the like shall
not be used.
Valves fitted on the ends of pipework shall not be accepted as a means of preventing the
ingress of foreign materials.
Failure to comply with these requirements shall mean that the CA shall have the right to instruct
that pipework so left uncovered to be dismantled for such lengths as the CA requests and the
pipework blown through and/or cleaned at no cost to the contract.
Remove all cement adhering to pipework surfaces and brackets.
Remove scale or rust by wire brushing and paint pipework and brackets as stated elsewhere in
the specification.
1.3 PIPEWORK SPACING

Pipe runs shall be spaced in relation to one another, other services and the building structure.
Ensure adequate spacing for access to pipe joints, etc and allowance for the specified thickness
of thermal insulation.
The following are recommended as minimum clearances in the spacing of pipe runs:
Between insulated or un-insulated pipeline and

Wall finish 25 mm
Ceiling finish or soffit 50 mm
Floor finish 50 mm above top of skirting or 150mm
whichever is greater
Between adjacent pipelines

both insulated 25 mm
Part 5
Section 1 - Page 2
one insulated, one un-insulated 75 mm
both uninsulated 150 mm
Insulated pipes to adjacent 50 mm

conduit or trunking
Un-insulated pipes to adjacent 100 mm

conduit or trunking
Adjacent electrical cables not in 150mm

conduit or trunking 150mm
1.4 STEEL PIPEWORK

Pipework up to and including 150mm. nominal bore shall be carried out in black mild steel heavy
quality mild steel tube to BS:1387. Pipe work up to and including 450mm. diameter nominal bore
shall be carried out in seamless black mild steel to ASTM A53, Grade B Schedule 40, plain
ends, ANSI B36.10
Above this bore, carbon steel pipes shall comply with BS EN 10216-1 and BS EN 10217-1.
Pipework 50mm. nominal bore and below shall not be welded and shall be supplied in random
lengths with screwed ends.
Where screwed pipework joints are used, tapered threads as BS 21 and BS EN 10226-1 or
threaded to ANSI B16.4 class 150 will be accepted subject to being able to withstand maximum
operating pressure. Class 300 shall be provided where system pressures exceed 8.6 Bar. All
jointing systems shall be suitable for the operating pressure of the system. The joints shall be
clean threaded, pulled up tightly and made with an approved jointing compound and long
stranded fine hemp. After joints have been formed, all surplus hemp shall be cut away and the
joint wiped clean ready for painting.
Where pipes are held in vices to allow when screwing or jointing care shall be taken to ensure
that the surface of the pipe is not damaged. Any pipework so damaged will not be accepted and
if installed shall be replaced.
Flanges shall comply with BS EN 1092 -1 to the appropriate dimensions for the specified
pressure ratings given in tables 6 to 13.
Fittings 50mm and smaller shall be malleable iron ASTM A126, threaded, to ANSI B16.4
minimum of class 150. A higher class may be required depending on the particular system
operating pressure and the contractor shall make any due allowance in this regard. Class 300
fittings shall be provided where the system pressure exceeds 8.6 bar. Alternatively where
appropriate screwed fittings on steel piping shall be best quality malleable cast iron banded or
beaded pattern to BS 143 and external screwed tapered thread to BS 21 and BS EN 10226.
Certain fittings which have parallel threads shall be to BS EN ISO 228-1 and BS EN ISO 228-2.
Long screw connections, running nipples, reducing nipples, back nuts, shall not be acceptable.
All bends and tees shall be of the long sweep pattern; elbows and square tees shall not be
permitted on pumped systems. Also bushed fittings shall not be permitted on pipelines.
Where unions are used these shall have bronze spherical seats suitably ground in; flat seated
unions shall not be permitted.
Pipework for welding shall be supplied with plain ends, joints being made with butt welds on site.
The installer shall allow only for electric arc welding for pipework above 100 mm bore. Pipework
below 100mm bore may be oxyacetylene or electric arc welded
Fittings 65mm and larger diameter shall be black steel ASTM A234, Schedule 40, with butt-
welded ends to, ANSI 16.9 or rolled groove fittings complying with ANSI B31.9.
Part 5
Section 1 - Page 3
Pipework with a nominal bore of 65mm and above shall employ flanges for jointing at periodic
distances. Where flanges are used these shall comply with BS EN 1092-1 and BS EN 1515-1
or ASTM A181, class 150 (minimum) ANSI B16.3 and be of the table/class suitable for the
working pressure of the system. Flanges shall be machine faced and trimmed at the edges. All
joints shall be flush and shall use full face Taylor's corrugated rings coated with an approved
jointing compound. All flanges shall be fillet welded to the pipework.
Any branches made into 20mm. and 15mm. pipes shall be by drilling and reamering, not
welding. Where branch welds and shoes are utilised these will not be allowed unless the
branch weld is at least two sizes less than the main size. Welding metal or flux shall not project
into the pipe bore and shall be finished clean, smooth and of even thickness.
Remove scale, rust and temporary protective coating and paint with one coat of red oxide primer
as work proceeds.
1.5 PRE-INSULATED STEEL PIPEWORK LAID IN GROUND

The pre-fabricated pipes and fittings shall be made of a steel pipe, polyurethane foam insulation
with an integrated leak detection system and an outer casing of high-density polyethylene.
The materials shall be bonded together to form a solid unit. When tested according to EN 253,
the following properties of the bonded system shall be proved:
Axial shear strength: min. 0, 12 N/mm2 (MPa)

Tangential shear strength: min. 0, 2 N/mm2 (MPa)
All components in the pipe system shall fulfil the technical requirements as described in the
following EN standards:
EN 253 Pre-insulated bonded pipe systems for underground hot/chilled water networks
EN 448 Pre-insulated fitting assemblies.
EN 488 Pre-insulated steel valve assembly.
EN 489 Joint assembly for pre-insulated underground chilled water networks.
Pipe work up to and including 450mm. diameter nominal bore shall be carried out in seamless
black mild steel to ASTM A53, Grade B Schedule 40, plain ends, ANSI B36.10
All pipework joints shall be welded.
Pipes shall be furnished in lengths of 6.00 m or 12.00 m. Tolerance of lengths is 0/+15mm.
Pipe ends shall be prepared for welding as described in EN 253 or equal standard.
Prior to insulation, every steel pipe shall have the outer surface cleaned by shot blasting so that
it is free from rust, mill scale, oil, grease, paint, moisture and other contaminants. Items not
cleaned accordingly, shall be rejected.
All fittings shall be delivered as pre-insulated components, which after their installation shall
appear of the same quality as the pre-insulated pipes. They shall be ready to install and comply
with EN 448 and EN 488.
No flanges shall be allowed
Welds between PE pipework and fittings is to be done strictly according the standard EN 448.
All welds shall be absolutely leak-tight to ensure a waterproof system, and comply with the
requirements of the test for PE welds as described in the standard EN 448.
If any PUR foam is visible on the outside of a weld, the item shall be rejected and the whole
production series of equal products shall be inspected.
Part 5
Section 1 - Page 4
No welding to the PE casing pipe shall be done in the area where the Field Joints are to be
installed.
The PUR insulation material shall fulfil requirements of the most recent EN 253
Minimum requirements to insulation properties of each pipe size.
Diameter steel pipe Diameter casing pipe Maximum transmission

coefficient
D D U-value
Mm mm W/mK
21.3 90 0.09
26.9 90 0.10
33.7 90 0.12
42.4 110 0.15
48.3 110 0.17
60.3 125 0.19
76.1 140 0.23
88.9 160 0.24
114.3 180 0.30
139.7 200 0.38
168.3 225 0.47
219.1 280 0.56
273.0 355 0.53
323.9 400 0.66
355.6 450 0.67
406.4 500 0.68
457.0 560 0.70
508.0 630 0.71
610.0 710 0.96
711.0 800 1.27
813,0 900 1,50
914,0 1000 1.73
1016.0 1100 2.01
The materials for field joints, shall meet the requirements of EN 489: Pre-insulated bonded pipe
systems for underground hot/chilled water network. Joint assembly for steel service pipes,
polyurethane thermal insulation and outer casing of high-density polyethylene.
All joints for underground pre-insulated pipe networks shall be approved by an independent
testing institute, having first past the soil stress test in a sand box as described in EN 489.
Joints shall be made of shrinkable closed PE sleeves fulfilling the same specifications as that of
the PE casing pipes.
All joints shall be watertight and double sealed or pressure tested as described in EN 489.
The insulation material shall be made from pre-fabricated PUR insulation shells or by PUR
insulation material injected into the PE sleeve on site.
The jointing materials shall be delivered wrapped, protected against moisture and other
contaminants and stored according to the suppliers recommendations until installation on the
pipe system.
Part 5
Section 1 - Page 5
1.6 ABS PIPEWORK (CHILLED WATER ALTERNATIVE)
1.6.1 Materials
Where pressure rating permits ABS pipework may be used for chilled water installations. ABS
pipework shall be manufactured in accordance with BS 5391-1 or to Australian Standards AS
3518:2004 and ISO 9002 certified. ABS resin type should be MRS 160.
Installation as described in manufacturers installation manual, covered under Australian

Standard AS 3690 or equivalent. Manufactured according to AS 3518:2004. The manufacturer
should be ISO 9002 certified.
The layout of all pipe work shall be checked on site prior to installation and all care shall be
taken to ensure a neat and workmanship appearance of the installation.
The maximum distance between pipe supports shall be in accordance with the manufacturers
recommendations. The bearing width of the pipe supports shall be a minimum of 50mm and in
accordance with the manufacturers recommendations. Pipe supports shall not exert undue
pressure on the pipe wall or deform the pipe wall against the clamps or support. The pipe
supports shall be fabricated in such a way that they allow only the axial movement of the pipe
and prevent any lateral movement.
Adequate care shall be taken to accommodate expansion and contraction of pipes. Anchor
points, expansion loops / compensators shall be acceptable means of accommodating thermal
movement as recommended by the manufacturer. The Contractor shall carry out a total pipe
work analysis and submit calculations along with selection data for compensation devices, if
required for approval by the CA.
Submit catalogues including specific installation instructions and dimensioned drawings for each
type of pipe and fittings. Submit piping schedule showing manufacturer, pipe weight, fitting type,
and joint type for each piping system
Pipes shall be stacked to a maximum height of 1.8m and fittings in their respective packs. Care
should be taken to prevent gouging of the pipes & fittings. Metal slings or chains shall not
come in contact with the bare pipe, nylon slings are preferred. Do not sling from the middle of
the pipe.
Where possible store pipes and in-doors fittings are protected from the weather. Where
necessary to store outside, elevate above ground (using 75mm wide planks at a span of 1.5m
spacing) and enclose with durable, waterproof wrapping.
General Conditions of Contract to be referred to and complied with in respect of warranty

requirements.
Provide pipe and tube of type, joint type, grade, size and weight (wall thickness or class)
indicated for each service. When type, grade or class is not indicated, provide the proper
selection as determined by the Contractor and approved by the CA for installation requirements,
and comply with governing regulations and industry standards. The proposed manufacturer
shall have at least 10 years reference of installation is GCC countries.
ABS pipework shall be manufactured in accordance with BS 5391-1 or to Australian Standards

AS 3518:2004 and ISO 9002 certified. ABS resin type should be MRS 160.
General: Provide factory-fabricated fittings type, materials, grade, class and pressure rating
indicated for each service and pipe size. Provide sizes to the type matching that at the pipe,
valve or equipment connection in each case. Where not otherwise indicated, comply with
governing regulation and industry standard selection and with manufacturers recommendations
where applicable as approved by the CA.
Fittings for ABS Pipes: The ABS pipes and fittings shall be manufactured in accordance with
Australian Standard AS 3518:2004. The pipe manufacturer shall be accredited with ISO 9002-
1994.
Part 5
Section 1 - Page 6
Installation shall be in accordance with AS 3690 installation of the pipe and fittings system the
manufacturers recommendations and approval of the engineer.
1.6.2 Installation
Protect flanges, fittings and valves from moisture and dirt by indoor storage and enclosure or by
packaging with durable, waterproof wrapping
Each run shall be installed with minimum joints and couplings, but with adequate accessible
unions for disassembly and maintenance/ replacement of valves and equipment.
Reduce sizes (where indicated) by the use of reducing fittings. Align piping accurately at
connections, within 1.6mm (/16) misalignment tolerance.
The installation shall be carried out under the supervision of the nominated manufacturers
representative carrying a qualification certificate for installing ABS pipes and fittings. The
certificate shall be submitted for the approval of the CA. The manufacturers representative shall
be employed by the Contractor to monitor the installation on a full time basis for the duration of
the Works to ensure quality of the workmanship is maintained. All technicians employed by the
Contractor shall be trained by the local representative and duly certified.
Piping runs shall be located, except as otherwise indicated, vertically and horizontally (pitched to
drain) and avoid diagonal runs wherever possible.
Orient horizontal runs are to be parallel with walls and column lines. Locate runs as shown or
described by diagrams, details and notations or, if not otherwise indicated, run piping in shortest
route which does not obstruct usable space or block access for servicing the building and its
equipment.
The Contractor is to ensure that all pipework is secured close to walls, overhead construction,
columns and other structural and permanent- enclosure elements of the building; limit clearance
to 13mm (1/2) where furring is shown for enclosures or for the concealment of piping, but allow
for the insulation thickness, if any.
Where mechanical handling is employed, metal slings, hooks, or chains must not come into
direct contact with the pipe surface. Fabric slings shall be used and be attached at two points
on the load. Do not sling from the middle of the pipe. Care shall be taken to provide for not
damaging the external surfaces of pipes by rough handling or dragging along the ground.
ABS fittings shall be stored in the original plastic wrap bags until ready for use. Fittings supplied
in cardboard cartons must be suitable for external storage. Under general climatic conditions,
ABS pipes need not be stored under cover except when the storage period is likely to exceed 3-
4 months. When extended storage periods are expected, pipes should be covered and
protected with cover against a high temperature climate and stored on a level site free from
large stones and dust.
For cold cement welding correctly make joints using the technique and tools required as
instructed by manufacturers manual and by using the proper ABS cement and MEK cleaner to
the manufacturers recommendations.
Measure the pipe and cut clean and square.
Remove internal & external swarf and file two 10mm 30deg chambers on the outer edges of the
pipe.
Lightly abrade the gloss from the outer surface of the pipe and the inner surface of the fitting
using emery tape.
Clean the abraded surface with a clean rag moistened with MEK.
Part 5
Section 1 - Page 7
Mark the pipe distance back from the end equal to the depth of the socket plus 10mm. This is to
allow you to identify when the joint is fully home.
For sizes above 100mm, position a winch to pull the joint together after cement is applied.
Apply the cement as quickly as possible first to the socket then to the pipe using longitudinal
brush strokes.
Immediately after application of the cement, push the pipe fully home using the mark on the pipe
as a guide. Do not twist fittings on to pipes if using a winch does not exert additional force once
the pipes are fully home.
Wipe excess cement from the joint. Care should be taken to avoid excess deposits of cement
inside small diameter fittings.
For pipes running in trenches follow the procedures in the manufacturers manual as directed by
the CA.
The Contractor shall flush out piping systems with clean water before proceeding with the
required tests. Inspect each run of each system for completion of joints, supports and accessory
items.
The Contractor shall provide piping and gate valves to allow the complete flushing of the system
without allowing flushing water to enter any coil bank.
The Contractor is to provide temporary equipment for testing, including pumps and gauges.
The entire piping system is to be tested by the Contractor before insulation is installed.
The Contractor is to test sections of each piping system independently, and must not use piping
system valves to isolate sections where test pressure exceeds the valve pressure rating.
The extent of each section tested is to be approved by the CA.
Testing shall not be carried out until the ample time is elapsed since completion of last joint and
as recommended by the manufacturer.
Test each piping system at 150% of operating pressure indicated, but not less than 1033 KPa
(150 psi) test pressure.
Observe each test section for leakage at end of test period. The test has failed if leakage is
observed or if pressure drop exceeds 5% of test pressure.
The Contractor shall repair piping systems sections which fail required piping test, by
disassembly and re-installation, using new materials to extent required to overcome leakage.
The contractor shall install pressure relief valves on all ABS pipework networks rated to
discharge water when the pressure reaches within 1 bar of the pipework pressure rating at 46
deg C. Relief valves shall be as detailed elsewhere in this specification.
Do not use chemicals, stop-leak compounds, mastics, or other temporary repair methods.
Pipe supports shall not exert undue pressure on the pipe wall or deform the pipe wall against
the clamp or support.
Thermal Expansion
The Contractor shall ensure adequate care shall be taken to accommodate expansion and
contraction of pipes.
Expansion loops and/or expansion compensators shall be provided as an acceptable means to

accommodate thermal movement. These shall be as specified elsewhere in this specification.
Part 5
Section 1 - Page 8
The Contractor shall carry out a total pipe work analysis and submit calculation along with
selection data compensation devices for approval by the CA. These shall also be certified by the
approved pipework manufacturer.
The Contractor shall provide factory supplied plastic end-caps on each length of pipe or as
recommended by manufacturer. Maintain end-caps through shipping, storage and handling as
required to prevent pipe ends damage and avoid dirt and moisture accumulating inside the pipe.
packaging with durable, waterproof wrapping.
Acceptable Manufacturers: Refer to Appendix A Preferred Mechanical equipment suppliers
1.7 GRP PIPEWORK (CONDENSER WATER)

GRP pipework shall be manufactured in accordance with BS 5480, BS 7159, EN 1450 and BS
EN 14161.
The maximum distance between pipe supports shall be in accordance with the manufacturers
recommendations.
The width of the pipe supports shall be in accordance with the manufacturers
recommendations.
The Contractor shall provide factory-fabricated fittings type, materials, grade, class and pressure
rating indicated for each service and pipe size. And to provide sizes type matching pipe, valve or
equipment connection in each case. Where not otherwise indicated, the Contractor shall comply
with governing regulation and industry standard selection and with manufacturers
recommendation where applicable as approved by the CA.
The Contractor shall install pipe and fittings in accordance with recognized industry practices
and this specification
Each run shall be installed with minimum joints and couplings, but with adequate accessible
unions for disassembly and maintenance/ replacement of valves and equipment.
Reduce sizes (where indicated) by use of reducing fittings. Align piping accurately at
connection, within 1.6mm (/16) misalignment tolerance.
The installation shall be carried out under the supervision of the nominated manufacturer
representative or by qualified person carrying qualification certificate of installing GRP pipes and
fittings. The certificate shall be submitted for the approval of the CA.
Piping runs shall be located, except as otherwise indicated, vertically and horizontally (pitched to
drain) and avoid diagonal runs wherever possible.
Orient horizontal runs parallel with walls and column lines. Locate runs as shown or described
by diagrams, details and notations or, if not otherwise indicated, run piping in shortest route
which does not obstruct usable space or block access for servicing building and its equipment.
The Contractor is to ensure that all pipework is secured close to walls, overhead construction,
columns and other structural and permanent- enclosure elements of building; limit clearance to
13mm (1/2) where furring is shown for enclosure or concealment of piping, but allow for
insulation thickness, if any.
Where mechanical handling is employed, metal slings, hooks, or chains must not come into
direct contact with the pipe surface. Fabric slings shall be used and be attached at two points
on the load. Do not sling from the middle of the pipe. Care shall be taken to provide for not
damaging the external surfaces of pipes by rough handling or dragging along the ground.
Clean exterior surfaces of installed piping systems of superfluous materials and prepare for
application of specified coatings.
Part 5
Section 1 - Page 9
The Contractor shall flush out piping systems with clean water before proceeding with required
tests. Inspect each run of each system for completion of joints, supports and accessory items.
The Contractor shall provide piping and gate valves to allow the complete flushing of the system
without allowing flushing water to enter any coil bank.
The Contractor is to provide temporary equipment for testing, including pumps and gauges.
The entire piping system is to be tested by the Contractor before insulation is installed.
The Contractor is to test sections of each piping system independently, and must not use piping
system valves to isolate sections where test pressure exceeds valve pressure rating.
The extent of each section tested is to be approved by the CA.
Testing shall not be carried out until the ample time is elapsed since completion of last joint and
as recommended by the manufacturer.
Test each piping system at 150% of operating pressure indicated, but not less than 1033 KPa
(150 psi) test pressure.
Observe each test section for leakage at end of test period. The test has failed if leakage is
observed or if pressure drop exceeds 5% of test pressure.
The Contractor shall repair piping systems sections which fail required piping test, by
disassembly and re-installation, using new materials to extent required to overcome leakage.
Do not use chemicals, stop-leak compounds, mastics, or other temporary repair methods.
Pipe supports shall not exert undue pressure on the pipe wall or deform the pipe wall against
the clamp or support.
Thermal Expansion
The Contractor shall ensure adequate care shall be taken to accommodate expansion and
contraction of pipes.
Expansion loops and/or expansion compensators shall be acceptable means to

accommodate thermal movement.
The Contractor shall carry out a total pipe work analysis and submit calculation along with
selection data compensation devices for approval by the CA.
The Contractor shall provide factory supplied plastic end-caps on each length of pipe or as
recommended by manufacturer. Maintain end-caps through shipping, storage and handling as
required to prevent pipe ends damage and avoid dirt and moisture accumulating inside the pipe.
packaging with durable, waterproof wrapping.
1.8 COPPER PIPEWORK (ABOVE GROUND)

Copper tube shall conform to BS EN 1057-R250
Fittings for copper pipework shall be either:
Copper or cast gunmetal capillary type to BS 864: Part 2. Only lead free soft solder will be
permitted for capillary type joints.
Part 5
Section 1 - Page 10
Capillary type to BS EN 1254 or BS 864: Part 2 suitable for waste services. Tees, crosses
Where bends of other angles are required or where more suitable, formed bends in copper
tubing shall be used.
Formed bends to copper piping shall be made with the use of springs or an efficient bending
machine and shall be made with the minimum loss of local wall thickness. They shall maintain
the diameter of the pipe and shall not involve rippled or scored work.
End feed capillary fittings shall not be permitted.
Fittings above 54mm. diameter shall be prefabricated in light gauge copper tube as specified
above using machine made bends and silver brazed swept branch connections.
Brass compression fittings shall comply to BS EN 1254-2 or BS 864: Part 2.
Screwed joints on copper pipework shall be provided where specified and at screwed valves
and fittings. Screwed joints shall have taper threads complying with BS 21.
Jointing materials shall be approved by the CA prior to commencement of the Works. The
Contractor shall obtain the approval from the relevant Local Authority for all jointing materials to
be used.
1.9 COPPER PIPEWORK (LAID IN GROUND)

Copper pipework, where laid in the ground shall be copper tube to BS EN 1057-R250 (class Y)
and shall be jointed with copper or cast gunmetal, capillary type fittings to BS.864 Part 2.
All pipework shall be protected by wrapping with two layers of Denso tape or equal and
approved.
Only lead free soft solder complying with BS.864 Part 2 will be permitted for capillary type joints.
1.10 COPPER PIPEWORK (INSTALLED WITHIN SCREED)

Copper pipework where laid in a concrete screed shall be plastic coated, pre-insulated copper
tube to BS EN 1057-R250 (class X)
No fittings are to be installed within the screed, and all bends are to be pulled.
1.11 STAINLESS STEEL PIPEWORK

Pipework shall be installed using stainless steel pipe and fittings to DIN EN 1088/BS 316 516
Joints shall be made using proprietary push-fit fittings with seal rings that are completed using a
proprietary clamp/pressing tool.
Pipework shall be installed in light gauge stainless steel tube to BS EN 10312.
Jointing shall be means of unpolished chromium plated compression type fittings to BS 864 Part
2.
Where bends or angles are required, then formed bends in the stainless steel tubing shall be
used.
Stainless steel tubing shall not be used where pressures exceed 13 bar.
Part 5
Section 1 - Page 11
1.12 POLYETHYLENE PIPE (LAID IN GROUND)
Installations shall be carried out using medium density polyethylene (MDPE) Series SDR II pipe
and fittings coloured blue (potable water services), black (non-potable water services) and
yellow (gas services).
MDPE pipework for pressurised potable water systems shall be manufactured in compliance
with Water Industry Specification (WIS) WIS 4-32-17 and BS EN 12201.
MDPE pipework for pressurised non-potable water systems (excluding reclaimed water) shall be
manufactured in compliance with WIS 4-32-17 and BS EN 13244.
MDPE pipework for pressurised non-potable re-claimed water systems shall be black with
longitudinal green stripes marked Reclaimed Water and manufactured in compliance with WIS
4-32-17 and BS EN 13244. Installation of pipework associated with reclaimed water systems
shall follow the guidance contained in the Water Regulations Advisory Service (WRAS)
Guidance Note IGN 9-02-04.
MDPE pipe for natural gas systems shall be manufactured in compliance with British
Gas/Transco specifications GBE/PL2 Parts 1 & 6 (up to 5.5 bar) or Part 8 (up to 7 bar). MDPE
fittings for gas systems shall be manufactured in compliance with specifications BGE/PL2 Parts
2 & 3.
Pipework shall be jointed using approved proprietary electro-fusion of butt weld methods carried
out by competent personnel suitably trained.
1.13 GALVANISED MILD STEEL PIPEWORK

For working pressures below 20 bar the pipework shall be seamless factory galvanized
steel in accordance with ASTM A 53 grade B schedule 40.
Fittings on 50 mm and below shall be galvanised malleable cast iron fittings conforming to
class 250, ANSI B16.4 and shall be UL listed, FM approved.
Fittings 65mm and above shall be factory galvanized mechanical roll grooved fittings and
shall be UL listed, FM approved. These shall be class 250 to ANSI B16.9.
For working pressures above 20 bar the pipework shall be seamless factory galvanized
steel in accordance with ASTM A 53 grade B schedule 80.
Fittings on 50 mm and below shall be galvanised malleable cast iron fittings conforming to
class 300, ANSI B16.3 and shall be UL listed, FM approved.
Fittings 65mm and above shall be factory galvanized mechanical roll grooved fittings and
shall be UL listed, FM approved. These shall be class 300 to class 16.9.
Care shall be exercised when threading the tube to ensure that threads are carefully cut to
minimise the number of exposed threads.
All pipework and fittings shall be internally and externally galvanized.
Where galvanised steel pipework and screwed fittings are used on domestic hot and cold
water services, including cold water mains, joints shall be clean threaded, pulled up tightly
using PTFE tape (Boss Permanite GT) and a suitable jointing compound as approved in
the current "Fittings and Materials Directory" as published for the Water Research Centre.
On cold water services, including cold water mains, Boss Blue jointing compound is
approved and recommended.
Stranded hemp and Boss white shall not be used under any circumstances.
Part 5
Section 1 - Page 12
1.14 PRESS-FIT PIPEWORK SYSTEMS
The use and extent of press-fit pipework systems shall be as indicated elsewhere including the
limitations of pipe sizes.
Press-fit systems shall not be used for natural gas or other gas systems.
Pipework
Pipes shall adhere to the required specification of the press-fit system manufacturer.
Carbon steel (OD 12 to 54 mm) to DIN 2394. The pipe shall be manufactured from unalloyed
high purity low carbon steel. The outside of the pipe shall be primed and protected with a 1mm
thick polypropylene coating.
Copper tube to BS EN 1057 - R250/R290
Stainless steel tube manufactured from Cr-Ni-Mo Steel material No 1.4401 to DIN EN 10088/BS
316 and conforming to DVGW W541.
Pipes shall be supplied with plastic end caps to prevent ingress of dirt and stored in dry
conditions prior to installation. Pipe lengths shall not exceed 6m.
Fittings
System operating temperatures and pressures shall be commensurate with the seal ring
material. Maximum operating pressure shall be 16 Bar and working temperatures of -20C to
110C.
Purpose-made press-fit jointing fittings shall incorporate factory-fitted butyl rubber seal rings
within a circumferential profile.
The joint shall be accomplished by use of a jawed circumferential crimping tool or a similar tool
utilizing press slings.
Pipe fittings shall be primed and painted matt white to match the factory finished plastic coated
tubes. In areas of high humidity and where moisture will contact the surface of a fitting, a layer
of anti-corrosion tape shall be applied after priming and prior to the application of the insulation.
Installation
Where the use of press-fit type pipework system is selected, the whole of the pipework system
shall be installed with a single manufacturers range. The installer shall not use more than one
press-fit manufacturer on a pipework system. Press-fit capillary and compression type fittings
shall not be used on the same system.
Pipe for press-fit jointing shall be prepared fully in accordance with the published instructions of
the jointing system manufacturer including the neat removal of any plastics coatings to pipes.
Pipe and jointing fittings within a system shall be fully compatible. A complete system shall be
of one manufacturers supply only.
Submit to the CA prior to the commencement of the Works documentary evidence that
operatives have adequate and sufficient training by the joint system manufacturer.
Procedures shall be adopted to ensure that all joints are successfully made and fluid-tight and
include a checking regime to ensure that all joints are properly completed and documented
before systems are filled and pressure-tested. Documentation shall be available for inspection
by the CA.
Account shall be taken of the overall dimensions of fittings in order to achieve neat and
economic installations.
Part 5
Section 1 - Page 13
Pipes shall be cut square and true using tube cutters. Pipe ends must be de-burred internally
and externally, prior to insertion with fittings.
No oils shall be used for lubrication of pipe cutting or fitting insertion.
Only press-fit tools which will not operate with an incorrectly set-up joint and/or inadequate
power supply, and will not disengage until the joint is completed, shall be used.
Tools shall be regularly cleaned and otherwise maintained to the manufacturers published
instructions.
Bending tools must be approved by the pipe manufacturer. No heat shall be directly applied to
the pipe for bending purposes.
All changes in direction < 35mm diameter shall be achieved by the use of press-fittings
Bending radii for pipes shall be in accordance with the recommendations of the pipe
manufacturer.
Pipe supports shall comply with the requirements of the manufacturer.
Connections to equipment items shall be by threaded or flanged press-fit conversion fittings.
Press-fit joints shall not be made within 300mm of brazed or welded joints.
All systems shall be leak tested on completion.
Water treatment regimes shall be to the approval of the manufacturer of the tube/fittings.
All metallic pipework systems shall comply with the equipotential requirements of the current
edition of BS 7671.
1.15 VICTAULIC JOINTING SYSTEMS

As an alternative to welded, screwed or press fit jointing systems the Contractor may offer a
system comprising Victaulic (mechanical) couplings for off site prefabrication and minimisation
of on site hot works.
Mechanical couplings may be used in lieu of unions, welded, flanged or screwed pipework
connections except where exposed in occupied areas, for connections to units incorporating
reciprocating equipment or where the water temperature exceeds 95oC.
Couplings shall be self-centering, engage and lock in place the groove or shouldered pipe fitting
ends in a positive watertight couple providing some allowance for angular pipe deflection,
contraction and expansion. Coupling housing clamps shall consist of two or more malleable iron
castings holding in place a composition water sealing gasket so designed that the internal water
pressure increases the water tightness of the seal. The coupling assembly shall be securely
held together by two or more track head, square or oval-neck heat treated carbon steel bolts
and nuts. All pipe fittings connected to mechanical pipe couplings shall have groove or
shouldered ends and be malleable iron castings. Flanged or threaded end valves may be used
with grooved adapters.
For external use whether above or below ground couplings and their fasteners shall be provided
with an approved thermo-plastics coating
Pipes may be cut or roll-grooved except that pipes with a wall thickness less than the minimum
recommended by the manufacturer for cut-grooving shall be roll-grooved without the removal of
any metal.
Before couplings are assembled pipe ends and the outside of gaskets shall be lightly coated
with an approved lubricant to facilitate installation and prevent pinching of the sealing ring.
Part 5
Section 1 - Page 14
Supports shall be as Clause 1.30 except that they shall be positioned close to the joints rather
than between them and under no circumstances shall any pipe be left unsupported between
successive joints.
To prevent pipes snaking in horizontal runs sufficient lateral restraint at supports must be used.
Some lightweight drop hangers are not suitable for use with this method of jointing.
Where two or more supports are provided in any length of pipe care shall be taken to ensure
their alignment or lateral forces may be set up in the pipe causing overstressing of the joints.
The entire coupling installation shall be in accordance with the latest published manufacturers
recommendations and with the manufacturers approved equipment and components.
Couplings and fittings shall be suitable for a test pressure of 960 kPa or 11/2 times the working
pressure whichever is the greater.
Ensure that cut ends are square, free of bumps, dents and score marks and are within
manufacturer's tolerances. Form groove to manufacturer's detail.
Assemble joint in accordance with manufacturer's instructions.
Earth continuity: Use manufacturer's earth continuity clips to ensure compliance with IEE
Regulations and BS 7271.
1.16 CAST IRON PIPEWORK

Cast iron soil, waste and ventilation pipework and fittings shall be installed using coated
standard grade cast iron complying with the requirements of BS 416.
All cast or ductile iron pipes and fittings shall be subjected to the optional hydraulic test at the
manufacturers works as referred to in the British Standard Specification.
Cast iron below ground drainage pipework and fittings shall be installed using coated cast iron
complying with the requirements of BS.437.
The jointing method of the pipework and fittings shall be either:-
Socket and spigot pipework and fittings jointed using hemp spun yarn and run molten lead well
caulked and finished flush with the socket rim.
Spigot ended pipe and fittings:-
Glynwed "Timesaver" system jointed using two piece cast iron bolted couplings and synthetic
rubber gaskets.
Glynwed "Ensign" system jointed using one piece ductile iron bolted couplings and synthetic
rubber gaskets.
Stanton and Stavely "Stanflex" system jointed using two piece ductile iron bolted couplings and
nitrile rubber gaskets.
Stanton and Stavely "SMU" system jointed using one piece stainless steel couplings with EPDM
elastomer flexible gaskets.
All couplings used with plain ended spigot pipe and fittings shall be installed in strict compliance
with the manufacturers instructions. All bolts shall be tightened to the correct torque as
specified and only pipe, fittings and couplings manufactured to the system specified shall be
used throughout the installation. Any connection to existing pipework or fittings shall be
undertaken using the correct transitional coupling.
Above ground and suspended below ground double spigot ended pipe and fittings, jointed with a
bolted coupling shall be fitted with an electrical earthing continuity clip at every joint to comply
with the latest edition of the IEE Regulations.
Part 5
Section 1 - Page 15
1.17 CAST IRON WATER MAIN
Cast iron water main where laid in the ground shall be carried out in metric size ductile iron pipe
and fittings to BS EN 545 having 'Tyton' spigot and socket joints.
Jointing and installation shall be in accordance with the manufacturers instructions.
Concrete thrust blocks shall be included where necessary at changes in direction, tee pieces
and blanked ends. Thrust blocks shall be installed prior to filling and testing of the water main.
1.18 PLASTIC SOIL AND WASTE PIPEWORK

Soil, waste and ventilation pipework, 75mm. diameter and above shall be installed, using
PVC-U pipe and fittings complying with BS EN 1329-1.
Waste and anti-syphon pipework, 50mm diameter and below, shall be installed, using
PVC-U pipe and fittings complying with BS EN 1329-1.
UPVC external rainwater pipework shall be installed, using materials complying with BS
EN 607.
All fittings shall be of compatible materials of the same manufacture, with solvent weld or seal
ring joints, and are to be stored, assembled, supported and tested in accordance with the
manufacturer instructions.
Where jointing to different materials, the correct transitional fittings shall be used in accordance
with the manufacturers instructions.
All drainage pipework run in the ceiling voids of the building above noise sensitive areas (or as
required to achieve specified room NC/NR levels for services in Part 2) shall be insulated with
acoustic lagging to minimize noise transmission. The acoustic insulation shall be minimum
25mm thick and shall achieve a minimum noise reduction of 20dBA. The surface density of the
insulation shall be 4.5kg/m2 or as required to achieve the necessary sound reduction.
The Contractor shall allow for contraction and expansion of pipework and anchoring as required.
Particular attention shall be given to the base of main stacks where long radius bends shall be
provided and suitably anchored/restrained to cater for the higher pressures experienced. The
Contractor shall submit suitable fittings and support system as recommended by the
manufacturer for the CAs approval.
1.19 REFRIGERANT PIPEWORK

Copper tubes for refrigerant pipework shall comply with BS EN 12735-1 and shall be suitable for
the refrigerant and oil used. Pipework shall be dry, completely free from scale and internally
degreased.
Where the refrigerant pressure is above the limits for copper pipe then heavy grade mild steel
tube shall be used instead.
Refrigerating system and installation of refrigerant pipework shall comply with BS EN 378.
Refrigeration pipework joints shall be brazed or silver soldered. Joints shall be kept to the
absolute minimum. Formed bends shall be used in preference to fittings.
Flared or screwed joints shall only be used with the approval of the CA.
Brazing shall be carried out in accordance with BS EN 14324 by operatives having approved
qualifications in accordance with the necessary standards.
Part 5
Section 1 - Page 16
Dry nitrogen shall be passed continuously through the pipework at minimal pressure and at an
adequate velocity during brazing or soldering to eliminate internal oxidation. All excess solder
and flux shall be removed on completion of joints.
Fittings shall be integral ring solder type complying with BS EN 1254 -1.
Connections shall be provided in the high and low pressure sides of each system to facilitate
evacuating and charging.
Piping and other components which have been prepared and are not to be used immediately
shall be capped and sealed. During installation no component or length of tubing shall be left
un-blanked longer than necessary for installation.
Suction lines shall be sized to provide a minimum practical pressure drop commensurate with
sufficient velocity for oil entrainment.
The suction lines shall be designed to slope back to the compressor to avoid oil logging around
the system.
Where the vertical rise exceeds 3 metres, an oil trap shall be formed in the suction line at the
base of the riser and at 3 metre intervals throughout the length of the riser, or at such intervals
as are recommended by the refrigerant equipment manufacturer.
Where compressors unload, provisions shall be made where necessary to ensure adequate oil
return at all stages of unloading without causing an excessive pressure drop.
Include expansion joints if required to accommodate expansion and contraction. Cold bridging
is to be prevented.
Refrigerant pipework shall be adequately supported with maximum support spacing as follows:
Pipe nominal bore (mm) Spacing (m)

15 to 20 1.0
22 to 54 2.0
54 to 67 3.0
Where the pipework cannot be adequately supported at these spacing directly from the building
structure, continuous proprietary channel, angle or tray support systems shall be provided.
Pipework shall be supported using sheradised steel clips with a rubber or plastic sleeve to
prevent chafing or vibration. The arrangement of pipework and support shall be agreed with the
CA before commencement of the Works.
For refrigeration copper pipework 15 to 28 mm diameter support on continuous plastic coated

cable tray.
Electrical cables shall not be fixed to refrigerant pipework.
Enclosed spaces containing equipment or pipework charged with refrigerant shall be provided
with refrigerant leak detectors. The detection system shall be capable of providing remote
indication of an alarm condition. Where indicated the alarm shall be transmitted to the building
management system.
Detectors shall be wall mounted and shall alarm concentrations of refrigerant in excess of
500ppm. Where required units shall be located within equipment or provided with a remote
sensor for location within equipment.
1.20 BRAZING AND BRONZE WELDING

Brazing and bronze welding shall be executed by competent qualified/certified operators fully
experienced in the type and size of work being carried out.
Part 5
Section 1 - Page 17
Brazers shall hold a valid certificate of competency issued by an approved body. Brazers
without valid certificates and those without relevant brazing work experience within the
preceding three months shall undertake an approved competency test, witnessed and certified
by an approved body. Brazers shall present a copy of their current certificate for examination by
the CA before any works are commenced.
If so requested by the CA, and prior to commencement of the Works, brazers shall perform
samples at all sizes for the inspection of the CA. Only certified brazers providing acceptable
samples shall be permitted to undertake the works.
The CA will place a strong emphasis on the standard of brazing and the associated quality
control procedures in order that the required standards are achieved in all cases.
Copper joints shall be silver soldered, brazed or bronze welded to suit the operating
temperature and pressure and shall comply with BS EN 14324.
In addition the recommendations of the HVAC and Copper Development Association shall be
adhered to.
Welding rods, brazing filler materials, fluxes etc, shall comply with relevant British Standards.
Brazers shall permanently identify each of their joints with their own unique mark which will
withstand site conditions without damaging system or component performance. Methods of
marking shall be approved by the CA prior to commencement of the works.
During the installation of the Works the CA shall select at random installed brazed joints to a
maximum number of 3% of total or 10 number and the installer shall remove these to enable a
thorough inspection to take place. In the event of finding a faulty joint a further 10 joints made
by the relevant brazer shall be cut out and tested. Should any of the second batch fail then the
CA shall have the right to instruct the cutting out and replacement of all brazed joints and the
replacement of all brazers previously employed on the site. Cutting out and consequential
rectification works shall be carried out by the installer at no expense.
Visual examination and non-destructive testing of joints shall be carried out by an independent
specialist approved by the CA prior to commencement of the works.
1.21 COPPER CAPILLARY FITTINGS

Excess flux and solder shall be removed and the joint cleaned to give a clean neat finish
1.22 EXPANSION OF PIPEWORKS

Adequate provision shall be made for expansion and contraction of all pipework, and, where
possible, advantage shall be taken of pipework changes in direction to accommodate movement
in pipe systems.
Anchors and guides shall be positioned to contain all movement and resist the maximum loads
imposed.
Anchors and guides are to be located at points which prevent excess stresses on pipework,
joints and equipment connections.
Similar provisions shall be made for building movement or building settlement.
Where natural flexing of the pipework is not practicable thermal and building movement shall be
accommodated by the use of expansion joints.
Expansion joints may be of the restrained or unrestrained type and shall be provided with
welded, screwed or flanged ends as appropriate and as indicated.
Expansion joint convolutions shall be of a stainless steel, super multi-ply construction fitted with
stainless steel inner sleeves.
Part 5
Section 1 - Page 18
Expansion joint shall be capable of not less than 2000 complete reversals of movement at the
given working conditions and the manufacturer shall be able to produce calculations to that
effect.
Expansion joints shall be capable of withstanding a pressure test of twice their design pressure
without loss of performance.
The manufacturer's guidelines for selection and installation shall be strictly adhered to. On
completion of the installation, prior to heat being applied, the installer shall arrange for the
manufacturer's representative to inspect and check that the installation of the expansion joints is
in accordance with his instructions. This shall be agreed with the manufacturer prior to placing
an order.
Axial unrestrained expansion joints shall only be used in positions where their pressure thrust
can be contained by adequate anchor points. The installer shall arrange for the manufacturer to
submit calculations for loadings on main anchors. Recommended guide spacing must be strictly
adhered to.
Restrained expansion joints may be used for angular or lateral movement. Their restraints shall
be capable of absorbing the full pressure thrust of the bellows, plus forces due to the connecting
pipework.
Angular expansion joints shall be constructed using an ultra low friction rocking hinge
mechanism, which limits the movement to one plane. Angular expansion joints shall be used in
pairs or in threes.
Lateral expansion joints shall be fitted with threaded tie bars and low friction self lubricating
hemispherical nuts allowing movement in two planes.
Stainless steel convoluted hose with a stainless steel wire braid may be used to absorb small
lateral movements in pipework branches or for building movement in accordance with the
manufacturer's recommendations.
Pipework subject to expansion and contraction shall be supported via swivel type hangers.
The installer shall be responsible for arranging the manufacturer to approve the expansion joints
provisions prior to ordering of materials and commencement of the works.
1.23 EXPANSION LOOPS

Prefabricated expansion loops shall be constructed in same pipework class and finish as the
pipework system.
Where access is limited prefabricated expansion loops shall be used and only on pipework up to
65 mm.
1.24 ANCHORS AND GUIDES

Anchors and guides shall be provided to control the direction and effects of movement of the
pipework systems and to resist stresses and loading on pipework due to forces acting on the
pipework system.
The anchor loads, anchor and guide locations, method of fixing to the structure and design
details shall be submitted to the CA for review prior to commencement of the works.
Ensure the structure is suitable for the transmitted stress.
Use similar or compatible materials with the pipework system.
Anchors shall be as follows:
Part 5
Section 1 - Page 19
Steel pipe
On mild steel pipework, mild steel anchors capable of resisting the maximum stresses
shall be provided and preferably shall be welded to the pipework.
Where it is impracticable to weld the anchors to the pipework, cast-iron chairs with at least
two wrought-iron stirrup bolts shall used, the bolts being provided with sufficient thread to
ensure an effective grip on the pipe.
Copper pipe
The anchors shall be provided by wide copper straps secured to the pipework in such a
manner that the pipe is not damaged.
PVC pipe
Use PVC coated over straps to clamp pipework to mid steel channel section firmly attached
to the building structure.
The installer shall supply, and fix in position ready for building-in, all cleats, brackets and
steelwork required for anchor points.
Steelwork secured in trenches or ducts to which anchors are attached shall be hot-dip
galvanised.
Anchors attached to pipework shall be finished with two coats of aluminium paint.
Where bellows are used the manufacturers recommendations shall be submitted for review and
strictly adhered to.
Thrust blocks and suitable anchors shall be provided where pipework internal pressures are not
contained by the jointing system.
Direct movement of expansion and contraction from pipe anchor points towards loops, bellows
or flexible inserts. Ensure that thrust is linear relative to the axis of the pipe.
Provide a friction reducing material between adjacent metal surfaces subject to movement.
The anchor and guide components shall be of suitable size and design to withstand and transfer
the pipeline thrust.
1.25 SETS AND PULLED BENDS

Sets and pulled bends shall not be allowed in:
galvanised pipework
ungalvanised tube 25 mm and above
Sets and bends shall be free from kinks and ripples and formed in a suitable bending machine.
Wherever possible the pipe shall be bent cold by the gradual application of pressure to radius of
not less than 3 times the nominal bore.
1.26 PIPE SLEEVES AND PLATES

All pipework passing through floors or walls shall be provided with sleeves of similar material
and of such diameter as to allow free movement of pipework.
Sleeves shall be of sufficient length to finish flush with finished faces of wall or ceiling and
15mm. proud of the finished face of floors. All sleeves shall be retained in position before
making good by lugs or plates welded on at sub-floor level.
The weight of pipework shall not be borne by sleeves.
Sleeves shall be manufactured from mild steel tube painted with two coats of zinc rich primer.
Part 5
Section 1 - Page 20
Copper sleeves shall be used in conjunction with uninsulated copper pipework.
Where pipework is insulated, the pipe sleeve shall be of sufficient size to allow the thermal
insulation to pass between the pipe and the sleeve over its entire length.
In areas where floors are washed down install with a 50 mm protrusion above floor finish and
shall have its edge rounded or bevelled. The protrusion length shall be agreed with the CA prior
to installation.
Chromium plated plates shall be installed wherever pipes pass through walls, floors and ceilings
exposed to view. Samples shall be submitted to the CA for approval prior to installation.
1.27 PIPE SLEEVES THROUGH FIRE BARRIERS

Sleeves which are contained in walls, ceilings or floors which are fire barriers shall be
additionally packed with a non-combustible material for the entire length to form a fire/smoke
stop of the required fire rating.
The material shall be subject to approval of the CA and must comply with Civil Defence
requirements.
The ends of sleeves packed with material shall have suitable fire resistant mastic applied to seal
the fibres and present a neat appearance.
Sleeves for UPVC pipes shall contain an in tumescent material to BS 476.
1.28 PIPE SLEEVES THROUGH ACOUSTIC BARRIERS, ENCLOSURES AND PLANT

ROOMS
Sleeves on pipes which are contained in walls, ceilings or floors which are acoustic barriers, or
through acoustic enclosures, or plant room walls, floors or ceilings, shall be packed with a 12
mm thick resilient neoprene inner sleeve around the pipe and filled with a non-setting mastic
compound. The outer edges of the sleeve shall be made air-tight by sealing with a dense non-
setting mastic compound. Where such barriers are also fire barriers the material shall comply
with Local Authority regulations.
1.29 PUDDLE FLANGE ASSEMBLIES

Puddle flange assemblies shall be provided where pipes pass through walls or floors which
require proofing against liquid penetration. They shall consist of a length of pipe and an un-
drilled flange welded onto the pipe at a distance midway through the structural thickness.
The assembly shall extend beyond both sides of the wall or floor and shall be terminated in
flange connections.
The assembly shall be manufactured from the same class of piping as the adjoining pipework
and the complete assembly shall be wrapped in two coats of petroleum jelly impregnated tape.
1.30 PIPE SUPPORTS

General requirements
Pipework supports are to be arranged so that no undue stress is imposed upon the pipes.
Ensure that all materials used for pipework supports are compatible with the pipeline materials.
Pipework supports shall not exceed the maximum intervals stated elsewhere.
Additional supports shall be provided for equipment such as valves, strainers and ancillaries so
that minimum stress is imposed on the pipework and the weight is not taken by the pipework.
The support arrangement shall allow safe operation and removal of the component.
Part 5
Section 1 - Page 21
All brackets and supports shall allow free movement of the pipes due to expansion and
contraction with special regard to prevention of damage to any thermal insulation and vapour
barrier.
Where multiple pipe runs of differing bores are supported from a common point, use support
spacing of pipe requiring the closest spacing with adequate provision for the unequal movement
due to expansion and contraction. Supports shall also be provided at bends where there is a
run of pipework 1 metre or more both sides of the bend.
Cantilever type supports from walls will not be allowed except for single pipes of diameters up to
50 mm.
Obtain approval for all fixings to structural concrete or structural steelwork and loads imposed
on the structure. Shot fired fixings shall not be used or any reinforcement drilled through.
Static point loadings transferred to the structure which cannot be accommodated by the
structural fixings shall be spread over a larger area by means of additional brackets and/or
additional load spreading primary steelwork.
The installer will be responsible for marking out the exact positions where pipe brackets are to
be built in and for checking the accuracy, levels and alignment of supports after building in by
others.
For vertical support spacing check total self-weight and pressure loading against manufacturers
recommendations when using mechanical joints or end load capable flexible couplings. Ensure
adequate support when using non-end load capable flexible couplings.
Steel pipework maximum support spacing
Pipe bore Maximum support spacing (m)

Nominal horizontal vertical
(mm) bare insulated bare or insulated
up to 15 1.8 1.8 2.4
20 2.4 2.4 3.0
25 2.4 2.4 3.0
32 2.7 2.4 3.0
40 3.0 2.4 3.6
50 3.0 2.4 3.6
65 3.7 3.0 4.6
80 3.7 3.0 4.6
100 3.7 3.0 4.6
125 3.7 3.0 5.4
150 4.5 4.5 5.4
200 5.0 5.0 6.0
250 5.0 5.0 6.0
300 6.1 6.1 9.0
350 9.5 7.0 9.0
400 9.5 7.5 9.5
450 10.0 8.0 10.0
500 11.0 9.0 11.0
Copper pipework maximum support spacing

up to 15 1.2 1.2 1.8
22 1.2 1.2 2.1
28 1.8 1.5 2.4
35 2.4 1.8 3.0
Part 5
Section 1 - Page 22
42 2.4 1.8 3.0
54 2.7 1.8 3.0
67 3.0 2.4 3.5
76 3.0 2.4 3.5
108 3.0 2.4 3.5
133 3.0 3.0 3.5
159 3.5 3.5 3.5
Cast iron pipework maximum support spacing

All sizes 1.8 1.8 3.0
At least one fixing shall be provided for each unit length.
UPVC and polyethylene pipework maximum support spacing

UPVC pipework

Nominal
(mm) horizontal vertical
32 40 0.5 1.2
50 0.6 1.2
75 - 100 0.9 1.8
150 1.2 1.8
Polyethylene pipework

Nominal
(mm) horizontal vertical
up to 15 0.5
20 0,55
25
32 40 0.5 1.2
50 0.7 1.2
For plastic pipework space vertical support intervals at no greater than 1.5 times the horizontal
spacing.
For UPVC and ABS pipework reduce spacing between supports for operating temperatures
above 20 C in accordance with manufacturers recommendations. Support continuously for
operating temperatures above 60 C.
1.31 PIPEWORK BRACKETS

Where expansion takes place in pipework, pipes shall be supported on cast iron roller chair
assemblies with retaining strap or U bolts to restrain transverse movement.
Where expansion is minimal pipework shall be held in position by U bolts, split bands or split
pipe rings. Single pipe supports from walls shall be held in position by two piece screw-on clips
which shall be removable without disturbing the fixings. Calliper, single piece rings, or snap on
type brackets will not be allowed.
Part 5
Section 1 - Page 23
Brackets shall be manufactured from the following materials:
Steel and cast iron pipework
Mild steel or malleable iron, with cast iron rollers, mild steel nuts, bolts and washers and mild
steel screws.
Copper pipework
Brass or gun metal with cast iron rollers plastic coated, and brass screws, nuts, bolts and
washers. Alternatively mild steel plastic coated pipe brackets may be used on larger diameter
pipework.
Plastic pipework
PVC coated steel for 75 and 110 mm diameter plastic pipework and plastic or polypropylene for
smaller diameter pipes. Fixing screws, nuts and bolts shall be steel with a galvanised or
sheradized finish.
1.32 VENTING AND DRAINING

All pipework must be graded accordingly.
Equipment shall be provided with drains and vents which shall be accessible from outside the
casing.
Adequate drains and vents shall be provided to facilitate draining and venting the pipework
system.
Drain points shall be located in accessible positions and shall include drain cocks with hose
union and removable key.
Where pipework sections can be isolated, drain and vent points shall be provided to facilitate
draining down and venting of that section of pipework.
Drain points on medium and high temperature pipework shall be fitted with a flanged valve and
blank flange.
In plantrooms a 30 m length of 25 mm flexible rubber/armoured hose pipe shall be provided and

fixed to a wall. The hose shall have a connection to match the drain valves.
The installer shall allow for the provision of fast fill and drain connections in accordance with the
water treatment specialists requirements and also in accordance with the current COP relating
to water treatment and cleaning.
1.33 AIR BOTTLES

On pipework up to and including 80 mm size, each bottle shall be manufactured from 50 mm
size tube 300mm long with a screwed or brazed cap. Air bottles on pipework up to 100 mm size
and over shall be manufactured from 100 mm size tube, each 380 mm long. Bottles shall be
manufactured from galvanised steel tube on ferrous pipework or copper tube on non-ferrous
pipework systems.
All air bottles shall be complete with a 10 mm gun metal key operated, needle seated air cock.
Where the air cock is at high level or inaccessible from floor level a 15 mm size a steel or
copper extension tube shall be provided to a position approved by the CA within 1.5 m of the
floor and fitted with a 10 mm size needle-seated globe valve or air cock.
Automatic air eliminators shall be provided where air bottles are not practicable to install or at
locations approved by the CA.
Part 5
Section 1 - Page 24
1.34 AUTOMATIC AIR VENTS
Shall be 15 mm and have a bronze body, copper or stainless steel float and guides, non-
corrodible needle valve and seats and be suitable for the system temperature and pressure.
Each automatic air vent shall be complete with a lock-shield valve.
The discharge pipe from the automatic air vent shall be manufactured in copper tube and shall
be run to discharge over the nearest gully, tundish or other suitable location to the approval of
the CA.
Air venting devices and any air release pipes installed in exposed positions where freezing is
likely to occur shall be insulated to the required standard.
1.35 DIRT POCKETS

Full-bore dirt pockets shall be provided at the bottom of all vertical pipework risers and valved to
allow pockets to be drained without draining the system.
The dirt pockets shall be formed from 300mm. length of similar full bore pipework beyond the
last branch and/or connection complete with isolating valve and drain cock.
The isolating valve shall be line size up to a maximum of 50 mm.
1.36 OVERFLOWS AND CONDENSATE DRAINS

Equipment which has a continuous or intermittent discharge of waste water shall have an
overflow/drain connection and discharge pipe which shall fall continuously to the nearest gully.
Overflow/drains shall be the same diameter as the connection size to the equipment and
increased as soon as possible to 25 mm.
A 150 mm diameter by 150 mm high tundish shall be provided adjacent to the equipment into
which the overflow/drain shall discharge.
On connections to coils/cooling towers a waste trap shall be installed between the coil/cooling
tower and the drain.
Where more than on overflow/drain runs into a common pipework drain the diameter of the
pipework shall be sized, by the installer, to ensure that the system drains to the gully at all times.
An air break trap shall be provided to each drain to comply with CIBSE TM 13.
Glass traps shall be used in all healthcare and clean room applications.
The contractor shall allow for an insulated and trapped condensate drain pipe (UPVC class E or
Copper) from each fan coil unit. The condensate drain shall terminate in the nearest floor drain.
Where this is not practical it may be allowed to discharge in to a waste pipe via an additional
75mm deep seal trap. It shall not under any circumstances be allowed to terminate in to soil or
contaminated waste pipework. For air handling units, the condensate drain shall be provided
with galvanized steel pipework, with a trap of adequate depth of seal to overcome maximum fan
static pressure.
1.37 FAN COIL CONNECTIONS

Flexible hose fan coil connections shall be provided unless stated otherwise.
Fan coil connections shall consist of an EPDM inner liner with a stainless steel wire braid. The
fittings shall be nickel plated brass with stainless steel ferrules.
Part 5
Section 1 - Page 25
Hoses shall have an overall length of not less than 300mm. and resist kinking when bent
through 180 degrees and shall be designed for a working pressure of 20 bar and a temperature
of 1100C.
The hoses shall be colour coded red and blue to indicate its suitability for hot or chilled water.
Chilled water connections shall be fully insulated and the insulation fitted with end caps.
1.38 FLUSHING BYPASSES

Provision shall be made for flexible or fixed full-bore by-passes to be fitted across all major
items of plant in order to facilitate the circulation of water during dynamic flushing operations.
Items which could be damaged by the flushing and cleaning process shall be isolated and
cleaned by approved alternative methods.
1.39 POSITIONING OF CONTROL COMPONENTS

Pipeline control components shall be installed in accordance with the manufacturers
recommendations and in the positions indicated.
For control components incorporated in insulated pipework submit to the CA for approval details
of insulation methods proposed.
Supports shall be provided to ensure no strain is imposed on the components.
The components shall be installed so as to ensure adequate and safe access for operation and
maintenance.
1.40 REFERRED DOCUMENTS

Documents referred to in this section.
BS 21 Specification for pipe threads for tubes and fittings where

pressure tight joints are made on the threads (metric
dimensions)
BS 143 and 1256 Threaded pipe fittings in malleable cast iron and cast copper
alloy
BS 416 Discharge and ventilating pipes and fittings, sand-cast or spun in
cast iron. Specification for spigot and socket systems.
BS 437 Specification for cast iron spigot and socket drain pipes and
fittings.
BS 476 Fire tests on building materials and structures
BS 1387 Specification for screwed and socketed steel tubes and tubulars
and for plain end steel tubes suitable for welding or for screwing
to BS 21 pipe threads
BS 1724 Specification for bronze welding by gas
BS 1965 Butt welding pipe fittings for pressure purposes
BS 3506 Specification for unplasticized PVC pipe for industrial uses
BS EN 10088 Stainless steels
BS EN 10216-1 Seamless steel tubes for pressure purposes. Technical delivery
conditions. Non-alloy steel tubes with specified room
temperature properties.
BS EN 10217-1 Welded steel tubes for pressure purposes. Technical delivery
conditions. Non-alloy steel tubes with specified room
temperature properties.
BS EN 10226 - 1 Pipe threads where pressure tight joins are made on threads.
Taper external threads and parallel internal threads. Dimensions,
tolerances and designation.
BS EN 10253-1 Butt welding pipe fitting. Wrought carbon steel for general use
and without specific inspection requirement
BS EN 10312 Welded stainless steel tubes for the conveyance of aqueous
Part 5
Section 1 - Page 26
liquids including water for human consumption. Technical
delivery conditions.
BS EN 1057 Copper and copper alloys. Seamless, round copper tubes for
water and gas in sanitary and heating applications.
BS EN 1092 Flanges and their joints. Circular flanges for pipes, valves, fittings
and accessories, PN designated.
BS EN 12201 Plastic piping systems for water supply. Polyethylene (PE)
BS EN 12449 Copper and copper alloys. Seamless, round tubes for general
purposes
BS EN 12450 Copper and copper alloys. Seamless, round copper capillary
tube
BS EN 1254 Copper and copper alloys. Plumbing fittings.
BS EN 12735-1 Copper and copper alloys. Seamless copper tubes for air
conditioning and refrigeration. Tubes for piping systems
BS EN 13244 Plastics piping systems for buried and above ground pressure
systems for water for general purposes, drainage and sewerage.
Polyethylene (PE).
BS EN 1329-1 Plastics piping systems for soil and waste discharge (low and
high temperature) within the building structure. Unplasticized
poly (vinyl chloride) (PVC-U). Specifications for pipes, fittings and
the system.
BS EN 14324 Brazing. Guidance on the application of brazed joints.
BS EN 1452 Plastics piping systems for water supply. Unplasticized poly
(vinyl chloride) (PVC-U).
BS EN 1453-1 Plastics piping systems with structured-wall pipes for soil and
waste discharge (low and high temperature) inside buildings
Unplasticized poly(vinyl chloride) (PVC-U). Specification for
pipes and fittings.
BS EN 378 Specification for refrigerating systems and heat pumps. Safety
and environmental requirements.
BS EN 545 Ductile iron pipes, fittings, accessories and their joints for water
pipelines. Requirements and test method.
BS EN 598 Ductile iron pipes, fittings, accessories and their joints for
sewerage applications. Requirements and test method.
BS EN 877 Cast iron pipes and fittings, their joints and accessories for the
evacuation of water from buildings. Requirements, test methods
and quality assurance.
BS EN ISO 228-1 Pipe threads where pressure-tight joints are not made on the
threads. Dimensions, tolerances and designation
BS EN ISO 8434 Metallic tube connections for fluid power and general use
CIBSE:TM13 Minimising risk of legionnaires disease
Part 5
Section 1 - Page 27
Section 2 Valves and Pipework Accessories
Contents
Section 2 Valves and Pipework Accessories 1

2.2 Provision of lockshields on valves 3
2.3 Pipeline strainers 3
2.4 Radiator valves 4
2.5 Thermostatic radiator valves 4
2.6 Safety and relief valves 4
2.7 Isolating valves (LTHW, CHW, Condenser water) 5
2.8 Valves for flow regulation 6
2.9 Check valves 7
2.10 Commissioning sets 7
2.11 Automatic balancing valves 9
2.12 Isolating valves (potable water, hot and cold water services) 10
2.13 Check valves (Potable water, hot and cold water services) 11
2.14 Double check valves (Hot and cold water services) 11
2.15 Butterfly valves 11
2.16 Float operated valves 12
2.17 Stop valves 15mm 50mm 12
2.18 Tundishes 12
2.19 Drain / Draw off cocks 12
2.20 Natural gas service isolation valves 12
2.21 Gas shut-off valves 13
2.22 Flexible pipe connections (up to 10 bar and 100C) 13
2.23 De-aerators and dirt Seperators (LTHW, CHW ) 14
Section 2 Valves and Pipework Accessories
Valves, cocks, air vents and pipework accessories shall be provided where indicated on the
drawings and at all positions necessary for the proper working, regulation, control and
maintenance of the installation (whether or not indicated on the design drawings) with the
approval of the CA.
All valves, cocks, vents and accessories installed in the Works shall be approved by the CA
prior to ordering. Valves shall be as far as it is practicable of the same manufacture and style to
provide conformity and to simplify maintenance. In addition they shall comply with the
requirements of DEWA or the Local Water Authority.
Ensure that valves and cocks are pressure tested at the manufacturers works, in accordance
with appropriate British Standards specification.
All valves required to comply with the Pressure Systems Safety Regulations shall carry the CE
mark and have a declaration of conformity.
All valves, cocks, vents and accessories must be fitted in such a manner that they are
accessible for operation and maintenance. Valve operating handles must be easily accessible
and operation must not be impeded by structure or other services.
Seals, discs, gland packing, plug lubricants etc. shall be suitable for the application and
operating conditions.
Where available, BSI kite marked valves shall be supplied. For fire fighting systems all valves
and accessories shall be UL listed and FM approved. They shall also be approved by the local
civil defence department.
Civil Defence/NFPA certified valves shall be used on gas service.
Only Water Research Council approved valves shall be used for potable mains, hot water
service and cols water services.
Institution of Gas CAs (IGE) certified valves shall be used on gas service. Valves must also be
Civil Defence approved models.
The pressure rating of valves must equal or exceed system working pressures at the relevant
temperature and the system test pressure. Valves shall be rated at a minimum of 16 Bar,
however PN20 or above shall be provided where system working pressure dictates.
.
The installer is responsible for ensuring that all balancing and flow regulation valves are
correctly selected and installed to suit the flow rates indicated. All regulating/balancing valves
must be approved by the CA prior to installation.
Valves shall be provided on all pipework wherever necessary to achieve proper isolation and
regulation of the whole systems. They shall be installed to isolate and balance every section of
the pipework network including but not limited to the following locations, whether indicated on
the design drawings or not:-
To isolate each item of equipment including heat transfer terminal units, fan coil units, air
handling units, plate heat exchangers, De-aerators, dosing systems, pressurisation sets,
pumps etc.
Part 5
Section 2 Page 1
To regulate and balance the flow through each item of equipment including heat transfer
terminal units, fan coil and control valves etc.
To isolate every section of the pipework network including sub-branch mains, sub-
circuits and to multi-connections to heat transfer terminal units. They shall also be
provided to isolate each floor and each riser.
To regulate and balance the flow through every section of the pipework network
including sub-branch mains, sub-circuits, and to multi-connections to heat transfer
terminal units
To isolate, regulate and balance the flow to any item of equipment supplied by or, to be
connected to the systems, by others (Should the equipment or plant not be connected
up prior to balancing, temporary by-pass connections and a regulating valve shall be
installed to achieve balancing)
To isolate, and allow the removal of all control valves, flow meters, BTU meters,
strainers, and other similar pipeline ancillaries.
To isolate, regulate and balance the whole, the sub-branch and the sub-circuit on hot
water services flow and return systems.
To isolate each float operated valve or pressure reducing valve.
To isolate water services to individual items of sanitary equipment, ranges of kitchen

equipment, ranges of sanitary fittings and individual water draw-off fittings
To isolate immediately inside the building incoming utility services
Stopcocks may be used for isolation within buildings on all mains or pressurised water services
and in addition on tank fed services on pipework up to 22 mm diameter only. Above 22 mm
diameter gate type isolating valves only shall be used.
Regulation and balancing of the systems shall be achieved by the installation of commissioning
stations and isolating valves.
A commissioning station shall be provided on the return branch or sub-circuit return main and an
isolating valve shall be provided on the corresponding flow connection, flow branch or sub-
circuit flow main. The commissioning station shall consist of a double regulating valve and
orifice plate as detailed elsewhere.
The commissioning stations shall be installed to the manufacturers recommendations, with

special regard to straight pipe lengths required before and after the assembly.
A regulating valve shall be provided on the return pipe from each terminal unit and an isolating
valve shall be provided on the corresponding flow connection to each terminal unit.
Access to double regulating valves must be such that scales and verniers are clearly visible.
At least 100 mm clearance from pressure test points must be allowed to enable manometer
tubes to be connected without kinking. Ensure test points are located to enable safe, positive
quickcoupling and uncoupling of the flexible connections.
Large valves shall not be supported by the pipework to which they are supported and additional
supports positioned close to each side of the valve shall be provided. Removal of the valve
shall not allow the adjacent pipework to sag.
Check valves shall be installed where plant operates on an automatic changeover basis or
where flow reversal can occur. Check valves shall be installed in accordance with the
manufacturers recommendations.
Part 5
Section 2 Page 2
Air vents shall consist of either open air pipes to atmosphere manually operated air cocks or
automatic air release valves.
Open air vent pipes shall not be less than 20mm diameter continued up beyond the highest
point of the system and turned to discharge over the feed and expansion tank. All open vents
shall run with a continuous rise from the point of connection to the system, to the point of
discharge.
Where indicated, valves or cocks shall be lockable, with purpose-made locking devices which
do not impede the fast closure of the valve where that is necessary. The locking device shall
remain attached to the valve in both open and closed position.
Where modifications or extensions to existing services are to be undertaken, all valves which
are to be removed and re-fixed shall be overhauled thoroughly, with glands and seals renewed,
all to the satisfaction of the CA.
All valves shall be constructed from asbestos free materials.
2.2 PROVISION OF LOCKSHIELDS ON VALVES

Where valves are shown as lockshield pattern or where the accidental closure or opening of a
valve from its normal functioning position could cause harm to equipment or persons, then the
valve shall be of the lockshield type with a bronze, chromium plated, or cast iron shield as
indicated and complete with a loose key. In all other respects the valve shall be as specified for
wheel type valves but of the lockshield type.
2.3 PIPELINE STRAINERS

Strainers shall be provided on the inlet connections to all pumps, meters, pressure reducing
valves and where stated elsewhere or shown on the drawings to safe guard against dirt and
other foreign particles.
They shall be of the 'Y' type up to 150 mm and pot or "Y" type on 200 mm and above as
indicated elsewhere and shall be located between isolating valves with a convenient drain
adjacent and installed in such a way that the strainer element/basket can be readily removable
below the level of the body.
Strainers shall be the same size as the pipeline immediately before any reduction in size of
pipeline to suit a control valve or pump/plant connection.
Strainer elements shall be cleaned and free from dirt prior to practical completion.
Provide plugged connections for drain, air vent and differential pressure monitoring located in
the adjacent pipework or within the strainer body. Threads shall be to BS 21 and BS EN 10226-
1.
Provide pressure gauges on the inlet and outlet of each strainer on sizes 32 mm and above
unless stated otherwise.
Strainers over 100 mm shall be complete with an adequate size of blow-down connection and
drain cock and shall have a discharge pipe which shall run to the nearest gully.
Unless otherwise stated strainers shall have a stainless steel element with perforation size as
indicated below. Screen free flow area shall be not less than 250% of the pipe bore.
Screen perforations:
Nominal pipe size Screen perforations

15 mm to 50mm Within range 0.7 0.9 mm diameter
65 mm and over Within range 1.5 1.8 mm diameter
The installer shall submit to the CA for approval details of all strainer elements prior to ordering.
Part 5
Section 2 Page 3
Baskets shall be capable of withstanding the maximum pressures without distortion.
Strainers shall be complete with an asbestos free non-stick gasket.
Strainer bodies up to 50 mm shall be bronze to with compression ends to BS EN 1254-2.
Strainer bodies above 50 mm shall be cast iron with flanged ends to BS EN 1092-2.
2.4 RADIATOR VALVES

Valves shall be in accordance with BS 2767
The valves shall be bronze angle or gate pattern as determined by the radiator connections and
as indicated.
Connections shall be of the type to suit the pipework into which they are installed and shall have
male union screwed connections to the appliance. Connections shall be threaded to BS 10226-1
or compression to BS EN 1254-2 to suit pipework as indicated.
Angle patterns shall have spherical brass discs, free to rotate on stem and gate patterns shall
have solid bronze wedge disc. Both patterns shall be complete with non-rising stem, hand
wheel or lockshield manufactured from white moulded polycarbonate, bronze screw in bonnet
and screwed gland and one piece moulded packing. Valves shall be suitable for operating
pressures and temperatures on systems up to 1000 kPa at 120C
The valve finish shall be to match the respective thermostatic valve or as otherwise stated and
shall be approved by the CA prior to ordering.
The valves shall have hand-wheels on the radiator flow connections and lockshield type on the
return unless otherwise specified.
2.5 THERMOSTATIC RADIATOR VALVES

The radiators shall have on the flow connection a thermostatic radiator valve to BS EN 215-1
and BS 7556 and installed to the manufacturers recommendations.
Valves shall be straight or angle pattern to suit the application and as indicated.
Where thermostatic valves are used, the return valve from the radiator shall be of the lock shield
type with the same body finish as the thermostatic valve unless otherwise indicated.
The valves shall be complete with integral sensor unless stated otherwise and suitable for
locking at any temperature setting in its range and complete with frost protection facility.
Valve connections shall be of the type to suit the pipework into which they are being installed,
and shall have male union screwed connections to the appliance.
The finish of the valves shall be either polished brass or chromium plate or as stated otherwise
and approved by the CA prior to ordering.
Where installations are fitted with thermostatic radiator valves, the sensing heads must not be
fitted until commissioning has been completed, witnessed and approved by the CA.
2.6 SAFETY AND RELIEF VALVES

Safety to discharge with rapid opening action to prevent pre-determine safe pressure being
exceeded.
Relief to discharge with opening action proportional to increase in pressure above set pressure.
Safety and relief valves shall meet the requirements of the appropriate British Standard for the
equipment to which they are connected, and be suitable for the operating conditions of the
system. Valves shall be sized for the rated output of the appliance.
Part 5
Section 2 Page 4
Direct acting safety valves shall be in accordance with BS EN 4126-1.
Pipework connections shall be fitted, where indicated, to provide discharge connection to safety
and relief valves. Discharge and waste pipes shall terminate at visible and safe positions to be
agreed with the CA. Connections to drains shall be provided as indicated.
Safety and discharge pipework for hot water systems shall be laid with a continuous downward
gradient.
Spring type safety valves
Valves shall be of the enclosed spring loaded high lift type.
Valves up to 50mm nominal diameter shall be bronze or DZR copper alloy body as indicated
and threaded to BS 21 and BS EN 10226-1.
Cast iron valves shall be flanged to BS EN 1092-2.
They shall have a screwed on or bolted on spring casing, cadmium plated carbon steel spring
and a gun metal valve head, seat and adjustable screws and ferrule.
Valves shall be complete with a screwed on top cover, testing lever and padlock and shall have
a discharge pipe of the same diameter as the valve which shall terminate 300 mm from the floor
level.
The valve release pressure shall be set at a pressure above the system operating pressure and
as agreed with the CA. The spring range shall be selected to give equal adjustment either side
of the operating pressure.
Valves shall be stamped with their set pressure and limiting temperature.
2.7 ISOLATING VALVES (LTHW, CHW, CONDENSER WATER)

Ball Valves 15 mm up to 50mm
Type: Ball valve

Body material: Bronze or DZR brass (corrosion resistant)
Pressure rating: PN25
End connections: Threaded to BS EN 10226-1
Specification: PTFE seat and packing
DZR brass ball
Mild steel (zinc plated) with PVC covered lever
WRAS listed and BS kitemark approved.
Temperature range: -10C to 100C
Operation: Lever operated, quarter turn, tight shut-off
Operation of the valve shall generally be by lever fitted with stop permitting a 90 movement of
the ball between fully open and closed position. In areas where space is limited a T-handle
shall be fitted. Valves on insulated pipework shall be provided with an extended stem in which
the lever is held above the pipe insulation.
As indicated, valve spindles shall be suitable for operation by a screwdriver where the valve is
liable to unauthorised use or lever operation
Gate valve 65mm and above
Type: Gate valve to BS EN 1171

Body material: Cast iron
Pressure rating: PN16 (Minimum)
End connections: Flanged to BS EN 1092-2
Specification: Wedge disk
Non-rising stem of manganese bronze
Part 5
Section 2 Page 5
Inside screw
Bronze disc
Malleable iron hand-wheel
BSI kite mark approved
Operation: Hand-wheel
Butterfly valve 65 mm and above (To be used only where specifically agreed by the CA.
Gate valves are the standard approved type)
Type: Butterfly to EN 593

Specification: Short wafer lugged type
WRAS approved EPDM liner Stainless steel shaft and disc
WRAS approved
Operation: Lever operated up to 150 mm.
Valves 200 mm and above shall be complete with gear unit.
Valves shall have a pressure rating to suit the maximum operating pressure of the system.
Valves shall be suitable for fitting between flanges fully lugged type complying with BS EN 1092,
centrally located by the fixing bolts.
2.8 VALVES FOR FLOW REGULATION

Valves shall be selected to produce the required pressure drop at between 50% and 75% of the
fully open position.
Double regulating valve up to and including 50mm
Type: Double regulating valve to BS 7350

Body material: Bronze
End connections: Threaded to BS 21 and BS EN 10226-1
Specification: Oblique or Y pattern
WRAS approved; BS Kitemark
Valves shall be of the screwed end pattern and shall be complete with position indicator and
lockable adjustable setting position.
Where necessary, valves shall be selected for low flow conditions.
65mm and above
Type: Double regulating valve to BS 7350

Pressure rating: PN16 (Minimum)
Specification: Oblique or Y pattern
Rising stem
Bolted on bonnet
Screwed boss into which an in-built drain
cock/valve or air vent can be provided
BS Kitemarked
Hand-wheel material: Cast iron
Valves shall be complete with:

-position indicator and lockable adjustable setting position
-drain plug facility
-independent means for positive isolation on pressure tapping
Part 5
Section 2 Page 6
2.9 CHECK VALVES
All valves shall have flow direction indicators and shall have a pressure rating to suit the
maximum operating pressure of the system. Where used on systems with operating
temperatures in excess of 65C the disk and seating shall be suitable for the conditions.
Non-return valves shall be of the straight pattern, swing check type. Check valves shall be
installed in horizontal pipework unless they are specifically selected for operation in vertical
pipework. They shall be selected to present a low resistance to flow.
Up to and including 50m
Type: Swing type check valve to BS 5154

Body material: Bronze
Temperature range: -10 to 100C
End connections: BS21 taper
Specification: Metal disc; screwed in cap; BSI Kitemark; WRAS listed.
65mm and above
Type: Swing pattern check valve to BS EN 12334

End connections: Flanged BS EN 1092-2
Specification: Cast iron disc; fibrous gasket.
Valves for pipes of 400 mm diameter and larger shall be wafer pattern, manufactured from cast
iron or cast steel, with a stainless steel stem and disc and EPDM or reinforced PTFE seat and
shall be suitable for installation between flanges. Wafer check valves shall be correctly aligned
to achieve efficient valve operation with minimum head-loss, and prevent the valve disk fouling
downstream piping.
2.10 COMMISSIONING SETS

The installer shall be responsible for the final selection of all commissioning sets. The installer
shall refer to the drawings and specifications for guidance on when Autoflow balancing valves
are to be used in lieu of commissioning sets.
Commissioning sets shall comprise metering stations and double regulating valves installed in
the positions indicated on the drawings or as stated elsewhere for the proportional balancing of
heating and chilled water pipework systems.
The metering station shall be fitted to the upstream valve connection in accordance with the
The installer shall submit to the CA, prior to ordering, a comprehensive schedule, prepared by
the manufacturer, detailing the correct selection of each commissioning set in respect to signal
pressure and valve position.
Flow measurement devices must always be sized using pressure differential flow rate criteria
and the general assumption that line size devices will suffice will not be acceptable.
Double regulating valves shall be selected to ensure that the required head absorption occurs at
valve settings not less than 25% open.
Flow measurement devices should be selected and sized to meet the following requirements at
the design flow rate:
The minimum pressure differential signal should not be less than 1kPa
Part 5
Section 2 Page 7
The minimum head loss across the device should be consistent with the minimum
pressure differential signal requirements
With water flow rates of 0.04 l/s or less, low flow measurement units shall be used.
The accuracy of the flow rate derived from the pressure differential across the signal generating
device shall be within 5%.
Where orifice valves are specified, these shall be used in their fully open position to ensure
minimum pressure drop across the valve and the valve must provide positive shut-off.
Commissioning sets shall be fitted in a straight length pipe run. The installer shall be
responsible for obtaining from the flow measurement device manufacturer the appropriate
number of pipe diameters to be allowed upstream and downstream of the device. Typical
values are 10 pipe diameters downstream and 5 diameter upstream of any change in pipe
direction to minimise the effect of turbulence on the pressure signals at the measuring device.
Flow charts allowing the manometer readings to be converted into flow rates shall be provided
for each size of measuring station.
The installer shall take due care throughout the installation and during the flushing and cleaning
process to ensure that the flow measurement devices remain clean and undamaged.
Ensure that test points are not installed so as to become dirt traps. Where practical, high
pressure test points shall point upwards to allow ease of venting.
Up to 50mm
Single unit commissioning valve with combined functions of regulation and flow measurement
Type: Fixed orifice double regulating valve to BS 7350

Valve body material: Bronze
End connections: Threaded to BS 21
Specification: Fitted with two insertion points allowing quick connection; WRAS
approved; integral orifice plate
BS Kitemark
For water flow rates of 0.04 l/s or less, low flow measurement units shall be used
65mm and above

Shall consist of a flanged oblique pattern double regulating valve complete with cast iron
metering station installed on the return side of any circuit or sub-circuit
Type: Fixed orifice double regulating valve and close

coupled fixed orifice fitting manufactured to BS 7350
Valve body material: Cast iron
Orifice plate: Stainless steel orifice plate with two stainless steel
extension tubes fitted with insertion test points
End connections: Flanged BS EN 1092-2
Specification: Cast iron disc; cast iron bonnet;
Hand-wheel material: Cast iron
Independent means shall be provided for positive isolation on pressure tappings. Valves shall
be BS Kitemarked.
Flow measuring device 15mm up to 65mm
Type: Flow measuring device

Valve body material: Bronze
Part 5
Section 2 Page 8
Specification: Fitted with two insertion points allowing quick connection; WRAS
approved; integral orifice plate; flow measurement accuracy 3%. BS
kitemark.
2.11 AUTOMATIC BALANCING VALVES

15 mm to 50 mm
Automatic balancing valves complete with control valve and actuator shall be supplied for each
fan coil unit. Auto flow valves shall be provided for all AHUs without control valve functionality.
Automatic balancing valves shall be complete with fully modulating actuator, test points (with
extended length binder points) and shall have replaceable cartridges with flow rates determined
at the factory which shall be maintained within 5%.The flow cartridge shall be stainless steel or
nickel finish and each cartridge shall be coded to indicate flow rate duty. The cartridge shall be
removable from the body to provide access for change, inspection and cleaning without
removing the body from the pipeline.
The valve shall be complete with two colour coded pressure tapping ports. Independent means
shall be provided for positive isolation on pressure tappings.
If the unit is not isolated during system flushing the flow cartridge shall not be fitted and a blank
flushing cap installed.
The stem and test points shall be provided with extension pieces to allow for insulation.
Body material: DZR copper alloy CW602N

Maximum Pressure: 25 bar (PN25)
End connections: Threaded to ISO 228
For fan coil units a combination of automatic balancing valve with full stroke modulating control
(that guarantees 100 % authority) shall be used for high precision temperature control. The
valve should have two independent movements for the presetting and modulating function. The
automatic balancing valves shall be combined type, with auto flow and fully modulating control
features. The intelligent control valve shall adjust itself automatically to the preset flow in order
to provide full stroke modulating control. When the valve is preset according to the maximum
design flow, the stroke of the control valve shall remain the same thus providing 100%
modulating control. In practical terms, the valve shall ensure that no overflow can occur and that
below the design flow, the actuator has total authority.
The valve design should consist the following:
Automatic balancing cartridge

Modulating control component
Presetting scale
Electrical actuator
The presetting should be done after flushing and the same should be tamper resistant when
actuator is mounted. The differential pressure operating range shall be up to 450kpa.
The presetting of the valve shall not influence the length of stroke and the cartridge can be
removed without dismantling the valve.
The valve housing shall be made of DZR (De Zincification resistant Brass CW 602N), with
EPDM O rings, PN25 rated, female threaded ends.
The modulating actuator shall be normally closed, suitable for 24VAC power supply, 0-10V DC
control voltage, 5mm stroke and to be provided with manually operated clutch. The valve
actuator shall be IP 40 rated.
The valve adapter should be supplied along with all actuators.
Part 5
Section 2 Page 9
The valve shall be complete with fully modulating 0-10V actuator. The valves shall be capable to
operate with differential pressures of up to 450Kpa. The valve actuator shall be IP 40 rated, 24
or 240v.
For 50 mm and above
For sizes 50mm and above: The valve shall automatically control specified flow rates with +/-
5% flow accuracy.
Valves shall have replaceable cartridges with flow rates determined at the factory.
The flow cartridge shall be Tin-Nickel coated DZR Brass / Stainless steel, which should be anti
corrosive. Each cartridge should be coded to indicate specific flow rate. The valve body should
house one or multiple flow limiting cartridges; Differential pressure range should be 13 kPa to
600 kPa.
Wafer type body made from ductile iron GGG 40 suitable in between flanges of EN / ANSI
Standards, EPDM O rings, and Stainless steel 306 fasteners; The valves should be delivered
with 4 long test points; For sizes 100mm and above, eye bolt to be provided on the body;
Pressure rating for sizes up to 80mm to be PN25 as standard and 100mm and above PN16.
The manufacturer shall be ISO 9000 certified for their design & development, production, sale
and delivery of automatic balancing valves. Valves to be BSRIA tested.
Necessary hydraulic calculations are to be submitted for CAs approval prior to installing the
cartridges.
Valves cartridges and body are to be provided with 5 year warranty against corrosion.
2.12 ISOLATING VALVES (POTABLE WATER, HOT AND COLD WATER SERVICES)
15 mm to 22 mm (Ball valve type)
Where stated elsewhere or on the drawings, isolating valves to appliances shall be of the ball
valve type.
Type: Ball type valve

Body material: Bronze or DZR copper alloy body (chrome finish
unless stated otherwise)
Pressure rating: Suitable for working pressures up to 16 bar
End connections: Threaded to BS 21 or compression to BS EN 1254
(BS 864) as applicable
Specification: Chrome or nickel plated DZR sphere with full bore aperture; PTFE seats
and stem seals; shall be fitted with internal stop permitting a 90
movement of the ball between fully open and closed position; anti-blow
out stem; WRAS approved; BS Kitemark
Operation: Screw driver operated or key operated
15 mm to 50 mm (Ball valve type)
Type: Ball type valve

Body material: DZR copper alloy / DZR brass
Specification: Quarter turn; tight shut-off; chrome plated DZR copper alloy or brass
sphere with full bore aperture; PTFE seats and stem seal; anti-blow out
stem; WRAS approved; BS Kitemark.
Operation: Lever operated (in areas where space is limited a T- handle shall be
fitted)
Valves on insulated pipework shall be provided with an extended stem in which the lever is held
above the pipeline insulation.
Part 5
Section 2 Page 10
65 mm to 300 mm (Gate valves)
Type: Gate valve to BS EN 1171

Specification: Wedge disk; non-rising stem; inside screw; cast or
malleable iron hand-wheel; BSI Kitemark
Operation: Hand-wheel operated
65 mm and above (Butterfly valves where approved for use by the CA)
Type: Butterfly valve to BS EN 593

Specification: Lugged type; WRAS approved EPDM
liner; stainless steel shaft; stainless steel disc; WRAS approved; lever
and gear operated valves to be complete with long body neck for
lagging clearance; BS Kitemark
Operation: Lever operated up to 150 mm. Valves 200 mm and
above shall be complete with gear unit.
2.13 CHECK VALVES (POTABLE WATER, HOT AND COLD WATER SERVICES)
Check valves shall permit flow in one direction only and close automatically if flow reverses.
15 mm to 50 mm
Type: Swing type check valve to BS 5154

Body material: Gunmetal or bronze
Pressure rating: PN 25 Series B
Specification: Metal disk; screwed in cap; metal to metal seat;
WRAS approved; BSI Kitemark; flow direction indication.
Valves shall be suitable for mounting in horizontal and vertical pipe (with vertical flow upwards).
Where specified elsewhere the disc material shall be nitrile rubber but restricted to 90 C
maximum temperature and WRAS approved.
2.14 DOUBLE CHECK VALVES (HOT AND COLD WATER SERVICES)

Double check valves where indicated for the purpose of prevention of water contamination by
back-siphonage, backflow or cross connection, shall be to BS 6282-1 and be WRAS approved.
The body material shall be bronze or DZR copper alloy with compression connections to BS EN
1254-2 or threaded to BS 21.
The valve shall be the in-line pattern type, be suitable for vertical or horizontal installation and
provide positive closure.
2.15 BUTTERFLY VALVES

Valves shall be manufactured with cast iron bodies and comply with EN 593 with the pressure
rating to suit the maximum operating pressure of the system.
Valves shall be provided with lever operation up to 150mm diameter and gear operation on
200mm diameter and above.
The valve body liner shall be a WRAS approved EPDM liner with stainless steel disc and shaft.
They shall be the short wafer lugged type and suitable for fitting between flanges complying with
BS EN 1092, centrally located by the fixing bolts.
Part 5
Section 2 Page 11
Butterfly valves shall only be provided where approved for use by the CA.
2.16 FLOAT OPERATED VALVES

All float operated valves and materials shall be WRAS approved.
When installed float operated valves shall be capable of achieving the minimum air gap as
required by the Water Supply Regulations and DEWA.
Ball float valves shall be fitted with a servicing valve on the inlet.
Valves shall be manufactured from cast gunmetal or bronze of a dezincifiable grade.
To prevent back siphonage no connection of a dip tube or silencing pipe to the discharge port
shall be permitted.
Float valves fitted to feed and expansion tanks shall be provided with an approved modified float
arm such that it allows the float to move a sufficient distance to accept or allow the anticipated
expansion/contraction volume of water within the tank.
Float valves to WC cisterns shall be fitted with a collapsible silencing tube in compliance with BS
1212 -3.
15 mm float operated valves shall be of the plastic body diaphragm type to BS 1212 unless
stated otherwise. Plastic floats shall be to BS 2456.
22 mm and above float operated valves shall be the full bore bronze or gunmetal body
equilibrium pattern ball float type to BS 1212 with copper float to BS 1968.
2.17 STOP VALVES 15MM 50MM

Stop taps shall be manufactured in bronze or DZR copper alloy and the washer material shall
be suitable for the service fluid and operating temperature. The valve shall be the straight
pattern type with connections to suit the service pipeline.
Stop valves for potable water supplies shall be in accordance with BS EN 1213. The valves
shall be the straight pattern type manufactured in copper alloy with connections to suit the
service pipeline. Valves shall be easy clean polished finish where visible.
2.18 TUNDISHES
Tundishes shall be provided adjacent to equipment as indicated. The units shall be formed from
either 3mm copper sheet or mild steel sheet (galvanised after manufacturer). The tundish shall
be a tapered reducing cone with a minor diameter to suit the drain line. The major diameter
shall be 50 mm larger than the minor diameter, tapering at approximately 30 degrees.
2.19 DRAIN / DRAW OFF COCKS

15 mm 50 mm draw-off cocks shall be the straight type, gland pattern, taper plug, with
gunmetal or bronze body, threaded to BS 21 and complete with brass hose union outlet,
screwed blank cap and strap. Plugs shall have a square head with a slot to indicate plug
position. A loose malleable iron lever shall be provided with each plug valve. Each draw-off
cock shall be hydraulically tested to 20 bar.
2.20 NATURAL GAS SERVICE ISOLATION VALVES

The installation of valves and cocks shall be as indicated and comply with the recommendations
of the IGE.
2.20.1 15 mm to 50 mm isolating valve

Type: Millikan plug valve
Part 5
Section 2 Page 12
Pressure rating: PN 16
End connections: Threaded to BS 21 and
Operation: Wrench
Specification: Full bore; lubricated parallel plug; self sealing
Valves shall be complete with a suitable sealing compound to suit the pipeline service media.
2.20.2 65 mm to 200mm isolating valve

Type: Plug valve BS 5158
Pressure rating: PN 16
End connections: Flanged to BS EN 1092
Operation: Wrench
Specification: Full bore; lubricated parallel plug; self sealing
Valves shall be complete with a suitable sealing compound to suit the pipeline service media.
2.21 GAS SHUT-OFF VALVES

Solenoid operated gas shut-off valves shall be provided to automatically isolate the gas supply
as indicated.
Gas shut-off safety valves shall be in accordance with IGE requirements.
Where possible the valves shall be located remote from the areas being protected, provided that
the location will not permit unauthorised interference.
Gas shut-off valves shall comply with BS EN 161 and BS EN 126. Valves shall be electrically
operated and arranged to provide a positive shut-off. Valves shall be hand re-settable.
Operation and control of gas shut-off valves shall be as indicated elsewhere.
2.22 FLEXIBLE PIPE CONNECTIONS (UP TO 10 BAR AND 100C)

Flexible pipe compensators shall be installed on pipe connections to pumps, compressors,
chillers, cooling towers, cooling and heating coils on air handling units supported on anti
vibration mounts.
Rubber bellows shall be a single convolution of multi-ply EPDM rubber with corrosion resistant
steel wire mesh reinforced body.
The units shall be suitable for the working pressure and temperature.
The units shall have an indelible identification indicating manufacturer, date of manufacture,
type, size, pressure rating and a batch number.
Ensure flexible connections have a design life of 10 years at 100 C. Units shall be in
accordance with DIN 4809 and after a service life of 10 years at 100 C must have a burst
pressure of not less than 30 bar.
Flanges shall be to BS 4504 and shall be able to swivel and be removable.
Threaded ends shall be to BS 21 with one union end.
Where untied bellows are used the manufacturers recommendations for anchors and guides
shall be followed.
Tie bars shall be threaded and with adjustable length. Tie bars with rubber top hat washers shall
be used where the working pressure exceeds 1.5 bar.
Ensure flexible connections are tied when the plant is on vibration isolation mountings.
Part 5
Section 2 Page 13
For working temperatures between 65 C and 90 C the bellows shall be steel wire mesh
reinforced throughout and manufactured in accordance with DIN 4809.
For working temperatures up to 65 C the rubber bellows shall be high tensile synthetic fibre
reinforced.
For hot water services the bellows liner shall be of a food grade butyl rubber.
2.23 DE-AERATORS AND DIRT SEPERATORS (LTHW, CHW )

As indicated, a combined inline de-aerator and dirt separator shall be provided on each closed
circuit system where the maximum operating temperature does not exceed 100C.
Units shall be installed in accordance with manufacturers recommendations.
The static head for heating systems shall not exceed 15m and 5m on chilled water systems.
Units shall be horizontally mounted in the main supply pipe at the point of maximum system
temperature and be adequately supported to be stress free.
The units shall be designed to prevent clogging and to maintain a constant pressure drop across
the unit irrespective of the amount of dirt trapped.
Water velocities through the unit shall be in accordance with the manufacturers
recommendations but through a standard unit shall not exceed 1.5 m/s unless otherwise stated.
Units for velocities between 1.5 m/s and 3 m/s shall be specially selected.
Casings shall be manufactured from mild steel incorporating internal spiral wound copper mesh
system. Connections shall be line size with flanges complying with BS EN 1092 for sizes 50
mm and above.
A drain valve capable of permitting dirt removal while the system is operational shall be provided
at the base of each unit.
An automatic air release mechanism shall be provided at the top of the unit comprising solid
polycarbonate floats and spring loaded self-closing valve to ensure positive seal to prevent
leakages. The valve shall be tamper proof and the unit guaranteed against leakage for a
minimum of three years.
The unit shall be suitable for a maximum operating temperature of 110C and 10 bar maximum
pressure unless otherwise stated.
Where indicated, a demountable unit shall be provided in which the lower section can be
opened and the internal mechanism removed for cleaning and inspection.

Documents referred to in this section:
BS 21 Specification for pipe threads for tubes and fittings where pressure-
tight joints are made on the threads (metric dimensions)
BS EN 593 Industrial valves. Metallic butterfly valves
BS 759 Valves, gauges and other safety fittings for application to boilers and
to piping installations for and in connection with boilers. Specification
for valves, mountings and fittings.
BS1212-2 Float operated valves. Specification for diaphragm type float operated
valves (copper alloy body) (excluding floats)
BS1212-3 Float operated valves. Specification for diaphragm type float operated
valves (plastics bodied) for cold water services only (excluding floats)
BS1212-4 Float operated valves. Specification for compact type float operated
valves for WC flushing cisterns (including floats)
Part 5
Section 2 Page 14
BS 2456 Specification for floats (plastics) for float operated valves for cold
water services
BS 2767 Specification for manually operated copper alloy valves for radiators
BS 2879 Specification for draining taps (screw-down pattern)
and accessories. PN designated.
BS EN 1171 Industrial valves. Cast iron gate valves
BS EN 13789 Industrial valves. Cast iron globe valves
BS EN 12288 Industrial valves. Copper alloy gate valves
BS 5158 Specification for cast iron plug valves
BS 5163 Valves for waterworks purposes
BS 5164 Specification for indirect-acting electrical indicating and recording
instruments and their accessories
BS 6282 Devices with moving parts for the prevention of contamination of
water by backflow.
BS EN ISO 4126-1 Safety devices for protection against excessive pressure. Safety
valves
BS 7350 Specification for double regulating globe valves and flow
measurement devices for heating and chilled water systems
BS EN 215 Thermostatic radiator valves. Requirements and test methods
BS EN 1092 Flanges and their joints. Circular flanges for pipes, valves, fittings and
accessories, PN designated.
BS EN 1213 Building valves Copper alloy stop valves for potable water supply in
buildings Tests and requirements
BS EN 1254-1 Copper and copper alloys. Plumbing fittings. Fittings with ends for
capillary soldering of capillary soldering or capillary brazing to copper
tubes.
BS EN 1254-2 Copper and copper alloys. Plumbing fittings. Fittings with
compression end for use with copper tubes.
BS EN 1254-3 Copper and copper alloys. Plumbing fittings. Fittings with
compression end for use with plastic pipes.
BS EN 12334 Industrial valves. Cast iron check valves
BS EN 161 Automatic shut-off valves for gas burners and gas appliances
BS EN 126 Multifunctional controls for gas burning appliances
Part 5
Section 2 Page 15
Section 3 Ductwork
Contents
Section 3 Ductwork 1
3.1 General Requirements 1

3.2 Ductwork fabrication 2
3.3 Stainless Steel Ductwork 3
3.4 Aluminium Ductwork 3
3.5 Ductwork Finishes for Special Locations 3
3.6 Access Doors 3
3.7 Test holes 4
3.8 Provision for controls and instrumentation 4
3.9 Air turning vanes 5
3.10 Ductwork connections to builders work holes 5
3.11 Flexible joint connections 5
3.12 Flexible ducting 6
3.13 Control and balancing dampers 6
3.14 Fire Dampers 8
3.15 Smoke control dampers 9
3.16 Air leakage testing 10
3.17 Ductwork supports 10
3.18 Ductwork internal cleanliness 11
3.19 Bird wire guards 11
3.20 Fire rated ductwork 11
3.21 Acoustic duct liner 12
3.22 Pre Insulated Ductwork 12
Section 3 Ductwork
Ductwork shall be fabricated and installed in accordance with the recommendations of the
HVCA as their specifications DW144, DW 154, DW 143, DW 191, DW 172 and TR/19 as
appropriate unless stated otherwise. Copies of the documents shall be kept on site at all times.
The approval of the CA shall be obtained where other forms of construction or jointing are
dictated by restrictions on space or access.
Sizes of ductwork indicated are clear internal dimensions. Where applicable make allowance
for internal lining. Ductwork gauge shall be dependant on pressure class, size and use and shall
strictly adhere to the standards listed above. The Contractor shall furnish one calibrated new
micrometer to the CA in order for the CAs inspectors to carry out random checks on installed
ductwork thickness during the site installation phase.
Components shall be installed in accordance with manufacturers recommendations.
Electrical bonding terminals shall be provided as necessary to ensure electrical continuity in
accordance BS 7671 (latest edition of the IEE Regulations).
Ductwork shall be true in section, correctly aligned, rigid and free from movement,
independently supported and free from all contact with the building structure.
Ensure that there are no sharp edges or corners on cut edges on ductwork, flanges and
supports. Raw edges on ductwork, formed seams, welds and rivets shall be painted with two
coats of zinc rich paint at works and again after erection.
The installer shall be responsible for obtaining all site dimensions and the preparation of
drawings as stated elsewhere.
Any deviation from the routes indicated on the drawings shall be subject to the approval of the
CA.
Materials of accessories/components shall be compatible with the ductwork in which they are
incorporated and the finishes shall comply with any special requirements. Casing losses of
accessories/components shall also be compatible.
Full technical details of all accessories/components to be provided within ductwork systems
shall be submitted to the CA for approval.
The installer shall be responsible Party for all necessary inspections and obtaining all approvals
for ductwork sections or systems.
Any section of ductwork causing noise due to poor construction shall be removed, corrected and
reinstated at no expense to the contract.
Ensure that long runs of air ducts incorporate the necessary provision for absorbing movement
due to expansion or contraction resulting from thermal change.
During installation the installer shall ensure that dust and debris are prevented from entering the
ductwork system and that the installation is clean prior to commissioning. Commissioning shall
not commence until the cleanliness of the ductwork system has been inspected and certified.
Part 5
Section 3 - Page 1
3.2 DUCTWORK FABRICATION
Ductwork shall be fabricated to meet the leakage classification in accordance with DW 144
Table: HVCA DW 144 Ductwork classification and air leakage limits
Static pressure limit Maximum Air leakage limits

Duct pressure class Positive Negative velocity l/s per m2 of duct
Pa Pa m/s surface area
Low-pressure Class A 500 500 10 0.027 x p0.65
Medium-pressure
1000 750 20 0.009 x p0.65
Class B
High-pressure
2000 750 40 0.003 x p0.65
Class C
Internal jointing of ducting shall be avoided wherever possible, but if unavoidable, joints shall be
constructed so as to minimise air turbulence at these sections. They shall give a smooth
internal surface with no reduction in cross sectional area of duct. Approval shall be required
before internal jointing is utilised.
Where ducting is exposed ensure that the seams are concealed from view to provide a neat
appearance.
An approved liquid or mastic sealant shall be used on all longitudinal and cross joints at works.
'Socket and spigot' and 'cleated' joints made on site, joints shall be applied during or after
assembly of the joints to suit.
The use of self adhesive tape as a primary sealant over both longitudinal and cross joints on air
supply and air extract ductwork is not permitted.
Self tapping screws will not be permitted unless in circumstances where the use of rivets and
nuts and bolts are not practicable.
Edges of galvanised sheets cut to form joints and rivets shall be coated inside and out with zinc
rich or aluminium paint. All bolts and nuts shall be of mild steel protected by the electro-
galvanising, sheradising or cadmium plating process.
All ductwork shall be adequately stiffened, and where necessary braced to prevent drumming or
vibration and ducts shall be free from internal sharp edges or projections.
In special cases where internal stiffening is found necessary, these shall be streamlined and
details shall be approved by the CA.
The use of panel stiffening on rectangular ductwork shall be subject to the approval of the CA.
Where rigid slab insulation is to be applied to ductwork, plain construction only shall be
acceptable.
Ductwork connections to plant and equipment (e.g. heating, cooling coils etc.) shall, in the case
of bolted flanges, be provided with matching flanges of similar size and thickness. Sheet metal
returned flanges shall not be permitted. Where connections have transformations with angles
on one side to axis more than 25 splitters shall be provided. Splitters shall not obstruct the use
of access doors.
Ductwork hangers and supports shall be adjustable for height, spaced to ensure adequate
support and where practicable, fitted at each ductwork joint or spaced at not more than the
maximum centres in DW 144 for rectangular, circular and flat oval horizontal ducting. Securing
of formed brackets to corners of ductwork as a means of suspension shall not be permitted.
Supports for vertical ductwork in buildings shall be generally located at each floor slab but
subject to a maximum spacing of 4 metres.
Part 5
Section 3 - Page 2
All ductwork shall be securely supported from the building structure and approved inert packing
material shall be provided between ducts and supports to prevent direct contact of the ducting
with the structure.
3.3 STAINLESS STEEL DUCTWORK
Wherever specifically elsewhere or shown on the drawings, ductwork and fittings shall be
manufactured from stainless steel to DW144 Appendix F.
3.4 ALUMINIUM DUCTWORK
Where stated elsewhere or indicated on the drawings, aluminium ductwork and fittings shall be
manufactured from aluminium sheet to DW144 Appendix H.
3.5 DUCTWORK FINISHES FOR SPECIAL LOCATIONS
For external ductwork exposed to the weather and for ducting adjacent to air washers, fresh air
and exhaust louvres, spray coils and humidifiers, black steel sheet galvanised after manufacture
shall be used. Where this is not possible due to construction difficulties then galvanised sheet
steel ductwork with two coats of cold galvanising zinc rich epoxy ester primer at cut edges will
be permitted.
The internal ductwork adjacent to such items of plant shall be coated with two coats of black
bitumastic paint for at least 2 metres and on louvres for a distance equal to twice the louvre
height and in all cases the duct shall slope down towards a plugged drain point.
On kitchen exhaust ductwork and steam/moisture producing apparatus, the first 10 metres of
ductwork from the apparatus or canopy shall be constructed from aluminium sheets to the same
specification and installation details as galvanised sheet metal ductwork unless stated
otherwise.
For ductwork systems where this clause is applicable the complete ductwork sections shall
slope towards drain points throughout its entire length or where applicable to an agreed and
approved distance from the canopies or steam moisture producing apparatus.
3.6 ACCESS DOORS
Access/inspection openings shall be provided for inspection, cleaning, adjustment, calibration

and maintenance of all ductwork systems. Access shall be provided to all ductwork ancillaries
such as dampers, fire dampers, smoke dampers, heating and cooling coils, etc.
Access/inspection openings in metal ductwork shall be provided in accordance with DW 144
Part 7, Section 20 and Appendix M Table 25 Level 2 unless otherwise stated.
Access/inspection openings in glass fibre ductwork shall be provided in accordance with DW
191 Section 8 unless otherwise stated.
Access/inspection openings in plastic ductwork shall be provided in accordance with DW 154
Part 6, Section 15 and Appendix D Table 14 unless otherwise stated.
For kitchen ventilation ductwork, access doors for cleaning shall be provided at distances not
exceeding 3 metres and installation shall be in accordance with DW172.
Location of access/inspection openings shall be located to ensure safe and ease use without
obstruction from other services and the building structure.
The number of access panels provided for cleaning purposes shall suit the method cleaning to
be adopted as agreed with the CA and in accordance with HVCA TR/19.
Part 5
Section 3 - Page 3
The installer shall demonstrate physically and with a method statement that the systems can be
inspected, maintained and cleaned. The approved method statement shall be included in the
operating and maintenance manual.
Access panels/doors shall not be less than 200mm x 150mm. Where the duct size is below
150mm X 150mm access panels shall be fitted on both sides of the duct.
Inspection covers for visual inspection of internal elements shall not be less than 150mm
diameter.
Small size access openings on ductwork shall not project into the air stream.
A steel retaining wire shall be provided between the door and the frame.
Where duct sizes permit, larger sizes up to 535mm x 235mm shall be provided to enable fire
damper fusible linkages to be accessible, thus facilitating single handed access at head and
shoulder heights. Where duct connections to dampers are smaller than 150mm the ducting
local to the dampers shall be expanded to accept the smallest size access doors.
The access doors shall be of the insulated double skin 1.00mm thick galvanised steel type
having a compressible fire resistant gasket on periphery, handling ring and 12 ply x 200mm long
galvanised security cable secured to a one piece deep drawing duct mounting 1.00mm thick
galvanised steel frame. The frame shall be pre-drilled for fixing to duct opening either flush or
surface mounting to suit application. The frame shall be fitted with 1.40mm thick stainless steel
sliding latches and lugs fitted to the door to provide a quick door opening action. When fixing
the frames to the ductwork fire resistant sealant shall be used.
Man access doors shall be provided where it is necessary to gain access inside ductwork
connections between items of equipment (e.g. heating and cooling coils, front withdrawal air
filters, etc.) and where access is required to multiple fire dampers in large ducts. These doors
shall be not less than a clear opening size of 500 mm square. Ensure that the floor is of
sufficient strength to comply with safety standards and safety bars are provided where
necessary. For safety reasons incorporate operating handles both inside and outside the duct
to prevent personnel from being trapped inside the duct.
The doors shall be of the insulated double skin 1.6mm thick galvanised steel type having a flat
bar external stiffening frame fitted with a neoprene airtight sealing gasket, the door suitably
hinged and sealed against a mild steel flat bar frame assembly drilled and bolted to ductwork.
The doors shall be provided with quick release fasteners and robust handles on both sides to
enable doors to be opened without difficulty, especially on the negative pressure side of the
systems.
Demonstrate that fire links can be replaced and where more than one fire damper is installed in
a frame ensue access is provided to all fire dampers.
3.7 TEST HOLES
Test holes in ductwork shall be provided to allow complete testing and commissioning of the
system in accordance with CIBSE Commissioning Codes and BSRIA recommendations.
Test holes shall be drilled in accordance with DW 144 for metal ductwork.
All holes shall be plugged, using effective removable plastic airtight sealing plugs. Samples of
plugs shall be approved by the CA.
3.8 PROVISION FOR CONTROLS AND INSTRUMENTATION
Where control sensors, thermostats, pressure switches, instruments and the like specified
elsewhere are installed in sheet metal ductwork provide mounting flanges or plates, additional
stiffening and bracketing to ensure that no vibration or strain is applied to the ductwork or the
Part 5
Section 3 - Page 4
control instrument and that the fixing is a rigid mounting. On insulated ductwork, extend the
hole such that it finishes flush with the insulation.
3.9 AIR TURNING VANES
Air turning vanes shall be provided on all supply air 90 bends, branches, etc., except on
ductwork up to 150 mm wide, and shall be purpose made from preformed double aerofoil
section 0.8 mm thickness galvanised steel blades at 44 mm pitch of a maximum length of
1250 mm between fixings or division plates on ducts wider than 1250 mm. Fixing shall be by
means of galvanised mounting plates spot welded to the blade and secured to the ends of the
blades and the ductwork walls at 150 mm centres.
Where indicated adjustable air turning vanes shall be provided to regulate the volume of air
passing through a branch 'take off'. They shall be of similar construction to turning vanes and
shall have an adjustable bracket which shall be accessible from outside the duct to enable
balancing of the airflow through the branch.
3.10 DUCTWORK CONNECTIONS TO BUILDERS WORK HOLES
Where ductwork, fan inlets or outlets connect directly to a builders work duct/hole or wall, the
hole shall have a hardwood timber frame or angle/channel iron mating frame built in onto which
the sheet metal connection shall be made utilising an angle iron flange and gasket.
3.11 FLEXIBLE JOINT CONNECTIONS
Flame proof flexible connections shall be fitted on all inlets and outlets of axial flow fans,
centrifugal cased fans and air handling units (if fans in units are not anti-vibration mounted).
They shall also be fitted to all ductwork systems crossing building expansion joints and/or rocker
slabs.
Flexible connections shall prevent all transmission of vibration.
Install flexible joint connections as DW 144 and DW 154 as appropriate.
All flexible connections shall conform to BS 476 and comply with the Building Regulations and
local Building Control requirements. The material must withstand the specified conditions of
temperature, noise attenuation and air pressure.
The minimum distance between duct ends shall not be less than 50mm with a maximum
dimension of 250mm. The flexible connection shall not restrict airflow within the ductwork
system, nor should the joint be used to correct x and y alignment of the ducts on either side.
On rectangular connections, the material shall be held in place by a mating flange with a
backing plate.
Flexible connections to circular ducting on fan inlet spigots shall be secured by clip band
fasteners having adjustable screws or toggle fittings.
The material is to be fitted to give a tightly clamped joint with no air gaps, the connection
remaining flexible without strain and distortion, and shall be correctly aligned.
The flexible material and the joints shall comply with the standard of air tightness specified for
the ductwork system of which it forms part.
Flexible connections shall not be painted.
Part 5
Section 3 - Page 5
3.12 FLEXIBLE DUCTING
Flexible ducting shall be provided for connections between ductwork, terminal units, diffusers
and where indicated on the drawings. It shall comply with BS 476, the Building Regulations and
to the requirements of the local Building Control.
The flexible connection shall not restrict airflow within the ductwork system, nor should the joint
be used to correct x and y alignment of the ducts either side. Ensure that flexible ductwork does
not become kinked or flattened.
Flexible connections shall be kept as short as possible and shall be supported rigidly to prevent
movement due to air flow. All bends in flexible ducting shall be carefully formed to prevent
puncturing on the inside radii with consequent increase in pressure drop.
Maximum lengths shall be 1.0 metre unless stated elsewhere and all ducting shall be
adequately supported to prevent oscillation and noise generation.
Steel wire helical reinforcement in flexible ducts is to be carried over the spigots of grilles and
diffusers and connections to these items are to be painted matt black for the visible depth.
Changes of direction shall be of long radius and no kinking or flattening of ducting will be
allowed.
Joints shall be made by means of hose type metal clamps which tighten around the
circumference of the ducting and be finally sealed with 100 mm wide plastic adhesive tape.
Flexible ducting shall be of the insulated type for all supply air ductwork and of the un-insulated
type for return air ductwork. Flexible ducting shall be rot, fungus and corrosion resistant and
shall generally be constructed with a woven fibreglass coated with neoprene inner lining,
galvanised steel helical spring and a woven fibre-glass impregnated and coated with neoprene
outer cover retaining a neoprene impregnated reinforcement cord. On supply air ductwork
where the surrounding air dew point temperature is below the supply air temperature an
additional 25 mm of mineral fibre flexible insulation shall be provided with a suitable vapour
barrier.
The dimensions and mechanical requirements of flexible ducts shall comply with BS EN 13180.
3.13 CONTROL AND BALANCING DAMPERS
3.13.1 General
On ductwork air distribution and extract/exhaust systems control/balancing type dampers shall
be installed at the following positions to regulate air flow and where indicated elsewhere:
At terminal grilles, diffusers, outlets, etc., unless a terminal balancing damper is specified
with the terminal unit grille, diffuser, etc.
Within sub-branch ducts which serve 3 or more terminal units, grilles, diffusers, etc.
Within branch or zone ducts.
Within the main supply, return or extract/exhaust duct which carries the total air flow, located
in the plantroom near to the fan and on the plant side of any silencer, to regulate the total air
volume.
On fresh air inlets, exhausts and return air arrangements to regulate the volume
The number and location of dampers shall be in accordance with the latest editions of CIBSE
Commissioning Code Series A - Air Distribution and BSRIA AG3 Commissioning air systems to
facilitate balancing and regulation of the complete and/or part of the system. Volume control
dampers shall be installed in all locations necessary to adequately balance the system to the
CAs satisfaction, whether or not these are indicated on the drawings
Part 5
Section 3 - Page 6
The exact location of the damper shall be determined by the installer and shall be subject to
approval. Care shall be taken to ensure that noise is not generated within the ductwork or
breakout noise is not generated which would exceed the noise level rating of the area or area
served as stated elsewhere.
Where regenerated noise is unavoidable, in areas served or adjacent to the damper where the
ambient noise level rating is NR 35 or below additional acoustic internal lining shall be provided
to reduce the regenerated noise level to an acceptable level and if necessary, acoustic wrapping
around the damper shall be provided to reduce the breakout noise.
Dampers shall be in accordance with DW 144 or DW 154 as appropriate unless stated
otherwise.
All dampers shall be sourced from a single manufacturer.
3.13.2 Automatic control dampers
Where dampers are automatically controlled, motors or thrusters shall be rigidly mounted onto
the damper frame and adequately sized to satisfactorily operate the damper as required by the
specification.
The motor / thruster manufacturers instructions shall be complied with and the unit shall be
carefully aligned.
The construction of the dampers shall be as for manual dampers.
3.13.3 Single-blade dampers
Shall be single or double skin steel single blade in accordance with DW 144. These shall only
be used by permission of the CA. Multi blade VCDs as specified below shall be the standard
volume control damper type used.
3.13.4 Multi-blade dampers

Shall be multi-leaf opposed blade type with the damper blade traversing the narrower dimension
of the ductwork
Dampers shall be sized and selected to limit the face velocity to a maximum of 7.0 m/s when
fully open and shall have a free area not less than 82% of the ductwork area unless stated
otherwise.
Casing frames shall be constructed from 1.2 mm mild steel galvanised channel outer frame and
1.0 mm galvanised steel inner frame to give a double skin construction.
Frames shall have all welded corner integral flanges for duct connections and the frame shall
contain die cast zinc alloy gears, out of the air stream, operating the blades from either an
externally mounted low torque hand wheel and spring loaded locking gear with pointer indicator,
or a motor driven unit. Hand wheels shall have a minimum of 10 settings, shall be circular knob
type and have a locking mechanism.
Damper blades shall be of the aerofoil low aspect ratio, stainless steel construction with non
ferrous bearings at both ends of each blade.
Damper blades shall be a maximum length of 1200 mm and a maximum width of 75 mm and
where dampers are required in large ducts or large louvres, etc., a galvanised steel channel
frame connecting strips shall be provided to house banks of individual dampers.
Where automatic operation is required a geared drive spindle shall be provided, in lieu of the
control box and hand-wheel, to suit the motor driven link or spring assembly control unit.
Part 5
Section 3 - Page 7
3.13.5 Air tight dampers
Where dampers are required for automatic control or a tight shut off is necessary then a fixed
compressible neoprene or rubber gasket shall be provided along the entire length of the tips of
the blades to ensure an air tight seal between blades and the frame. In all cases, air tight
dampers shall be provided on all fresh air inlet and exhaust dampers in addition to any other
locations specified. On all rooms provided with gaseous fire suppression systems automatic
dampers shall be air tight.
3.13.6 Iris control dampers

Shall be of the multi-plate circular shutter type dampers constructed in galvanised sheet steel
with a lockable controller lever, control scale and pressure differential measuring connections
located either side of the shutter blades.
Dampers shall be sized and selected to limit the velocity to a maximum of 5 m/s and shall have
a free area not less than 95% of the ductwork area when fully open unless stated otherwise.
On circular ductwork above 800 mm diameter dampers shall be of the multi-leaf opposed blade
type as specified elsewhere with circular spigot flange connections to suit the size of adjoining
ductwork.
3.13.7 Non return dampers

Shall be the 'off centre pivot' weighted multi-leaf parallel blade type damper constructed in
galvanised sheet steel contained in a galvanised sheet steel frame with flanges to suit the
ductwork connections and shall have neoprene strips at the ends of the blades to provide an air
tight shut off against air flow in the opposing direction to the normal air flow.
Dampers shall have a minimum free area of 90% and a pressure drop not in excess of 30 kPa
when fully open under fan pressure unless stated otherwise.
3.14 FIRE DAMPERS
Fire dampers shall be provided and installed wherever ductwork systems pass through floors,
fire compartment walls and wherever deemed necessary by the Fire Officer or other relevant
statutory authority. The complete fire damper assembly shall have a fire resistance rating equal
to the fire barrier it penetrates and rated in accordance with BS 476.
Fire damper installation shall be in accordance with the manufacturers recommendations in
accordance with DW 144 or DW 151 as appropriate.
The installer shall submit to the CA evidence of the fire rating of all fire dampers in accordance
with BS 476.
Fire dampers shall be installed within the thickness of the structure, set up in the open position
and 'fired' to ensure satisfactory closure.
Fire dampers shall be of the quick release stainless steel folding curtain type and shall provide
positive closure to maintain integrity and not permit the passage of flame when exposed to a
time/temperature curve of BS 476 Part 8 for a period of four hours as tested and approved at
the Fire Research Station. They shall be constructed of 18 gauge galvanised steel casings with
continuously welded corners and spigot connections formed as an integral part of the
construction for ease of duct attachment. Ensure damper casings meet the equivalent air
leakage performance standard for the ductwork system they are installed.
They shall also be complete with installation frames or an alternative building in fixing method
(depending on the type of fire rated structure) and approved by the local Building Control or
other relevant statutory authority.
Part 5
Section 3 - Page 8
Unless otherwise stated the 22 gauge stainless steel folding curtain shall be held open outside
of the air stream by a fusible link mechanism (rated at 72 C).
The fire damper shall have stainless steel side seal gasketing inserted to minimise blade end
clearance, thus retarding and further impending the spread of smoke and other products of
combustion and stainless steel constant tension closure springs to ensure correct operation
regardless of whether the damper is horizontally or vertically mounted.
Duplicate external indicators shall be fitted to both sides of the damper casing and the twin sight
apertures provided shall give flexibility of visual indication of damper blade position. Integral
torsion springs shall ensure automatic external indication in either the horizontal or vertical
application.
The bottom blade of the folding shutter shall be fitted with a manual release device to facilitate
the opening of the damper from either side of the damper.
Where indicated, provision shall be made to remotely indicate that a fire damper is in the closed
position.
The installer shall demonstrate that satisfactory access for operating and resetting of all
dampers in their installed locations has been provided and that fire links can be replaced.
Where more than one fire damper is installed in a frame ensure access is provided to all fire
dampers.
The installer shall confirm with all relevant authorities (Civil defence) that fire and smoke
dampers are acceptable prior to ordering of equipment.
Fire Dampers shall be provided as part of the contract in all fire rated walls, barriers, floors etc.
whether indicated on the drawings or not.
3.15 SMOKE CONTROL DAMPERS
Automatic fire and smoke dampers shall be tested and comply with BS IS0 10294; BS 476 Part
20; EN 1366-2 and approved by the Loss Prevention Council
Dampers shall comply with HVCA Ductwork Specification DW 144 and DW 143 air leakage
requirements classes A, B and C.
Dampers shall have fully welded galvanised steel casings and spigot connections. Damper
blades shall be formed of stainless steel and of sealed aerofoil riveted double skin construction.
The design shall ensure low closed blade smoke leakage at ambient temperature.
Dampers will fail safe by means of an electrical thermal release which operates at 72C or by
loss of power and complying with BS 5588: Part 9. Smoke control dampers shall be arranged to
fail safe in the event of mechanical or electrical failure.
The dampers shall be of the motorised open / spring closure type and all dampers shall be
complete with a motor actuator suitable for a 230v supply. The damper shall be arranged to
open when a power supply is provided to the actuator or alternatively by depressing the switch
on the motor.
The dampers shall have suitable voltages and controls to allow the dampers to be controlled by
the smoke control system and / or fire alarm system
Closure of the damper shall be achieved by:
Fusible link failure due to high temperature
Interruption of mains power
Depressing the lighted indicator
Part 5
Section 3 - Page 9
The damper motor shall be provided with two auxiliary contacts for remote monitoring of the
damper open and closed status.
The dampers shall be complete with installation frames or alternative fixing method (depending
on the type of fire rated structure) approved by Building Control. The dampers shall be mounted
with the installation frames in accordance with the manufactures recommendations.
On large ducts, it may be necessary to have a multi-damper assembly mounted within a frame.
Building Control approval shall be obtained for all multiple damper assemblies.
The actuator and control assemblies shall be supported in accordance with manufacturer
recommendations.
Dampers shall incorporate visual indication of the damper blade position.
Operation of all smoke dampers shall be demonstrated to the CA and also Civil Defence (where
required by CD).
Each damper shall be tested during commissioning and the commissioning documentation shall
include a report scheduling all dampers with the test results.
3.16 AIR LEAKAGE TESTING
For medium and low pressure ducts the CA shall select at random a maximum of 10% of the
duct system to be tested for air leakage.
All systems served by fans with a design flow rate greater than 1 m/s and whose pressure class
is such that DW 143 recommends testing shall be tested for air leakage.
Tests shall be to the pressures recommended in DW 144 and DW 143 for the classification of
the selected ductwork.
All high pressure ducts shall be air leakage tested.
Air leakage testing shall be in accordance with DW 144 and procedures as DW 143 unless
otherwise indicated.
Tests shall be carried out as the Works proceed and prior to the application of insulation.
In the event of test failure of the randomly selected section, the CA shall have the right to select
two further sections at random for testing. Where successive failures are identified there shall
be the right to require the installer to apply remedial attention to the complete ductwork system
and carry re-testing at no cost to the contract.
Should any air leakage test fail the CA shall have the right to instruct the air leakage testing of
all medium and low pressure ducts at no additional costs.
The installer shall provide documented evidence of the calculations used to arrive at the
allowable loss for the section to be tested. The results of the test shall be witnessed and
signed.
On completion of all air leakage testing the installer shall submit a report signed by a competent
person confirming the results of the leakage tests.
3.17 DUCTWORK SUPPORTS
Ductwork shall be supported in accordance with DW 144 Part 6 Section 19, DW 154 Part 5 or
DW 192 Section 7 as appropriate.
Ductwork supports shall be arranged so that minimum stress is imposed upon the ductwork and
additional supports shall be provided either side of equipment such as attenuators, coils, etc.
Part 5
Section 3 - Page 10
Where the duct is large enough to allow human access for cleaning, the duct and its supports
shall withstand the additional load and the type and access components should allow the
cleaning person to enter and exit the duct in a safe manner.
Ensure that all materials used are compatible.
3.18 DUCTWORK INTERNAL CLEANLINESS
The level of cleanliness and protection shall be as defined in HVCA TR/19 and provided to
protection, delivery and installation standard PDI Level 2 unless otherwise stated.
At a time agreed with the CA but prior to practical completion, the installer shall demonstrate the
internal cleanliness of all ductwork systems are within the recommendations contained within
HVCA TR/19 by the deposit thickness test (DTT). Sufficient samples shall be taken to
demonstrate the overall cleanliness of all ventilation systems.
Any systems or parts of systems found to be outside the specified limits shall be cleaned by the
installer and retested until the results are satisfactory at no cost to the contract.
A certificate of cleanliness shall be submitted to the CA detailing the DTT tests as part of a
ductwork completion report and included in the record documentation. The report shall include
details of any systems that were cleaned, the cleaning method used and COSHH data on any
chemicals used for cleaning or biocidal treatment. Recommendations for future testing and
cleaning shall also be provided.
3.19 BIRD WIRE GUARDS
Supply and install bird screens of 13 mm square plastic coated wire mesh on all intake and
extract louvres to atmosphere unless otherwise stated. The wire gauge shall be not less than 1
mm.
3.20 FIRE RATED DUCTWORK
Fire resisting ventilation duct: A duct or ductwork system used for the distribution, or
extraction of air designed and tested to satisfy the criteria of test defined in BS 476 Part 24 1987
IS0 6944 1985
Smoke extract/outlet duct / Kitchen fire rated duct: A duct or ductwork system used for the
extraction of products of combustion, designed and tested to satisfy the criteria of test defined in
BS 476 Part 24 IS0 6944. Additionally this duct must prove by test that within the fire
compartment, its cross sectional area is maintained above 75% when subjected to the full fire
temperature.
Fire resistant ductwork shall be installed where stated in the specification and as indicated on
the drawings.
Fire rated ductwork shall be manufactured and installed by a specialist providing a system
tested and certified to BS 476 Part 24 IS0 6944 for the required rating. Systems shall be
capable of meeting the requirements for minimum periods of fire resistance listed in Approved
Document B of the Building Regulations unless a more severe requirement is required.
Fire rated ductwork shall be constructed and protected to ensure that the stability, integrity and
insulation of the ductwork system is maintained for the required duration. Supports and fixings
shall be of sufficient strength and arranged to ensure that the ductwork is maintained in position
throughout the period.
Testing to the requirements of BS 476 Part 24 shall be by a recognised NAMAS/UKAS
accredited laboratory.
Part 5
Section 3 - Page 11
Where the duct passes through compartment walls the space between the duct and the wall
shall be reinforced and packed with proprietary fire stopping material to maintain the stability
and integrity of the system for the required period.
Drop rods and exposed bearers to be insulated in accordance with manufacturers
recommendations and instructions.
In the case of existing metal ductwork where the application of fire insulation cladding material
to provide fire resistance is required, the installer shall check the construction standard of the
duct for conformity with the appropriate standards and submit a report to the CA prior to
commencement of the Works.
Upon part or complete installation of the Fire Rated Duct the local licensed supplier of the fire
resistant ductwork and coating shall issue a Certificate of Conformance after satisfactory
inspection.
3.21 ACOUSTIC DUCT LINER
Rectangular Duct Liner meeting ASTM C 1071 with air surface coated with acrylic coating
treated with EPA registered anti-microbial agent proven to resist microbial growth as determined
by ASTM G21 and G22.
Noise Reduction Coefficient: 0.70 or higher based on Type A mounting and tested in accordance
to ASTM C 423.
Adhesive: Meeting ASTM C 916
Fasteners: Duct liner galvanised steel pins, welded or mechanically fastened.
Round Duct liner will be rigid preformed round liner with air surface coated with acrylic coating
treated with EPA register anti-microbial agent proven to resist microbial growth as determined
by ASTM G 21 and G 22.
Noise Reduction Coefficient of .70 as per ASTM C 423 (Type A mounting)
Duct lining shall be provided to achieve specified noise ratings in part 2 of these specifications.
3.22 PRE INSULATED DUCTWORK
Pre-Insulated ductwork systems shall meet the standards described in the latest HVAC Duct
Construction Standards handbook from Sheet Metal and Air Conditioning Contractors National
Association (SMACNA) or DW144 as applicable.
Duct dimensions shown on Drawings are net, inside insulation and acoustic duct lining.
Combination fire and smoke dampers and fire dampers shall be UL listed and labelled, and
meet requirements of NFPA - 90A.
Pre-Insulated ductwork fittings and ancillaries are to be sourced from the suppliers detailed in
the Schedule of Approved Manufacturers or equal and approved.
PID manufacturer must be approved and in compliance with UL181 Standard from USA.
PID of PIR is not acceptable for Indoor Applications.
PID should be suitable for following limits:
- Mean Air Velocity : 15 m/s maximum

- Total Pressure : 1,000 Pascal + or maximum
- Temperature : Maximum internal up to 70C
Part 5
Section 3 - Page 12
- Air Leakage : Class A & B
PID shall not be used for Kitchen Extract, Chemical or Fume Exhaust Systems or for High
Pressure Systems.
PID shall consist of CFC Phenolic Foam Thermo-bonded Insulation between Aluminium Foil
laminates having Low Vapour Permeability.
PID must have maximum density of 55 kg/m3 and the compressive strength shall not be less
than 190-200 kw/m.
PID should have the following properties:
- Flexural Strength : 1, 200 kw/wt as per BS 2972

- Moisture Vapour Transmission: 0.00005 micrograms per Newton sec.
- Heat Resistance : Maximum 80C & 70C continuous
- Thermal Conductivity : Shall not be > 0.018 watt/m/C @ 10C.
- Sound & Vibration Absorption : 17 db average weighted sound level (50 Hz to 10,000 Hz)
reduction as per Bs5821, Part1 & BS 2750 Part 3; ISO 140/3 Breakout Noise.
Friction Resistance : Absolute roughness should be 15%.
Effects of Fire : a) Compliance to Class O based on B.S. 476 part 6 & 7

(Fire propagation and Flame spread)
b) Smoke related to B.S. 5111 Part 1 & 3.
Toxicity Index : NES 713 & 64
Duct Air Leakage : Flanged sample to be tested by manufacturer to DW 144 Class
C Standard and result should be within acceptable limit.
External Duct required coating of # 10 glass scrim cloth and weather proof Vapour Barrier;
30mm thickness; 80/200 micron to be used (PIR) and for Indoor 80/80 micron arrangement is
suitable of 22.0 mm thickness (Phenolic Insulation).
Manufacturer must demonstrate that all the properties and requirement written in this
specification must be reflected on their leaflet/catalogues and same shall be in circulation for
past few years.
BS 7671 Requirements for electrical installations (IEE Wiring Regulations

Sixteenth Edition)
BS 5588 Fire precautions in the design, construction and use of buildings
BS IS0 10294 Fire resistance tests. Fire dampers for air distribution systems
EN 1366-2 Fire resistance tests on service installations in buildings
BS EN 13180 Ventilation for buildings. Ductwork. Dimensions and mechanical
requirements for flexible ducts
CIBSE
Code A Commissioning Code A Air distribution systems
BSRIA
AG 3 / 89.3 Commissioning air systems
Part 5
Section 3 - Page 13
HVCA (Heating and Ventilating Contractors Association)
DW 144 Specification for sheet metal ductwork
DW 143 A practical guide to ductwork leakage testing
DW 151 Specification for plastic ductwork
DW 191 Guide to good practice: Glass fibre ductwork
DW 172 Specification for kitchen ventilation systems
DW/TM2 Guide to good practice: Cleanliness of ventilation systems
DW/TM 3 Guide to good practice for the design for the installation of fire and
smoke dampers
TR/19 Internal cleanliness of ventilation systems
Part 5
Section 3 - Page 14
Section 4 Thermal Insulation
Contents
Section 4 Thermal Insulation 1

4.2 Definitions 1
4.3 Standards 2
4.4 Workmanship 2
4.5 Fire performance 4
4.6 Vapour barrier 4
4.7 Materials 5
4.8 Insulation thickness 6
4.9 Application 10
Section 4 Thermal Insulation
Thermal insulation shall be provided for the following functions:
1. Prevent the formation of condensation on pipework, ductwork or equipment

2. To protect personnel from exposure to extremes of temperature
3. Conserve energy for both cooled and heated systems
4. Control process temperatures
Ensure that all thermal insulation is made from materials with zero ozone depletion potential
(CFC and HCFC free). Submit to the CA, prior to ordering, written confirmation from the
insulation manufacturer(s) that the products to be installed are CFC and HCFC free.
All insulation products shall maintain their thermal performance for a minimum of the plant
design life.
Submit to the CA, prior to ordering, details from the manufacturer(s) that define the life
expectancy of the materials to be installed.
Submit to the CA, prior to ordering the manufacturers declared values of thermal conductivity
for each material proposed. The declared values shall be appropriate to the mean temperature
of the applied insulation and based on results of tests carried out in accordance with the
appropriate British Standards.
Where two or more layers of dissimilar insulating material are used, submit to the CA the
declared value of thermal conductivity for each layer under the appropriate temperature
conditions. The thickness of each layer shall also be stated. Ensure that the interface
temperature between the two materials does not exceed the limiting temperature for the material
of the outer layer.
All insulating material and associated products shall be applied in accordance with the
manufacturers recommendations and instructions and using manufacturers associated
supplementary products i.e. adhesive, UV protective paint etc.
4.2 DEFINITIONS
Chilled water water after passing through cooling plant (typically 0 C to +10 C)
Cold water water delivered from the mains, natural supply or cooled domestic water at 200C
Warm air ducts supply or return air ducts in which the air inside the duct is always above
ambient.
Air conditioning ducts supply or return air ductwork where the air may be cooled or
dehumidified
Domestic hot water hot water up to 60 C
Finishing materials materials used to cover the insulation whether pre-applied or applied on
site
Pre-applied covering material applied to the insulation prior to delivery to the point of use
Vapour barrier water vapour retarding layer.
Part 5
Section 4 Page1
LTHW Heating water between 60C - 80C
MTHW Heating water between 90C - 110C
HTHW Heating.-.water between 110C - 130C
Steam - Medium whose temperature is greater than 100C
Surface temperature the temperature of the surface to be insulated is taken to be the

temperature of the fluid inside the pipe, tank, duct, vessel or other piece of equipment unless
otherwise stated
4.3 STANDARDS
Thermal insulation materials, methods of application and tests shall conform with the following
British Standards, Codes of Practice and Regulations unless otherwise stated:

Part 4: Non-combustibility test for materials
Part 6: Method of test for fire propagation
Part 7: Method of test to determine the classification of the surface
spread of flame of products
Part 11: Method for assessing the heat emission from building
materials
Part 12: Method of test for the igniability of products by direct flame
impingement
BS 874 Methods for determining thermal insulating properties
BS 2972 Methods of test for inorganic thermal insulating materials
BS 3533 Glossary of Thermal Insulation Terms.
BS 3927 Specification for rigid phenolic foam (PF) for thermal insulation in the
form of slabs and profiled sections.
BS 3958: Thermal Insulating Materials
Part 3: Metal mesh faced man-made mineral fibre mattresses.
Part 4: Bonded pre-formed man-made mineral wool pipe section.
Part 5: Specification for bonded man-made mineral wool slabs.
BS 5111 Part 1 Laboratory method of test for determination of smoke
generation characteristics of cellular plastics and cellular rubber
materials.
BS 5422 Method for specifying thermal insulating materials for pipes, tanks,
vessels, ductwork and equipment operating within the temperature
range, -40C to +700C
BS EN ISO 5659-2 Plastics. Smoke generation. Determination of optical density by a
single chamber test.
BS 5970 Code of Practice for thermal insulation of pipework and equipment (in
the temperature range -100C to + 870C).
BS EN ISO 12241 Thermal insulation for building equipment and industrial installations.
Calculation rules.
Building Regulations
4.4 WORKMANSHIP
Thermal insulation work shall be undertaken by suitable experienced companies who employ
skilled craftsman conversant with the class of work.
All thermal insulation materials shall be supplied by manufacturers assessed and registered in
accordance with British Standard quality systems standards.
manufacturers recommendations and instructions. The CA will not accept any work not
complying with these recommendations.
Thermal insulation shall not be applied to pipework and ductwork services until:
Part 5
Section 4 Page2
a. The installation, or sections of the installation have been fully pressure tested and all joints
proved sound
b. The surface to be insulated has been cleaned, dried and is free of rust, scale and other
foreign matter
c. All painting, where specified elsewhere, has been completed and is dry. Damage caused to
pre-painted surfaces during installation shall be repaired at no additional cost
d. Copper pipework has been cleaned thoroughly to remove all traces of surplus jointing flux,
building materials and debris, dust and moisture.
e. Steel pipework has been suitable painted with approved painting system i.e. red oxide.
Protect all surrounding equipment during installation and leave the area clean and tidy.
Each pipe or duct shall be insulated separately and adjacent parallel pipes or ducts shall not be
married together in one insulation covering. There shall be a minimum clearance of 25 mm
between adjacent surfaces of insulation.
Where services pass through a fire compartment wall or floor the space between the pipework
and the sleeve shall be completely filled with a certified fire resisting material having a
performance equal to the fire rating of the structure. In this instance the thermal insulation shall
not pass through the sleeve, however the fire resistant material used shall have sufficient
thermal resistance to prevent occurrence of condensation.
All materials delivered to site shall be new and kept dry, and maintained in this condition
throughout the progress of the work. Materials shall be stored and adequately protected from
damage or deterioration until installed. Protection shall also cover any adverse effects of
environmental conditions prevalent in the stored and installed location. Insulation shall be
protected from UV to avoid any degradation immediately upon installation.
All joints, surfaces, edges and overlaps shall be neatly finished. Where possible arrange
overlaps to be on the 'blind' side and parallel to circumferential and longitudinal joints.
Where allowance for expansion and/or contraction has to be accommodated, the insulation shall
be finished in a neat and approved manner permitting easy access and disconnection of
removable items without disturbing adjacent insulation.
All insulation work shall be to a good standard and the insulating materials, coverings and/or
coatings shall be of a uniform thickness throughout.
All insulation shall be complete with a smooth and clean finished surface, no damaged ends or
edges and with no irregularities in the thickness of the insulating material or in the material
covering. Rigid sections shall be concentric and accurately matched.
Three sections of each type of insulation shall be cut out for inspection by the CA to ensure that
the correct thickness has been achieved. If the inspection reveals any defects the installer shall
cut out a further three sections for inspection. If these also prove defective then the insulation
shall be rejected and all insulation shall be stripped off and reinstated at the installers expense
and with no delay to the programme.
The CA shall also be entitled to send selected insulation samples from the site periodically
throughout the installation period for testing at independent laboratory to establish the approved
material is being used and that it complies with the manufacturers published data.
All insulation joints shall be installed close butted together. Sections having damaged ends or
edges will not be accepted.
Filling voids with adhesive, joint sealer or mastic will not be accepted.
Pipework and ductwork supports are to be provided with inserts to match the insulation
thickness, to enable the insulation finishes to be continuous through the supports. The inserts
shall be supplied from insulation manufacturer where the insulation company also
manufacturers appropriate inserts.
Part 5
Section 4 Page3
All support brackets for cold services pipework and ducting shall be provided with purpose
designed load bearing high density phenolic foam inserts to facilitate installation of a continuous
thickness of vapour sealed insulation and finish.
All connections and brackets for sensors, equipment labels and other pipe, duct or equipment
mounted accessories shall be extended to project past the insulation thickness and enable
items and accessories to be fitted or removed without disturbing the insulation or cladding.
Insulation applied to vessels and pipeline and ductwork ancillaries shall be neatly cut and
finished around all manufacturers name and test plates, test points, and dampers to leave these
visible.
Where an insulated duct or pipe penetrates the building, adequate precautions shall be taken to
prevent the entry of water.
The Contractor shall ensure that all insulating materials, adhesives and finishes specified herein
or added to this contract conform with the requirements of the Local Authority and CA. Installed
insulation that is rejected by the CA shall be stripped out and replaced with acceptable materials
at the contractors expense and with no delay to the programme.
When directed by the CA arrange for thermal conductivity performance testing of selected
materials, at either the manufacturers works or at an approved testing laboratory. Testing shall
be in accordance with the relevant British Standards. Chemical testing shall also be carried out
to ensure the installed material meets the manufacturers stated chemical properties in order to
ensure the approved material has been supplied. This shall be at the contractors cost.
Electrical bonding terminals suitable for connection of 6 mm maximum conductor shall be

provided for electrical earthing continuity which shall be carried out in accordance with the latest
edition of the IEE Regulations for buildings.
Components of dissimilar metals shall not be brought into contact with each other.
4.5 FIRE PERFORMANCE

Insulation materials shall have a European Classification for reaction to fire performance of
either A1, A2, or B and should not have a potential to flashover.
All insulation materials installed inside buildings and building service ducts shall conform to
Class O (unassisted by facing material) in accordance with the Building Regulations.
The complete assembly of materials, as installed, shall satisfy the spread of flame
requirements to Class 1 of BS 476-7.
The insulating material itself (i.e. without any facing) shall satisfy the spread of flame
All insulation materials, adhesives, sealants and facings installed shall have a smoke
obscuration rating less than 5% when tested in accordance with BS EN ISO 5659-2.
Where fire and surface spread of flame certificates relate to factory made products, ensure that
the certificates are valid where materials are incorporated in pre-insulated equipment.
If there is a potential hazard from contamination by oil or other flammable chemicals, a suitably
resistant finish, eg a metal sheet or appropriate non-absorbent coating, shall be applied over the
vulnerable areas. The lapped joints of sheet finishes shall be arranged to shed contaminating
fluids away from the insulating material.
4.6 VAPOUR BARRIER

On surfaces operating below ambient temperature a complete vapour barrier seal shall be
provided.
Part 5
Section 4 Page4
The vapour barrier shall take the form of a coating or sheet material.
Vapour barriers shall be continuous and the integrity maintained. Where this is not possible, the
vapour barrier shall be effectively sealed to the pipe to prevent any ingress of moisture or water
vapour.
External vapour barriers shall be pre-applied or applied immediately after fitting the insulating
material and before the fluid in the pipe, duct, or vessel is cooled.
The function of an external vapour barrier shall not be compromised by its additional use for
other purposes e.g. as a form of weather protection or as mechanical protection for the thermal
insulation. Where required separate layers in the form of coatings or sheet material and shall be
used for the individual purposes. Where such additional protection is required, the installer shall
ensue that its application does not cause any damage to the vapour barrier during installation
and is unlikely to cause damage in service.
The vapour barrier shall not reduce the fire performance of the system as installed below the
limit specified as appropriate to the type of application.
The values for water vapour permeance of barriers shall be as BS 5422: 2001
4.7 MATERIALS
All materials shall be strictly in accordance with this specification.
The installer shall ensure that the selected material and finish is suitable for the operating
environment.
Materials and their method of application shall not constitute a known risk to health during
application or use.
Thermal conductivity values shall be in accordance with BS 874 and BS 2972.
The uses of galvanised or zinc coated insulation steel jacketing and accessories on or near
austenitic stainless steel and austenitic nickel steel/alloy equipment and piping, is prohibited.
Dissimilar metals and materials subject to galvanic corrosion shall not be installed in contact
with one another.
Where the complete assembly is liable to mechanical damage in use, the final finish shall be
sufficiently strong to ensure that the insulation does not become exposed.
Materials in contact shall be compatible and shall not cause corrosion of degradation under
normal site conditions.
Insulation materials and finishes shall be inherently proof against rotting, mould and fungal
growth and attack by vermin, be non-hygroscopic and in all respect be suitable for continuous
use throughout the operating temperatures and within the environment where installed.
Materials shall be free from objectionable odour at the temperature at which they are to be used.
The insulation shall be suitable for the specified conditions of use without the physical properties
falling outside the tolerances allowed in the appropriate British Standard for the material.
Protect insulated stainless steel surfaces from the risk of stress corrosion in accordance with the
recommendations of BS 5970.
4.7.1 Phenolic foam

All phenolic foam shall be CFC and HCFC free.
Part 5
Section 4 Page5
Phenolic foam pipe and duct insulation shall have a thermal conductivity of not more than 0.018
W/mK at 10 C mean temperature. (Fully aged values shall be in accordance with BS3927).
Phenolic foam shall not be used on steam services or services operating above 100 C.
Where there is risk of corrosion being initiated by the pipework insulation a standard passivating
bore coating shall be provided to reduce the risk. Any aluminium foil overlaps shall not be
tucked in between the butt joints of the insulation sections.
All phenolic pipe insulation shall be a nominal density of 35 kg/m.
All duct insulation shall be a nominal density of 40 kg/m.
The perpendicular compressive strength shall not be less than 150 kN/m for pipe insulation and
100 kN/m for duct insulation.
4.7.2 Closed Cell Elastomeric Rubber Insulation

Closed cell elastomeric rubber insulation sections to meet the following criteria
Temperature Range: -100 C + 105 C.

Thermal Conductivity: < 0.034 W/mk at 0C
Water Vapour Permeability: 7000 (DIN 52 615), 0.09 gm/Nh BS 4370/2.
Fire Rating: Class (UN 8457 UNI 9174), Class 1 BS 476: Part 7: 1987/ Class
0 BS 476 part 6.
Density: 45 kg/m up to 65 kg/m.
Noise Reduction: 35 db (A) to the frequency of 500 Hz, European Standard EN
20140 10.
Closed Cell Content: > 90%
Corrosion Risk: Assessment certified according DIN 1988/7.
Ozone Resistance: ASTM-D-1171- No crack.
Materials shall be CFC free and FM Approved.
4.7.3 Mineral wool

For all mineral wool insulation products, test evidence must be submitted to the CA for approval,
prior to ordering, showing that the fibres from which the products are made are not classified as
a possible human carcinogen, as detailed by European Directive 97/69/EC and the approved
supply list of CHIP98.
Mineral pipe insulation sections shall have a nominal density of not less than 120 kg/m. Pre-
formed pipe sections shall be resin bonded with a thermal conductivity not exceeding 0.038
W/mK at 50 C mean temperature
Mineral wool duct slab shall have a nominal density of not less than 45 kg/m with a thermal
conductivity not exceeding 0.04 W/mK at 50 C mean temperature.
4.7.4 Calcium Silicate

Calcium silicate preformed pipe sections shall have a normal bulk density of 200 220 kg/m
and a thermal conductivity not exceeding 0.05 W/mK at 100 C mean temperature.
Calcium silicate is prohibited on cold water, chilled water and air conditioning services.
4.8 INSULATION THICKNESS

Thickness of insulation shall be in accordance with BS 5422: 2001.
The insulation thickness stated in the following tables are given for thermal conductivities
appropriate to the usual materials used for the application. The thickness for intermediate
thermal conductivities and pipe sizes shall be deduced by calculation or interpolation in
accordance with the relevant British Standards.
Part 5
Section 4 Page6
Pipe nominal diameters stated in insulation thickness tables are based upon steel pipework.
Where copper or plastic pipework is used the equivalent outside diameter of the pipe shall be
used. Reference should be made to BS 1387 for the outside diameters and bore diameters of
pipes not covered by BS 3600.
If the thickness given in, or interpolated from, the tables in the British Standard or the
specification do not correspond with available thickness, the nearest higher available thickness
shall be used.
In multi-layer applications, where material thickness is rounded up to suit available commercial

thickness, the installer shall ensure by calculation (in accordance with the appropriate British
Standard) that each interface temperature is below the maximum continuous operating
temperature of the materials involved.
4.8.1 Minimum insulation thickness for chilled and cold water supplies to prevent
condensation (BS 5422: 2001 Table 8)
Ambient temperature 25 C Relative humidity 80%

Phenolic foam = 0.018 W/mK
Elastomeric Rubber Insulation = 0.034 W/mK
Mineral wool = 0.038 W/mK
Emissivity outer surface = 0.05 (low eg aluminium, bright)
Temperature of contents (C)

Steel
+ 10 +5 0
pipe
nominal Insulation thickness (mm)
pipe size Pheno- Pheno- Phe
Rubber Mineral Rubber Mineral Rubbe Mineral
(mm) lic lic no-lic
Insu wool Insu wool r Insu wool
foam foam foam
15 15 19 20 15 19 25 20 25 30
20 15 19 20 15 25 30 20 32 35
25 15 25 25 20 25 30 25 32 35
32 15 25 25 20 25 30 25 38 40
40 15 25 25 20 32 35 25 38 40
50 15 25 30 25 32 35 30 38 45
65 20 25 30 25 32 35 30 38 45
80 20 25 30 25 32 40 30 38 50
100 20 32 35 25 32 40 30 38 50
150 20 32 40 30 38 50 35 50 60
200 25 32 40 30 38 50 40 50 60
250 25 32 40 35 38 50 40 65 70
300 25 32 40 35 50 60 40 65 70
Flat
surfaces
30 38 52 40 50 70 50 65 90
=thermal conductivity at mean temperature of insulation.

Thicknesses given in the above table are calculated specifically against the criteria stated.
4.8.2 Minimum insulation thickness for chilled and cold water supplies to prevent
condensation (BS 5422: 2001 Table 8)
Ambient temperature 46 C Relative humidity 80%
Emissivity outer surface = 0.05 (low eg aluminium, bright)

Part 5
Section 4 Page7
Steel Temperature of contents (C)
pipe + 10 +5 0
nomina
l pipe
Insulation thickness (mm)
size Phenol Rubber Mineral Phenol Rubber Mineral Phenoli Rubber Mineral
(mm) ic foam Insu
wool ic foam Insu wool c foam Insu wool
15 19 25 30 20 25 30 25 32 35
20 19 25 30 20 32 40 25 38 40
25 19 32 35 25 32 40 30 38 40
32 19 32 35 25 32 40 30 50 50
40 19 32 35 25 38 40 30 50 50
50 19 32 40 30 38 40 40 50 50
65 25 32 40 30 38 40 40 50 50
80 25 32 40 30 38 50 40 50 60
100 25 38 40 30 38 50 40 50 60
150 25 38 50 35 50 65 40 65 70
200 30 38 50 35 50 65 50 65 70
250 30 38 50 35 50 65 50 65 80
300 30 38 50 40 50 80 50 65 80
Flat
surface 30 38 52 40 50 80 50 65 100
s
4.8.3 Environmental insulation thickness for non-domestic heating installations to control heat
loss (BS 5422: 2001 Table 12)
Hot face temperature (C)
Steel
+ 75 + 100 + 150
pipe
nominal Insulation thickness (mm)
pipe size Pheno- Pheno-
Rubber Mineral Rubber Mineral
(mm) lic lic Mineral wool
Insu wool Insu wool
foam foam
15 15 25 35 15 32 40 60
20 15 25 35 20 32 40 60
25 15 25 35 20 38 45 70
32 20 32 40 25 38 45 70
40 20 32 40 25 50 50 70
50 20 32 40 25 50 50 70
65 20 32 40 30 50 50 80
80 25 32 40 30 50 60 80
100 25 38 45 30 50 60 80
150 30 38 50 35 50 60 90
200 30 38 50 35 50 60 90
250 30 38 50 35 50 65 90
300 30 38 50 40 50 65 90
Flat
surfaces
30 38 50 40 64 70 90

4.8.4 Environmental insulation thickness for non-domestic hot water service areas to control
heat loss (BS 5422: 2001 Table 13)
Part 5
Section 4 Page8
Steel pipe Water temperature of 60C
nominal pipe Insulation thickness (mm)
size
(mm) Phenolic foam Rubber Insulation Mineral wool
15 15 25 30
20 15 25 35
25 15 25 35
32 20 25 35
40 20 32 40
50 20 32 40
65 20 32 40
80 25 32 40
100 25 32 45
150 25 38 50
200 30 38 50
250 30 38 50
300 30 38 50
Flat surfaces 30 38 50
=thermal conductivity at mean temperature of insulating material

4.8.5 Environmental insulation thickness for ductwork carrying warm air (BS5422:2001 Table
11)
Temperature difference between air inside ductwork and ambient air (C)
10 25 50
Environmental insulation thickness (mm)
Pheno- Rubber Mineral Pheno- Rubber Min. Pheno- Rubber Min.
Lic foam Insu wool lic foam Insu wool Lic foam Insu wool
25 25 40 25 25 50 40 50 65
=thermal conductivity at mean temperature of insulating material

Thicknesses stated in the above table are calculated specifically against the criteria stated.
4.8.6 Minimum insulation thickness for condensation control on ductwork carrying air in
ambient conditions (BS5422:2001 Table 10)
Ambient temperature 25 C
Relative humidity 80%
Dewpoint temperature 21.3 C
External surface emissivity 0.05 (low eg aluminium, bright)
Minimum air temperature inside duct (C)

15 10 5 0
Minimum thickness of insulating material (mm)
Phenolic
Phenolic
Phenolic
Phenolic
Rubber
Mineral
Rubber
Mineral
Rubber
Mineral
Rubber
Mineral
Foam
foam
foam
foam
wool
wool
wool
wool
Insu
Insu
Insu
Insu
Part 5
Section 4 Page9
20 25 29 30 32 52 40 50 75 50 64 96
=thermal conductivity at mean temperature of insulating material at 10 (C)

4.8.7 Minimum insulation thickness for condensation control on ductwork carrying air in
ambient conditions (BS5422:2001 Table 10)
Ambient temperature 46 C
Relative humidity 80%
Dewpoint temperature 21.3 C
External surface emissivity 0.05 (low eg aluminium, bright)
Minimum air temperature inside duct (C)

15 10 5 0
Minimum thickness of insulating material (mm)
Phenolic
Phenolic
Phenolic
Phenolic
Rubber
Mineral
Rubber
Mineral
Rubber
Mineral
Rubber
Mineral
Foam
foam
foam
foam
wool
wool
wool
wool
Insu
Insu
Insu
Insu
25 30 40 40 50 60 50 60 100 60 75 120
=thermal conductivity at mean temperature of insulating material at 10 (C)

4.9 APPLICATION
4.9.1 Heating, hot water and condenser water pipework

Internal pipework (concealed)
Pipework shall be insulated with approved insulation. All rigid preformed pipe sections having a
factory applied bright Class O foil facing.
Rigid preformed Sections shall be close butted and all longitudinal and circumferential joints
sealed with Class O aluminium foil self adhesive tape applied over a clean surface and firmly
pressed down. The minimum width of aluminium foil tape shall be 50mm. For Flexible
Elastomeric Insulation Pipe Sections, all longitudinal and circumferential joints should be sealed
with 50mm wide and 3mm thick foam tapes recommended by insulation manufacturer. Where
provided, the longitudinal joint overlap shall be sealed with a suitable adhesive to the
Rigid Sections shall be firmly secured by additional bands of aluminium foil tape applied
circumferentially at not greater than 300 mm centres, ensuring a minimum of three self adhesive
bands per metre run.
The insulation shall be further retained in position by light gauge aluminium bands at a
maximum of 450 mm spacing and not nearer than 50 mm to the end of the section.
All bends, sets, tees and elbows are to be correctly mitred and segmented with insulation to the
necessary thickness to match the adjoining. All joints to be securely sealed with 50 mm wide
Class O aluminium foil self adhesive tape OR 50mm wide 3mm thick foam tapes for flexible
elastomeric rubber insulation.
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Section 4 Page10
The insulation shall not be left exposed at termination points. Insulation edges shall be over
taped and returned and adhered to the exposed insulation face. Ensure the aluminium foil does
not come into contact with the insulated metal face.
Bends, fittings, flanges and pipe clips shall also be insulated with preformed sections of foil
faced insulation, cut to suit on site with joints sealed with adhesive and matching self adhesive
tape. Bends shall be insulated with mitred segments.
If cold and damp conditions are anticipated during installation, consideration shall be given to
utilising a Class O aluminium foil tape with an acrylic adhesive.
Plantrooms
Pipework shall be insulated with approved insulation. Rigid preformed pipe sections must have
a factory applied bright Class O aluminium foil facing as for internal pipework. Insulated
Pipework shall be finally protected with aluminium cladding.
Workmanship and installation requirements for preformed pipe sections shall be as stated
elsewhere for internal pipework except aluminium bands are not required.
External Pipework
Pipework shall be insulated with approved insulation. Rigid preformed pipe sections having a
factory applied bright Class O aluminium foil facing as for external pipework. Insulated
pipework shall be finally protected with aluminium, or aluzinc cladding
All joints and protrusions through the cladding shall be sealed with an approved sealant to
provide a water and weatherproof finish. The cladding shall be additionally secured with metal
banding at 450mm centres. The banding shall be selected to complement the sheet cladding
and not contribute to bi-metal corrosion.
External pipework and pipework in purpose built external trenches
All pipework shall be insulated with approved insulation. Rigid preformed sections must be
Class O aluminium foil faced. Pipework insulation shall be finally protected with aluminium or
aluzinc cladding.
4.9.2 Chilled and cold water pipework

Internal pipework (concealed)
factory applied bright Class O foil facing to form a continuous vapour barrier.
Sections shall be close butted and all longitudinal and circumferential joints sealed with Class
O aluminium foil self adhesive tape OR 3mm thick Foam Tape applied over a clean surface
and firmly pressed down. The minimum width of tape shall be 50mm. Where provided, the
longitudinal joint overlap shall be sealed with a suitable adhesive to the manufacturers
recommendations.
Sections shall be firmly secured by additional bands of aluminium foil tape applied
circumferentially at not greater than 300 mm centres, ensuring a minimum of three self adhesive
bands per cut section.
All bends, sets, tees and elbows are to be correctly mitred and segmented with insulation to the
necessary thickness to match the adjoining. All joints to be securely sealed with 50 mm wide
Part 5
Section 4 Page11
Class O aluminium foil self adhesive tape. For Elastomeric Insulation, joints shall be securely
sealed with 50mm wide, 3mm thick foam tape recommended by manufacturer.
The insulation shall not be left exposed at termination points. Insulation edges shall be over
taped and returned and adhered to the exposed insulation face. Ensure the aluminium foil does
not come into contact with the insulated metal face.
Bends, fittings, flanges and pipe clips shall also be insulated with preformed sections of foil
faced insulation OR flexible rubber insulation, cut to suit on site with joints sealed with adhesive
and matching self adhesive tape. Bends shall be insulated with mitred segments.
If cold and damp conditions are anticipated during installation, consideration shall be given to
utilising a Class O aluminium foil tape with an acrylic adhesive.
All ends of the insulation and points where the covering is penetrated shall be sealed so that the
continuity of the vapour barrier is maintained.
Particular care shall be taken to vapour seal insulation termination points on pipework, valves
and equipment operating below ambient temperature. A suitable vapour barrier sealant shall be
applied to moisture proof the interface between the insulation and the underneath metal face at
all termination points and the vapour barrier shall be returned affectively and sealed to the butt
end of the insulation section so as not to allow any ingress of moisture or water vapour.
All metal parts of valves, strainer caps, etc., projecting beyond the insulation shall be painted
with an approved anti-condensation compound. All mild steel pipework prior to being insulated
shall be painted two coats of red oxide paint. Particular care shall be taken to ensure neither
water nor water vapour enter the insulation system via valve spindles etc.
Plantrooms, Riser shafts and where not concealed
factory applied bright Class O aluminium foil facing as for internal pipework. Insulation must be
finally protected with aluminium or aluzinc cladding. This also applies to all insulated services
exposed to view i.e. not in false ceiling voids.
Care shall be taken to avoid damaging the integrity of the underlying vapour barrier facing.
Rivets and screws which may damage the vapour barrier are not to be used. The cladding shall
be secured with aluminium bands at 150 mm centres, of a suitable type and dimension.
External Pipework
factory applied bright Class O aluminium foil facing as for internal pipework. Insulation must be
finally protected with aluminium, or aluzinc cladding
All joints and protrusions through the cladding shall be sealed with an approved sealant to
provide a water and weatherproof finish. The cladding shall be additionally secured with metal
banding at 450mm centres. The banding shall be selected to complement the sheet cladding
and not contribute to bi-metal corrosion.
and equipment operating below ambient temperature.
Part 5
Section 4 Page12
External Pipework and Pipework in purpose built external trenches
All pipework shall be insulated with approved insulation. Rigid preformed sections must have
Class O aluminium foil facing. Insulation must be finally protected with aluminium or aluzinc
cladding.
and equipment operating below ambient temperature.
4.9.3 Ductwork
Internal ductwork (concealed from view) - air conditioning and warm air
Rectangular ductwork
All rectangular ductwork shall be insulated with either:
a. Mineral wool having a factory applied bright Class O reinforced aluminium facing
complying with BS 5422: 2001 and BS 5970 water vapour permeance
b. Closed Cell Elastomeric rubber insulation having fire rating Class O and Class 1 as per
BS476, part 6 & 7 and Water Vapour Permeability: 7000 (DIN 52 615).
c. Phenolic foam insulation having a factory applied bright Class O reinforced aluminium
facing complying with BS 5422: 2001 and BS 5970 water vapour permeance
For all mineral wool insulation products, test evidence must be submitted to the CA for approval,
prior to ordering, showing that the fibres from which the products are made are not classified as
a possible human carcinogen, as detailed by European Directive 97/69/EC and the approved
supply list of CHIP98.
All insulation slabs shall be cut to fit on site.
The insulation shall be bonded to the ductwork surfaces with a contact adhesive suitable for the
materials and applied in accordance with the manufacturers instructions.
The insulation on the underside of the ductwork shall be additionally secured by means of
suitable nylon insulation hangers, fixed at maximum 300mm centres. Insulation hangers shall
be additionally attached to the vertical faces of the duct where mineral wool insulation is used.
Where support hangers puncture the foil, they shall be sealed using aluminium foil tape to
maintain the vapour barrier.
All joints shall be sealed with 100mm minimum wide self adhesive aluminium reinforced foil tape
to form a continuous vapour barrier seal, including ductwork and equipment flanges which shall
be encased. All insulation slabs shall be secured with a minimum of three self adhesive tape
bands per linear metre of ductwork.
Where a vapour barrier is required, provision should be made for exposed slab edges to carry
the aluminium foil to the adjoining edge.
Insulation shall be additionally supported by means of 22 swg x 50mm mesh galvanised wire
netting, drawn tightly around the insulation with 150 mm overlaps at edges and secured with 0.9
mm galvanised lacing wire. Care shall be taken when applying the wire mesh support to avoid
damaging or puncturing the vapour barrier.
Circular/oval ductwork
Circular and oval ductwork shall be insulated with either:
a. Flexible duct mineral wool insulation having a factory applied bright Class O reinforced
aluminium facing complying with BS 5422: 2001 and BS 5970 water vapour permeance.
Part 5
Section 4 Page13
facing complying with BS 5422: 2001 and BS 5970 water vapour permeance
Workmanship and installation requirements shall be as for rectangular ductwork as stated

elsewhere.
Ductwork in Plantrooms - air conditioning and warm air
Rectangular ductwork
Rectangular ductwork shall be insulated as for internal ductwork and finally protected with
aluminium cladding.
Extreme care shall be exercised in the case of cladding air conditioned supply air ductwork to
ensure any riveting of the aluminium cladding does not perforate the aluminium foil facing on the
insulation and destroys the vapour barrier in case of Mineral wool.
Circular/oval ductwork
Circular/oval ductwork shall be insulated as for rectangular ductwork and finally protected with
aluminium, or aluzinc cladding.
External Ductwork, ductwork in risers or exposed to view
Rectangular and circular/oval ductwork shall be insulated as for internal ductwork and finally
protected with aluminium, or aluzinc cladding.
Insulation for the top surface of horizontal ducts shall be factory prepared to provide a fall of
1:25 to ensure that surface water does not cause ponding on the upper surface. The minimum
thickness of insulation shall be maintained including at all flanges and supports.
Vertical cladding joints shall overlap to ensure no top metal edge exposure and prevent water
penetration.
All joints and fixing shall be sealed with mastic to provide a water proof installation and maintain
the integrity of the vapour barrier.
4.9.4 Heat exchangers, calorifiers and cylinders

Circular calorifiers and cylinders shall be insulated with approved insulation. Mineral wool
flexible duct insulation must have factory applied Class 'O' facing of reinforced aluminium foil.
Insulation shall be cut to suit on site and bonded to surfaces by means of a suitable adhesive,
applied in accordance with the manufacturer's requirements.
The insulation shall be protected with aluminium or aluzinc sheeting, all joints lapped and neatly
secured with cadmium plated self-tapping P.K. screws or pop rivets along longitudinal seams.
Before applying the cladding the insulating material shall be completely smooth finish with no
gaps or crevices between sections, ensuring that it is tight fitting adjacent to all connections,
inspection covers and other protrusions.
The cladding when finished shall be free from dents, burrs, sharp corners and all tappings and
protrusions such as access covers, bosses, tappings, etc., shall be separately clad in the same
material but removable for inspection purposes. Fit cut outs with purpose made over-plates or
collars.
Part 5
Section 4 Page14
Remove manufacturers name plate and re-fix on cladding.
4.9.5 Tanks and cisterns

Cold water storage tanks and cisterns shall be insulated with either:
a. Mineral wool having a factory applied bright Class O reinforced aluminium facing
complying with BS 5422: 2001 and BS 5970 water vapour permeance
facing complying with BS 5422: 2001 and BS 5970 water vapour permeance.
d. Water storage tanks may be GRP insulated panels if specified elsewhere.
Insulation shall be bonded to tank sides by means of suitable adhesive, applied in accordance
with the manufacturer's requirements.
All insulation slabs shall be closely butted together and joints sealed by means of matching self
adhesive tape 100mm. wide. Any exposed edges of the insulation and any points where the
covering is penetrated shall be sealed, using a suitable sealant.
Tanks shall be insulated on the sides and top only - not on their undersides.
Insulation for loose covers and access manholes shall be made in separate sections completely
removable.
The insulation shall be protected on the four vertical corners with 75mm. x 75mm. aluminium
angles.
The insulation surfaces shall be protected by means aluminium, or aluzinc sheeting, all overlaps
being secured with cadmium plated self-tapping PK. screws or pop rivets.
Ensure the vapour barrier is not damaged when applying the sheet metal cladding.
4.9.6 Insulated support blocks

At the points of support where insulation bears the weight of pipework and contents, purpose
designed load bearing, high density blocks as recommended / manufactured by insulation
manufacturer shall be installed at all support positions to facilitate installation of a continuous
thickness of vapour sealed insulation and finish.
The pipe insulation shall be butted up to the block and the joints sealed with a suitable adhesive
tape to provide a continuous vapour seal through the support.
Sharp edges on metal support brackets/clips shall be ground smooth to ensure that the
brackets/clips do not perforate the foil facing, thus destroying the vapour seal.
Where pipework is supported on steel bearers/rollers, purpose designed high density blocks of
an approved material fitted with galvanised metal wearing plates shall be used. The support
blocks shall be butt jointed, wrapped with adhesive tape and vapour sealed.
4.9.7 Valve and flange insulation

Provide thermal insulation to all valves, flanges, strainers and all ancillaries. The insulation shall
be suitable for the service to be insulated and provide the same thermal performance as the
adjoining pipework and maintain the continuity of the vapour barrier where required.
Part 5
Section 4 Page15
All chilled water valves and flanges shall be insulated and complete with vapour barrier.
Flexible thermal insulation jackets
Heating and hot water valves up to 50 mm shall be provided with flexible thermal insulation
jackets as specified.
Flexible thermal insulation jackets shall be secured by way of draw string collars and Velcro
fasteners. The outer layer of the valve cover shall be aluminised polyester film coated glass
fabric. The inner layer shall be a woven glass fibre fabric, capable of withstanding a continuous
hot face temperature of 260 C. Flexible thermal insulation jackets shall be removable and
reusable.
Valve and flange aluminium casing
Aluminium boxes shall be the split casing type fabricated from 0.91mm aluminium sheet or 0.7
mm fitted with spring clip fasteners and neoprene or similar seals. The internal insulating
material lining shall have the same thermal performance as the adjoining insulation and be
secured to ensure the lining will not collapse when the box is removed and re-installed.
Aluminium boxes shall be re-useable and facilitate removal without disturbing the adjacent
insulation.
All valves shall be provided with valve boxes unless otherwise stated.
4.9.8 Aluminium and Aluzinc cladding

Aluminium and Aluzinc cladding shall be formed to fit tightly over the outer circumference of the
insulation with longitudinal overlaps of not less than 40 mm the outer part of the overlap to be
secured with self tapping screws or rivets of the appropriate type at centres of not more than
150mm. All longitudinal joints shall be hidden from view as far as possible.
Circumferential overlaps to be not less than 40 mm and secured with secured with self tapping
screws or rivets of the appropriate type, not less than four, equally spaced. One circumferential
joint should be left free at maximum intervals of 5 metres to allow for expansion and contraction.
All joints shall be so arranged as to shed liquids and shall be sealed with a suitable gun applied
water resistant sealant.
All bends and fittings shall be covered with matching aluminium sheet cladding tailored to fit the
application but using specially segmented purpose made pieces, or mitred bends where
applicable.
All insulation termination points shall be trimmed with compatible aluminium coiled end capping
pieces secured over the aluminium cladding with closed head pop rivets.
All aluminium metal work shall be pre-formed, neatly and correctly installed, and manufactured
to ensure a smooth, clean, uniform installation free from sharp and dangerous edges.
Minimum thickness of cladding
Aluminium Thickness Aluzinc Thickness
Pipework 0.60
0.4
up to 150 mm OD
above 150mm OD 0.71
0.6
Ductwork 0.71 0.6
Heat exchangers and 0.7
0.9
vessels
Flange and valve boxes 0.91 0.7
Removable covers 0.91 0.7
Part 5
Section 4 Page16

Part 4: Non-combustibility test for materials
Part 6: Method of test for fire propagation for products
Part 7: Method of test to determine the classification of the surface
Part 11: Method for assessing the heat emission from building
materials
Part 12: Method of test for the igniability of products by direct flame
impingement
BS 874 Methods for determining thermal insulating properties
BS 1387 Specification for screwed and socketed steel tubes and tubulars and
for plain end steel tubes suitable for welding or for screwing to BS 21
pipe threads
BS 2972 Methods of test for inorganic thermal insulating materials
BS 3533 Glossary of Thermal Insulation Terms.
BS 3600 Specification for dimensions and masses per unit length of welded
and seamless steel pipes and tubes for pressure purposes.
BS 3927 Specification for Rigid Phenolic Foam (PF) for Thermal Insulation in
the form of slabs and Profiled Sections.
BS 3958: Thermal Insulating Materials
Part 3: Metal mesh faced man-made mineral fibre mattresses.
Part 4: Bonded pre-formed man-made mineral wool pipe section.
Part 5: Specification for bonded man-made mineral wool slabs.
BS 5111 Part 1 Laboratory methods of test for determination of smoke
generation characteristics of cellular plastics and cellular rubber
materials.
range, -40C to +700C
BS EN ISO 5659-2 Plastics. Smoke generation. Determination of optical density by a
BS 5970 Code of Practice for thermal insulation of pipework and equipment (in
the temperature range -100C to + 870C).
BS EN ISO 12241 Thermal insulation for building equipment and industrial installations.
Calculation rules.
BS EN 10215 Continuously hot-dip zinc-aluminium (AZ) coated steel strip and
sheet. Technical delivery conditions.
Part 5
Section 4 Page17
Section 5 Identification of Services
Contents
Section 5 Identification of Services 1

5.2 Valve labels and charts 1
5.3 Identification of services 1
5.4 Pipework services 1
5.5 Ductwork services 2
5.6 Identification of plant 3
Section 5 Identification of Services
All methods of identification shall be compatible with the pipe and operating conditions.
Identification of services shall comply with BS1710 and BS 4800.
When it is required to supplement the warning colour with warning sign to comply with statutory
requirements reference should be made to BS 5378: Part 1.
Identification bands shall be applied in a logical and tidy manner with lettering and flow arrows
clearly visible. Where several pipelines are installed in parallel to each other the identification
bands shall be applied at the same location on each pipe.
5.2 VALVE LABELS AND CHARTS

Each valve shall be provided with a label indicating the service being controlled, together with a
reference number corresponding with that shown on the valve chart (s) and record drawings.
The labels shall be made from 3 ply (black/white/black) traffolyte material showing white letters
and figures on a black background. Labels shall be tied to each valve with chromium plated
linked chain.
A wall mounted, glass covered plan to the approval of the CA shall be provided and displayed in
each plantroom showing the plant layout with pipework, valve diagram and valve schedule
indicating size, service, duty, etc.
5.3 IDENTIFICATION OF SERVICES

Pipework and ductwork shall be identified by colour bands 150mm. wide or colour triangles of at
least 150mm/side. The bands or triangles shall be applied at termination points, junctions,
entries and exits of plantrooms, walls and ducts, and control points to readily identify the
service, but spacing shall not exceed 4.0 metres.
5.4 PIPEWORK SERVICES

Basic colours for pipeline identification:
BS identification colour
Basic identification colour
Pipe contents reference
names
BS 4800
Water 12 D 45 Green
Steam 10 A 03 Silver-grey
Oils 06 C 39 Brown
Gas 08 C 35 Yellow/Brown
Air 20 E 51 Blue
Drainage 00 E 53 Black
Electrical 06 E 51 Orange
Colour code indicator bands shall be applied as colour bands over the basic identification colour
in the various combinations as listed below:-
Pipeline Contents Colour Band to BS.4800

Water Services:
Cooling 00 E 55
Fresh/drinking 18 E 53
Part 5
Section 4 Page1
Boiler feed 04 D 45/00 E 55/04 D 45
Condensate 04 D 45/14 E 53/04 D 45
Chilled 00 E 55/14 E 53/00 E 55
Central Heating Services:
below 100C 18 E 53/04 D 45/18 E 53
above 100C 04 D 45/18 E 53/04 D 45
Cold water storage tanks: 00 E 55/18 E 53/00 E 55
Hot water supply 00 E 55/04 D 45/00 E 55
Hydraulic power 04 C 33
Sea/river untreated Basic colour only
Fire extinguishing 04 E 53
Steam Services: Basic colour only
Compressed air Basic colour only
Vacuum White
Natural Gas 10 E 53
Oils:
Diesel 00 E 55
Lubricating 14 E 53
Hydraulic power 04 C 33
Transformer 04 D 45
Drainage and other fluids: Basic colour only
Electrical Services: Basic colour only
In addition to the colour bands specified above all pipework shall be legibly marked with black or
white letters to indicate the type of service and the direction of flow, identified as follows:-
Service Marking
High temperature hot water HTHW
Medium temperature hot water MTHW
Low temperature hot water LTHW
Chilled water CHW
Condenser water CONDW
Steam Steam
Condensate Condensate
Domestic hot water service HWS
Potable water MWS
Cold water down service CWDS
Pipes shall have the letters F and R added to indicate flow and return respectively as well as
directional arrows.
5.5 DUCTWORK SERVICES

The size of the symbol will depend on the size of the duct and the viewing distance but the
minimum size should not be less than 150mm. length per side. One apex of the triangle shall
point in the direction of airflow.
BS.4800
Service Colour
Colour reference
Conditioned Air Red and Blue 04 E 53/18 E 53
Warm Air Yellow 10 E 53
Fresh Air Green 14 E 53
Exhaust/Extract/Re-circulated Air Grey AA 0 09
Foul Air Brown 06 C 39
Dual duct system
hot supply air Red 04 E 53
cold supply air Blue 18 E 53
In addition to the colour triangles specified above all ductwork shall be legibly marked with black
or white letters to indicate the type of service, identified as follows:-
Part 5
Section 4 Page2
Supply air S
Return air R
Fresh air F
Exhaust air E
The colour banding and triangles shall be manufactured from self adhesive cellulose tape,
laminated with a layer of transparent ethyl cellulose tape.
5.6 IDENTIFICATION OF PLANT

Each item of plant and equipment shall be labelled with a traffolyte or metal label indicating its
unique reference code as used in the operating and maintenance documentation.
The plant numbering system shall be agreed with the CA prior to the commencement of the
Works.
The plant numbering system shall be fully compatible with any existing numbering system.
All items of plant and equipment shall be provided with a manufacturers nameplate indicating
the plant type, reference, serial number, year of manufacturer, performance and electrical data.
Pressure vessels which have been hydraulically tested at the manufacturers works shall
indicate the test pressure, working pressure and date of test.

BS 1710 Specification for identification of pipelines and services

BS 4800 Schedule of paint colours for building purposes
BS 5378 Safety signs and colours
Part 1 Specification for colour and design
Part 5
Section 4 Page3
Section 6 Pipe Cleaning and Water Treatment
Section 6 Pipe Cleaning & Water Treatment 1

6.2 Inspection and witnessing 2
6.3 Water samples 2
6.4 Mains water 3
6.5 Pseudomonas and closed systems 3
6.6 Preliminary checks 3
6.7 Disposal of chemicals 4
6.8 Treatment prior to system handover 4
6.9 Initial flushing of pipework 4
6.10 Pre-commission flushing and chemical cleaning 4
6.11 Sterilization of domestic water pipework systems 5
6.12 Chemical injection and dosing methods for closed systems 6
6.13 Chemical injection and dosing methods for open recirculating systems 6
6.14 Monitoring 6
6.15 Sampling 6
6.16 Sampling kits 7
6.17 Chemical provision, standard agreement 7
6.18 Dosing pots 7
6.19 Connections between new and existing systems 7
6.20 Temporary pump sets 8
6.21 Preventative maintenance 8
6.22 Employer training 8
Section 6 Pipe Cleaning & Water Treatment
This section covers the water treatment of chilled water, condenser water, hot and cold water
pipework systems.
Use a water treatment specialist, as agreed with the CA, for the analysis, design, supply,
installation and operation of any system cleaning and chemical treatment process.
Ensure the water treatment and pipe cleaning processes comply with statutory authority,
COSHH Regulations and health and safety requirements.
The installer shall before commencement of the works:
Provide a detailed method statement for the chemical cleaning and ongoing water quality
treatment for the water systems provided under the contract. The method statement shall
include the maximum agreed Pseudomonas (cfu/l) and TVC (cfu/l) levels. These levels shall be
agreed with the CA prior to addition of any water filling of the systems
Prepare drawings that show the detailed provisions for incorporating the cleaning facilities. The
drawings should show the details of all temporary facilities required
Determine the potential for partial or phased cleaning of a system and locate suitable isolating
valves to prevent cross contamination
Provide details of the method by which flushing velocities are to be achieved, ie pumping
requirements and motor power requirement for temporary pumping facilities
Agree witnessing and reporting stages for confirmation that system cleaning is being conducted
in accordance with the agreed procedure, and that the results are acceptable
Obtain approval from the local Water Authority for the disposal of contaminated flushing water,
and in particular, for the disposal of cleaning chemicals. If approval cannot be obtained make
preparations for removal of the waste by other means.
During the fabrication and installation of pipework systems, the installer shall comply with the
recommended Codes of Practice and take sufficient care to prevent the ingress of extraneous
matter.
Ensure that the flushing and chemical cleaning procedures are planned so that the whole
operation is carried out as a continuous process, ie there are no delays during the flushing
stage, or between the flushing and chemical cleaning stages. Chemical cleaning must be
carried out immediately after the pre-flush.
Chemical cleaning shall not be undertaken unless the system has been thoroughly clean-water
flushed to the satisfaction of the cleaning specialist.
Notify manufacturers and suppliers of equipment of proposed system cleaning and chemical
treatment processes. Establish for all equipment requirements of any particular cleaning and
chemical treatment process due to size of waterways or materials used.
All chemicals for system cleaning, corrosion inhibition and bacteria control must be selected by
a water treatment and chemical cleaning specialist and agreed with the CA prior to
commencement of the works.
Part 5
Section 6 Page 1
Maintain progressive records of a staged cleaning process.
It is the responsibility of the installer to advise the water treatment specialist of the materials
used in the construction of the plant and systems.
Comply with the Water Supply Regulations in undertaking cleaning and flushing activities.
Chilled Water and Condenser Closed Loop Pipework Systems

The recommendations of BSRIA Application Guide AG 2/93, Appendix A, Table A2 shall be
consulted in the selection of chemicals for corrosion control.
Cooling Tower Open Recirculating Water Systems

The recommendations of BSRIA Application Guide AG 2/93 shall be consulted in the selection
of chemicals for corrosion control, specifically:-
a. Scale control: Pre-treatment - Base Exchange softening plant.

b. Corrosion control: Chemicals as BSRIA Application Guide AG 2/93, Appendix A Table A3.
c. Control of microbiological fouling.
d. Chemical: Biocides and bio dispersants. Chemicals as BSRIA Application Guide AG 2/93,
Appendix A Table A3 (See 2.2.15).
Water Treatment for Boilers

Provide water treatment for boiler plant in accordance with BS 2486. Ensure water treatment
plant changes the area raw water characteristics to those recommended within BS 2486 for
boiler plant installed.
Domestic Hot and Cold Water

Disinfect all domestic water pipework with Sodium Hypochlorite in accordance with British
Standards 6700.
6.2 INSPECTION AND WITNESSING

The installer shall ensure that inspection and witnessing of the cleaning process shall be
conducted as the work is in progress and shall be carried out in accordance with BSRIA
Application Guide AG 1/2001.1.
The installer shall advise the CA at least five working days in advance of flushing and cleaning
activities so procedures can be witnessed at the discretion of the CA.
6.3 WATER SAMPLES

Carry out all necessary tests to ensure that cleaning and chemical treatments are operating as
required.
All water samples taken for chemical and microbiological analysis shall be submitted to an
independent laboratory. The laboratory used shall have NAMAS accreditation or equivalent for
the tests to be undertaken.
Use sterile containers to take samples.
Results shall be submitted to the CA for review, if poor results are obtained, then remedial
action shall be taken at no additional cost to the contract. Under this condition tests shall
continue until stability of the system(s) is proved.
Water samples from agreed locations shall be taken throughout the cleaning process to prove
the quality and chemical and microbiological stability of the systems. Water samples shall be
taken from representative system extremities and low points.
Prior to commencement of the Works on site obtain an analysis of mains water taken from the
site supply point and ensure the results are typical for the site location with the local water
authority. Submit a sample of water to the water treatment specialist.
Part 5
Section 6 Page 2
6.4 MAINS WATER
An adequate supply of mains water should be made available for flushing.
Back-flow protection in compliance with the Water Supply Regulations must be provided
between the incoming mains connection and systems fill point.
All temporary mains shall be cleaned and chlorinated in accordance with BS 6700 before being
used for system filling.
Where the quality of the mains water is not satisfactory, a biocide dosed, temporary supply of fill
water to reduce risk of bacterial contamination shall be provided
6.5 PSEUDOMONAS AND CLOSED SYSTEMS

Water samples shall be taken from the proposed source of water for testing, flushing and final
filling before the Works commence and shall be tested for Pseudomonas bacteria. The
laboratory used shall have NAMAS accreditation or equivalent for the tests to be undertaken.
The test results shall be submitted to the CA before commencement of the Works.
On Pseudomonas being detected, a method statement detailing testing, sourcing and treatment
regimes shall be agreed with the CA in time for the procedures to be incorporated within the
construction programme.
The Tenderer shall include two sums within the tender for:
Undertaking the necessary treatment to overcome a Pseudomonas contamination

Providing and maintaining a temporary water treatment plant on site for initial filling and
hydraulic testing. The plant shall be maintained until practical completion.
If no contamination is found at the time of practical completion the sums shall be removed by
instruction.
Before practical completion the installer shall commission a final water analysis report based on
samples taken in the presence of the CA. The report shall demonstrate that the systems do not
contain any microbiological activity and are in accordance with the water treatment specialists
recommendations. If microbiological activity is still present, the systems shall be retreated and
tested until clear.
6.6 PRELIMINARY CHECKS

Prior to the cleaning and chemical treatment process, the installer shall ensure that:
No damage can occur to any item of plant or equipment due to the cleaning and/or chemical
treatment process or blockage due to cleaning. Equipment or fittings that will restrict the
cleaning procedures or will be subject to damage must be either by-passed or removed, and
the flow and return connections cross connected unless otherwise stated. The extent of
these measures and any others that could restrict effective circulation shall be discussed and
agreed with the CA prior to carrying out the cleaning process.
All foreign matter is removed.
Certified pressure tests have been undertaken to the satisfaction of the CA.
Chemicals to be used are compatible with system materials and equipment and approved.
All necessary temporary by-passes are provided.
All drains provided have been tested and approved together with any associated pumping
equipment.
Adequately sized drains are fitted at all low points that cannot be emptied via the main
drains.
Temporary strainers and filters are installed as required for removal of solids during the
cleaning and/or chemical treatment process.
Dirt pockets are installed at low points to facilitate removal of solids and are complete with
drain valve to pipework size.
All automatic/manual air vents are fully commissioned.
Part 5
Section 6 Page 3
All necessary electrical supplies are available to undertake the works.
Dead legs more than 3 pipe diameters in length are looped to allow effective cleaning.
Connections shall be of a similar bore to the pipework.
Adequate and safe means of access is provided to the pipework system during the cleaning
and chemical treatment process.
Circulation has been demonstrated and approval obtained on all parts of the system.
All necessary approved precautions are undertaken where there is a risk of freezing.
6.7 DISPOSAL OF CHEMICALS

The installer shall obtain all necessary permissions from the local Water Authority before any
chemical is discharged into public foul or surface water drains and comply with the requirements
of all necessary legislation. Provide documented evidence to the CA of all necessary
permissions prior to commencement of the works
The installer shall make applications to all necessary authorities and provide details of the
chemicals to be discharged, the maximum quantity, the maximum rate of discharge, the
temperature, and the proposed date on which the discharge will take place.
Where required by the local water authority, provide effluent tanks for storage of all waste
products of cleaning and chemical cleaning processes.
Upon local water authority approval, either dispose to drain of all waste products after
neutralizing to the required standard or ensure authorised disposal at registered sites.
6.8 TREATMENT PRIOR TO SYSTEM HANDOVER

Prior to handover the installer shall be responsible for regular monitoring of water quality and
ensuring the system water is circulated and if necessary further dosed until the system is
handed over and put into normal use. This may also necessitate the provision of all necessary
precautions to prevent freezing.
Should the installer for any reason, partially or completely drain down the system, it is essential
that the CA is informed and the water treatment specialist is advised so that the chemical
concentrations can be checked and if necessary, a further treatment introduced or remedial
action taken before the final commissioning of the systems.
Prior to handover the water in each system shall be analysed to confirm that the correct
condition and chemical concentration has been achieved, before a completion certificate is
issued. Water sampling procedures shall be as stated elsewhere.
6.9 INITIAL FLUSHING OF PIPEWORK

The installer shall be responsible for thoroughly flushing with mains cold water to a satisfactory
quality, via a break tank, all pipework to remove traces of loose dirt, scale and extraneous
matter, prior to pre-commission cleaning and placing into operation the various pipework
systems.
Flushing of water systems shall be carried out in accordance with BSRIA Application Guide AG
1/2001.1.
When all sections of a system have been flushed, the installer shall notify the CA for the
cleanliness of the systems to be witnessed.
6.10 PRE-COMMISSION FLUSHING AND CHEMICAL CLEANING

The installer after completing the initial flushing of the heating and chilled water pipework
services to the satisfaction of the CA, shall arrange for the water treatment specialist to carry out
the pre-commission flushing and chemical cleaning of the pipework systems.
Pre-commission flushing and chemical cleaning procedures shall be in accordance with BSRIA
Application Guide AG 1/2001.1.
Part 5
Section 6 Page 4
6.11 STERILIZATION OF DOMESTIC WATER PIPEWORK SYSTEMS
All cold water mains, rising mains, storage tanks, cold water down services and hot water
services pipework systems used for domestic purposes shall be sterilized by a water treatment
specialist in accordance with BS. 6700 and the requirements of the local water authority.
Prior to sterilization ensure each system is flushed, cleaned and drained.
The CA may choose to witness this operation and the installer shall give at least 48 hours notice
prior to the commencement of any sterilization process.
Following sterilization submit samples for microbiological analysis to an independent laboratory.

The laboratory used shall have NAMAS accreditation or equivalent for the tests to be
undertaken. Results shall be submitted to the CA, if poor results are obtained, then remedial
action shall be taken at no additional cost to the contract.
Immediately prior to handover, retake samples and submit for analysis and report. Where
necessary repeat the sterilisation of potable water system(s) immediately prior to handover.
The following basic information shall be provided to the water treatment specialist by the
installer to enable the extent of the sterilization process to be fully assessed:
Building description, gross area and number of stories

Total capacity of each of the system to be treated
Location, type, size and number of draw-off points served by:
incoming cold water main
storage tank(s)
Systems to be treated in one visit to site.
The following facilities shall be provided to enable the water treatment specialist to carry out the
sterilisation process:
Should the local water authority not permit the opening of the town main isolating valve until
the incoming main and rising main have been sterilised (to avoid the possibility of
contaminating the town main) an adequate supply of water must be arranged from an
independent source. The cost for any such arrangement shall be included in the contract
price.
For chlorination of tanks and down services the town main supply may be used subject to the
approval of the local water authority.
Provide a suitable electrical supply for the operation of associated equipment.
It is the responsibility of the installer to ensure all components of the system(s) are
completely sterilized.
Provide a 22 mm valved drain connection on the incoming main immediately downstream of
the mains isolating valve.
Ensure unrestricted access to all draw-off points during the whole of the process.
It is the responsibility of the installer to ensure that all tanks are cleaned, the systems have
been flushed with clean water to remove all debris, refilled and pressure tested before the
water treatment specialist attends site.
The installers attention is drawn to the importance of carrying out a thorough initial cleaning of
all systems using mains cold water from an independent source to avoid the possibility of re-
chlorination.
The installer shall ensure:
Deposits of iron oxide or other foreign materials such as brick dust, cement, etc., all of which
allows the "hide-out" of bacteria in pipework systems have been thoroughly flushed out.
Tanks are cleaned of extraneous matter and left in a thoroughly clean condition.
The installer shall comply with the latest Water Regulations and ensure that:
Part 5
Section 6 Page 5
Cold water installations
Water storage tanks are situated in cool locations, shaded from sunlight.
Water storage tank rooms are adequately ventilated either by natural or mechanical means,
dependent on location.
Cisterns and tanks are insulated to ensure water in storage is held below 20C.
Equal flow occurs through each tank on a multi tank coupled installation.
Ball valves are installed on the opposite side of the tank to the outlet pipe to minimise the risk
of static water.
Insulation of all distribution pipework.
Dead legs to drinking water points, low water consuming fixtures, showers and spray taps
are avoided
Pipes are installed to falls to avoid air locks.
Hot water installations
Construction of calorifiers and cylinders shall include the following features:

Bolted access doors for cleaning purposes
Sparge pipe on cold feed inlets to avoid stagnation
Drain valves sized to drain the contents of water within 30 minutes in order to remove sludge
and debris. On large calorifiers longer periods may be permitted.
Bottoms to be convex - concave bottoms should be avoided.
Where duplicate vessels are employed, equal flow rates must be achieved through each
calorifier or cylinder.
Minimise the lengths of dead legs, especially to showers, spray taps and low water
consuming fixtures. Secondary pumped return connections to extend beyond the last draw-
off connection on branches.
Install pipes to falls to avoid air locks.
Control the storage of water at 60C and maintain return water at not less than 50C.
Avoid temperatures of storage water exceeding 60C in order to prevent excessive corrosion
and scale formation.
Should the installer have any queries relating to the above provisions, these must be discussed
and approved by the CA prior to commencement of the works.
6.12 CHEMICAL INJECTION AND DOSING METHODS FOR CLOSED SYSTEMS

Method of introducing chemicals shall be dosing pots; manually initiated timer controlled dosing;
or proportional dosing as appropriate.
6.13 CHEMICAL INJECTION AND DOSING METHODS FOR OPEN RECIRCULATING

SYSTEMS
Method of introducing chemicals:
Chemical dosing for scale and corrosion inhibitors

Continuous; timer controller; or proportional dosing as appropriate.
Bleed-off control.
Biocide dosing - automatic dosing control.
6.14 MONITORING
Provide monitoring system to enable on-line analyses, system alarms and chemical stock levels
to be monitored by water treatment specialist. Where indicated, provide facility for system to be
monitored by water treatment specialist at remote location.
6.15 SAMPLING
Provide testing equipment to carry out tests for all inhibitors used in treatment programme
indicated.
Part 5
Section 6 Page 6
6.16 SAMPLING KITS
Provide the following test kits as appropriate.
Boiler water test kit for steam boilers; conductivity test kit; pH test kit; inhibitor test kit;
hardness test kit where a softener is installed; chloride level test kit.
Install a corrosion test rig to enable corrosion rates to be monitored using corrosion coupons.
Bacteriological monitoring with use of dip slides.
Log sheets for recording of test results, bacteriological analysis and any actions required or
taken.
6.17 CHEMICAL PROVISION, STANDARD AGREEMENT

Provide consumables for a period of 12 months.
6.18 DOSING POTS

Dosing pots shall be a fabricated welded steel container manufactured with welded end caps
and complete with:
air cock
conical filling funnel
non-return valve at the base
flow and return valves including connections
drain valve`
The dosing pot shall be suitable for the system operating pressures.
Dosing pot shall be installed between the flow and return lines in accordance with the
manufacturers recommendations to ensure satisfactory mixing of the concentrated chemical
solution with the total water capacities of the systems. The unit shall be located in a convenient,
fully accessible position, either fixed by wall brackets or suitably supported on a mild steel angle
iron stand from plantroom floor
The dosage pots shall be of the following sizes unless stated otherwise:
System volume up to 2000 litres 3.5 litre dosing pot

System volume more than 2000 litres 13.5 litre dosing pot
6.19 CONNECTIONS BETWEEN NEW AND EXISTING SYSTEMS

To protect water quality when systems are extended or modified, newly installed pipework shall
be cleaned and treated before being connected to existing pipework.
Pre-commission cleaning of heating and cooling pipework systems shall be carried out in
accordance with BSRIA Application Guide AG 1/2001.1
The water quality in the existing system shall be checked by the installers water treatment
specialist and the results submitted to the CA prior to the commencement of the Works. Water
sampling points shall be agreed with the CA.
Cleaning and treatment of existing systems (or new systems incorporating old pipework) shall
be advised by the installers water treatment and chemical cleaning specialist and agreed with
the CA prior to the commencement of the Works.
Any necessary remedial measures shall be agreed with the CA and undertaken before
connecting to new plant or equipment. The installer shall allow adequate time so as not to delay
the programme.
If a system has been previously dosed with chemicals establish the type and for what purpose.
Ensure that new chemicals are compatible and there is no interference or reaction between
chemicals or system materials.
Part 5
Section 6 Page 7
Final connections shall only be made when satisfactory water analysis results have been
achieved for both existing and newly installed pipework. Water analysis records for both
existing and new systems shall be submitted to the CA prior to connection.
6.20 TEMPORARY PUMP SETS

Temporary pumps shall be provided to circulate chemicals and achieve flushing velocities in
new circuits which do not have their own pumps.
The temporary pump set shall be sized so that it can achieve the flushing velocities in
accordance with BSRIA Application Guide AG 1/2001.1, or the design velocity plus 10%,
whichever is the greater. The flushing velocity shall be selected based on the largest pipe size
in the system or circuit to be flushed.
Locations for temporary pumps shall be agreed with the CA and shall be away from emergency
exit routes but within reach of electrical, water supply and drain facilities. All temporary pumps
sets shall have surrounding protection barriers, and shall be located in bunds to assist water
collection in the event of a leak.
6.21 PREVENTATIVE MAINTENANCE

Include for the preventative maintenance of water treated services during the 12 months defects
liability period.
Provide monthly visits for one full year by a fully qualified chemist to undertake the following:
Review water analysis records, correspondence and reports since previous visit
Test water samples on site for:
hardness
all inhibitors
dissolved solids
Ph
total alkalinity
Carry out a micro-biological analysis of water in each system
Check performance of water treatment plant and testing equipment on site
Submit a written report to the employer and CA
The preventative maintenance works shall also include:
Drain down, manually clean and refill cold water storage tanks (twice/annum).
Drain down completely and refill hot and cold water pipework service installations
(twice/annum).
Disinfection of domestic hot and cold water pipework services and cold water storage tanks
(twice/annum)
Disinfection of hot water service calorifiers (twice/annum)
Manual cleaning and chlorination of water cooling towers including chlorination of condenser
water systems (twice/annum).
Works shall be based on weekend working unless otherwise indicated.
6.22 EMPLOYER TRAINING

Provide a complete training programme for the Employers staff to include but not limited to:
Methods of basic water testing
Explanation of results obtained
Actions to be taken on test results

Part 5
Section 6 Page 8
BS 6700 Specification for design, installation, testing and maintenance of
services supplying water for domestic use within buildings and
their curtilages
BSRIA AG 2/93 Water treatment for building services systems
BSRIA AG 1/2001.1 Pre-commission cleaning of pipework systems (2nd edition)
Part 5
Section 6 Page 9
Section 7 Heating
Contents
Section 7 Heating 1

7.2 Boilers 1
7.3 Burners 3
7.4 Chimneys And Flues 3
7.5 Radiators (not used) 5
7.6 Convectors (not used) 6
7.7 Trench heating (not used) 6
7.8 Perimeter heating systems (not used) 6
7.9 Under-floor heating (not used) 7
Section 7 Heating
Gas fired boiler installation, materials, workmanship and testing shall comply with the
requirements of BS 6644 and BS 6798.
All equipment and assemblies which fall within the scope of the Pressure Equipment Directive
(PED) 97/23/EC, implemented in the UK through the Pressure Equipment Regulations, must be
tested by the manufactures, and be certified as compliant with the Directive. Compliance shall
be evidenced by displaying the appropriate CE Mark on the equipment and assemblies.
Electrical safety and performance of gas fired space heating appliances shall be in accordance
with BS 5986.
Gas fired equipment and appliances shall comply with the requirements of the Gas Safety
(Installation and Use) Regulations and Local Civil Defence regulations.
Ventilation to plant spaces shall be adequate to meet the requirements of combustion and be in
accordance with Local Civil Defence requirements and Municipality Regulations, British
Standards and manufacturers recommendations.
Comply with the manufacturers recommendations and installation instructions.
7.2 BOILERS
7.2.1 General
Boilers shall be selected to achieve the required output when operating at the design
temperature and pressure conditions as stated elsewhere.
Units shall be suitable for the proposed arrangement of fuel supply and flue systems.
The thermal performance of boilers shall be in accordance with BS 845-1, BS 7190 and BS
6332-1 as necessary.
Boilers and burners shall be selected as matched units previously tested by the manufacturer to
ensure satisfactory operation. Details of tests showing the unit output and efficiency ratings at
full and part loads shall be submitted to the CA. The unit shall be capable of meeting the
required efficiency stated elsewhere when operating at the design conditions and the NOX
emissions.
Boilers shall be provided with an adequately constructed and stiffened sheet steel casings with
stove enamelled finish. Adequate safe access for cleaning and maintenance shall be provided
and demonstrated to the CA on completion of the installation.
Boilers shall be thermally insulated securely attached to the boiler and thickness complying with
BS 5422.
Site assembly of boilers shall be undertaken by the manufacturer. Boilers shall be set up and
commissioned by the manufacturer and fully performance tested on site after commissioning.
Boiler flow and return pipework connections shall be arranged and supported that no strain is
placed upon the boiler throughout its operating temperature range.
Boilers shall be mounted on concrete bases unless otherwise indicated.
Part 5
Section 7 - Page1
Each boiler shall be provided with the following mountings and fittings unless otherwise
indicated. Mountings and fittings shall comply with the appropriate sections of this specification:
Temperature gauges on the flow and return connections

Pressure gauges on the flow and return
Flue gas temperature indicator
Temperature and pressure test points on the flow and return
Isolation valve on flow and return
Lockshield valve on cold feed
Safety valve in accordance with BS EN ISO 4126. On pressurised and sealed systems two
safety valves shall be provided. Safety valves shall be complete with discharge pipe
extended to floor level and clear of the boiler shell or casing.
Connection on flue outlet to permit the taking of flue gas samples
Drain valve
Flame sight glass
Boiler mountings shall be installed in accordance with manufacturers recommendations and BS

759-1.
As indicated facilities for the transmission of the status, operating temperatures and pressures
for each boiler to the main control panel or building management system shall be provided.
Facilities shall be provided for cleaning the flue-ways.
Each boiler shall be hydraulically tested on completion of the installation in accordance with the
appropriate British Standard and as described elsewhere.
The manufacturers specialist CA shall attend site and start up and commission the boilers. The
commissioning of the boilers shall be in accordance with CIBSE Commissioning Code for Boiler
Plant and as stated elsewhere. The commissioning shall be witnessed by the CA and carried
out to their satisfaction.
The commissioning tests on each boiler shall include, but not limited to:
Boiler output related to the required boiler performance

Boiler efficiency tests at full, 50% and 30% loads
Flue gas analysis including CO2 and NOX emissions. Analysis of flue gases in accordance
with BS 1756.
Certificates for each boiler shall be submitted to the CA and copies issued as part of the record
documentation as stated elsewhere.
Each boiler plant shall be provided with the following equipment:
Tools to permit access for inspection and maintenance purposes

Flue brush
Spare set of gaskets
Each boiler shall have a plate attached to it, in a visible, legible and indelible form stating:
manufacturer's name
a unique serial number to identify the boiler
date of manufacture
standard to which the boiler was built
maximum design pressure
minimum design pressure of the boiler if it is other than atmospheric
design operating temperature.
7.2.2 Cast iron boilers

Cast iron sectional boilers shall be constructed in accordance with BS EN 303.
Part 5
Section 7 - Page2
Boilers shall be suitable for a maximum operating water temperature of 95C and a maximum
working pressure of 4 Bar. Cast iron boilers shall be tested to a pressure at least 1.5 times the
maximum system operating pressure unless otherwise indicated.
The units shall be designed to maximise heat transfer from the flue gases to the water and to
prevent local hot spots or deformation due to uneven expansion.
Where possible boilers shall be provided as fully assembled and works tested packaged units.
Where boilers are delivered as individual sections they shall be site erected and tested by the
boiler manufacturer.
7.2.3 Steel shell boilers

Boilers shall comply with the requirements of BS EN 303, BS EN 12953 and BS 2790.
Units shall be fully assembled and works tested packaged units.
7.2.4 Modular boilers

Modular boilers for low temperature hot water heating shall comply with the clauses for cast iron
or welded steel boilers as appropriate and the requirements of the relevant British Standards.
The modules shall be connected in parallel so that water from the common return header flows
through the modules to the common flow header.
The installation shall ensure that adequate air can reach all modules.
It shall be possible to maintain any module without affecting the operation of adjacent modules.
7.3 BURNERS
Burners shall be selected to provide the required output.
Units shall be fully automatic and matched to the boiler and be complete with electric ignition
and flame failure protection.
Gas fired burner units shall comply with the requirements of BS 5885, BS EN 676 and BS 5978.
Oil fired burner units shall comply with the requirements of BS 5410 and BS 799. Safety, control
and monitoring of monobloc oil burners shall be in accordance with BS EN 230.
Dual fuel burners shall comply with the appropriate requirements for gas and oil burners. In
addition the requirements of
The controls and safety features shall comply with all current British Standards.
7.4 CHIMNEYS AND FLUES
7.4.1 General
Each boiler and direct fired water heater shall be provided with a flue connection from the outlet
to atmosphere as indicated.
Chimneys and flues shall be designed to remove the total products of combustion from the
boilers and discharge them to atmosphere when the boilers are operating at maximum and
minimum duty.
Chimneys and flues shall comply with the Clean Air Act, Municipality Regulations and all
appropriate British Standards.
The final discharge height of all chimneys and flues shall be approved by the local
Environmental Health Department prior to installation.
Part 5
Section 7 - Page3
Connections shall be provided for flue gas temperature indication and flue gas analysis, on each
flue.
Final connections to boilers shall be purpose made to suit the application.
Flues and chimneys shall be resistant to corrosion and be compatible with the boiler
manufacturer's requirements.
All flues shall be tested for air-tightness on completion.
Flues and flue structures shall be in accordance with the requirements of BS 5854. For gas
appliances of rated input not exceeding 70kW comply with BS5440-1.
7.4.2 Flue Dilution System

Flue dilution systems shall be capable of reducing the CO 2 emission from the boiler plant to less
than 1%.
Dilute flue systems shall be constructed from stainless steel sheet with a minimum thickness of
1.2mm. Access doors shall be provided at each change of direction an opposite each branch
connection.
Ductwork shall be erected to permit drainage to a low point. Condensation drainage from within
the flue system shall be trapped by drains of at least 25 mm nominal diameter, provided at all
low points.
Inlet and outlet louvres, shall be as indicated and be complete with anti-vermin screens. The
inlet air velocity shall not cause rain water to penetrate into the duct. The diluted exhaust gases
shall be discharged from the same side of the plantroom as the air inlet to ensure wind
pressures are balanced.
As indicated, a draught stabiliser shall be fitted in the vertical flue from the boiler to the dilution
header to avoid excess suction from the dilution fan acting on the flue gas outlet.
Systems shall be totally independent of any boiler room ventilation systems and shall comply
with the Clean Air Act and all necessary legislation, regulations and standards.
Fans shall be either centrifugal or axial as indicated. They shall be manufactured from stainless
steel or provided with an internal coating resistant to the flue gas and condensation. Fans and
motors shall comply with the requirements as stated elsewhere. Axial fans shall be either
bifurcated units or shall have an externally mounted motor.
Dilute flue inlets shall be provided with a volume control damper and quadrant with lockable
setting.
An air flow switch on the fan discharge or pressure differential switch connected across the fan,
as indicated, shall be provided to prevent the boilers firing unless the fan is operating. The fail
safe system shall comply with BS 6644, BS 5440and IGE/UP/10.
Where fan dilution systems are routed externally, they shall be of a double skin construction.
Facilities for monitoring and control via the main control panel or building management system
shall be provided.
7.4.3 Chimneys
Chimneys shall be installed and supported in accordance with manufacturers
recommendations.
The installation shall comply with the manufacturers requirements to provide an airtight and
gas-tight chimney capable of operating without leakage.
Part 5
Section 7 - Page4
Adequate provision shall be made for movement due to thermal expansion. Where indicated
thermal expansion of the flue shall be accommodated by means of proprietary bellows.
Metal chimney systems shall be in accordance with BS EN 1856-1 and tested in accordance
with BS EN 1859.
Chimneys for flue systems operating at below atmospheric pressure shall be constructed of
stainless steel in a twin-wall formation. The construction shall be in sections with twist lock
couplings secured by a locking band. An access cover shall be provided at all changes of
direction.
The gap between inner and outer skins of the chimney shall be filled with a high temperature
insulation material with a thermal transmittance no greater than 1.4 watts/m K at 540 C.
Chimneys shall be supported at the base on a purpose made support foot and shall have
purpose made wall brackets and intermediate supports secured to the structure of the building.
All joints in the chimney shall be positioned such that they do not occur within the floor thickness
of the building and are readily accessible for inspection.
External sections shall be braced or secured to provide adequate wind resistance.
An access door and drain valve shall be provided at the base of the chimney and also at the flue
connection to each boiler.
Where flues and chimneys pass through walls or floors they shall be protected by suitably
designed sleeves. Unless otherwise indicated the sleeves shall be 50 mm greater in length than
the structure and be a minimum of 25 mm greater in diameter than the flue to allow for sealing
and fire stop protection.
Flues shall be constructed in the same material as the chimneys and shall be complete with
135 access bends and an explosion door at the boiler connection
7.5 RADIATORS (NOT USED)

Radiators shall be of the types, ratings and dimensions indicated, and shall be manufactured
and tested in accordance with the requirements of BS EN 442.
Radiators shall be constructed of mild steel or cast iron as indicated.
The radiator heating surface provided in any space shall be not less than the aggregate
indicated.
All radiators shall have a factory applied paint finish to an approved colour which shall be
agreed with the CA unless otherwise indicated.
The positions and heights above floor of all radiators shall be confirmed with the CA.
The Installer shall allow for marking out and fixing all radiators to the manufacturers
requirements and shall allow for taking down radiators twice after initial installation and for re-
fixing for the purpose of other trades.
Fixings for radiator brackets shall be suitable for the application and loads. Supports for
radiators fixed direct to lightweight partitions shall be approved before installation.
Existing radiators shall be disconnected and re-fixed in the same or new positions as indicated
and shall be thoroughly washed out, wire brushed for re-painting by others.
Each radiator shall be provided with valves on the flow and return connections as detailed
elsewhere. Each radiator shall be provided with an air vent and plug.
Part 5
Section 7 - Page5
Provision shall be made to allow expansion and contraction of the radiator without generation of
noise within the occupied space.
The installer shall ensure that the tails to the radiators are adequate for expansion purposes.
7.6 CONVECTORS (NOT USED)

Convectors shall be of the types, ratings and dimensions indicated.
For natural convectors the manufacturer's declared ratings shall have been obtained from tests
in accordance with BS EN 442-1. For fan convectors the manufacturer's declared ratings shall
have been obtained from tests in accordance with BS 4856-1.
The positions and heights above floor of convectors shall be agreed with the CA. Where
recessed or built-in convectors have been specified, the Installer shall supply full details of the
openings and of any fixings or framing required.
7.7 TRENCH HEATING (NOT USED)

Trench heating casings shall be manufactured from galvanised mild steel sheet or adequate
section and suitably braced to fit into the floor void or trench as indicated.
A longitudinal vertical division plate shall be provided to form a return path to the underside of
the elements.
Casings shall be provided with interlocking and levelling facilities to permit fixing in a straight line
flush with the floor. Casings shall be internally finished with matt black paint.
Element supports shall be manufactured from galvanised mild steel sheet. Angle supports shall
be provided to allow a flush fitting floor grille to be incorporated. As indicated elements shall
compromise aluminium fins bonded to copper tube run in either single or double rows and a size
capable of meeting the required output.
Grilles shall be formed of extruded aluminium bars selected for heavy-duty floor use. The grille
shall be capable of removal in sections to permit cleaning of the casing. The grille finish shall be
as indicated.
7.8 PERIMETER HEATING SYSTEMS (NOT USED)

Continuous perimeter heating shall provide the heating outputs as indicated.
Heating elements shall be arranged to give an even distribution of heat throughout the space.
Heating elements shall be of the finned tube convective type enclosed in removable style steel
casings or arranged for enclosure in a purpose designed casing as indicated. Where indicated
casings shall incorporate provision for accommodating other services.
Heaters shall be complete with all necessary ancillary components including back plates,
internal and external cover strips, dummy sections and valve boxes and provide a continuous
unbroken appearance.
The installer shall be responsible for determining all site dimensions.
Pipework shall be installed with adequate provision for venting, draining and thermal expansion.
The manufacturers recommendations regarding provision for thermal expansion shall be
included.
Heating elements shall be fabricated from copper tube to BS EN 1057 with non-ferrous fins
bonded to the tube unless otherwise stated.
Unless otherwise stated the connecting pipework shall be run in copper with capillary or
compression joints to suit the finned elements.
Part 5
Section 7 - Page6
Unions shall be provided at a maximum of 18 metre intervals to facilitate disconnection of the
elements or as otherwise indicated.
7.9 UNDER-FLOOR HEATING (NOT USED)

A specialist company shall be employed to carry out the design, supply, installation, testing and
commissioning of the under-floor heating system instructed by the installer.
The under-floor heating system shall be in accordance with BS EN 1264 Parts 1 to 4 and DIN
4735-4 and DIN 4725-200.
The under-floor heating system installation shall be carried out fully in accordance with the
The under-floor heating specialist shall be responsible for ensuring the under-floor system and
pipework spacing is adequate to provide the output when operating within the design flow and
return temperatures as stated elsewhere.
The maximum design flow temperature to the system shall be limited to prevent damage to the
flooring.
The installer shall submit to the CA prior to commencement of the works, a detailed programme
covering the under-floor heating installation including testing, witnessing, inspection,
commissioning and screed drying time. Scheduling shall take account of the timing for pipework
commissioning, screed curing, and screed drying together with flooring requirements.
The building shall be both wind and watertight before the installation of the under-floor heating
pipework commences.
Headers shall be provided as required to suit the layout. They shall be made up of sufficient
flow and return distributors for the number of coils attached. Each coil shall be provided with a
brass connecting block with connections for vent, drain and filling valves. Each flow header
distributor shall be provided with an isolating valve. Each return header distributor shall be
provided with a close coupled commissioning set and sight glass as indicated.
There shall be no pipe joints in the screed or distribution pipework systems up until the final
connection into the distribution headers.
The under-floor distribution pipework shall be run from headers in thermosetting plastic
pipework incorporating a protection layer and an electronic tracing layer as indicated. The
pipework shall be fixed in position by means of a proprietary floor plate mounting system.
Floor panels shall be laid to ensure that the maximum size of screed panel is 40 m and that no
side exceeds 8 m. The pipework layout shall be designed to suit movement joints.
Thermal insulation shall be provided of adequate thickness and thermal conductivity. The
insulation shall have adequate compressive strength to support the floor screed, floor finish and
any super imposed load and to protect the under-floor pipework systems and other in floor
services that may be incorporated into the under-floor heating zone.
The insulation shall be laid to provide a firm base for the pipework and shall incorporate a top
cover designed to protect the insulation and provide positive location for the pipework. The type
and thermal transmittance of the insulation shall be as indicated. A barrier shall be provided
over the insulation where necessary to prevent moisture and fresh screed materials penetrating
the joints between the insulation.
An insulating edge strip shall be provided around the perimeter of the heated floor areas.
Where required a damp proof membrane shall be provided and laid with sufficient overlap to
provide adequate protection.
Part 5
Section 7 - Page7
The installer shall provide all necessary protection of the floor pipework systems and insulation
up until the floor screed is laid. The installer and under-floor heating specialist company shall
provide all necessary supervision during the floor screeding operations.
After installation the under-floor heating pipework shall be subject to a pressure test at twice the
working pressure or as recommended by the under-floor heating specialist and as agreed with
the CA. This pressure shall be maintained during the laying of the screed as agreed with the
CA.
The screed shall be laid to requirements of the specialist and structural CA, to suit the depth of
the floor finish and provide the minimum cover over the pipework systems as indicated.
On completion of the screeding the system shall be drained and refilled with anti-freeze solution
as agreed with the CA.
The screed shall be left to cure completely for the maximum period recommended by the
specialist before the system is commissioned.
After the screed has properly cured the system shall be flushed and re-filled. Pre-
commissioning cleaning shall be as described elsewhere.
The temperature of the water entering the circuits shall be raised slowly to between 20C and
25C for three days, and then raised slowly to the maximum design temperature and maintained
for a further four days which shall be agreed with the under-floor heating specialist and CA or
other limits as recommended by the under-floor heating specialist.
Controls for the floor heating system shall be provided by the under-floor heating specialist as
indicated elsewhere.
Prepare record drawings comprising floor plans showing the dimensioned layout and pipe
centres of all floor coils and run-outs. The drawings shall include details of insulation thickness,
expansion provision, floor temperatures, heat emissions and thickness of screed. Location of
headers including particulars of coil connections to each header shall be indicated together with
water flow rates and pressure drops required at each header.

BS EN 230 Automatic burner control systems for oil burners

BS EN 303 Heating boilers. Heating boilers with forced draught burners
BS EN 442 Specification for radiators and convectors. Evaluation of conformity
BS EN 676 Automatic forced draught burners for gaseous fuels
BS 759-1 Valves, gauges and other safety fittings for application to boilers
and to piping installations for and in connection with boilers.
Specification for valves, mountings and fittings
BS 799 Oil burning equipment
BS 845 Methods for assessing thermal performance of boilers for steam,
hot water and high temperature heat transfer fluids
BS 853 Specification for vessels for use in heating systems
BS EN 1264 Floor heating. Systems and components
BS 1756 Methods for sampling and analysis of flue gases.
BS EN 1856 Chimneys. Requirements for metal chimneys
BS EN 1859 Chimneys. Metal chimneys. Test methods
BS 2790 Specification for design and manufacture of shell boilers of welded
construction
BS EN ISO 4126 Safety devices for protection against excessive pressure.
BS 4856 Methods for testing and rating fan coil units, unit heaters and unit
coolers
BS 5410 Code of practice for oil firing.
Part 5
Section 7 - Page8
range $-40 DC to +700C
BS 5440 Installation and maintenance of flues and ventilation for gas
appliances of rated input not exceeding 70 kW net (1st, 2nd and
3rd family gases).
BS 5854 Code of practice for flues and flue structures in buildings
BS 5885 Automatic gas burners
BS 5978 Safety and performance of gas-fired hot water boilers (60 kW to 2
MW input).
BS 5986 Specification for electrical safety and performance of gas fired
space heating appliances with inputs 60 kW to 2 MW
BS 6332 Thermal performance of domestic gas appliances.
BS 6644 Specification for Installation of gas-fired hot water boilers of rated
inputs between 70 kW (net) and 1.8 MW (net) (2nd and 3rd family
gases)
BS 6798 Specification for installation of gas-fired boilers of rated input not
exceeding 70 kW net
BS 7190 Method for assessing thermal performance of low temperature hot
water boilers using a test rig
BS EN 12953 Shell boilers
Part 5
Section 7 - Page9
Section 8 Circulating Pumps
Contents
Section 8 Circulating Pumps 1

8.2 Gauges 2
8.3 Centrifugal pumps 2
8.4 Twin pump sets 5
8.5 Glandless pumps 5
8.6 Sump pumps 5
8.7 Semi rotary Hand pumps 5
8.8 Oil circulating and oil transfer pumps 6
8.9 Guards 6
8.10 Belt drives 6
8.11 Closed system pressurisation 6
8.12 Cold Water Booster Set 7
Section 8 Circulating Pumps
Pumps shall have the performance and duty as stated elsewhere.
All pumps shall be suitable for the service pumped and the operating temperatures and
pressures stated elsewhere.
Pumps shall be capable of providing the duties required at the design operating conditions.
The Contractor shall recalculate the total system resistance based upon the final plant selection
and installed drawings and revise the pump duty as necessary to achieve the design flow rate.
The Contractor shall similarly reselect the necessary electrical requirements or any other
variation in associated equipment caused by a change in system pressure drop.
Pumps shall be type tested in accordance with BS EN ISO 5198 and BS EN ISO 9906.
Performance curves showing head, volume flow rate, efficiency and absorbed power of each
pump shall be submitted to the CA prior to equipment being ordered. Pump curves shall
indicate performance under all likely operating conditions. Pump test data shall comply with BS
EN ISO 9906 and BS EN ISO 5198. Data shall be related to pump speed to allow the effect of
speed changes to be assessed.
Pumps shall be selected to ensure that they are not operating at the extremes of their range by
basing the selection on a mid range impeller.
Where pumps are operated under variable speed control then they shall be selected to the right
hand side of the best efficiency point (BEP). A constant speed pump shall be selected within +/-
20% of the BEP. For constant flow pumps the contractor shall allow for trimming of the impellor
at commissioning.
All pumps shall have the motor, motor frame, impeller casing and drives of sufficient size to
allow the capability of a 10% minimum increase in head generated at the stated flow rate by
increasing the impeller size only. The motor shall be selected such that the power curve does
not cross the pump curve at any point (non-overloading).
Pumps shall comply with the requirements of BS EN 60335-2-51, BS 4082 Parts 1 and 2 and
BS 5257, as applicable.
Connecting pipework shall be arranged to ensure that no stresses are transmitted to the pump
casings.
Pumps shall be provided with anti-vibration mountings and flexible connections. The Contractor
shall ensure that the complete unit is effectively balanced to eliminate noise and vibration.
Pumps shall be arranged to be fully accessible for maintenance with adequate space to allow
motors to be safely removed from the pump assembly and with space for left available lifting
equipment if required.
Single case twin impeller/twin motor pumps shall be provided with a blanking plate to allow one
pump to continue operating while the motor of the other is removed.
Unless otherwise stated pumps shall have a maximum sound pressure level of 75 dBA at a
distance of 1 metre
Part 5
Section 8 Page 1
Minimum pumping efficiency shall be 70-75% at the stated duty unless stated otherwise.
Pumps on closed circuit systems shall be selected with a maximum operating speed of 1450rpm
unless otherwise stated or agreed with the CA.
Motors shall comply with the relevant sections of this specification. All motor selections shall be
agreed with the CA prior to the equipment being ordered.
Where stand-by pumps are indicated with automatic change-over, the change-over shall be
initiated and verified by means of flow sensing devices of an approved type. Non-return check
valves, selected to have low resistance flow, shall be incorporated in each discharge line.
Each pump shall be fitted with an isolating valve on the inlet and outlet connections. Valves and
strainers shall be pipeline size, not connection size and shall be in accordance with the relevant
sections of this specification.
Pump connections shall be provided with flanges or unions, as appropriate, to permit the
pipework to be removed for casing and impeller inspection and cleaning without draining the
system or major dismantling of pipework.
Pump connections shall be screwed to BS 21 for sizes up to 50mm diameter, and flanged to BS
EN 1092 to suit the system maximum pressure on sizes 65mm and above.
Pumps shall be complete with a drain plug and, except where the pump is inherently self-
venting, a manual air vent.
Bedplates, incorporating drain pans shall have a piped drain arranged to discharge over a
protected tundish.
The contractor shall be responsible for providing all dimensions and details to enable pump
bases to be set out.
Equipment shall be arranged so that is safely accessible for maintenance.
8.2 GAUGES
Each pump shall be provided with two pressure gauges, one connected to the suction side and
one to the discharge side.
Where stand-by pumps are installed, one pair of gauges shall be so connected with isolating
cocks that the pressure head of each pump can be read.
8.3 CENTRIFUGAL PUMPS

General
Pumps shall be provided with cast iron casings unless otherwise stated.
Shafts shall be stainless steel and impellers shall be manufactured from high grade gunmetal or
bronze as indicated. Shafts shall be corrosion resistant.
Shaft seals shall be the drip-less mechanical type suitable for the operating conditions.
Pumps shall be suitable for mounting on a prepared base, being either concrete or inertia type
where indicated.
Horizontal Split Case Pumps
A. Pump Casing
Part 5
Section 8 Page 2
The pump casing shall be split and the halves shall be accurately machined, bolted and
doweled together. The pump shall be of the double suction type. A non-asbestos type gasket
material shall be furnished between the casing halves. The casing material shall be close-
grained cast iron to BS1452 Grade 220 with a minimum tensile strength of 2300 kg/cm2.
Removal of the uppercasing half shall permit removal of the complete rotating assembly without
disturbing piping connections. Pump efficiency shall be a minimum of 80%.
The pump casing shall be designed for the scheduled working pressure and shall be
hydrostatically tested. Suction and discharge flanges shall be drilled to British Standards and be
machined flat face.
The pumps shall be fitted with bronze renewable case wear rings indexed with a dowel pin for
fixed positioning.
B. Impeller
The impeller shall be of high-grade gun metal (Bronze) to BS1400 Grade LG2-C. The impeller
shall be an enclosed type double suction design, hydraulically and dynamically balanced. The
impeller shall to be securely mounted on the stainless steel shaft, and attached using a stainless
steel impeller key. The impeller shall be locked in position using threaded sleeves.
C. Pump Shaft
The pump shaft shall be manufactured from high-grade stainless steel to BS970 Grade 431S29
and ground to fine limits.
D. Bearings
The pump shaft shall be adequately supported by the pump bearings which shall limit the shaft
deflection to 0.05mm.
The bearings shall be the ball type, pre-packed with high temperature grease and shall be
locked to the shaft using positive locks of ample size to withstand the axial thrust loads.
E. Shaft Seal
The seals shall be flexible bellows type having a carbon face running against a stationary
ceramic seat. The liquid cavity shall be sealed off at the pump shaft by an internally-flushed
mechanical seal with ceramic seal seat and carbon seal ring these seals shall be suitable for
continuous operation at 107oC.
F. Shaft Sleeves
Bronze shaft sleeves shall be firmly attached to the pump shaft through threading and locking
means. The shaft sleeve design shall prevent corrosion and wear to the shaft. A replaceable
bronze shaft sleeve shall completely cover the wetted area under the seal.
G. Base, Coupling and Guard
The pumps shall be mounted on a heavy-duty mild steel channel and directly connected though
a heavy-duty flexible coupling to a horizontal motor. The base shall be provided with a drip rim.
The pump manufacturer shall provide a coupling guard, which shall be mounted between the
pump and motor and attached firmly to the base. The pump and motor assembled set shall be
supplied factory mounted on heavy-duty mild steel channel frame. The pump set assembly shall
be fully treated and painted with anti-corrosive epoxy paint system prior to dispatch from the
factory.
H. Motor
The motor shall be sized to operate continuously without exceeding the horsepower rating
regardless of the flow and head throughout the entire range of operation. The motors shall be 4-
pole TEFC operating at a speed of 1450RPM. Windings shall have Class F insulation and
Part 5
Section 8 Page 3
shall be mounted on a common base plate and be connected to its motor via a shrouded flexible
coupling.
Pump and motor shall be factory aligned, and shall be realigned by the Contractor after
installation.
Each pump shall be factory tested in accordance with Hydraulic Institute Standards. It shall
then be thoroughly cleaned and painted with at least one coat of high-grade machinery enamel
paint prior to shipment. Factory test Certificates shall be provided. When used in a variable
speed pumping system the motor shall be suitable for use with the selected VSD or VFD etc.
Long Coupled End Suction Pumps
The complete pump unit shall consist of pump, base plate, coupling guard and electric motor.
A. Pump Casing
The pump casing shall be accurately machined, bolted and doweled together. A non-asbestos
type gasket material shall be furnished between the casing halves. The casing material shall be
close-grained cast iron to Class 35-40 ASTM or EN-JL1040 DIN W.-Nr. Pump efficiency shall be
minimum of 85%.
The pump casing shall be designed for the imposed working pressure and shall in all cases be a
minimum of 16 bar and shall be hydrostatically tested. Suction and discharge flanges shall be
drilled to British Standards and be machined flat face.
Pump and motor are mounted as separate units on a common base plate and connected via a
flexible coupling.
B. Impeller
The impeller is hydraulically as well as dynamically balanced. The shaft sealing is by means of a
replaceable shaft sleeve (stuffing box versions). The shaft seal shall be type BAQE. The
impeller shall be high-grade gun metal (Bronze) to BS1400 Grade LG2-C. The impeller shall to
be securely mounted on the stainless steel shaft,
C. Pumps Shaft, Base, Coupling and Guard
The pump shaft shall be manufactured from high-grade stainless steel to BS970 Grade 431S29
and ground to fine limits.
The pumps shall be mounted on a heavy-duty mild steel channel and directly connected though
a heavy-duty flexible coupling to a horizontal motor. The base shall be provided with a drip rim.
The pump manufacturer shall provide coupling guard, which shall be mounted between the
pump and motor and attached firmly to the base. The pump and motor assembled set shall be
supplied factory mounted on heavy-duty mild steel channel frame. The pump set assembly shall
be fully treated and painted with anti-corrosive epoxy paint system prior to dispatch from the
factory.
D. Motor
The motor shall be sized to operate continuously without exceeding the horsepower rating
regardless of the flow and head throughout the entire range of operation. The motors shall be 4-
pole TEFC operating at a speed of 1450RPM and enclosure class IP55. Windings shall have
Class F insulation and shall be mounted on a common base plate and be connected to its
motor via a shrouded flexible coupling.
When used in a variable speed pumping system the motor shall be suitable for use with the
selected VSD or VFD etc.
Pump and motor shall be factory aligned, and shall be realigned by the Contractor after
installation.
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Section 8 Page 4
Each pump shall be factory tested in accordance with Hydraulic Institute Standards. It shall
then be thoroughly cleaned and painted with at least one coat of high-grade machinery enamel
paint prior to shipment. Factory test Certificates shall be provided.
8.4 TWIN PUMP SETS

Twin pump sets shall comprise direct in-line pumps connected in parallel with common inlet and
outlet connections.
The assembly shall incorporate non-return check valves to isolate the stationary pump.
Twin pump sets shall be suitable for mounting on a prepared base or on wall brackets as
indicated.
Impeller and motor assemblies shall be readily removable and a blanking flange shall be
provided.
8.5 GLANDLESS PUMPS

Canned rotor and glandless pumps up to 2 kW input power shall comply with BS EN 60335-2-
51.
8.6 SUMP PUMPS

Submersible sump pumps shall be provided with fully waterproof motors suitable for the
application and to the correct IP rating.
Pumps shall be provided with a flexible electrical harness capable of permitting withdrawal from
the sump. Each pump shall be complete with a chain and guide rails to enable withdrawal.
Each pump shall be protected by a removable non-ferrous strainer on the suction.
Suction lift pumps shall terminate with a foot valve of diameter not less than the pipework. A
non-return valve shall be provided on each pump discharge.
Duplicate pumps shall be provided with isolation valves on each pump discharge. Level
controls shall be staggered to run the pumps as duty and support. Lead pump changeover
facilities shall be provided.
Sump pumps shall operate automatically under level control and high and low level controllers
shall be provided. A high level alarm to indicate when normal high water level is exceeded shall
also be provided.
A locally mounted control panel with on/off/hand/auto control, starter, and isolator shall be
provided. Facilities for remote monitoring shall be provided as indicated.
Studs, bolts, nuts, screws and washers shall be stainless steel.
8.7 SEMI ROTARY HAND PUMPS

Semi rotary hand pumps shall be manufactured from materials suitable for the particular
requirements.
Pumps shall have a foot valve and strainer and be fixed securely in position to allow for ease of
manual operation.
Pumps for boiler rooms and plant room drainage shall be suitable for use with hot water at
temperatures up to 98C.
For drainage of oil storage catch-pits, shaft seals of the O ring pattern shall be used.
A non-return valve and isolating valve shall be provided on the pump discharge.
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Section 8 Page 5
8.8 OIL CIRCULATING AND OIL TRANSFER PUMPS
Oil pumps shall be electrically driven positive displacement screw or gear type or of the
centrifugal type, suitable for the viscosity and temperature of the grade of oil to be pumped as
stated elsewhere. An integral pressure relief valve shall be fitted to positive displacement
pumps.
Pumps for transferring oil from a bulk storage tank shall be started manually and switched off
automatically by means of a float switch fitted in the service tank unless otherwise stated.
8.9 GUARDS
All power transmission shafts, belts and pulley drives shall be guarded and be in compliance
with PD 5304.
Guards shall be installed to prevent inadvertent contact with dangerous parts of machinery and
the mesh size and/or the location of the guard shall prevent finger contact with any enclosed
danger point.
Construction and installation shall ensure strength and rigidity and it shall not be possible to
remove any guard or access panel without the aid of a tool.
Where required removable access panels shall be provided to permit tachometer readings to be
made of motor and drive shafts and belt tension to be tested.
8.10 BELT DRIVES

Belt drives shall comply with BS 3790. A minimum of two belts shall be provided and the drive
sized so that the rated power output of the motor can be transmitted with one belt removed.
Belts shall be of rubber and fibre V section unless otherwise indicated.
Provision for positive adjustment of belt tension and alignment shall be made.
Pulleys shall be correctly aligned in accordance with the manufacturer's requirements.
8.11 CLOSED SYSTEM PRESSURISATION

Closed system pressurisation units shall be complete package units containing expansion
vessel(s), pumps, break tank and all controls, interlocks and ancillary equipment necessary to
maintain the system operating conditions.
The whole unit shall be factory wired and shall be controlled via an integral control panel.
Where required all ferrous metal shall be factory primed and gloss painted on site to an
approved colour.
Expansion vessels shall be in accordance with BS 4814. Vessels shall be an all welded steel
construction and contain a removable butyl rubber membrane or diaphragm enclosing a
permanent pre-charged air cushion.
Each unit shall be provided with a sufficient number and capacity of expansion vessels. These
shall handle the full expansion volume of the system from normal cold fill or ambient conditions
to normal working temperature.
The actual system water contents and the capacity of the pressure vessel and break tank shall
be calculated by the Contractor to achieve and accept the total system contraction/expansion
volume of water.
The system pressure shall be maintained with the pressurisation pump operating for only 20%
of the total operating hours and the vessels shall be sized to prevent over frequent operation of
the pump.
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Section 8 Page 6
The integral break tank shall be manufactured from GRP and be complete with a removable lid,
ball valve inlet, overflow connection with discharge pipe, drain cock and outlet connection to the
pump. The ball valve inlet shall comply with Water Supply Regulations.
Duplicate direct-coupled pumps shall be provided comprising cast iron casing with gunmetal
impeller, stainless steel shaft, motor, mountings and fittings or as otherwise indicated.
Pumps shall be complete with drain plug, isolating valves and neoprene/rubber flexible
compensators. Pressure test points shall be provided on the suction and discharge
connections.
Automatic changeover of the pumps shall be provided on pump failure. The changeover shall
be remotely indicated. Provision shall be incorporated for periodic variation of the duty pump.
Each pump shall be fitted with an hours run counter. The over frequent starting of the duty
pump shall be indicated.
High and low level pressure switches shall be provided for pump control. Separate high and low
pressure switches shall be provided to interlock and shut off the boiler or chiller plant if the
system operating limits are exceeded. The switches shall be hand reset. A low-level alarm
shall be provided on the break tank to stop the pump-set if the water level in the tank drops to a
dangerous level.
Facilities for the transmission of the status of pumps, operating pressures and alarms from the
unit to the main control panel or building management system, as indicated, shall be provided.
A safety valve shall be provided on closed systems with expansion vessels wherever required
by BS 7074 Parts 1 and 2.
For initial system filling, a proprietary flexible hose system, complete with water stop valve,
backflow prevention devices, braided hose, isolating valves, strainer etc shall be provided and
comply with Water Supply Regulations. Suitable wall mounted racking shall be provided to
store the hose filling equipment.
8.12 COLD WATER BOOSTER SET

Cold water booster sets shall be self contained, fully automatic packaged units capable of the
required duty and pressure as stated elsewhere. Each unit shall be supplied assembled and
tested as a complete unit and suitable for the ambient operating conditions.
Hydraulic and performance test data shall be submitted to the CA prior to despatch from the
manufacturers works.
Equipment, fittings, jointing, valves etc in contact with water shall be approved by the WRAS for
the application and listed in the current edition of the Water fittings and materials directory.
Equipment not complying shall be rejected and replaced at no cost to the contract. All headers
and interconnecting piping shall be stainless steel to DIN W.-Nr. 1.4571. Common section and
discharge headers shall have threaded ends or flange adapters. The entire assembly shall be
complete with full port ball valves, check valves and pressure gauges for each pump.
The set shall be complete with jockey, duty, support and standby pumps to meet the duty as
indicated as per the equipment schedules. Unless otherwise stated the unit shall have a
maximum sound pressure level of 60 dBA at a distance of 1 metre. Pumps, motors and drives
shall comply with the appropriate clauses of the specification. Each duty pump on the booster
set shall be provided with an individual VFD where specified in the equipment schedules or in
any case where the booster set duty exceeds 10 l/s.
Pumps shall be multi-stage type with mechanical seals, cast iron bodies, stainless steel shafts
and impellers. Pumps shall be capable of providing the required performance indicated with a
minimum efficiency of 66%.
The unit shall be provided with a membrane pressure vessel that is sized to maintain the
required system duty while limiting the number of starts by the duty pump to a maximum of 15
Part 5
Section 8 Page 7
per hour unless indicated otherwise. Pressure vessels shall be constructed of mild steel and
shall be fitted with an internal diaphragm on non toxic material capable of holding the entire
water contents of the vessel. The unit shall be capable of withstanding a minimum working
pressure of 10 bar or 1.5 times the working pressure whichever is the greater unless otherwise
indicated.
Where booster sets are VFD controlled a BS 4814 hydro-accumulator shall be provided to allow
shutdown during periods of no demand.
The motors shall be totally enclosed fan cooled type (TEFC) to I.E.C. standards with insulation
class (F) and IP54 protection and rated for continuous operation up to 50 oC ambient.
An automatic control panel with hinged access door, mains isolator and controls for operation
and safety protection shall be provided as part of the unit. The panel shall include facilities for
the transmission of plant status to the BMS via a direct communication protocol such as LON,
BacNet or M-Bus. Visual LED display and monitoring shall included for low water level, pump
run and tripped status, system pressure and fault alarms or as otherwise indicated.
The panel shall include the following features, unless otherwise indicated:
Hand/off/auto switch for each pump

Low water cut out alarm
Auto rotation of duty pump
Auto pump change over
Door interlocked isolator
Adjustable run and start delays
Hours run counter for each pump
A low level alarm shall be provided in the water tank, together with a low pressure switch on the
incoming water pipework to prevent the unit from operating with low inlet water conditions.
Pump operation shall be controlled by the manufacturers proprietary intelligent controller (PLC
or DDC) and shall be capable of the following functions:
Constant pressure control through continuously variable adjustment of speed of the pumps
(where variable speed sets are specified|)
On/off control of the pumps under low flow.
Automatic changeover to on/off operation in case of defective frequency converters
Automatic cascade control of pumps
Set point influence: (i) proportional influence (proportional pressure) (ii) external set point
influence.
Pump and system monitoring functions to BMS shall be as listed:
a. inlet pressure
b. motor protection
c. pump status
d. pump fault
e. general alarm/fault
f. high / low pressure alarms
g. Display and indication functions on panel
h. BUS BacNet Lon or other approved network communication
The unit shall be mounted on a single galvanised steel base and shall incorporate anti-vibration
provision to prevent the transmission of noise or vibration to the structure or connecting
pipework. Where required all ferrous metal shall be factory primed and gloss painted on site to
an approved colour.
Part 5
Section 8 Page 8

dimensions)
BS 3790 Specification for endless wedge belt drives and endless V-belt
drives
BS 4814 Specification for expansion vessels using internal diaphragm,

sealed hot water systems
BS EN ISO 5198 Centrifugal, mixed flow and axial pumps. Code for hydraulic
performance tests. Precision class.
BS 5257 Specification for horizontal end-suction centrifugal pumps (16

bar)
PD 5304 Safe use of machinery
BS 7074 Application, selection and installation of expansion vessels and

ancillary equipment for sealed water systems. Code of practice
for domestic heating and hot water supply.
BS EN ISO 9906 Rotodynamic pumps. Hydraulic performance acceptance tests.

Grades 1 and 2.
BS EN 60335-2-51 Specification for safety of household and similar electrical

appliances. Particular requirements. Stationary circulation
pumps for heating and service water installations.
Part 5
Section 8 Page 9
Section 9 Inspection, Testing & Commissioning
Contents
Section 9 Inspection, testing & commissioning 1
9.1 Definitions 1
9.3 Testing and commissioning programme 3
9.4 Reports 3
9.5 Fuel for testing 4
9.6 Instruments for testing and commissioning 4
9.7 Inspection by Employers Insurance company 4
9.8 Manufacturers off-site testing 4
9.9 System demonstration 5
9.10 Load and performance simulation tests 5
9.11 Pipework pressure testing 5
9.12 Ductwork air leakage testing 7
9.13 Refrigeration systems 7
9.14 Electrical services 8
9.15 Pre-Commissioning checks 8
9.16 Commissioning 8
9.17 Fire fighting systems 10
9.18 Authority witnessing and testing 10
9.19 Testing and commissioning record sheets 11
9.20 Performance testing 11
9.21 Post practical completion 11
9.22 Referred Documents 12
Section 9 Inspection, testing & commissioning
9.1 DEFINITIONS
Where used in the specification the following definitions shall apply
Commissioning the advancement of an installation from the stage of static completion to

working order to the specified requirements.
Testing the measurement and recording of specified quantifiable characteristics of an

installation or parts thereof. This includes off site testing.
Setting to work the process of setting a static system in motion
Regulation the process of adjusting the rates of fluid flow in a distribution system to achieve
specified values
Environmental testing the measurement and recording of internal environmental conditions
System proving the measuring, recording, evaluating and reporting on the seasonal
performance of the systems against their design values
System demonstration demonstrating the capability of the installation to achieve and

maintain the specified performance criteria
Fine-tuning the adjustment of the system where usage and system proving has shown such a
need. This may include the re-assessment of design values and control set points to achieve
the required system performance.
Pre-commissioning checks systematic checking of a completed installation to establish its

suitability for commissioning.

The entire commissioning and performance testing of the Works shall be undertaken by an
approved commissioning specialist employed by the installer unless stated otherwise. The
installer shall be responsible at all times for the supervision of the commissioning specialist and
providing all necessary attendances.
The installer shall ensure satisfactory completion of the testing and commissioning together with
the recording of results.
At the time of tender the installer shall declare the commissioning specialist. A complete
company profile including recent projects, references, a preliminary commissioning programme
and "method of working" must be submitted prior to approval. The CA reserves the right to
reject any company considered unacceptable.
Appoint a competent person (CAs approval required) to supervise the whole of the testing,
commissioning, system proving, system demonstration and instruction of the employers staff.
Co-ordinate the activities of all specialised personnel, including manufacturers representatives,

together with providing any attendance required.
Undertake the following:
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Section 9 Page 1
Testing, pre-commissioning checks, commissioning, regulation and setting to work of the
Works
Prepare comprehensive programmes, commissioning plans, schedules and method
statements and procedures supported by risk assessments for the pre-commissioning
checks, setting to work, commissioning, system proving and environmental testing of the
complete Works
Provide and submit standard performa for the various requirements for commissioning
records and certification for agreement with the CA prior to commencement of the Works
Monitor progress against the program of works and provide weekly reports detailing progress
of testing and commissioning activities
Maintain a diary/log of all significant activities and document any faults, snags or queries and
how these were resolved. The diary/log shall be fully noted and available for inspection by
the CA at any time.
Measure and reconcile noise levels at agreed locations to verify compliance with design
criteria
Ensure all certification is attained and witnessed as necessary for inclusion in the record
documentation
Provide and submit a report for every test, demonstration, balance or commissioning activity
witnessed, together with an CAing appraisal on the performance, either on or off-site
As necessary co-ordinate and liaise with the Employers representative
Co-ordinate, give notice and obtain all approvals from the necessary authorities
Performance testing, system demonstration, system proving or environmental and capacity
testing, until commissioning of the system is completed to the satisfaction of the CA.
If the Works include extensions, modifications or alterations to existing systems the installer
shall allow for the balancing and commissioning of the new works in conjunction with the re-
balancing of the existing works.
The CA will examine, subsequent to setting to work and regulation of the Works the results of
the commissioning and the documentary records thereof.
The object of the witnessing stage is to enable the CA to establish a level of confidence in the
commissioning results being presented. The extent and proportion of results to be witnessed by
the CA will be at the discretion of the CA.
The CA will only witness test proceedings to confirm recorded results and determine if the
specified requirements have been satisfied.
If the tests fail to demonstrate that the plant and equipment are properly installed and
functioning correctly, the cause of the failure shall be investigated. Should the failure be due to
incorrect or faulty work then without delay the Contractor shall carry out such remedial
measures and adjustments as may be necessary and repeat the commissioning and testing
procedure to the satisfaction of the CA. If faults are not rectified to the satisfaction of the CA,
the CA may exercise the right to demand removal of that particular part of the installation and it
be replaced with new at no expense to contract or delay to the programme.
Where it is not possible at the particular time of commissioning and testing for full load
conditions to be obtained or simulated the Contractor shall undertake to repeat such operations
of full load or a simulation thereof at a time when this can be achieved as agreed with the CA.
The Works shall be fully tested, commissioned and be fully operational prior to witnessing and
inspection by the CA.
Where portions of the work are required to be commissioned and tested separately, then upon
final completion, demonstrate to the CA that all the several portions are capable of proper
simultaneous operation in accordance with the requirements of the specification.
In cases where the construction programme is such that the commissioning, testing, balancing,
adjustment, needs to be undertaken in an area of the building taken over and occupied by the
Employer, then take all necessary precautions against and be responsible for any damage
caused whilst working in such areas for that purpose.
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Section 9 Page 2
All certification documents shall be submitted to the CA for examination before any system is
offered for final acceptance.
Provide a written statement to the CA confirming that each installation has been correctly tested
and commissioned and that the performance requirements can be achieved.
The installer shall ensure that all testing and commissioning undertaken on specialist equipment
by a manufacturer is completed to the satisfaction of the commissioning specialist and to the
satisfaction of the CA.
Any special equipment not covered by clauses in this section of the specification shall be tested
in accordance with the manufacturers recommendations and with any particular clauses stated
elsewhere.
Include for carrying out the tests as stated, together with such additional inspections and tests
during the process of manufacturing, erection or otherwise as the CA shall prescribe, to prove
the physical characteristics of all materials and manufactured parts incorporated in the works to
ensure the overall suitability of all equipment, and to satisfy the requirements of the Local
Authority.
All costs, apparatus, measuring equipment, instruments, and meters required for inspection,
testing, balancing, regulation, setting up, etc., of the systems shall be deemed to be included for
by the installer.
It will be necessary for the building to be in an acceptable condition prior to commissioning and
that all building works, including finishing trades such as painting and decorating are complete
prior to commissioning of any air systems.
Indicate on drawings where access is required into ceiling voids, service risers etc. and ensure
these points are not closed up until the commissioning and testing is complete.
9.3 TESTING AND COMMISSIONING PROGRAMME

Within one month of appointment, unless stated otherwise, submit to the CA a preliminary
commissioning programme. The programme shall be of the itemised bar chart format and shall
clearly indicate the proposed approach and all key activities.
The installer and commissioning specialist shall together produce the detailed and final
commissioning programme. This document shall amplify and expand upon the preliminary
commissioning programme and include all necessary detailed method statements and
procedures.
The programme shall be fully integrated with all other site activities envisaged to be occurring
during the period of commissioning and shall also indicate all necessary witnessing and
acceptance dates.
9.4 REPORTS
Submit to the CA written reports signed by a qualified person to confirm that:
Prior installation - all system designs can be commissioned

Post installation - installations complete and ready for commissioning
System cleanliness - specified cleanliness has been achieved
Pre-commissioning checks completion of pre-commissioning checks
Commissioning and testing to demonstrate compliance with specified requirements and
confirm that each installation has been correctly tested and commissioned and achieving the
specified performance.
The final documentation of reports and completed record sheets shall be compiled into a
systems commissioning manual for inclusion in the operating and maintenance documentation.
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Section 9 Page 3
9.5 FUEL FOR TESTING
Fuel for testing and operating the Works will be by others unless stated otherwise.
9.6 INSTRUMENTS FOR TESTING AND COMMISSIONING

All instruments shall be provided by the installer or the commissioning specialist.
Submit to the CA a schedule detailing the equipment and instruments to be used in the testing
and commissioning of the complete works.
Ensure all instruments are correctly calibrated and are marked with a unique reference for
identification.
Submit evidence of correct calibration of all instruments used in connection with commissioning
and testing to the CA prior to commencement of the works. Test methods shall be
demonstrated to the CA where required.
Instrument calibration data and identification shall be included on the respective test record
sheets.
9.7 INSPECTION BY EMPLOYERS INSURANCE COMPANY

Where indicated elsewhere installations, equipment, plant or materials are to be inspected by a
representative acting for the Employers insurers.
The installations, equipment, plant or materials shall satisfy the insurance companys
requirements in all respects.
Provide a programme for the inspection and certification and inform the CA when the installation
or equipment is ready for examination.
Ensure all necessary information is provided to enable the insurers to approve the design before
manufacture.
Arrange for the attendance of the insurance companys representative at agreed stages of
manufacturer and installation and provide all necessary attendance, access and facilities for
inspecting and testing as is required.
No equipment or installations subject to inspection and certification will be accepted on behalf of

the employer unless a satisfactory certificate has been received from the insurers.
All costs associated with such inspections shall be included in the contract price unless stated
otherwise.
9.8 MANUFACTURERS OFF-SITE TESTING

Equipment shall be tested for duty and performance at works prior to despatch. Test to the
appropriate British Standard or the requirements/standards stated elsewhere, if these exceed or
are different to the British Standard.
Testing shall be to the satisfaction of the CA and the Employers insurance representative.
Duplicate certificates of all such tests shall be provided to the CA within 3 days of testing and
copies included in the operating and maintenance documentation. All certificates shall be
signed by a competent person and witnessed.
For certain equipment manufacturers tests will be required to be repeated on site to prove the
operating performance.
Each item of equipment tested at works shall be stamped or fitted with a plate to provide the
following minimum data:
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Section 9 Page 4
Normal working conditions
Test conditions
Individual equipment reference
British Standards applicable
Date of test
Manufacturers details
The above information shall be included on the test certificate for each item of equipment
together with details of the test location.
9.9 SYSTEM DEMONSTRATION

Subsequent to the completion of all testing and commissioning to the satisfaction of the CA,
when directed by the CA operate the plant and demonstrate that the overall systems function
correctly in accordance with the requirements of the specification.
Full running and operation for a period of time considered suitable for the project size (and a
minimum of 1 week) shall be agreed with the CA shall be for this demonstration and this period
shall be allowed for in the programme to be submitted as specified above.
During this period the installer shall be responsible for the recording of results and the operation
and maintenance of the plant. If appropriate, use this time to train the Employer's staff in the
operation and maintenance of the systems.
Provide an operational report of the demonstration and print out of the conditions maintained
within the space for a period of 48 hours.
9.10 LOAD AND PERFORMANCE SIMULATION TESTS

Unless stated otherwise items of equipment indicated below shall be load, duty and
performance tested at works under simulated conditions.
Simulated conditions and testing procedures shall be approved by the CA prior to testing.
Ensure that the tests prove the performance of the equipment when finally installed on site.
Where manufacturers works facilities are not available for the simulated tests, the installer shall
arrange for testing to be undertaken at an approved laboratory, research establishment or other
suitable and agreed location at no additional cost.
All costs, including the expenses of the CA and Employers representative, shall be included in
the contract price.
Simulated tests shall be carried out on the following equipment:
Control panels and motor starter panels (functional tests only)

Air handling units
Packaged chiller units
Cooling Towers
Boilers
Circulation Pumps and Packaged booster sets
Terminal units (VAV boxes and Fan coil units)
CRAC units
The results of such tests shall in no way relieve the installer of his responsibilities to ensure that
all materials and equipment used in the Works are suitable for the applications and conditions of
operation.
9.11 PIPEWORK PRESSURE TESTING

General
Part 5
Section 9 Page 5
Comply with the procedures given in the HVCA Guide to good practice for site pressure testing
of pipework and ensure all safety precautions detailed in the necessary HSE guidance notes are
adopted.
When a section of any installation is completed and ready for testing the installer will advise the
CA, giving three working days notice, for the CA to witness such tests at the discretion of the
CA.
Provide a blanked connection to accommodate a check gauge in addition to the gauge used for
test purposes.
All buried or concealed pipework shall be tested before any permanent covering is applied.
Pipework installations shall be hydraulically tested after erection and before thermal insulation is
applied. For welded mains every weld shall be hammered while under pressure and the test
period may be extended to allow this activity to be undertaken.
Test section by section as the work proceeds.
The term pipework installation shall include valves, heat exchangers and controls etc, subject
to the system pressure when in operation.
The installer shall be responsible for ensuring that all valves, ancillaries and equipment are
suitable for the test gauge pressure.
Pressure testing of water pipework systems shall be carried out generally in accordance with BS
6880-3 and BS 6700.
Test pressures generally shall be twice the working pressure up to and including working
pressures of 280 kPa and thereafter 1.5 times the working pressure plus 140 kPa.
Tests pressure shall be maintained for a minimum of two hours without loss of pressure or
visible evidence of leakage.
The cleaning and testing of domestic water services shall be in accordance with the
recommendations in BS 6700.
Water mains
Water mains shall be tested to Local Water Authority requirements (DEWA) and the
recommendations of the HVCA Guide to good practice for site pressure testing of pipework for
testing underground CWS mains.
Gravity drainage systems inside buildings
Test section by section as work proceeds and subsequently on completion with all appliances
installed and working.
All soil, waste, ventilation, anti-siphon and rainwater installations shall be tested in accordance
with BS EN 12056.
Systems shall be subject to a separate air and hydraulic test.
On completion of the work, performance tests shall be carried out to simulate the probable
worse conditions in practice.
The installer shall undertake all testing required for local authority approval and the CA shall be
given due notice of all tests.
Underground drainage
Test section by section as work proceeds.
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Section 9 Page 6
On completion of backfilling and compaction carry out testing to the satisfaction of the CA and
all necessary local authorities.
Testing shall be in accordance with BS 8301 and shall include water test and test for
straightness and obstruction.
Gas pipework
Gas pipework shall be pressure tested in accordance with BS EN 12327 and the Gas Board
requirements.
Soundness testing and purging of industrial and commercial gas installations shall comply with
IGE/UP/1 or IGE/UP/1A as appropriate.
Medical gases
Medical gas installations shall be tested in accordance with Hospital Technical Memorandum No
2022.
Dry rising fire mains
Testing of the dry riser installation shall be to the satisfaction of the CA and the Local Civil
Defence.
The pipework shall be hydraulically tested to a pressure of 10 bar (gauge) measured at the top
outlet and the pressure maintained for not less than 1 Hour. During this period all joints and
valves shall be checked for leaks. If any leaks occur the tests shall be repeated after the repair.
On completion of satisfactory pressure testing carry out flow tests. The installer shall arrange
for flow tests to be undertaken and all necessary attendances shall be provided by the installer.
9.12 DUCTWORK AIR LEAKAGE TESTING

Unless otherwise stated for medium and low pressure ducts, the CA shall select at random a
maximum of 10% of the duct system to be tested for air leakage. Tests shall be to the pressures
recommended in DW 144 for the classification of the selected ductwork.
All high pressure ducts shall be air leakage tested.
Air leakage tested in accordance with DW 144 and procedures as DW 143 unless otherwise
indicated.
Tests shall be to the pressures recommended in DW 144 for the classification of the selected
ductwork.
Tests shall be carried out as the works proceed and prior to the application of insulation.
In the event of test failure of the randomly selected section, the CA shall have the right to select
two further sections at random for testing. Where successive failures are identified there shall
be the right to require the installer to apply remedial attention to the complete ductwork system
and carry re-testing at no cost to the contract.
The installer shall provide documented evidence of the calculations used to arrive at the
allowable loss for the section to be tested and the results of the test shall be witnessed and
signed.
9.13 REFRIGERATION SYSTEMS

Procedures for refrigeration systems shall be in accordance with CIBSE Commissioning Code R
and manufacturers instructions for the following:
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Section 9 Page 7
use and handling of refrigerants
pressure and leak testing
evacuation and dehydration
charging and lubrication
preliminary checks
setting to work and adjusting
apparatus and instruments
In the presence of the CA show the correct operation of the refrigeration equipment, that is: air
on/off d.b. and w.b. temperatures for the cooling coil for steps of control together with suction
and discharge temperatures/pressures on the refrigerant side and chilled water flow and return
temperatures (which ever applies), all recorded against the prevailing ambient conditions and
recorded room conditions.
Air cooled condensers and water cooling towers shall be demonstrated to show that correct
refrigerant condensing temperatures and water on/off temperatures can be achieved against
outdoor d.b. and w.b. air temperatures respectively.
9.14 ELECTRICAL SERVICES

Inspection and testing shall be carried out during installation and after completion of the works.
Tests shall be carried out on site after completion to ascertain the insulation resistance of the
conductors, cables and accessories and fittings to earth and between poles, the electrical
continuity of metal sheaths surrounding conductors, and the polarities of all accessories and
fittings, complying with the latest edition of the IEE Wiring Regulations 16th Edition (with
amendments ruling at the date of testing) and the Local Authority regulations.
All tests shall be made in the presence of the CA who shall have been duly notified of the
installers intentions. The CA will require triplicate copies of test certificates covering all tests
carried out on the completed installation.
9.15 PRE-COMMISSIONING CHECKS

The installer shall undertake all necessary pre-commissioning works and checks as detailed in
the CIBSE Commissioning Codes and the BSRIA Application Guides stated elsewhere.
The installer shall submit to the CA a written report, including record sheets, for each system
indicating completion of the pre-commissioning works and checks.
System commissioning shall not commence until the pre-commissioning works and checks have
been completed and accepted as satisfactory by the CA.
9.16 COMMISSIONING
General
Commissioning provisions and procedures shall follow the guidance and recommendations
contained within the following documentation unless stated otherwise:
CIBSE current Commissioning Codes
Series A Air Distribution Systems - High and Low Velocity

Series B Boiler Plant
Series C Automatic Control Systems
Series R Refrigeration Systems
Series W Water Distribution Systems
BSRIA Application Guides
AG 3/89.3 Commissioning of air systems

AG 2/89.2 The commissioning of water systems in buildings
Part 5
Section 9 Page 8
AG 1/91 Commissioning of VAV systems in buildings
AG 1/2001 Pre-commission cleaning of pipework services
Particular attention shall be given to the permitted tolerances in the above documentation.
In addition to the requirements stated elsewhere, the installer shall perform and record the
following:-
Test all equipment in accordance with manufacturers recommendations, checking rotation,

revs, running current on each phase of electrical motors, etc., and recording.
The ventilation and air conditioning systems shall be run without air filters to disperse all dust,
etc., and commission the system before the introduction of the Client's filters.
Check air volumes, sound levels, speeds, running currents and pressures generated of fans.
Check hydraulic pressure drops across all items of equipment.
Check air on/off, water on/off temperatures to all heater batteries, cooler batteries, circuits,
boilers and other relevant plant.
Air distribution systems
Preliminary checks, procedures, setting to work, regulation and measurement of air flow shall be
in accordance with CIBSE Commissioning Code A and as defined in BSRIA Application Guide
AG 3/89.3 - Commissioning air systems.
Pre-commissioning checks shall be as listed in BSRIA Application Guide AG 3/89.3 -

Commissioning air systems.
VAV air distribution systems
Preliminary checks, setting to work and regulation shall be in accordance with CIBSE
Commissioning Code A and BSRIA Application Guides AG 1/91 and AG 3/89.3.
Where variable air volume systems are to be commissioned, these shall be carried out with full
simulated supply air volumes. To achieve this all variable air volume terminal units shall be
supplied with a device, ferrule or control mechanism which shall override the controlling
thermostat and cause the unit to operate at its design maximum volume as stated elsewhere.
Static pressure readings, at design supply volume, shall be taken and recorded for every
variable volume terminal unit.
Where the VAV air supply and extract fans duties are regulated by speed change, the installer
shall arrange for the manufacturer of the variable speed control equipment, the controls system
specialist, the commissioning specialist and CA to attend site together to ensure that the fan
duties are matched over their range.
Where VAV terminal units include for the installation of an integral adjustable volume controller,
fitted after the main unit then the volume shall be set in accordance with the schedule prior to
being fitted within the VAV terminal unit.
In addition the volume regulator calibration shall be checked, by measuring of differential static
pressures across the unit and the reading of the resultant supply air flow from the manufacturers
pressure/air flow characteristic charts.
Air circulation and distribution shall be demonstrated after the systems have been balanced by
the installer to provide the specified air quantities. Pitot tube readings shall be taken in all
ductwork mains and branches together with terminal point readings. Smoke tests may be
required to prove distribution within enclosures and these shall be at the discretion of the CA.
Part 5
Section 9 Page 9
All controls associated with variable air volume system shall be demonstrated and checked at
full, 2/3 and 1/3 partial load operation. In addition all mixing damper systems shall have
minimum fresh air, maximum fresh air, and mixed conditions demonstrated.
Spot checks shall be made in the presence of the CA to ensure correct operation of the terminal
units, including air temperature and pressure checks.
Gas plant and systems
Commission gas fired plant on industrial and commercial premises in accordance with
IGE/UP/4.
Commission gas supply systems in accordance with BS EN 12327
Automatic Controls
Automatic control systems shall be tested and commissioned in accordance with CIBSE
Commissioning Code C.
The installer will be required to demonstrate every function and interlock relating to the
automatic controls. This demonstration shall be conducted under simulated occupancy and
shall include but not be limited to:-
All automatic temperature control functions including high limit and safety cut-outs.

All safety devices and 'position under failure settings' such as normally closed damper
positions; normally open valves; gas cut off valves; isolation of ventilation plant etc., shall be
demonstrated.

All automatic smoke detectors mounted within ductwork and their associated interlocks shall
be demonstrated including the 'plant available for use' facility offered to the Fire Officer in
emergency situations.

All optimiser and time clock energising of plant shall be demonstrated and set to the CAs
requirement. Demonstration of any optimiser shall include the switching of all required plant
during 'non occupation periods' under simulated frost and internal condensation conditions.

All controls associated with the fan coil terminal units. Spot checks shall be made by the CA
to ensure correct operation of the fan coil units including temperature, volume and pressure
checks.
At the completion of the installers commissioning and prior to any final approval from the CA,
simultaneous internal and external dry and wet bulb temperatures shall be taken, witnessed and
recorded. Should the contract programme determine that such temperature recording tests
occur during partial load conditions then the installer will be required to return to site and repeat
the tests. This rechecking shall occur during the months of July/August for air conditioning
systems.
9.17 FIRE FIGHTING SYSTEMS

Fire fighting systems shall comply with the requirements of the local Fire Civil Defence and with
the appropriate sections of NFPA.
9.18 AUTHORITY WITNESSING AND TESTING

As part of the commissioning procedure the installer shall arrange for all necessary checks and
witnessing by the Local Authority, Government Offices, Statutory Authorities, etc.
Such witnessed tests and signed certificates of acceptance shall be obtained from, but not
limited to, the following:-
Dubai Municipality (and or TECOM / JAFZA as applicable)
Part 5
Section 9 Page 10
Civil Defence (or JAFZA as applicable)
DEWA
Etisalat (or DU as applicable)
Police Department
The installer shall be prepared to carry out similar tests at the end of the defect liability period if
the CA deems it necessary to prove that the plant and installation are still functioning in
accordance with the requirements of the specification. The installer shall allow for this item at
the time of tender.
9.19 TESTING AND COMMISSIONING RECORD SHEETS

Maintain a systematic record of commissioning results.
The installer and commissioning specialist shall record results of inspections, checking, testing
and commissioning on record sheets approved by the CA prior to the commencement of the
works.
Where proforma record sheets are not issued by the CA use record sheets as described in
BSRIA Application Guide 3/89.3 for air systems and record sheets as detailed in BSRIA
Application Guide 2/89.2 for water systems.
The installer shall issue the completed sheets to the CA in a logical sequence as the Works
proceed.
Any witnessing or independent checking by the CA shall be carried out solely at the discretion of
the CA as considered necessary.
Two sets of the checking and testing record sheets shall be issued for use during the progress
of the Works and the installer shall provide any further or supplementary test record sheets as
required by the CA to provide a comprehensive record of all tests.
9.20 PERFORMANCE TESTING

Demonstrate the performance of installations including single, standby, multi-duty plants and
systems, and plants specified for future use.
Carry out environmental testing to prove the performance of the systems.
Apply artificial loads or provide test arrangements to simulate the full range of operating
conditions and duties of the systems.
As directed by the CA provide portable seven day space temperature and relative recorders
together with adequate charts.
Demonstrate by measured tests that noise criteria indicated have been achieved.
The outflow from all cold and hot draw off points shall be demonstrated with full bore delivery
from taps. In the case of hot water service installations storage recovery shall be demonstrated
with heat exchanger plant working at rated output.
The performance of sanitary systems shall be in accordance with BS EN 12056.
Air circulation and distribution shall be demonstrated after the systems have been balanced to
provide the correct air quantities. Smoke tests may be required at the discretion of the CA to
prove distribution.
9.21 POST PRACTICAL COMPLETION

During the 12 months after practical completion and in consultation with the CA undertake to:
Assess the need for fine tuning of the installations.
Part 5
Section 9 Page 11
Ensure the requirements for fine tuning are incorporated in the commissioning specification.
Ensure that fine tuning activities are programmed, planned in advance and agreed with the
CA and employer prior to commencement.
Arrange that the relevant parties are retained and appointed to provide input to fine tuning
activities.
Ensure that fine tuning activities are planned with regard to the health and safety of
occupants and such that any disturbance to them is minimised.
Provide a mechanism by which the Employer can provide feedback on the performance of
the building both before and after fine tuning.
Attended meetings as requested by the CA to deal with issues arising from fine-tuning of the
Works.
Costs for fine-tuning and adjustment of the Works during the 12 months after practical
completion shall be included in the contract price

BS 5306 Fire extinguishing installations and equipment on premises

BS 6880-3 Code of Practice for low temperature hot water heating
systems of output greater than 45 kW. Installation,
commissioning and maintenance.
BS 6700 Specification for design, installation, testing and
maintenance of services supplying water for domestic use
within buildings and their curtilages
BS EN 12327 Gas supply systems. Pressure testing, commissioning and
decommissioning procedures. Functional requirements
BS EN 12056 Gravity drainage systems inside buildings
CIBSE current Commissioning Codes

Series A Air Distribution Systems - High and Low Velocity
Series B Boiler Plant
Series C Automatic Control Systems
Series R Refrigeration Systems
Series W Water Distribution Systems
BSRIA Application Guides

AG 3/89.3 Commissioning of air systems
AG 2/89.2 The commissioning of water systems in buildings
AG 1/91 Commissioning of VAV systems in buildings
AG 1/2001 Pre-commission cleaning of pipework services
HVCA (Heating and Ventilating Contractors Association)

HVCA DW 144 Specification for sheet metal ductwork
HVCA DW 143 A practical guide to ductwork leakage testing
The Institution of Gas CAs

IGE/UP/4 Commissioning of gas-fired plant on industrial and
commercial premises
Part 5
Section 9 Page 12
Section 10 Instrumentation
Contents
Section10 Instrumentation 1
10.1 Water temperature gauges/thermometers 1

10.2 Pressure/altitude gauges 1
10.3 Temperature and pressure test points 2
10.4 Digital Temperature Meter 2
Section10 Instrumentation
10.1 WATER TEMPERATURE GAUGES/THERMOMETERS
Water temperature gauges/thermometers shall be installed at the following positions in addition
to any other particular position stated elsewhere or indicated on the drawing:
On flow and return connections to heating and chilled water coils, heat exchangers, and
other plant etc. except on individual fan coil units and induction type terminal units.
On flow and return chilled and condenser water connections to water chillers.
On the inlet and discharge connections to cooling towers.
On the cold feed connection to the HWS cylinders.
On the main HWS secondary flow and return connections to HWS cylinders.
On the flow and return connections to each heating boiler.
On the main common flow header from the water chillers and heating boilers.
On the primary flow and return connections to each HWS cylinder.
On branch return connections to the main return chilled water and heating headers.
On the flue connection to each boiler.
Temperature gauges/thermometers shall be 100 mm diameter gas filled type acting through
mechanical linkage to BS 5235 with matt black case and polished chrome bezel, horizontal or
vertical rigid stem to suit the particular application, black indicating pointer with red hand set and
graduated in C with the range equal to twice the normal operating temperature. The accuracy
of thermometers shall be 1% of the full scale reading.
Where gauges are externally located they shall be of weather resistant construction.
10.2 PRESSURE/ALTITUDE GAUGES

Pressure gauges and gauge cocks shall be fitted to indicate system pressures/heads at the
following positions in addition to any other particular position stated elsewhere or indicated on
the drawings:
On chilled water connections to each water chiller.

On chilled water connections to each Heat Exchanger.
On condenser water connections to each water chiller.
Pressure differential gauges across the suction and discharge connection of every circulating
pump.
On the discharge of every spray pump.
On flow connections to cooling towers.
On the primary heating connections to the HWS cylinders.
On the inlet and outlet connection to pressure reducing valves.
On the inlet and outlet connections to strainers (32 mm and above).
Each pressure/altitude gauge shall be 100 mm diameter and of the bourdon tube operation type
to BS EN 837-1 with red hand set and black indicating pointers, removable front glass face, matt
black case and polished chrome bezel, scale graduated in kPa to twice the pressure range
covered with normal indication mid-point of scale.
The pressure/altitude gauges shall be complete with the correct size of pocket and gunmetal
gauge cock with ebony handle. The accuracy of the gauges shall be 1% of the scale range.
Where gauges are externally located they shall be of weather resistant construction.
Part 5
Section 10 Page 1
10.3 TEMPERATURE AND PRESSURE TEST POINTS
Self sealing test plugs shall be fitted where indicated on the drawings and in addition the
positions listed below or as stated elsewhere. The plugs shall be fitted in to screwed bosses
welded into the pipeline at bends or other locations to ensure full penetration of the gauge probe
and shall be suitably rated for each application.
The test points shall be of gun metal construction and shall have long life ethylene-propylene
diaphragms and be complete with a screwed sealing cap, retaining strap and renewable
washer.
Two insertion pressure gauges and two thermometers shall be provided for each range of
conditions. Pressure gauges shall be of the 60 mm diameter bourden tube type (complete with
twinlock adaptor) and thermometer gauges shall be of the 45 mm diameter bi-metallic type.
Test plugs shall be installed at the following positions in addition to any other particular position
stated elsewhere or indicated on the drawings:
On the flow and return connections to each terminal heat transfer unit.
On each port of every automatic valve.
On flow and return connections to each heating and cooling coil.
On the suction and discharge of each circulating or transfer pump.
On the inlet and outlet connections to strainers (32 mm and below).
On the flow and return of each branch line.
10.4 DIGITAL TEMPERATURE METER

Provide in a suitable protective container for handing to the CA/Employer a digital battery
operated thermometer and interchangeable plug and socket sensing probe to suit test points.

BS EN 837-1 Pressure gauges. Bourdon tube pressure gauges. Dimensions,

metrology, requirements and testing
BS 5235 Specification for dial-type expansion thermometers
Part 5
Section 10 Page 2
Section 11 Noise and Vibration
Contents
Section 11 Noise and Vibration 1

11.2 Attenuators 1
11.3 Air transfer/Cross talk attenuators 3
11.4 Acoustic duct linings 3
11.5 Acoustic enclosures 3
11.6 Acoustic louvers 4
11.7 External acoustic duct lagging 5
11.8 Vibration isolation 5
11.9 Plant bases 8
11.10 Pipework flexible connections 9
11.11 Ductwork flexible connections 9
11.12 Acoustic testing 10
Section 11 Noise and Vibration
Attenuators and other noise control equipment shall be installed to achieve the stated noise
levels with minimum resistance to air flow.
The installer shall be take due consideration of the planning restrictions relating to the acoustic
requirements of the project and ensure compliance with the plant operating at all design
configurations.
All dynamic machinery shall be isolated from the building structure by vibration isolators and/or
vibration isolation materials which shall be selected to suit the machinery.
Noise level data for all items of plant, based on octave band analysis data, shall be submitted to
the CA prior to ordering.
Where sound power levels have been indicated for specific plant items these shall be the
maximum sound power levels.
The installer shall undertake the final selection of sound attenuation equipment to satisfy the
particular performance requirements of the specification and the spatial allowances based on
final plant/equipment selection and final co-ordinated installation drawings
The installer shall undertake the redesign of the final acoustic requirements associated with
approved alternative equipment or materials which subsequently varies the Works in any way
whatsoever.
All attenuating materials shall be inherently non-combustible and limit the surface spread of
flame to Class 1 when tested in accordance with BS 476: Part 7 and shall not emit toxic or
hazardous fumes if ignited. Non-flammable adhesives shall not be used.
All acoustic components shall be made from materials with zero ozone depletion potential (CFC
and HCFC free). Submit to the CA, prior to ordering, written confirmation from the
manufacturer(s) that the products to be installed are CFC and HCFC free.
For all acoustic infill material test evidence must be available and submitted to the CA showing
that the fibres from which the products are made are not classified as a possible carcinogen as
detailed by European Directive 97/69/EC. Fibres shall also comply with the requirements as
stated elsewhere and with HSE guidelines.
Ensure that isolation mounts are not bridged by rigid connections such as electrical conduits or
obstructions underneath the floating equipment.
Provide acoustic seals around all pipework and ductwork penetrations through plantroom
enclosures and other enclosures where acoustic separation is required and indicated.
11.2 ATTENUATORS
Attenuators shall be installed in accordance with manufacturers recommendations.
Attenuators shall be delivered to site and stored with ends sealed to prevent contamination or
damage.
The direction of airflow through the attenuator shall be clearly marked on the external casing.
Part 5
ection 11 -Page 1
Attenuator ratings shall be determined in accordance with BS EN ISO 7235.
Static pressure loss of attenuators shall not exceed those specified at the required airflow.
Attenuators shall be selected such that the following pressure drops are not exceeded for the
various background noise levels:
NR Maximum pressure drop (Pa)

20 30
25 30
30 35
35 45
40 and above 50
The dynamic insertion loss of attenuators shall include the effect of any facing materials. Facing
materials shall be provided for contaminated air streams such as Kitchen exhaust.
Casings shall be manufactured from galvanised mild steel sheet of not less than 0.8mm
thickness with continuously lock-formed joints and constructed to minimise air leakage. The
casing construction shall be in accordance with the ductwork specification for the connecting
ductwork as stated elsewhere.
The acoustic infill material shall be inorganic mineral or glass fibre of a density sufficient to
obtain the specified acoustic performance and packed to eliminate voids due to vibration and
settling. The infill materials shall be non-combustible, inert, non-hygroscopic, rot and vermin
proof. All internal surfaces shall be sealed against fibre release.
The infill material shall be guaranteed against erosion and to enable airway velocities of up to 25
m/s.
Infill materials shall be inherently non-combustible and limit the surface spread of flame to Class
1 when tested in accordance with BS 476: Part 7 and shall not emit toxic or hazardous fumes if
ignited.
Vapour barriers which are not an inherent part of the acoustic material, shall be of minimum
thickness not exceeding 0.07mm and shall be installed unstressed. The material shall be
inherently non-combustible and limit the surface spread of flame to Class 1 when tested in
accordance with BS 476: Part 7 and shall not emit toxic or hazardous fumes if ignited.
Membranes used shall be suitably supported and fixed. Any loss of acoustic performance due
to this treatment will be deemed to be accommodated in the overall performance of the noise
control equipment.
Splitters shall have aerodynamic leading and trailing fairings. Square ends will not be
acceptable unless approved by the CA.
Side attenuator elements shall be fitted as standard to reduce noise breakout and assist in
smooth airflow.
Splitter elements in straight rectangular attenuators shall stand vertically, and shall be a tight-fit
within the casing.
L-section and T-section splitter attenuators shall be designed for smooth air flow. Splitters in
bend attenuators shall be fitted perpendicular to the plane of the bend.
Horizontal splitter elements shall be stiffened to prevent flexing or airway restriction and provide
retention of acoustic infill.
Splitters shall preferably be in a vertical orientation and shall be a tight-fit within the casing. The
configuration shall have a regular splitter/airway dimension across the full width of the unit.
Where required intermediate stiffeners shall be fitted for rigidity.
Part 5
ection 11 -Page 2
In plantrooms it is preferred that attenuators be located immediately before penetration of the
plantroom enclosure but where this is not possible external acoustic lagging shall be installed on
the ductwork between the attenuator outlet and the plantroom enclosure to prevent noise break
in to the distribution ductwork.
Attenuators located in kitchen extract systems shall have an approved protective coating to
permit cleaning and grease removal.
11.3 AIR TRANSFER/CROSS TALK ATTENUATORS

Provide straight through attenuators for air transfer and cross talk applications as indicated
elsewhere.
The air transfer system shall match the acoustic performance of the intervening wall or ceiling
system. If cross talk is being assessed between two adjacent spaces with different noise criteria,
then the lowest criteria shall be used.
For non-ducted type units the attenuator cross section shall be sized to maintain a maximum
pressure drop of 5 Pa.
For ducted type units the attenuator cross section shall be sized to maintain a maximum
pressure drop of 10Pa.
Construction of air transfer/cross talk attenuator shall be as described under the attenuators
clause.
11.4 ACOUSTIC DUCT LININGS

Acoustic linings shall not be used inside ductwork unless indicated as being required and
approved by the CA.
Linings shall not reduce the required airway dimensions and the size of ductwork shall be
increased such that the internal cross-sectional area is maintained at the size indicated.
Insulation materials shall accurately fit the internal surfaces of the duct.
Inspection covers, in accordance with DW144, shall be provided at both ends of ductwork
sections containing sound absorbent linings.
The lining material shall be protected against product migration and erosion and shall be
securely retained by perforated galvanised steel sheet, hot dip galvanised after perforation.
Edges and joints shall be protected to prevent the lining lifting due to the action of the airflow.
11.5 ACOUSTIC ENCLOSURES

Acoustic enclosures shall provide an overall sound reduction index (SRI) of not less than that
stated elsewhere. Full allowance shall be taken of any loss due to doors, windows, ventilation
openings and panel joints.
Doors, access panels, windows and ventilation ducts or electrical cable penetrations shall be
treated so as to maintain the specified acoustic performance of the assembled enclosure.
Panels shall be structurally self-supporting without additional stiffening. All necessary steelwork
shall be provided and be galvanised after manufacture.
Demountable sections shall be designed to allow safe working and handling and provide easy
disassembly and re-assembly.
Removable panels shall give access to items requiring cleaning, adjustment, replacement and
other maintenance. Where enclosures are designed for personnel access, internal lighting and
viewing panels shall be provided. Access doors shall be open from both sides.
Part 5
ection 11 -Page 3
Enclosure panels shall be constructed from galvanised mild steel sheet at least 1.6 mm thick or
as otherwise stated. The absorbent internal lining shall be faced with a protecting membrane
and be retained by perforated galvanised mild steel sheet. The infill media shall be
compression packed to prevent settlement together with provision inside the panel to prevent
settling as necessary. Fibres of infill media shall be comply with the requirements as stated
elsewhere.
The assembled enclosure shall be designed and constructed to withstand the particular site
operating conditions. External enclosures shall be suitably weatherproofed and designed for the
site conditions including wind forces, snow loads etc.
The internal surfaces of the enclosure panels shall be designed to give the following minimum
average sound absorption coefficients when tested in accordance with BS EN ISO 354.
Frequency (Hz) 125 250 500 1k 2k 4k

Minimum average absorption
0.2 0.5 0.7 0.8 0.8 0.7
coefficient ()
The enclosure shall be isolated from the noise-producing equipment and also be isolated from
the building structure.
Provisions shall be made to dissipate heat emitted from the noise-producing equipment where
necessary.
11.6 ACOUSTIC LOUVERS

Acoustic louvres shall provide insertion losses under operating conditions of not less than those
stated elsewhere. Static pressure losses, under maximum operating duties shall not exceed
those stated elsewhere.
The louvre assembly shall be constructed to provide inherent structural rigidity and ensure
adequate blade support across the whole louvre width.
The louvre framework shall be constructed from suitable gauge galvanised mild steel.
The louvres shall be designed to prevent the penetration of water due to rain, snow, hail etc
under all meteorological conditions and shall be afforded protection against the ingress of sand
by sand trap louvres.
Louvre blades shall be constructed from galvanised mild steel not less than 0.7mm thickness
and shall be of an aerofoil or similar configuration. Each blade shall positively retain the
acoustic infill and shall have a galvanised perforated sheet steel lower and solid upper face.
The acoustic infill within the blades shall consist of inert, rot and vermin proof, non-hygroscopic
mineral wool or glass fibre of a density sufficient to achieve the stated acoustic performance,
packed and compressed so as to eliminate voids due to settling. The acoustic infill shall be
inherently non-combustible and limit the surface spread of flame to Class 1 when tested in
accordance with BS 476: Part 7 and shall not emit toxic or hazardous fumes if ignited. Fibres of
infill media shall be comply with the requirements as stated elsewhere.
The acoustic louvre assembly shall be finished in a high quality polyester powder paint as stated
elsewhere ensuring that all surfaces are thoroughly prepared and cleaned prior to application.
The louvers shall be supplied complete with all necessary fixings, flanged, etc for installation
into the builders work or other suitable opening or support frame.
Acoustic louvers shall be complete with integral bird screens of galvanised mild steel or
aluminium mesh, fixed to the internal face ensuring there are no protruding edges. The mesh
pitch shall not exceed 15mm x 15mm square grid. Alternatively, insect mesh is to be included
where indicated.
Part 5
ection 11 -Page 4
All gaps between the outside of the louver frame and the builders work opening or duct shall be
made good and sealed to the full depth with dense grout and/or dense non-hardening mastic
sealant. Mastic sealant design life shall be a minimum of 10 years unless otherwise stated.
All acoustic louvers shall be delivered to site with protective packaging and labelled to indicate
unit reference, location and description.
The installer shall be responsible for advising the acoustic louvre supplier of the final
manufacturing sizes allowing for suitable tolerance spacing to builders work, cladding or
ductwork.
11.7 EXTERNAL ACOUSTIC DUCT LAGGING

Provide external acoustic lagging where indicated. It shall consist of a resilient layer wrapped
around the duct together with an outer high mass skin. The total composite shall be inherently
non-combustible and limit the surface spread of flame to Class 1 when tested in accordance
with BS 476: Part 7 and shall not emit toxic or hazardous fumes if ignited.
All thermal insulation shall be made from materials with zero ozone depletion potential (CFC
and HCFC free). Submit to the CA, prior to ordering, written confirmation from the insulation
manufacturer(s) that the products to be installed are CFC and HCFC free.
The thermal performance of all insulation shall be maintained for a minimum of the plant design
life. Thickness of insulation shall be in accordance with BS 5422.
On surfaces operating below ambient temperature a complete vapour barrier seal shall be
provided. Vapour barriers shall be continuous and the integrity maintained.
Proprietary acoustic lagging products shall be approved by the CA before commencement of the
Works. Submit to the CA, prior to ordering, details that define the materials to be used including
thermal conductivity and acoustic performance, life expectancy, method of application and fire
performance.
All joints of the outer mass skin system shall be staggered and lapped by no less than 50mm.
Direct butt joints shall not be permitted.
manufacturers recommendations and instructions.
Fibres of infill media shall be comply with the requirements as stated elsewhere.
11.8 VIBRATION ISOLATION
11.8.1 General
Supply and install plant and equipment isolators as stated elsewhere to ensure that vibration
from plant is not transmitted to the building, other supporting structure, pipework or ductwork.
All anti-vibration mountings shall be supplied and fixed by the installer.
Isolators must be selected for the operating weight of equipment and shall be positioned for
equal deflection.
Mountings shall be clearly and permanently marked with their load capacity and colour coded to
BS1726 to enable easy identification during installation.
Mountings shall be constructed of materials that are passive or have low levels of electrolytic
action
The installer shall be responsible to ensure that all mountings are appropriate for the design
loads, operating and environmental conditions that will prevail. Particular attention shall be paid
to mountings exposed to atmospheric conditions to prevent corrosion.
Part 5
ection 11 -Page 5
The installer shall provide all necessary information, including but not limited to actual plant
loads and running speeds, to the vibration isolation specialist/supplier to enable final isolator
selections to be made. Selection shall allow for uneven load distributions such that the
minimum deflection is achieved on all vibration isolators under normal operating conditions.
The installer shall confirm to the CA the final vibration control equipment selections and their
compliance with the specification prior to commencement of the Works.
Pipework and ductwork connections to equipment mounted on anti-vibration mounts shall not
be rigid. Flexible couplings or connections shall be installed.
11.8.2 Vibration Isolation Equipment Performance

The vibration isolation devices shall meet the requirements of the vibration isolation system in
which they are used and are expected to function as shown on the drawings and as described
in the specification.
The minimum static deflection requirements for the equipment types are given in Table 1 below.
Equipment Location Minimum Isolation Type
Deflection
Pipework Plantrooms 25mm Springs
Pumps (Horiz.) Plantrooms 35-50mm Springs with base
Pumps (Vert.) Plant rooms 25mm Springs with heavy
base
FCUs General Area 25mm Springs
VAV boxes Offices 25mm Springs
Fan Powered VAV boxes Offices 25mm Springs
AHUs & PAUs Others 25-50 mm internal Internal springs, free
standing
2-3mm external Neoprene
Axial fans All 25mm Springs, free standing
or hung
Centrifugal fans All 25mm Springs, free standing
or hung
Propeller fans Not wall 25mm Springs, free standing
mounted-any or hung
location
Pumps-base mounted Any location 35-50mm Springs, free standing
c/w inertia base
Water Chiller Chiller plant 50mm Springs, restrain
Table 1: Requirements for vibration isolators:
11.8.3 Levelling and Height Adjustment of Vibration Isolators

Vibration isolators shall be provided with means of level adjustment to allow for unevenness of
the mounting surfaces. The amount of adjustment for floor mounted isolators shall not be less
than twice the permitted tolerance in the levelling of the floor. Levelling bolts or studs shall be
provided with lock nuts.
11.8.4 Lateral Stiffness of Isolators

The lateral stiffness of vibration isolators shall be selected to suit the lateral isolation efficiency
required without causing instability. For rotating machines with horizontal shafts, the horizontal
stiffness perpendicular to the shaft shall not be less than the vertical, if 'floor' mounted, and vice
versa if 'side' mounted.
11.8.5 Pipe and duct Hangers

Hangers used for vibration control shall consist of a mild steel welded cage containing a
helical spring, or neoprene /rubber /glass fibber isolator, (or both) and be suitable for
Part 5
ection 11 -Page 6
suspension from drop rods. Where both types of isolating elements are used together, the
spring shall be at the pipe or duct end of the hanger. The spring or active materials shall be
used in compression.
Steel springs shall be stable at all loadings up to full compression and full compression shall
not occur before 150% of the rated maximum loading. No permanent deformation shall
result from full compression. The load shall be transmitted to the spring through a neoprene
washer bushed into the moving end to prevent metal to metal contact.
Neoprene/rubber/glass fibber isolators shall be protected from overloading by metal to metal

restraints or lateral containment.
The hanger cage shall be capable of carrying five times the maximum rated normal service
load without permanent distortion. The drop rod arrangement shall allow 30 degrees
movement without metal to metal contact.
Stainless steel (minimum grade SS316) shall be used for external used spring mounts, and
for all isolators supporting condenser water pipe work.
11.8.6 Helical steel spring mounts

Helical steel spring mounts shall comprise single or multiple spring elements fitted to a plated
steel base plate. A rubber/neoprene pad shall be bonded beneath the bottom plate.
All mountings shall incorporate a lockable levelling device. There shall be provision for bolting
through the base plate in at least two places.
The springs shall have an outside diameter of not less than 75% of the operating height and be
selected to have at least 50% overload capacity.
11.8.7 Vertically restrained spring mounts

Mountings shall be as described under the clause for helical steel spring mounts but include a
mechanism that provided an adjustable vertical limit stop to prevent spring extension when load
is decreased.
Mountings used in the external environment shall be adequately protected against

environmental and atmospheric degradation.
11.8.8 Turret compression mountings

Turret compression mountings shall comprise a synthetic formulated rubber compound turret in
compression between two steel plates with complete lateral freedom for deformation. All metal
surfaces must be covered to avoid corrosion and have friction pads to and bottom. Bolt holes
shall be provided in the top and bottom plates to facilitate fixing.
The rubber turret shall be resistant to oil, sunlight, corrosion and ozone.
Turret compression mountings shall not be employed where ambient or equipment

temperatures exceed the manufactures recommendations.
11.8.9 Helical spring compression hangers

Spring compression hangers shall comprise a helical steel spring fitted with acoustic rubber end
caps fitted incorporated within a steel hanger box.
The lower box hole diameter shall be adequately sized to provide free drop rod movement up to
15 from vertical in any direction in order to compensate lateral movement.
The hanger bracket shall be designed to carry five times overload without failure.
Part 5
ection 11 -Page 7
Where hangers incorporate a positioning device, the adjustment system shall incorporate a
locking mechanism to prevent the hanger going out of adjustment as a result of vibration or
unauthorised tampering.
Spring hangers shall be installed to support all pipework and ductwork connected to rotating
and reciprocating machinery within plantroom areas or within 30 m of the plant which ever is the
lesser.
The hanger bracket shall be designed to carry five times overload without failure.
Hangers shall be colour coded for identification.
11.8.10 Neoprene element hangers

The hanger shall be essentially as described under the clause helical spring compression
hangers except it shall incorporate a neoprene in shear element. The element moulded in
special formulated rubber compound shall be resistant to oil, sunlight, corrosion and ozone.
Hangers shall be colour coded for identification
11.9 PLANT BASES
11.9.1 Steel equipment bases

Steel frame equipment bases shall comprise an all welded steel framework of sufficient rigidity
to provide adequate support for the equipment and adequately stiff to prevent resonances at
operating frequencies of the supported equipment. Cross framing shall be incorporated to
provide adequate strength and stiffness. The steel frame base shall incorporate isolator
mounting brackets and supported by spring isolator mounts appropriate to the plant type and
the standard of isolation required.
The frame depth shall be approximately 1/10 of the longest dimension of the supported
equipment, with a minimum of 150 mm.
11.9.2 Concrete inertia bases with steel springs

Concrete bases shall be formed from an all welded steel pouring framework and a frame depth
of approximately 1/12 of the longest dimension of the base, with a minimum of 150 mm and no
greater than 300 mm.
The bottom of the frame shall be blanked off and concrete (2300 kg/m unless otherwise stated)
poured in over the steel reinforcing bars. The reinforcing shall consist of 13 mm diameter bars
welded on 150 mm centres running cross-batch positioned 35 mm above the bottom of the
base or as specified by the Structural CA
The inertia base shall be sufficiently large to provide support for all parts of the equipment base,
including any components which overhang the equipment base such as suction and discharge
elbows on centrifugal pumps.
Unless stated otherwise, the weight of the base shall be twice that of the supported equipment.
All equipment must be rigidly coupled together as one mass on a single platform.
The vertical distance to the combined centre of mass from the top of the spring mounts must be
less than horizontal distance.
The base shall incorporate plated steel outrigger mounting brackets and supported by spring
isolator mounts appropriate to the plant type, load and the standard of isolation required.
Alternative constructions shall be submitted to the CA prior to commencement of the Works.
Part 5
ection 11 -Page 8
11.9.3 Concrete inertia bases with neoprene pads/mounts
The inertia base shall be sufficiently large to provide support for all parts of the equipment base,
including any components which overhang the equipment base such as suction and discharge
elbows on centrifugal pumps.
The inertia base should be cast onto a permanent bottom shuttering, and supported on the
specified neoprene mounts or pads, the whole resting on a plinth as required.
The construction of concrete bases on cork, expanded polystyrene or mineral wool slabs shall
not be permitted.
Where neoprene pads are used, small areas of pad must be equally spaced to provide the
required static deflection. The quantities, dimensions and locations of such pads shall be
advised by the supplier and confirmed to the CA prior to commencement of the Works.
Neoprene pads / mounts shall not be used for external applications or areas within direct
sunlight.
11.10 PIPEWORK FLEXIBLE CONNECTIONS

Flexible pipe compensators shall be installed on pipe connections to all rotating or reciprocating
plant isolated by vibration control equipment.
Construction
Type: single convolution rubber bellows
Liner: EDPM rubber
Reinforcement: steel wire mesh reinforced throughout and manufactured in accordance
with DIN 4809
Cover: EDPM rubber
Flanges: Carbon steel to BS EN 1092 and shall be able to swivel and be
removable
Threaded ends: BS 21 with one union end
Tie bars: Carbon steel zinc plated adjustable tie bar assembly
The units shall be suitable for the working pressure and temperature.
All units shall have an indelible identification indicating manufacturer, date of manufacture, type,
size, pressure rating and be colour coded.
The units shall have a design life of 10 years at 100 C. Units shall be in accordance with DIN
4809 and after a service life of 10 years at 100 C must have a burst pressure of not less than
30 bar.
Where untied bellows are used the manufacturers recommendations for anchors and guides
shall be followed.
Tie bars shall be threaded and with adjustable length. Tie bars with rubber top hat washers
shall be used where the working pressure exceeds 1.5 bar.
Ensure flexible connections are tied when the plant is on vibration isolation mountings.
The installer shall ensure that the flexible pipe connections proposed are capable of
withstanding the system operating temperatures and pressures.
11.11 DUCTWORK FLEXIBLE CONNECTIONS

Ductwork connected to rotating or reciprocating equipment shall be isolated by means of flexible
connections including all inlets and outlets of axial flow fans, centrifugal cased fans and air
handling units (if fans in units are not anti-vibration mounted).
Part 5
ection 11 -Page 9
Flexible connections shall be inherently non-combustible and limit the surface spread of flame to
Class 1 when tested in accordance with BS 476: Part 7 and shall not emit toxic or hazardous
fumes if ignited
Flexible connections shall prevent all transmission of vibration and be in accordance with DW
144 and DW 151 as appropriate.
The material must withstand the specified conditions of temperature, noise attenuation and air
pressure.
The minimum distance between duct ends shall not be less than 50mm with a maximum
dimension of 250mm. The flexible connection shall not restrict airflow within the ductwork
system, nor should the joint be used to correct x and y alignment of the ducts either side.
On rectangular connections, the material shall be held in place by a mating flange with a
backing plate.
Flexible connections to circular ducting on fan inlet spigots shall be secured by clip band
fasteners having adjustable screws or toggle fittings.
The material is to be fitted to give a tightly clamped joint with no air gaps, the connection
remaining flexible without strain and distortion, and shall be correctly aligned.
The flexible material and the joints shall comply with the standard of airtightness specified for
the ductwork system of which it forms part.
Flexible connections shall not be painted.
11.12 ACOUSTIC TESTING

Unless otherwise stated, sound pressure levels shall be measured in all spaces containing
supply or extract terminals, all plantrooms, all rooms immediately adjacent to plantrooms and all
rooms located above or below plantrooms.
The results shall incorporate a spectrum band analysis made at octave band centre frequencies
from 63 Hz to 8k Hz. Results shall be both tabulated and plotted on NR curves.
All plant such as fans, chillers, pumps, boilers etc shall be tested to ensure their acoustic
performance is within the respective manufacturers stated data at the time of order and results
submitted to the CA.
Noise readings shall be taken at the site boundaries and adjacent facades to demonstrate the
acoustic performance of the systems complies with the noise levels stated elsewhere.
Locations for noise readings shall be agreed with the CA prior to measurements being
undertaken.
Measuring of environmental noise shall be in accordance with BS 4142 and the local authority
guidelines.
All measurements undertaken to demonstrate compliance with the specification shall be

performed using sound measuring equipment conforming to BS EN 61672 and other relevant
standards. Calibration certification for all measuring equipment shall be submitted to the CA
prior to measurements being undertaken.
Duplicate records of all such shall be provided to the CA within 3 days of testing and copies
included in the operating and maintenance documentation. All records shall be signed by a
competent person and witnessed. Results shall be submitted to the CA for examination before
any system is offered for final acceptance.
Any witnessing or independent checking by the CA shall be carried out solely at the discretion of
the CA as considered necessary.
Part 5
ection 11 -Page 10
All necessary apparatus, measuring equipment, instruments, and meters required for acoustic
testing of the Works shall be provided by the installer at no additional cost.

BS 476: Part 7 Fire tests on building materials and structures.

Part 7 Method of test to determine the classification of the surface
vessels, ductwork and equipment operating within a temperature -
40 C to + 700 C
BS EN 354 Acoustics. Measurement of sound absorption in a reverberation
room
BS EN 61672 Electro-acoustics.
BS EN ISO 11820 Acoustics. Measurements on silencers in situ
BS EN ISO 7235 Acoustics. Laboratory measurement procedures for ducted
silencers and air terminal units. Insertion loss, flow noise and total
pressure loss
DW144 HVCA Specification for sheet metal ductwork
DW151 Specification for plastic ductwork
BS 4142 Method for rating industrial noise affecting mixed residential and
industrial areas
Part 5
ection 11 -Page 11
Section 12 Fans
Contents
Section 12 Fans 1

12.2 Motors and drives 2
12.3 Guards 2
12.4 Centrifugal fan sets 3
12.5 Axial flow fans 4
12.6 Variable pitch axial fans 4
12.7 Propeller fans 4
12.8 Roof extract fans 5
12.9 Aerofoil bifurcated fans 5
12.10 Axial smoke extract fans 5
12.11 Impulse fans 6
12.12 Kitchen extract fans 6
12.13 Electrostatic precipitator filtration systems for use in kitchen exhaust systems 6
Section 12 Fans
Fans shall have the performance and duty as stated elsewhere.
Fans shall be selected to deliver the required air volume flow rate and meet the noise levels
indicated. Any allowances required to meet manufacturing tolerances shall be included.
All fan resistances stated have been calculated based on a particular selection of equipment.
The installer shall recalculate the total system resistances based on the final selection of plant
and installation drawings and revise the fan resistance as necessary to achieve the design air
volume flow. Similarly, if the fan power requirements and sound power level changes, the
installer shall reselect the necessary motor size, wiring and suitable attenuation to achieve the
noise levels stated elsewhere at no additional cost.
The installer shall ensure that the fan is capable of generating sufficient pressure to meet the
required volume flow in the ductwork system as installed including any effect on fan
performance from suction and discharge connections.
Fan resistances shall take account pressure drop across filters in dirty conditions.
Individual components shall, in addition to the requirements of this section, comply with other
relevant sections of this specification.
Manufacturing drawings shall be submitted to the CA of all fans for approval prior to
manufacture.
Fans shall be installed in a manner strictly in accordance with the manufacturers

recommendations.
All fans shall be tested in accordance with BS 848 - 1 and BS ISO 13347. Fan impellers shall
be statically and dynamically balanced at the works of the manufacturer and test certificates
issued to the CA.
Manufacturers test certificates, acoustic data and fan curves shall be submitted to the CA. Fan
curves shall indicate performance under all likely operating conditions.
Fans shall be constructed to proven design standards and shall be capable of withstanding the
pressures and stresses developed during continuous operation at the selected duty, during
starting, during stopping and during speed and duty changes. Fan casings shall be of
substantial construction, adequately stiffened and braced to prevent vibration and drumming.
Bolted inspection covers shall be provided to allow easy access to internal working parts.
Lubrication points shall be extended to accessible positions external to the casings.
Unless otherwise stated all fans installed in air distribution systems shall have a minimum total
efficiency at the system operating conditions as follows:
Air volume Efficiency

Up to 1 m/s 65%
Over 1 m/s up to 2 m/s 70%
Above 2 m/s 75%
Externally mounted fans and internal exposed surfaces on fans handling outside air shall be
protected against corrosion.
Part 5
Section 12 - Page1
Fans and drives shall be resiliently mounted. Mountings and supports shall be arranged to
prevent undue movement of fans relative to adjacent ductwork systems or building structure.
Fans and drives shall be mounted on rigid base-frames or support structures to ensure that
proper alignment is maintained.
Belt-driven fans shall be capable of running continuously at 10% in excess of the selected duty
speed and shall have a minimum of two belts. A set of replacement belts and pulleys shall be
provided and fitted where required.
Duplicate extract fans for toilet extract systems should have automatic change-over.
12.2 MOTORS AND DRIVES

Centrifugal fans shall be belt-driven unless otherwise indicated. All other fans shall be direct
coupled unless handling hazardous substances where they shall be driven as required by the
application and provided with protection to the drive to ensure safe operation of the fan.
Each motor shall comply with BS 4999, BS 5000, and BS EN 60034 and shall be of such a size
and type to start and drive the equipment under normal conditions of service without
overloading.
Where mounted in external air, or highly moisture laden atmosphere, they shall be weatherproof
or separately protected. Motors in hazardous atmospheres shall be flameproof, certified to BS
5501.
Motors shall comply with other relevant sections of this specification.
Nameplates shall be positioned so that they are readable from normal access positions.
Motors arranged for automatic starting shall have a label of durable material, not less than
150mm x 100mm in size, permanently affixed in a prominent position and having, in clearly
inscribed characters, the legend:
Danger: This motor is automatically controlled and may start without warning. Isolate before
inspection.
Vee-belt drives shall comply with BS 3790. A minimum of two belts shall be provided and the
drive sized so that the rated output of the motor can be transmitted with one belt removed. A
complete set of spare belts shall be provided.
All final motor selections shall be agreed with the CA prior to any equipment being ordered.
12.3 GUARDS
with PD 5304.
Fan guards shall be purpose-made by the manufacturer or to the approval of the manufacturer
and be constructed from galvanised or plastic coated steel wire.
danger point.
Where required removable access panels shall be provided to permit tachometer readings to be
made of motor and drive shafts and belt tension to be tested.
Part 5
Section 12 - Page2
For duplicate motor installations, the guard provided shall be designed to protect both drives.
All fixings and mountings shall be installed to facilitate change-over of the drive.
12.4 CENTRIFUGAL FAN SETS

Shall be of the high efficiency backward curved aerofoil bladed type and be either single inlet
single width or double inlet double width type as indicated.
Fan casings shall be constructed from mild steel sheet, with welded or riveted joints and welded
angle stiffeners, constructed to permit withdrawal of the fan impeller. Casings shall be rigid
without deflection, drumming or excessive vibration.
For toxic or hazardous applications fan casing shall be gas tight all welded construction.
Finishes and materials of construction shall not be affected by gases handled by the fan or the
local environment.
Unless otherwise indicated the complete fan assembly shall be painted with two coats of primer
finish at the manufacturers works. Two coats of flat or gloss finish to an approved colour shall
be applied at site.
Inlet eyes shall be of the curved aerofoil profile to streamline the airflow into the impeller and of
adequate diameter to allow withdrawal of the impeller without splitting the fan scroll.
A drain connection shall be provided at the base of the fan scroll.
Permanent indicators shall show the direction of rotation of the impeller. Casings shall have
access panels incorporating air seals to facilitate cleaning and maintenance of the impeller.
The fan outlet shall be flanged and drilled to suit connections to the ductwork system flexible
connections.
Unless otherwise stated Impellers shall be of mild steel protected against corrosion. Impellers
shall be keyed to the driving shaft or fixed with tapered bush fittings.
Each fan impeller shall have a separate shaft. Where necessary, fan shafts shall be connected
with flexible couplings to ensure correct alignment.
Each fan impeller shall be supported by an individual bearing system. Bearings shall be ball or
roller type and shall be self aligning. Indirectly driven fans shall be provided with pedestals
incorporating two bearings. Bearings on the non-driven side of the fan shall be provided with a
scroll stiffening framework supported from the fan base to maintain bearing position and
alignment.
The impeller shaft shall be of solid stainless steel adequately sized such that its first critical
speed is not reached before the design fan speed is obtained.
The motor shall be a fan cooled squirrel caged type mounted on adjustable sliding rails.
Belt-driven centrifugal fans and drive motors shall be located on a common base. Anti-vibration
mountings to prevent the transmission of noise or vibration to the structure shall be provided as
indicated elsewhere.
Fans fitted with guide vanes shall have backward curved blades. The guide vane assembly
control actuator(s) shall be supplied by the fan manufacturer.
The guide vane assembly control shall fully modulate throughout the operating range of the
system volumes served by the controlled fan. The static pressure/volume characteristics of this
operating range at the fan discharge shall be as indicated.
Spring-return actuators used for fan guide vane control shall open or close the guide vanes as
indicated on control power failure.
Part 5
Section 12 - Page3
12.5 AXIAL FLOW FANS
Axial flow fans shall be of the long casing pattern with a heavy gauge, mild steel casing flanged
and drilled at each end. Casings shall be hot dip galvanised and be fully air tight.
Axial fan motors shall have non-overloading characteristics within the normal working range.
Fans shall be suitable for either vertical or horizontal mounting. They shall be mounted on
purpose made supports incorporating anti-vibration mountings and mounting feet.
Air-tight inspection doors shall be provided giving access to fan impeller and motor and other
components requiring regular servicing or maintenance.
The impeller shall be multi-blade aerofoil section constructed from high density PVC, reinforced
glass fibre, or die-cast aluminium alloy with provision for manual adjustment of the blade angle.
Rotors shall be statically and dynamically balanced. They shall be subject to X-ray tests and
documented results shall be submitted to the CA. Impellers for variable pitch fans shall in
addition be checked over the full blade angle range for vibration in accordance with BS 7854.
Multi-stage fans shall be arranged with contra-rotating stages. They shall be coupled together
in the sequence and arrangement recommended by the manufacturer.
Motors in the air stream shall be totally enclosed squirrel cage induction type with roller type
bearings.
Safety guards shall be provided on air inlet and air outlet connections where these are freely
accessible to personnel.
12.6 VARIABLE PITCH AXIAL FANS

Variable pitch axial fans shall comply with the requirements of the axial flow fan clause.
Fans with automatically variable pitch shall be controllable through a range of sufficient
angularity to vary volume and pressure across the system design range.
The variable pitch mechanism and control actuator shall give fully modulated control of the fan
air volume rate to match the system characteristic as indicated.
Pitch angle control shall be provided from sensors provided as part of the control system.
Safety facilities shall be incorporated to prevent blade settings being increased beyond the
maximum design.
12.7 PROPELLER FANS

Propeller fans shall be ring or diaphragm mounted as indicated to suit the application.
Impellers shall be constructed of mild steel protected against corrosion, aluminium or as a one
piece polypropylene moulding and comprise 3 or 4 blades. The impeller shall be secured fixed
to the motor shaft with key and keyway, locked by a setscrew.
The motor shall be suitable for continuous operation and a sealed electrical terminal box shall
be provided.
Safety guards shall be provided on air inlet and air outlet connections where these are freely
accessible to personnel.
The fan shall be capable of reverse flow.
Non-return shutters shall be fitted to all fans discharging externally to the building.
Part 5
Section 12 - Page4
12.8 ROOF EXTRACT FANS
Roof extracts units shall be curb mounted vertical discharge propeller or aerofoil driven type and
shall be robust in manufacture.
Cowls and bases shall be manufactured from materials which are resistant to the weather and
solar radiation, and appropriate to the location of the fan.
Casings shall be complete with integral weatherproofing provisions suitable for direct fixing to
the building structure in accordance with the manufacturer's instructions.
Adequate access to electrical terminals and lubrication points shall be provided by means of
either hinged cowls or access panels. A sealed electrical terminal block shall be provided.
The roof unit shall be finished to an approved colour.
Back-draught dampers and/or fire release dampers shall be provided where indicated.
Bird guards of not greater than 25 mm mesh shall be provided as an integral part of the unit.
An inlet attenuator shall be provided as indicated.
Impellers shall be multi-bladed steel on a aluminium or steel hub and shall be directly connected
to a fan cooled squirrel cage induction type motor.
12.9 AEROFOIL BIFURCATED FANS

Fans and ancillaries shall be constructed to withstand the rated temperatures for the required
duration as stated elsewhere.
High temperature units shall be suitable for operation in air stream temperatures up to 300C
unless otherwise stated.
Axial flow fans shall be long casing adjustable pitch aerofoil bladed type, which shall have non
overloading characteristics.
Casings shall be mild steel with continuously welded joints and be lined or finished as indicated.
Casings shall be of the same thickness throughout unless otherwise indicated, and shall extend
for the overall length of the impeller, hub, and motor protection tunnel where applicable, and
have circular flanged ends.
The impeller shaft shall have a seal at the tunnel wall to prevent leakage in either direction
between the motor tunnel and the fan interior.
Drive motors for axial flow fans of the bifurcated type shall be located out of the air-stream.
All fans shall be single type and shall be completed with mounting feet, rubber type anti-
vibration mountings to specification detailed elsewhere, mounting mild steel brackets and
hangers.
12.10 AXIAL SMOKE EXTRACT FANS

Smoke extract fans and dual purpose smoke extract fans shall comply with the requirements BS
7346 Part 2.
Fans and ancillaries shall be constructed to withstand the rated temperatures for the required
duration as indicated. Motors and drives shall be similarly constructed or protected and
ventilated to ensure that they are not subjected to fire conditions.
Units shall be suitable for normal operation in ambient conditions up to 60C and high
temperature conditions up to 300C for 1 hour or 400C for 2 hours as stated elsewhere.
Part 5
Section 12 - Page5
Motors shall be pre-wired with high temperature rated cable to an external terminal box through
high temperature flexible conduits. All components shall be rated for the operating conditions.
Fans shall be manufactured from galvanised steel. Run and standby fans shall incorporate inlet
and outlet flanges with pre-drilled bolt holes, and an external terminal box to IP55. The motor
shall be foot mounted and protected to IP55 (shall be either 6 or 8 poles), class H insulated and
shall have sealed for life bearings. Blades shall be manufactured from aluminium alloy. Day to
day ambient operation up to an ambient temperature of 46oC and fire operation at 300oC for 1
hour shall be possible.
The secondary power supply to the duty/standby fan arrangement shall be capable of providing
the power supply within 15 seconds of failure of the primary power. The diesel generator shall
be capable of providing power for at least 3 hours without the replenishment of fuel. The primary
and secondary power supply cables shall be fire rated MICC and shall terminate in the at the
control panel. This panel shall include a changeover device to automatically effect the transition
from primary to secondary power supply if the primary supply fails. Similarly change over of fans
shall be automatic upon failure of the duty fan.
12.11 IMPULSE FANS

The impulse fans shall be supplied by the same manufacturer as the main parking extract fans.
Fans shall be suitable and tested to 3000C for 2 hours.
The sound level shall not exceed 50/65 db (A) at 1m/450 in a free field. Fans motor shall be a
Western European make. The motor shall have protection class IP55 and shall be insulation
class F.
The fans shall be supplied with factory fitted inlet and outlet guide vanes, guards and silencers.
The fans shall be factory wired to a lockable isolator.
12.12 KITCHEN EXTRACT FANS

Backward inclined Belt Driven Centrifugal with motor, belts etc. out of air stream especially
configured for food service applications.
Fan shall in accordance with be UL 705 & UL 762 for kitchen applications and rated to 400 oF.
All steel fan components shall be epoxy coated and suitable for outdoor installation. Fan shall
also be AMCA certified.
Static pressure drop calculations based on shop drawings shall be submitted by Contractor for
approval.
12.13 ELECTROSTATIC PRECIPITATOR FILTRATION SYSTEMS FOR USE IN

KITCHEN EXHAUST SYSTEMS
Electrostatic precipitator units shall comprise of and electrostatic filter, a 95% DOP media filter
and Refillable carbon adsorption modules for odour control.
Each electro static module shall be provided with a 230V 50Hz power supply. LED power
indicator shall be provided on the casing of the unit for status. Unit shall be provided with wiring
terminal block and disconnect switch.
The Number of electrostatic modules shall be dependant upon the total air quantity to be
treated. Each kitchen exhaust electrostatic precipitator system shall comprise of the appropriate
number of modules, selected according to the manufacturers acceptable air volume flow rates
for each module. Depending on manufacturer selected the number of modules will vary. For
example a flow rate of 10,000cfm would usually require 3 filter modules for most manufacturers.
Full manufacturers selections are to be provided to the CA for approval.
Part 5
Section 12 - Page6
The filter system shall be housed in a double wall insulated fire rated and corrosion proof
enclosure of 20 gauge cold rolled steel suitable reinforced for rigidity. A drain pan with nipple
connector shall be provided.
Output voltage of Ionizer shall be 12.5-13.0kVDC. The collector shall be 6-6.5kVDC.
The collector cell shall be provided with perforated mesh pre filters.
Each module shall be provided with pressure switches connected to the BMS for monitoring of
filter status.

BS 7854 Mechanical vibration. Evaluation of machine vibration by

measurements on non-rotating parts.
BS 848-1 Fans for general purposes. Performance testing using
standardized airways
BS EN ISO 5136 Acoustics. Determination of sound power radiated into a duct by
(BS 848-2.5) fans and other air-moving devices. In-duct method.
BS ISO 13347 Industrial fans. Determination of fan sound power levels under
standardized laboratory conditions.
BS 14695 Fans for general purposes. Method of measurement of fan
(BS 848-6) vibration.
BS 4999 Specification for general requirements for rotating electrical
machines.
BS 5000 Rotating electrical machines of particular types or for particular
applications.
BS EN 60034 Rotating electrical machines.
BS 5501 Electrical apparatus for potentially explosive atmospheres.
BS 3790 Specification for endless wedge belt drives and endless V-belt
drives.
BS 7346-2 Components for smoke and heat control systems. Specification for
powered smoke and heat exhaust ventilators.
Part 5
Section 12 - Page7
Section 13 Air Handling Units
Contents
PART 5 MECHANICAL SERVICES 1
SECTION 13 AIR HANDLING UNITS 1

13.2 Construction 2
13.3 Installation 4
13.4 External units 4
13.5 Access sections 5
13.6 Fans 5
13.7 Belt drives 6
13.8 Guards 6
13.9 Variable speed drives 7
13.10 Coils 8
13.11 Cooling coils - Direct Expansion 10
13.12 Electrical heater batteries 11
13.13 Condensate drains 12
13.14 Humidifiers 12
13.15 Filters 13
13.16 Unit dampers 15
13.17 Mixing box/damper section 16
13.18 Heat recovery 16
Section 13 Air Handling Units
Air Handling Unit (AHU) shall mean an assembly of packaged plant components.
The Contractor shall provide factory-built Air Handling Units of the horizontal mode with
requirements and capacities as listed here below, on the drawings and in equipment schedules.
Manufacturers selections shall be subject to approval by the CA. Air Handling Unit
manufacturers and the specific unit models shall be Eurovent certified and in accordance with
the requirements of EN1886.
The duties and performance of the units shall be in accordance with the details indicated
elsewhere and include any allowance required to meet manufacturing tolerances.
Individual components shall, in addition to the requirements of this section, comply with other
relevant sections of this specification.
Air Handling Units shall be fully assembled and tested at the manufacturers works to
demonstrate that aerodynamic performance, leakage air flow, design resistance and noise
levels are in compliance with the specification and performance requirements. The results and
a compliance statement shall be submitted to the CA prior to delivery to site.
Submit the following information, where applicable, to the CA for approval in accordance with
the requirements of this specification:
Schedule of starting and full load currents

Details of connections for fans
Fan characteristic curves with operating point indicated
Sound pressure spectrums
Vibration mounting details, including isolation efficiency on high and low speed
Coil pressure drops, air side and water side
Coil air on and air off conditions
Coil water on and water off temperatures
Fan motor rating and design absorbed power
Fan and motor speeds
Drive belt sizes
Filter sizes and efficiencies
Fan static and total pressures
External to unit, static and total pressures
Humidifier model and rating
Attenuator insertion losses
Electric heater model and rating
Heat pipe selection details
Thermal Wheel selection details
Fully dimensioned manufacturing drawings shall be submitted to the CA of all units for approval
prior to manufacture.
The units shall be installed in a manner strictly in accordance with the manufacturers
recommendations.
Where units are delivered to site disassembled (only where specifically approved by the CA),
the manufacturer shall allow for erection of the units.
Part 5
Section 13 -Page 1
The manufacturer shall undertake a pre-commission check to ensure suitability for dynamic
commissioning and a report shall be issued to the CA.
Units and their components shall incorporate lifting facilities for installation.
Fan resistances shall take account of pressure drop across filters in a dirty condition.
Units shall be draw-through type, unless specifically required as blow-through units.
Fresh air and exhaust connections shall be provided with tight shut-off dampers arranged to
close when the system shuts down unless otherwise stated.
All necessary penetrations in the air handling unit casing e.g. to accommodate controls items
etc, shall be undertaken at the factory. Penetrations shall not be permitted on site.
13.2 CONSTRUCTION
Units shall be designed and constructed to minimise distortion, damage and drumming in
operation and at the maximum pressures generated by the fan operating under closed head
conditions.
The framework shall be rigid enough to prevent distortion during transportation and after final
assembly on site. Framework shall be fabricated from 3mm sheet steel unless otherwise stated.
Individual components and sections shall be assembled using proprietary and proven fastening
techniques. Locking devices shall be used with all fastenings which are subject to vibration.
Casings shall generally be of constant cross-sectional dimensions and designed to promote

even air distribution across the face of all components.
Casings shall be complete with internal flanged joints.
Each section shall be identified by a clear stencil description on the external surface.
Units shall be corrosion resistant.
Airtight seals shall be provided between the sections and completely around each access and
unit panel. The casing air leakage classification shall achieve class L1 (M) for both positive and
negative test pressures in accordance with EN1886.
Unit sections shall be fabricated from pressed multi-angled supports forming a pillar and post or
box frame construction with purpose made corner joints. Rebates in the frame shall allow the
access and infill panels to be flush with the frame and create a smooth surface inside and out.
Panels shall be manufactured from heavy gauge galvanised mild steel sheets at least 1.2 mm
thick. Panels shall be double skinned with heavy density acoustic and thermal insulation
between the skins.
The casing insulation properties:
Compliant with BS 476 -6 and BS 476-7

CFC and HCFC free
Inorganic, vermin proof and non-hygroscopic
Unless otherwise indicated, minimum thickness shall be:
i. 50 mm for units 1.0 m/s or greater and all external units

ii. 25 mm for units less than 1.0 m/s and installed in air conditioned spaces (unless
acoustic parameters require additional thickness)
Thermal conductivity no greater than 0.03 W/mK
Part 5
Section 13 -Page 2
Casing insulation shall be fixed securely to the panel and protected to prevent migration of fibre
into the air flow.
All insulation components shall be made from materials with zero ozone depletion potential
(CFC and HCFC free). Submit to the CA, prior to ordering, written confirmation that the
products to be installed are CFC and HCFC free.
For all insulation infill material test evidence must be available and submitted to the CA showing
that the fibres from which the products are made are not classified as a possible carcinogen as
detailed by European Directive 97/69/EC. Fibres shall also comply with the requirements as
stated elsewhere and with HSE guidelines. The Insulation shall comply with M1 fire class
according to the technical laboratory CSTB
Provide extruded, 3mm thick, aluminium profile frame joined by 3D cast aluminium corners,
forming the structural frame to house all internal components and able to comply with deflection
less than 4mm per meter under operation of design conditions (class D1(M) or better). A
thermal break is required on all frames between inside and outside to prevent cold bridging. The
aluminium profile frames shall insulated at the manufacturers factory.
Provide double skin construction constructing sandwich type 50mm minimum thick panels
comprising 0.9mm thick galvanized internal and external skins and with 50mm thick mineral
wool insulation of minimum 50 Kg/m3 density. Providing an overall thermal transmission
coefficient not to exceed 0.03 W/mC to prevent condensation from occurring. External skin to
be coated with a UV resistant plasticized coating for protection and easy cleaning.
Thermal breaks shall be provided in the frame construction.
The design of the unit shall ensure that there is no cold bridging and no direct metallic contact
between the inside and outside of the cabinets. The casing shall achieve thermal bridging
classification TB2 or better.
The colour and finish shall be as agreed with the CA.
Where unit surfaces are painted they shall, prior to priming, be thoroughly cleaned to remove all
scale, dirt and rust. The surfaces shall be treated to resist corrosion and rust formation and then
be correctly primed before application of final paint coats.
All panels shall be removable and shall be sealed against the framework. The seal shall be
mechanically fixed to the panel.
Unless otherwise stated the minimum sound attenuation of the casing shall be:
Panel thickness: 50mm
Frequency Hz 63 125 250 500 1K 2K 4K 8K

Sound db
17 18 24 31 33 37 42 45
Attenuation
All section casings shall have the same cross-section and shall be identical in appearance.
Panels are to be removable from the frame by means of a locking system made out of an
extruded aluminium profile, held in place with locking strip or clips and Allen key arrangement.
The fastening method, together with framework gasket to ensure good air tightness able to
comply with Class L1(M) of EN1886 as mentioned above.
Unit sections to be mounted on a 2.5mm thick galvanized steel bolted base frame, to assure
entire stability and permit easy lifting, handling and positioning onsite. Unit with sectional splits,
shall be provided with gaskets and sealing material as well as connection clamps, to permit
quick and airtight site assembly. Minimum overall height of base shall be 100mm.
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Section 13 -Page 3
Where units are large enough for man access the bottom/floor panels shall be suitably
strengthened to facilitate entry for maintenance (support the weight of two men, tools and
equipment) without deformation and/or damage to internal finishes. The units shall have
weatherproof bulkhead lighting and switches and non-slip floor surfaces.
Bulkhead lights shall be provided and operable from inside and outside via water resistant
switch.
Where flexible connections are mounted within the air handling unit they shall be to the same
specification as described elsewhere.
In every fan section and humidifier section visual inspection port holes shall be provided of at
least 200 mm diameter and one per 900mm height of section unless otherwise stated.
Bulkhead lighting shall be provided and each bulkhead light shall be wired to its own externally
mounted on/off switch.
The unit shall be delivered on a base frame constructed from galvanised steel. The base frame
shall be pre-drilled for fixing holding down bolts and shall have removable lifting lugs.
Air intake louvres shall prevent the ingress of rain and inhibit the ingress of sand/dust and shall
incorporate an insect screen. The colour and finish shall be approved by the CA prior to
manufacture.
13.3 INSTALLATION
Units shall be installed on concrete frames or steel sub frames.
Unless otherwise indicated, there shall be a clearance of at least 150mm between the underside
of the AHU and its base or the plant room floor. The bottom of the unit shall be located at such
a height that an adequate water seal, to suit the air pressure inside the unit, can be provided on
coil drains allowing for filter dirty conditions.
Supplementary steelwork necessary to support the unit shall be provided by the installer. The
steelwork shall be galvanised after manufacture and painted to match the air handling unit.
Pipework and electrical cable entry points to the unit shall be sealed after installation to maintain
the air-tightness of the unit.
External connections passing through panels shall be provided with flexible air tight gaskets.
Airtight sleeves shall be provided for control sensors, instruments and test holes
The discharge ductwork connection shall be suitable to maintain the aerodynamic performance
of the fan.
13.4 EXTERNAL UNITS

Where units are located externally they shall be weatherproofed including associated control
panels.
Units shall have a weatherproof outer casing with a pitched roof constructed of watertight metal
decking with water seals in all joints having suitable eaves overhang and complete with gutters
and drains.
Access doors shall be lockable.
Bulkhead light fittings shall be provided in each section with a weatherproof external switch with
all wiring contained in galvanised mild steel conduit.
Part 5
Section 13 -Page 4
13.5 ACCESS SECTIONS
Access sections shall be provided with doors to allow entry for internal inspection purposes.
Access sections shall be provided to facilitate access to upstream and downstream faces and
internal parts of all sections in the unit including thermostat, detector, air-flow switch and other
control/monitoring positions within the unit.
Access panels and hinged doors shall be 600mm wide minimum and sized for the full height of
the AHU
Access panels shall be secured with proprietary quick-release captive fastenings consistent with
effective air sealing. Hinged doors shall be retained with clamping type latches.
Self-tapping screws and set screws shall not be acceptable as a panel fastening method.
13.6 FANS
Fans shall have the duty as stated elsewhere.
All fan resistances stated have been calculated based on a particular selection of equipment.
The final selection of plant duties by the installer, such as filters, coils, attenuators, diffusers etc.,
and the actual ductwork fabrication drawings may produce different pressure drops and
therefore the installer shall recalculate the total system resistances based on the final selection
of plant and revise the fan resistance as necessary to achieve the design air volume flow.
Similarly, if the fan power requirements and sound power level changes, the installer shall
reselect the necessary motor size, wiring and suitable attenuation to achieve the designed
Noise Rating Level stated elsewhere at no additional cost.
Selection of fans shall take into account the factors influencing noise levels, including fan speed,
velocities, inlet and discharge conditions.
Outlet velocities shall not exceed 10 m/s unless indicated otherwise.
Fan drives or impellers shall be arranged to allow a 15% variation in airflow either volume flow
rate or pressure drop for final site adjustment as agreed with the CA. A set of replacement belts
and pulleys shall be provided (and fitted where required) for each AHU at no additional cost to
the contract.
All fans shall be tested in accordance with BS 848 - 1 and BS ISO 13347. Fan impellers shall
be statically and dynamically balanced at the works of the manufacturer and test certificates
issued to the CA.
Manufacturers test certificates, acoustic data and fan curves shall be submitted to the CA. Fan
curves shall indicate performance under all likely operating conditions.
Centrifugal fans shall be belt-driven unless otherwise stated.
Fans shall generally be of the high efficiency (minimum 75% efficiency) backward curved bladed
type, double inlet double width and for casings shall be of the lock-form casing type, all welds
heavy sheet steel, or split flanged type on the larger fans, adequately braced and stiffened with
steel angle with the bottom of the discharge outlet level with the axis of the impeller.
A bolted on access door shall be provided on the fan scroll to allow for inspection and cleaning
of the impeller. Inlet eyes shall be of the curved aerofoil profile to streamline the airflow into the
impeller and of adequate diameter to allow withdrawal of impeller without splitting the fan scroll
split cased fans shall be assembled on site by a qualified millwright to ensure that the fan set is
correctly assembled and aligned. A drain plug shall be fitted at the base of the fan scroll.
Part 5
Section 13 -Page 5
The fan outlet shall be a spigot connection to suit connections to the ductwork system flexible
connections within the fan section, or externally, depending on the anti-vibration requirements
stated elsewhere.
The fan supporting side frame shall be constructed in angle frame or steel plate and shall be
fixed to the fan casing to provide the required angle for the fan discharge arrangement shown
elsewhere.
Impellers shall be of welded steel constructed on a case steel hub suitably bored and key wayed
for mounting. The shaft and shall have high grade steel plate aerofoil blades or stitched welded
to a rigid back plate. The impeller shaft shall be of solid high grade steel adequately sized such
that its first critical speed is not reached before the design fan speed is obtained. The fan shaft
shall be supported at each side of the impeller with either sealed for life bearing or double roller
bearings.
The shaft shall be connected to the motor drive by cast steel machined pulleys, key wayed and
fixed onto the far and drive shaft by an Approved manner and a multi Vee belt drive
arrangement complete with a protective wire guard. The motor shall be a TEFC type mounted
on adjustable sliding rails.
The fan motors shall have IP55 degree of protection with mounting method B3 and class F
insulation. Fan motors shall be 4 pole 1450 rpm. Motors shall be rated at a minimum 25% higher
than the actual absorbed power of the selected fan and drive.
The fan motor shall be suitable for operating on 400V, 3Ph, 50Hz electrical power supply. The
fan section in the AHU shall be provided with cable inlet set at factory. Drilling panels at site is
not allowed.
The fan casing, side frames, bearing supports and motor shall all be mounted on a heavy steel
one piece channel on hollow section base frame and supported on independent spring type anti-
vibration mountings, within the fan section as selected by the AHU manufacturer and in
accordance with anti vibration details contained elsewhere in this specification
The fan sections shall be complete with an approved reinforced steel base to facilitate
maintenance within the fan section.
13.7 BELT DRIVES

Belt drives shall comply with BS 3790 and be capable of transmitting at least the rated power
output of the driving motor at any stage of operation with one belt removed. Unless otherwise
indicated, not less than two belts per drive shall be used and all multi-belt drives shall use
matched sets. Belts shall be of rubber and fibre V section unless otherwise indicated.
Pulleys shall be correctly aligned in accordance with the manufacturer's requirements.
Where duplicate motors are provided and fixed, the spare motor shall be complete with an
adjusting device to allow belt tensioning and shall be in all respects ready for operation. The
centre-to-centre dimensions between the common driven pulley and the duplicate driving
pulleys shall be the same.
Provision shall be made to permit drive alignment and adjustment of belt tension.
13.8 GUARDS
with PD 5304.
Fan guards shall be purpose-made by the Air Handling Unit manufacturer or to the approval of
the Air Handling Unit manufacturer and be constructed from galvanised or plastic coated steel
wire.
Part 5
Section 13 -Page 6
danger point.
Removable access panels shall be provided to permit tachometer readings to be made of motor
and drive shafts and belt tension to be tested.
Guards shall be designed for the extreme motor position.
For duplicate motor installations, the guard provided shall be designed to protect both drives.
All fixings and mountings shall be installed to facilitate change-over of the drive.
13.9 VARIABLE SPEED DRIVES

Variable speed drives shall be provided where indicated.
Variable speed motors, drives, control gear and accessories shall be selected by a specialist
variable speed drive manufacturer as a complete package. The specialist shall ensure that the
unit is capable of providing sufficient power and torque to enable the driven unit to start and
operate properly throughout the speed range. The drive shall be capable of providing the
additional capacity as indicated elsewhere.
The system shall be capable of interface with the BMS / controls system / control panel with the
necessary monitoring and control functions as indicated elsewhere. The installer shall be
responsible to ensure co-ordination between all parties.
The drive manufacturer, controls specialist and commissioning CAs shall co-ordinate the setting
to work of the variable speed drives.
Equipment shall be provided to maintain radio frequency interference and mains harmonic
distortion within acceptable levels as indicated elsewhere.
Drives shall be of the inverter type. Provision shall be made for the controllers to be by-passed
in the event of failure and the equipment manually operated at full speed. Inverters shall be
pulse width modulation type, complete with short circuit, earth fault, over voltage, under voltage
and over temperature protection. Inverter drives shall provide soft start facilities.
Motors shall be selected with sufficient capacity to allow operation at any point in their curve
with overheating limited so that the motor remains within its insulation classification.
Inverters shall be adequately ventilated, by natural means if practical, so that the temperature
remains within the normal operating range. The operating temperature range shall be 0 to 50
degrees Celsius.
Noise and vibration emission from the equipment shall be treated to ensure that the system
complies with the acoustic and vibration requirements stated elsewhere.
Inverters shall have the following characteristics:
Starting current not to exceed full load starting current

Near unit power factor throughout the speed range without the use of power factor
correction equipment
Independently adjustable ramp control for increase/decrease speeds
Capable of connecting to a reverse wind milling fan without causing tripping and able to
return to correct speed
Local control operation capability
Facility to set all operating parameters with door closed and without the use of additional
instrumentation
Provide the following protection:
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Section 13 -Page 7
Motor phase to phase and earth fault
Over voltage and under voltage
Harmonic Filtration
Inverter and motor overheat
Stall protection
Loss of control signal and auxiliary control voltage
Current limit by electronic shutdown prior to fuse action
Provide digital readout for :
Output frequency
Hand or auto mode
Motor current
Torque
Power
DC link voltage
Temperature
Fault memory
Provide remote monitoring of all operating conditions and full control capability
Enclosure construction shall provide protection of appropriate IP rating to BS EN 60529.
Inverters shall be CE marked to meet EMC requirements.
13.10 COILS
13.10.1 General
Coils shall be selected and located to ensure the full design air flow is evenly dispersed across
the full coil face area.
Water pressure drop through cooling coil shall not exceed 40kpa
Coil design and sizing shall be based on figures obtained from performance tests described in
BS 5141 for cooling and heating coils.
Coils shall be guaranteed to meet the specified performance. All coils shall be tested before
leaving the manufacturer's works. An independently witnessed test certificate shall be issued to
the CA for each coil. Each coil shall be indelibly marked with the details of the test.
Coils shall be pressure tested at the manufacturers works to a minimum of 1.5 times the
working pressure or 26 bar gauge pressure whichever is the greater.
The flow and return battery connections shall be labelled and the air flow direction shall be
indelibly marked on the battery casing.
Coils shall be mounted in the unit casing so that they can be removed from the side without
dismantling the entire unit.
Coils with minor damage to fins shall be combed straight. Coils with extensive fin damage will
not be acceptable.
Flow and return headers shall be arranged to ensure equal flow through all tubes. Provision
shall be made for expansion and contraction of the tubes and for effective venting and draining
of the coil. Each coil shall be provided with a full bore dirt pocket with drain valve on the lower
connection.
Coils shall be arranged in sections to facilitate removal.
Part 5
Section 13 -Page 8
The tube and fin spacing shall be arranged to ensure maximum heat transfer efficiency with
minimum coil depth and air resistance. Fins shall not be more closely spaced than 330 per
metre.
Tube wall thickness and coil construction shall be suitable for the system operating pressures
and temperatures, but not less than 0.7mm.
Connections up to and including 50 mm diameter for water pressures up to 350 kPa shall be
screwed to BS EN 10226-1. Larger sizes and connections for pressures over 350 kPa shall be
flanged to BS EN 1092. Connections shall be clear of coil casings with disconnection joints
positioned to permit full withdrawal and removal of coils without extensive dismantling of
adjacent pipework, ductwork or other equipment.
Coils shall be mounted in a mild steel framed casing having a minimum thickness of 1.2 mm.
Casings shall be hot dip galvanised in accordance with BS EN ISO 1461 after manufacture.
The casing shall be of adequate strength for the size of the coil.
Coils shall comprise solid drawn seamless copper tubes unless otherwise stated. Copper tube
shall comply with BS EN 12451 and have suitable wall thickness for the pressure application.
Headers shall be either copper or steel as stated elsewhere.
Fins shall make firm and continuous contact with the primary tubes and be constructed from
copper or aluminium, Aluminium fins shall not be less than 0.4mm thick and copper fins not less
than 0.3mm thick. Frames shall be stainless steel.
To combat the area acid and salt atmospheric conditions the cooling coils shall be electro
tinned. The coils shall have a warranty of 10 years against corrosion.
Where coil connections pass through the casing they shall be complete with sealing rings and
removable plates.
Unless otherwise indicated each coil shall be provided with a self sealing combined pressure
and temperature test point on the flow and return. All coils shall include an air vent and drain
plug.
13.10.2 Chilled Water
Cooling coil face velocities shall not exceed 2.4 m/s and the resistance to airflow shall not
exceed 125Pa unless otherwise indicated.
The air velocity across the coil shall be such that free water shall not be carried over from the
coil to the air-stream.
Unless otherwise indicated coils shall be constructed from copper tubes with copper fins
pressure bonded to the tubes through mechanical expansion and all housed in stainless steel
frames. Fins shall have solid drawn spacing collars.
Cooling coil casings shall incorporate a watertight drain tray complete with drain connection.
Trays and drains shall be arranged with longitudinal and cross gradients to ensure total removal
of all condensate.
Condensate drain pan shall be constructed from AISI 316 stainless steel of minimum thickness
1mm shall be provided under the cooling coil with threaded drain outlet. The condensate drain
pipe connection through the unit casing shall be insulated from the factory with 12 mm thick
closed cell elastomeric foam rubber insulation and sealed with plastic grommet.
Intermediate drain trays shall be provided where the coil height exceeds 1metre and for each
additional 1metre of coil height.
Large coils constructed in two horizontal sections shall have separate connections/headers and
shall be assembled correctly to ensure that the top section condensate flows evenly onto the
Part 5
Section 13 -Page 9
lower section. Where this is not possible a separate condensate baffle/catch plate shall be
installed with a separate drain to the coil drain pan.
Unless otherwise indicated, PVC eliminator blades retained in stainless steel plate shall be
provided after each coil and shall be located such that any carry over will collect and fall into the
drain pan. Eliminator sections shall be positioned to avoid damage from adjacent heater
batteries and shall be of materials unaffected by such heat. An access door shall be provided
between the coil and eliminator plates.
13.10.3 Heating Coils (Water)
Heating coil face velocities shall not exceed 3 m/s and the resistance to airflow shall not exceed
65Pa unless otherwise indicated.
Unless otherwise indicated, heat transfer surfaces shall consist of multiple seamless copper
tubes with extended surface of aluminium fin plates having solid drawn collars through which the
tubes pass.
The assembled fin blocks shall be supported with galvanised sheet steel framing, having end
plates with accurately formed collars for tube support, allowing tube movement during
expansion and contraction without abrasion or chafing. The fin block tubes shall be extended
and brazed into seamless copper headers.
Flow and return headers shall be arranged so as to provide reverse return water flow and with
the return header at the air inlet face of the coil. Return bends shall be of copper of the same
diameter as the tubes and shall be brazed into the expanded fin block tube ends.
Large coils shall be split horizontally for ease of handling and installation.
Coil blocks shall be insulated and fitted with removable galvanised sheet steel metal enclosures.
13.11 COOLING COILS - DIRECT EXPANSION

Unless otherwise indicated coils shall be constructed from continuous aluminium/plate fins,
mechanically bonded to seamless refrigerant quality copper tubes. All coils shall be provided
with suitable corrosion resistant coating to the approval of the CA and provided with a minimum
10 year warranty.
The tube and fin spacing shall be arranged to ensure maximum heat transfer efficiency with
minimum coil depth and air resistance.
Direct-expansion refrigerant cooler coil materials shall be selected to minimise electrolytic

action.
Coils shall be mounted in the unit casing so that they can be removed from the side without
dismantling the entire unit.
Refrigerant circuitry shall be designed to ensure equal distribution of refrigeration to each circuit
across the whole face of the coil.
Return or suction connections shall be arranged to ensure complete drainage of oil in the
evaporator.
The design of the refrigerant passages in direct expansion type evaporators shall be such that
any oil present is always carried back to the compressor at the lowest stage of capacity
reduction.
The complete evaporator coil shall be pressure tested at the manufacturers works to twice the
working pressure. After testing, the coils shall be dehydrated under vacuum and charged with
nitrogen before sealing.
Coil face velocity shall not exceed 2.5 m/s.
Part 5
Section 13 -Page 10
Evaporator and refrigeration shall be compatible with regard to duty and capacity control.
Evaporators shall be dehydrated and charged with an inert gas and sealed after manufacture.
Cooling coil casings shall incorporate a watertight drain tray complete with drain connection.
Trays and drains shall be arranged with longitudinal and cross gradients to ensure total removal
of all condensate.
Unless otherwise indicated drain trays shall be insulated and fabricated from mild steel
galvanised after manufacture prior to finishing with a two coat rubberised paint finish, or be
otherwise equally corrosion resistant and watertight.
Intermediate drain trays shall be provided where the coil height exceeds 1metre and for each
additional 1metre of coil height.
On large coils constructed in two horizontal sections they shall have separate connections
headers and shall be assembled correctly to ensure that the top section condensate flows
evenly onto the lower section. Where this is not possible a separate condensate baffle/catch
plate shall be installed with a separate condensate baffle/catch plate shall be installed with a
separate drain to the coil drain pan.
Unless otherwise indicated, PVC eliminator blades retained in galvanised steel plate shall be
provided after each coil and shall be located such that any carry over will collect and fall into the
drain pan. Eliminator sections shall be positioned to avoid damage from adjacent heater
batteries and shall be of materials unaffected by such heat. An access door shall be provided
between the coil and eliminator plates.
Where coil connections pass through the casing they shall be complete with sealing rings and
removable plates.
13.12 ELECTRICAL HEATER BATTERIES

Electrical heater batteries shall consist of a number of heating elements of the enclosed type
mounted in a sheet steel casing. Elements shall be so arranged to permit removal without
dismantling
Unless otherwise indicated the resistance to the air flow through the battery shall not exceed 25
Pa and the face velocity shall not exceed 6m/s nor be less than 2m/s.
An isolator and a hazard warning sign clearly indicating the operating voltage shall be fitted
immediately adjacent to the heater access opening.
In the proximity of hot areas, the electrical wiring insulation shall be suitable for the maximum
temperature.
The connections from each element shall be extended to a terminal box housed in an
accessible position with conduit/cable entry provision. They will be secured to the terminal box
with air tight glands and will be linked with either copper busbars or terminals as necessary to
achieve step control requirements stated elsewhere.
The number of elements in the heater shall be the same as or a multiple of the number of steps
in the controller. All heaters and heater sections of more than 3kW loading shall be balanced
over three phases and the complete heater bank shall be arranged for balanced operation on a
three-phase, four-wire system.
The elements shall be equally spaced over the open duct area.
The whole unit will be housed in a casing manufactured to the same dimensions as the Air
Handling Unit.
Part 5
Section 13 -Page 11
Each electrical heater battery shall be complete with a manually reset thermal cut that provides
an audible or visual alarm signal on high temperature cut-out as indicated elsewhere.
Unless otherwise indicated, the control of electrical heater batteries, except for remote boosters,
shall be interlocked with the system fan motor starter and an air flow sensing device to ensure
that the heater operates only when the fan is running and air flow is established. Capacity
control shall be via thyristor.
Electrical heater batteries which are installed as boosters in branch ducts shall each have a
local air flow sensing device to ensure that the heater operates when air flow is established.
13.13 CONDENSATE DRAINS

Provide condensate drains to all cooling coils, humidifier sections and recuperator sections of
the air handling units.
Condensate drains shall be run in a safe manner to discharge over an appropriate gully or to a
sump as indicated.
Connections shall be made by the installer, with glass "U" traps having a water seal depth of not
less than twice the fan static pressure, together with a tapping for maintaining the water seal.
Where necessary the trap shall be protected against accidental damage.
The drains shall discharge into a copper turndish.
Drains on pans under negative pressure are to have the outlet positioned low enough to prevent
condensation being held in the drip tray.
Where drains have to run across a walkway the installer shall provide a permanent step over.
Drains shall comply with recommendations in CIBSE Technical Memorandum TM13 and HSE
L8 in connection with Legionnaires disease.
13.14 HUMIDIFIERS
13.14.1 General
Humidification shall be achieved by the use of dry sterile steam generated by an automatic
steam humidifier selected to meet the duties as stated elsewhere. For the avoidance of doubt
the humidifier shall be selected to meet the final commissioned duty of the AHU inclusive of any
use of the 10% additional spare capacity of the fan duty described elsewhere in this
specification.
Distributor pipes shall be positioned to ensure equal mixing across the airway. In no
circumstances shall the distributor pipes be less than 75% of the width of the airway and shall
be designed for the Air Handling Unit section in which they are installed.
Injection pipes for introduction of dry steam from the unit into the air-stream shall be fabricated
in stainless steel.
The manufacturers recommendations regarding unobstructed space downstream of the

humidifier shall be adhered to.
Unless otherwise indicated, the control of humidifying plant shall be interlocked with the system
fan motor starter and a local air flow sensing device to ensure that the humidifying plant
operates only when the fan is running and full air flow in the humidifying section is established.
The unit shall be arranged to fail safe on interruption of the water or electrical supply.
Unless otherwise indicated the unit shall be supplied with a fully modulating control system
operating between 10% and 100%. Below 10% output shall be on-off only.
Part 5
Section 13 -Page 12
The unit shall be supplied with a control system which provides compatibility with the overall
control system. Provision for remote indication shall be provided to the main control panel or
BMS as indicated.
Packaged electric generator units shall be contained in sheet metal stove enamelled cabinets
for wall or floor mounting. Cabinets shall be provided as two separate compartments, one
containing the boiler and the other the controls. Casings shall be insulated as necessary to
prevent accidental contact with hot surfaces
Casings shall be provided with lockable front access doors permitting full access to either
compartment. Sufficient ventilation shall be provided to prevent overheating
Drainage, including unit drains, shall be arranged to discharge safely and incorporate an air
break.
13.14.2 Electric self generating humidifier
The unit shall be the electrode boiler type steam humidifier complete with stainless steel steam
distributor pipes within the humidifier section of the air handling unit.
The boilers outlet shall be connected by steam hoses up to 2 m in length to steam distributor
pipes in the ductwork.
The unit shall be designed for connection to a standard water supply with no necessary water
treatment.
The unit shall have the following connections:
Steam outlet pipe(s)

Cold water connection with solenoid feed valve and strainer
Drain connection with solenoid drain/blow-down valve cited with manual override, installed
into manifold and to building by others
A suitable sized cold water supply shall be connected to the unit which shall comply with the
Water Supply Regulations.
The humidifier shall be complete with disposable scale collection bag and shall have impulse
flushing to minimise sludge build-up.
Steam injection pipes/hoses shall be thermal insulated where installed outside of the ductwork
or air handling units.
The units shall be suitable for connecting to a 3 phase and neutral electrical supply. Unit
terminals shall be shrouded.
The control board shall have facility for remote indication including "change of scale collector
bag".
13.15 FILTERS
13.15.1 General
Filters within Air Handling Units shall be as detailed elsewhere and shall operate with not less
than the efficiencies specified.
Filter performance shall be measured in accordance with Eurovent standard 4/5 and BS EN
779.
Face velocities across filters shall be limited to a maximum of 2.5 m/s.
Filter unit or panels shall be selected to be of uniform size and pressure drop.
Part 5
Section 13 -Page 13
Filter media shall not be subject to erosion, deterioration or to the effects of temperature and
shall be manufactured from non-deleterious materials.
Filter material shall be non-hygroscopic, shall not support vermin and shall be proof against
fungal and bacterial growth and attack.
Filters shall be non-flammable and comply with BS 5588 9 and BS 476-4.
Frames, casings and filter cell holding frames shall be classified non-combustible when tested in
accordance with BS 476-4.
When exposed to heat or flame, the filter shall not generate significant quantities of smoke or
toxic fumes into the air-stream.
Filter material or wetting agents shall not be carried over in the air-stream.
Adequate access shall be provided for cleaning, removal and refitting of all filter cells and
replacement of gaskets in filter holding frames.
Combined pre-filters and main filters shall each be capable of being changed without disturbing
the other filter.
Filters shall be complete with robust purpose made holding frames which shall not distort in
operation and with seals to prevent air leakage or bypass.
Purpose made seals shall be provided to minimise air leakage around filters and the
effectiveness of the seals shall not be impaired by periodic removal and refitting of the filter
cells.
The entire framework shall be securely fixed in position with all edges and joints effectively
sealed to prevent air leakage.
Subsequent to commissioning and immediately prior to practical completion all disposable filters
shall be replaced. In addition one complete set of replacement media shall be provided for each
disposable filter. For cleanable units, sufficient replacements of each size and type to allow
individual units to be changed shall be provided. Where disposable filters are attached to
mounting grids or frames, other than by quick release fastenings, sufficient frames shall be
provided to meet the above requirements.
A copy of the type test certificate, issued by a NAMAS accredited air filter testing laboratory,
shall be submitted to the CA for each type of filter.
13.15.2 Panel filters
Pre-filters shall be arranged in flat or angle bank configuration, applicable to the required duty
and each cell shall consist of a pleated synthetic fibre element bonded to prevent fibre migration
and impregnated with special adhesive. The element shall be supported by a galvanised wire
mesh backing and enclosed within a stout fibre board frame with integral grid for added
reinforcement.
The average arrestance shall be 87% when tested in accordance with BS EN 779 clause G4 as
stated elsewhere.
Filters shall be contained in a standard air handling section and arranged for front or side
withdrawal depending upon space limitations.
Panels shall be of the disposable type unless otherwise indicated.
13.15.3 Bag filters
High capacity bag filters shall be arranged in a flat bank and shall comprise a permanent
corrosion-resistant holding frame housing a synthetic fire retardant media.
Part 5
Section 13 -Page 14
The media cartridge shall be pre-formed and shall be in accordance with BS EN 779 class F7
with an average efficiency of 80-90% or class F9 with an average efficiency of 95% as indicated
elsewhere.
Filters shall be capable of remaining fully inflated within the airstream.
Filters shall be contained in a standard air handling section and withdrawal/access shall be as
indicated
13.15.4 Activated carbon filters
Activated carbon filters shall comprise cells containing activated carbon granules selected to suit
the contaminants as indicated elsewhere.
Evidence as to both efficiency and adsorption capacity of the adsorbent at the indicated levels
shall be submitted to the CA for acceptance.
Air filters shall comprise of absorbent bed filled with uniform thickness of activated carbon
granules, constructed to prevent settlement and voids do not occur.
The media shall be of a disposable or reactivated type as indicated and housed in a permanent
corrosion resistant holding frame. Cell construction shall include provision to prevent migration
of the filter media.
Each filter assembly shall include two detachable test sections for use in predicting the service
life of the filter assembly. The test sections shall be exposed to full air flow and be removed and
replaced by a spare after 6 and 12 months operation and returned to the manufacturer for
analysis of saturation and report on service life remaining. The installer shall be responsible for
this removal and replacement during the defects liability period and shall include for the spares,
the manufacturer's costs for the analysis/report shall be included in the contract cost. Allowance
shall be made for housing the test sections as part of the filter assembly.
All metallic parts shall be adequately protected against corrosion.
Filters shall be contained in a standard air handling section and shall have withdrawal facilities
as indicated.
13.15.5 Filter Manometers
All filters shall be provided with an inclined manometer or differential pressure gauge which shall
indicate the actual pressure drop across the filter.
The filter clean and dirty pressures shall be indicated.
Where dirty filter monitoring is provided, each filter shall have a pressure sensor to indicate to
the control panel or BMS, as appropriate, filter dirty conditions.
13.16 UNIT DAMPERS

Unless otherwise stated dampers shall be multi-leaf opposed blade, manufactured from
galvanised steel construction with maintenance free nylon bearings and complete with suitable
linkages.
Unless otherwise indicated, air leakage through dampers when in the closed position shall not
exceed 5% of the maximum design air volume flow rate at the maximum design air total
pressure.
Manual dampers shall be complete with a locking hand quadrant. Manual and automatically
operated dampers shall include a means for indicating externally the position of the blades.
Mounting bracket and actuator shall be supplied by the controls specialist.
Part 5
Section 13 -Page 15
13.17 MIXING BOX/DAMPER SECTION
Mixing box sections shall be supplied having parallel blade dampers positioned across each air
opening.
On fixed quantities of mixed air, dampers shall be sized to give equal velocities through each
damper.
Access shall be provided into the damper mixing box section.
Each damper section shall be provided with a duct connection flange.
Mounting brackets and actuators shall be supplied by the controls specialist
13.18 HEAT RECOVERY

13.18.1 Plate heat exchanger
Plate to plate heat exchangers shall be of the diagonal flow type manufactured from separating
aluminium plates with a PVC coating or stainless steel plates as indicated elsewhere.
The unit shall be adequately sealed to prevent leakage or cross contamination.
The exchanger shall be mounted over a stainless steel removable drain tray.
Where indicated face and bypass dampers shall be fitted and shall be suitable for motorisation.
The minimum thermal efficiency shall not be less than that stated elsewhere.
The heat exchanger elements shall be designed to withstand the external and differential
pressures without deformation.
13.18.2 Run Around Coils
Run around coils shall comply with the requirements for coils previously stated elsewhere.
The AHU manufacturer shall provide a complete package consisting of pipework, circulating
pump and expansion vessel.
The pipework shall be arranged to provide full flow through the supply coil at all times.
The systems and components shall be suitable for 30% glycol to water mixtures.
Pumps shall be constructed with cast iron bodies, bronze impellers and mechanical seals driven
by totally enclosed or drip proof fan cooled motor suitable for single phase 230V electricity
supply. An isolating valve shall be provided on the inlet and discharge.
An altitude gauge and cock shall be provided on the system connection to the expansion vessel,
together with a 15 mm safety valve on the pump discharge, set to discharge at a pressure of 5
bar unless indicated otherwise.
The expansion vessel shall be of steel construction with internal flexible rubber diaphragm,
suitable for glycol/water mixtures, pre-charged with inert gas.
The system shall be complete with drain and make up valve with hose connection and vent
cock.
The pressurisation units shall be selected to accommodate the expansion in the system.
Where the system includes a coil likely to be subject to freezing conditions the system shall be
filled with a 30% glycol to water mixture.
Part 5
Section 13 -Page 16
13.18.3 Thermal Wheel Heat Exchanger
Rotating regenerative air-to-air heat recovery units shall transfer sensible or total heat as
indicated between the exhaust and intake airstreams, including the following:-
Integral purge section

Casing seals on periphery of rotor, on duct divider, and on purge section
Supported rotor on grease-lubricated ball bearings with extended grease fittings.
Tapered roller bearing for horizontal mounting of wheels
Heat wheels shall consist of a rigid mild steel casing protected against corrosion, containing a
sectioned wheel with radial reinforcement composed of pure aluminium treated with anti-
corrosion coating, desiccant 3A molecular sieve.
The coating or the heat exchange media shall not support bacteria, fungi or mould growth and
shall be coated to prohibit corrosion.
The media shall be easily cleanable and dry particles up to 800 microns, unless stated
otherwise, shall pass freely through the media.
The unit shall be provided with an adjustable purge sector designed to limit cross contamination
to less than 0.04 % of the exhaust air-stream concentration. This media shall be rigidly held in
place.
The rotor shall be speed controlled via an inverter allowing a turn down ratio as indicated and
shall be suitable for interfacing with the BMS as indicated elsewhere.
Provision shall be made for adjustment of drive belt or drive chain tension.
Thermal wheel heat exchangers shall have a minimum thermal efficacy of 70%.
The complete wheel and motor drive shall be mounted within an air handling unit section.
Access doors shall be located on each side of the heat recovery unit in the adjacent intake and
exhaust ductwork.
The wheel manufacturer shall guarantee wheel efficiency and shall provide certified wheel
selection and performance curves for approval. The efficiency shall be guaranteed for 5 years
with a maximum drop in efficiency of 10%.
The wheel shall be certified by an independent test laboratory for cross contamination using
tracer gas SF6 or equivalent. Cross contamination shall be less than 0.5%.
The maximum rotation speed shall be 20 rpm and maximum face velocity shall be 2.5 m/s.
Controls: Panel, factory mounted and wired to motor with air stream thermostat and manual
motor starter for field wiring; with pilot light indication of rotor rotation and provisions for setting
maximum and minimum speed.
Changeover Control:- Electronic automatic summer changeover system for field mounting of
room and outdoor air temperature sensors, to provide maximum rotor speed when air
temperature is less than outdoor air temperature.
Rotation Detection: - Electronic control module, electromagnetic sensor, and iron shuttle factory
wired and mounted, with alarm bell for field wiring and mounting, and remote alarm capability.
13.18.4 Heat pipes (wrap around type)
General
Heat pipes shall be included within the AHU and wrapped around the main cooling coil. The
wrap-around heat pipes precool the fresh/return air allowing more of the cooling coil surface to
Part 5
Section 13 -Page 17
be utilized for the removal of moisture. The dehumidified air is then passively reheated by the
heat pipe to the supply condition.
Heat pipes for enhanced dehumidification will comprise a precool fin block upstream of the main
cooling coil linked to a reheat fin block downstream of the cooling coil by means of wrap-
around pipes. The heat pipes will be delivered to the AHU manufacturer fully charged and
sealed, for inclusion in the air treatment section of the AHU.
Fins
The external fins shall be of aluminium with a minimum thickness of 0.15mm. Fins shall be of
the continuous plate type to maximize the external surface area rather the individually finned
tube pattern. The fins shall be of the louvered type to optimize the airside heat transfer and
spaced at such a distance as required by the conditions specified.
Tubes
Tubes shall be of refrigeration standard seamless copper C106 for heat exchanger use. Tube
diameter shall be 12mm with a grooved inner surface to enhance the internal surface area and
prevent pooling of liquid. The minimum root thickness of the tube shall be 0.35mm. The number
of rows of tubes shall be selected to suit the application. Multiple row heat pipes shall have
tubes in a staggered, equilateral pattern to optimize the airside heat transfer.
Casing
Casings shall be from galvanized sheet steel with a minimum thickness of 1.6mm. The casing
shall incorporate tube plates and top and bottom plates around both the precool and reheat heat
pipe blocks. Cover boxes shall be provided around the wrap-around pipes both to protect the
exposed pipes and to rigidly join the two sections. Extra sheet metal shall be provided to ensure
rigidity during manufacture and transport.
Working Fluid
The working fluid shall be refrigerant type classified as ASHRAE safety group A1. The
refrigerant shall be either R134a. The heat pipe circuits shall be factory charged and
hermetically sealed with the calculated weight of refrigerant.
The working fluid shall be refrigerant type classified as ASHRAE safety group A1. The
refrigerant shall be either R134a. The heat pipe circuits shall be factory charged and
hermetically sealed with the calculated weight of refrigerant.
Circuitry
Heat pipes shall be formed from an array of complete loops such that the working fluid flows
around the loop in only one direction i.e. liquid and vapour flow in the same direction to ensure
that returning liquid is not entrained by the vapour.
There shall be a multitude of loops in the height of the heat pipe and each loop shall be
individually charged. Heat pipes with header assemblies containing a single circuit are not
suitable as a single leak will render the entire heat pipe inoperative.
When multiple row heat pipes are used the rows shall be connected together in a counter flow
orientation to optimize the performance of the heat pipe. Rows shall not be manifolded together.
Heat pipe loops shall be arranged to slope down to the precool side to allow gravity assisted
liquid return to maximize the internal heat transfer.
Performance
Heat pipes shall be designed to comply with the specified conditions when subject to the air
volumes given in the specification. Heat pipe performance shall be independently type tested
and certified in line with the requirements of British Standards BS 5141 pt1 / European
Part 5
Section 13 -Page 18
Standards EN 305 & 306 / American Standards ARI 410 for testing and rating of heat
exchangers. All software used to predict the performance of heat pipes shall be based upon the
results of these independent tests.
Conditions
Heat pipes shall be specified based upon a standard set of conditions for the outside/return air.
These conditions can be either climatic design conditions or most commonly occurring
conditions for the location in question. Both dry bulb and wet bulb temperatures shall be
specified for the four points in question i.e. air onto the pre-cool leg, air off the pre-cool leg, air
onto the re-heat leg and air off the re-heat leg. The cooling coil must be selected to match these
specified temperatures.
Installation
The heat pipe shall be designed to fit around the main cooling coil and its dimensions will be
selected so as to allow this. Once installed within the AHU both the heat pipe and cooling coil
shall be blanked-off to ensure that there is no air bypass around the fin blocks of either the heat
pipe or cooling coil. The base of the air treatment section of the AHU shall form a drain pan.
Independent Test Report
The heat pipe should have a third party independent test report conducted by a certified
laboratory.
Manufacturing Experience
The heat pipe manufacturer shall have minimum 10 years experience in manufacturing of heat
pipes and must have heat pipes commissioned for a minimum period of 5 years.
Selection Criteria
The number of rows and fins spacing shall be selected at the most common ambient conditions
i.e. 33 OC (DB) & 27.5 OC (WB) to achieve the most optimum performance of heat pipe
throughout the year.

BS 848-1 Fans for general purposes. Performance using standardized

(ISO 5801) airways.
BS EN 12451 Copper and copper alloys. Seamless, round tubes for heat
exchangers
BS ISO 13347 Industrial fans. Determination of fan sound power levels under
standardized laboratory conditions
BS EN ISO 5136 Acoustics. Determination of sound power radiated into a duct by
fans and other air moving devices. In-duct method.
PD 5304 Safe use of machinery
BS EN 60529 Specification for degrees of protection provided by enclosures (IP
code)
BS 5141-1 Specification for air heating and cooling coils. Method of testing for
rating of cooling coils.
BS 5141-2 Specification for air heating and cooling coils. Method of testing for
rating of heating coils.
BS EN 10226-1 Pipe threads where pressure tight joints are made on threads.
(BS 21) Taper external threads and parallel internal threads. Dimensions,
BS EN 1092 Flanges and their joints.
BS EN ISO 1461 Hot dip galvanized coatings on fabricated iron and steel articles.
Specifications and test methods.
BS EN 779 Particulate air filters for general ventilation. Determination of the
Part 5
Section 13 -Page 19
filtration performance.
BS 5588-9 Fire precautions in the design, construction and use of buildings.
Code of practice for ventilation and air conditioning ductwork.
BS 476-4 Fire tests on building materials and structures. Non-combustibility
test for materials
HSE L8 Legionnaires disease. The control of legionella bacteria in water
systems. Approved Code of Practice.
CIBSE TM 13 Minimising risk of legionnaires disease
Part 5
Section 13 -Page 20
Section 14 Grilles, Diffusers and Louvers
Contents
Section 14 Grilles, Diffusers and Louvres 1

14.2 Linear slot diffusers 2
14.3 Ceiling Diffusers 2
14.4 Floor mounted outlets 3
14.5 Grilles 3
14.6 Swirl diffusers 4
14.7 Jet nozzles 4
14.8 Air valves 4
14.9 Plenum boxes 4
14.10 Displacement ventilators 5
14.11 External louvers (aerofoil type) 5
14.12 External louvers (sand trap type) 6
Section 14 Grilles, Diffusers and Louvres
Grilles, diffusers and louvres shall be provided to handle the required air quantities as stated
elsewhere whilst meeting the specified design criteria in respect of noise and comfort.
The acoustic performance of all diffusers, grilles and other terminal devices shall be in
accordance with BS EN ISO 5135 or any other approved standard.
Prior to the equipment being ordered, the installer shall verify the selection data.
The final layout shall be subject to agreement with the Architect. The installer shall allow for
detailed locations being adjusted suiting final setting out of ceilings, floors and walls.
The installer shall liaise with the manufacturer to ensure compatibility and coordination between
the grille/diffuser and ceiling support system.
The installer shall provide a method statement to CA outlining the final fixing methods and
details of all grilles, diffusers and louvers prior to installation.
Wherever indicated the room noise level rating shall not be exceeded with the system operating
at its maximum duty and taking into account all accumulative effects of the diffusers, area
served, and noise regenerated by regulating/balancing dampers immediately behind the diffuser
or grille to provide the correct air volume flow rate
Diffusers shall be draught free, shall provide rapid mixing of primary and re-circulation air to
ensure that the design air movement and room temperature gradient is not exceeded.
In this respect the maximum velocity at 1.5 m height shall not exceed 0.26 m/s and the room
temperature gradient shall not exceed 2 C from floor to normal office ceiling height unless
otherwise stated.
Air diffuser pressure drops shall be selected at a minimum to ensure that the Noise Rating of the
diffuser is achieved.
Grilles, diffusers and louvers shall be provided to an approved finish and sample charts and
samples shall be provided for approval.
Duct mounted grilles and diffusers shall be fitted with volume control regulators, adjustable from
the unit face unless otherwise indicated.
Mitres, end caps and corners shall be welded in such a manner as does not show on the
surface. The diffuser or grille face shall have the joint filled and finished so that it does not
show. The joint shall remain concealed after the finish has been applied (in the factory).
Grilles and diffusers visible in rooms shall be secured by concealed fixings. Units shall be
capable of being easily cleaned by having faces readily accessible or by removable centre cores
as indicated.
All grilles and diffusers shall be provided with a neoprene or other sealing strip to provide a
permanent seal against the adjacent surface and as a means of absorbing variations in the
surface.
Part 5
Section 14 - Page 1
14.2 LINEAR SLOT DIFFUSERS
Linear slot diffusers shall be constructed with extruded aluminium bodies unless otherwise
indicated.
Linear diffusers shall include means of independently adjusting the direction of the air jets,
unless otherwise indicated as fixed type. The method of air volume flow rate control shall be as
indicated.
Diffusers shall be from extruded aluminium with steel pattern controllers, 20 mm slot with
concealed fastening or as otherwise stated on the schedules/drawings. The number of slots,
lengths and air volume shall be as indicated on the design drawings & schedules. The
Manufacturer shall provide lined plenum boxes the same length of supply linear diffuser. Provide
acoustic lining with suitable facing in plenum boxes where necessary to achieve specified NR
levels.
Where linear diffusers are mounted in a continuous line, there shall be provision for ensuring
alignment between consecutive diffusers and each diffuser shall be provided with means to
ensure uniform air flow distribution along the diffuser.
Concealed alignment strips shall be provided to ensure square butting and proper alignment of
diffusers. Where diffusers are provided in sections the sizes of the individual section shall be
selected to provide as regular an appearance as possible without the use of short closure
pieces.
Active sections of linear diffusers shall be provided with plenum boxes fabricated by the diffuser
manufacturer to match output of the diffuser. The construction of plenum boxes shall be as
stated elsewhere and shall be in accordance with DW144.
Ceiling mounted linear diffusers shall be fitted into the ceiling grid with the plenum box properly
secured to the diffuser and sealed against air leakage.
All necessary diffuser and plenum box supporting and fixing brackets for the installation shall be
provided.
Dummy lengths of linear diffuser shall be provided with blanking plates, unless such plates are
to be omitted to provide a return air path, where the diffusers shall be provided with an
acoustically lined plenum box.
The installer shall be responsible for taking all site dimensions necessary for setting out and
manufacturing diffusers. This shall include any angles involved.
RAL Colour finishes to be allowed for to the CAs requirements
14.3 CEILING DIFFUSERS

Louvre face supply diffusers shall be all steel construction with removable core. Sizes indicated
on the drawings and schedules are neck sizes.
Diffusers shall be provided with a baked enamel finish to any RAL colour as per the CAs
requirement. Diffusers shall be installed with opposed blade damper, equalising grid where
appropriate and plenum box.
Diffusers shall be selected to provide adequate air distribution and mixing with room air outside
the occupied space. Baffle plates shall be provided as necessary or as indicated to avoid local
obstruction.
Each diffuser shall be provided with an air flow rate controller and a means of altering the
discharge air flow pattern. All controllers/dampers shall be adjustable from the front of the
diffuser.
Part 5
Section 14 - Page 2
Diffusers with ducted connections shall be provided with plenum boxes selected and fabricated
by the diffuser manufacturer to match the output of the diffuser. Construction shall be as stated
elsewhere. Each plenum shall be sealed to the back of the diffusers.
Where a diffuser is directly connected to a stub duct which has a straight length of less than two
equivalent diameters, an equalising deflector shall be used.
Circular diffusers, with adjustable air flow pattern, shall have the cone retained by a screwed
spindle fitted with upper and lower stop pins or other approved method.
14.4 FLOOR MOUNTED OUTLETS

Floor mounted outlets shall be of a heavy duty construction suitable for the floor use.
Unless indicated otherwise, the floor outlets shall be capable of withstanding point loads of 200
kg except in computer rooms and like where the minimum point load shall be 400 kg.
Outlets shall be constructed from mild steel, aluminium or plastic as indicated and comprise a
body and clamp ring to secure the outlet to the floor with a removable unit to provide a swirl
pattern to the discharging air.
The unit shall incorporate a galvanised mild steel dirt basket, removable from above the floor.
The basket shall incorporate an in-built galvanised steel throttling device.
The manufacturers limitations on flow rate, discharge velocity and temperature shall be
complied with in the selection and commissioning of the units.
14.5 GRILLES
Grilles shall be constructed from extruded aluminium or other materials as indicated and shall
be complete with matching surrounds.
Grilles for supply air shall have two sets of adjustable blades, one set horizontal and one set
vertical. Unless otherwise indicated, the air flow rate controller shall be a damper of the
opposed blade multi-leaf type or rhomboidal type.
Extract air grilles shall have a single set of adjustable blades either horizontal or vertical, or a
lattice or egg crate front as indicated. The air flow rate controller for extract air grilles shall be a
damper of the opposed blade multi-leaf type.
The blades of all grilles shall be adjustable from the front and shall have a friction device to
retain set positions. The air flow rate controller of all grilles shall be adjustable from the front.
Transfer grilles shall be of the non-vision type with inverted V vanes. The free area shall be at
least 80% unless otherwise stated. Where transfer grilles are visible from both sides and
located within a wall or similar thick structure a second grille shall be provided with one grille
located each side of the opening. Where located in doors they shall be provided with a
telescopic flush fitting installation frame suitable for the door width. Where installed in fire rated
doors, intumescent cores shall be provided to maintain the fire rating of the door.
Linear bar grilles shall be of the fixed vane pattern with the vane angel pre-selected to produce
the required air pattern. They shall be formed from extruded aluminium anodised linear bars
with aerofoil cross section for minimum turbulence.
Blades shall be 5.5mm 10mm pitch, and deflection as required to produce the most efficient air
pattern. The linear bar grilles shall be provided with a concealed fixing and a narrow
border/flange to the CAs approval.
All bar grilles (supply and return) shall be provided with GI plenum boxes with acoustic lining.
The diffuser size and lining shall be selected to achieve the specified NR level for the space
served. Where these are supplied from FCU's these shall be assumed to be operating at
Part 5
Section 14 - Page 3
medium speed. Acoustic lining to have suitable facing to prevent migration of fibres and shall be
black in colour.
RAL Colour finish to be allowed for to the CAs requirements
Linear grilles for floor trenches, perimeter heating systems and for floor supply or extract shall
be provided with mitred ends jointed and finished as indicated.
14.6 SWIRL DIFFUSERS

Swirl diffusers shall be with either circular or square faceplate as per the CAs requirements or
as indicated on the schedules. The faceplate shall be made from steel. The air control blades
shall be adjustable type.
The faceplate shall be removable, held in place with a central screw fixing covered with a
decorative cap. The diffuser shall be supplied complete with GI plenum box (acoustically lined)
from the factory.
The plenum shall be provided with volume control damper
Diffusers shall be complete with brushed steel faceplate
The face section shall be demountable held in position by a centre fixing bolt with cover cap.
The diffusers shall be supplied in a RAL colour to the CAs specification as advised during the
approvals process at no additional cost.
14.7 JET NOZZLES

Adjustable construction type jet nozzles, shall be provided where indicated on the
drawings/schedules, complete with front mounting flange and circular spigot for duct mounting.
The nozzles shall be capable of adjustment manually up to 300 in any direction. The jet nozzle
and face cover are to be baked enamel finish. The jet nozzle shall be supplied in a RAL colour
to the CAs specification as advised during the approvals process at no additional cost.
The discharge nozzle and face ring shall be from aluminium. The nozzle shall be
aerodynamically shaped, deep-drawn in one piece with fixing holes. The adjustable construction
shall consist of a discharge nozzle with spherical outlet mounted in a housing, a mounting flange
and for circular ducts a rear connection spigot. The mounting eyeball shall be with 2 plastic
rings. The duct connection elements and saddle shall be from galvanised steel sheet.
The nozzles shall be suitable for mounting on circular or square ductwork. The installer shall
allow for all necessary fixings and the flanges shall be provided from the manufacturer.
14.8 AIR VALVES

Air valves shall be constructed from the extruded aluminium and shall be provided with sub
frames formed to provide a seating ring for the face section. Flanges shall be provided with
sealing gaskets.
The air volume shall be adjusted by rotating the central disc to alter the space between the disc
and valve ring. The adjustment shall be capable of being locked. RAL Colour finish to be
allowed for to meet the CAs requirements
14.9 PLENUM BOXES

Plenum boxes shall be provided as indicated and shall be to the same ductwork specification as
the connecting ductwork and fitted with round inlets with flexible connections and butterfly type
balancing dampers unless otherwise stated.
Part 5
Section 14 - Page 4
Where connected to insulated ductwork the plenum box shall be insulated to the same standard
as the connecting ductwork.
Outlets from plenum boxes shall be either circular or rectangular to suit the diffuser neck
connection.
The dimensions of the plenum box shall be as recommended by the diffuser manufacturers and
shall be of adequate dimensions to ensure correct diffuser performance in terms of noise level,
throw and pressure drop.
Where appropriate plenum boxes shall be provided with galvanised steel perforated plates to
achieve equal air distribution and pressure drop across the whole face of connecting grilles or
diffusers. The details of all plenum boxes shall be submitted to the CA for approval prior to
ordering
Where plenum boxes are fitted with an opposed blade damper, dampers shall not be required
on the neck of the diffuser being served.
Plenum boxes shall be provided with acoustic lining (as specified elsewhere) to achieve room
NR levels. All return air terminals, grilles and diffusers open to the ceiling void for free return air
path shall be provided with acoustically lined plenum boxes to prevent noise transfer between
the void and room. Acoustic lining shall be as required to ensure noise levels of the space and
any adjacent rooms are maintained.
14.10 DISPLACEMENT VENTILATORS

Displacement ventilators shall be manufactured from galvanised mild sheet steel or aluminium
as indicated with perforated face panels, base plate and circular connection collar for ducts.
Ventilators shall be suitable for floor mounting and the outlet surfaces shall be to the shapes
indicated.
Ventilators shall contain low resistance baffle, equalising grid or other device to ensure even
distribution over the perforated face panels.
Perforated face panels shall be designed to be removable for cleaning, maintenance or

replacement of air distribution components.
Ventilators shall be suitable for floor mounting.
RAL Colour finish to be allowed for to the CAs requirements
14.11 EXTERNAL LOUVERS (AEROFOIL TYPE)

All air intake and exhaust points shall be protected with louvres designed to prevent ingress of
rain, dust and sand. Louvres shall be designed to prevent water carry over through the louvres
for the stated size and air volume.
The louvre system shall achieve minimum resistance to airflow, with louvre blades
aerodynamically shaped with no sharp edges or protrusions.
Louvres shall be mounted in large section angle frame having intermediate uprights as
necessary for rigid support of the louvres. An effective weather and acoustic seal shall be
achieved using approved packing and filling materials as necessary.
Frames and blades shall be fabricated from galvanised mild steel sections and sheet, or from
aluminium alloy of adequate stiffness to prevent vibration and/or damage as indicated. Louvres
frames and blades shall be a minimum 16 gauge.
Louvres shall be fully protected against corrosion. Louvres shall be provided in any RAL colour
as stipulated during the approvals process by the CA.
Part 5
Section 14 - Page 5
Louvre blades shall be roll formed to an aerodynamically efficient profile and clipped to
concealed structural supporting mullions with efficient water drainage on to cill.
The louvre system shall achieve the minimum aerodynamic performance coefficients (Cv) and
weathering classification against as indicated when tested in accordance with BS EN 13030.
Vermin/insect screens shall be fitted to all external louvres and shall be removable for cleaning.
The design should allow for additional resistance to airflow and reduced air flow rate
performance.
Each louvre assembly shall be complete with integral drip channel and drain outlets as
necessary.
Where sand trap louvres are specified they shall be selected according to the manufactures
recommendations for face velocity to achieve optimum sand removal.
Refer to Traz STLs Data sheets
14.12 EXTERNAL LOUVERS (SAND TRAP TYPE)

The contractor shall supply, deliver, off load, store, lift into position and fix sand trap louvers as
indicated on the drawings and detailed in the particular specification. Sand trap louvers shall be
manufactured by an approved ISO 9002 certified manufacturer. Sand trap louvers shall have
fixed vertical louver blades, in laberinth form, arranged to allow the passage of air but to resist
the entry of air borne sand into the building.
Sand trap louvers shall be self draining with holes in the lower edge to drain sand away
externally.
Louvre and casing may be manufactured from the following material and grades as defined in
Particular specification.
Construction Blade Size Casing Self Emptying Drain

Holes
Galvanised Steel 1.0mm 2.0mm Yes
Stainless Steel 1.0mm 2.0mm Yes
Aluminium 0.9mm 2.0mm Yes
Sand trap louvers shall be sized based on 1m/s face velocity and filtration performance shall be:
Particle Size Range Filtration Efficiency at 1 m/s Filtration Efficiency at 1m/s

(microns) face Velocity face velocity
350-700 90% 70%
75-700 60% 30%
Sand trap louvers shall have a sand rejection effectiveness as specified above when tested in
accordance with BSEN13181 and the contractor shall provide a material submittal complete with
type test certificate proving filtration efficiency for the CAs review prior to ordering.
A galvanised steel bird screen comprising a 13x 13x1.2 mm mesh shall be provided on all sand
trap louvers.
The contractor shall provide all necessary supports to frame, fix and support the louver, and in
cases of multiple louver modules all intermediate supports between modules. Secondary
framing shall be galvanised steel or aluminium matching the construction of louvers.
Part 5
Section 14 - Page 6
Final RAL colour finish shall be in accordance with the Particular specification but shall be a
Pvf2 powder coat finish
Sand trap louvers shall be securely fixed to the structure to resist local design wind loads as
specified in the particular specification and calculated in accordance with BS 6399-2. When
subjected to the design wind load it shall not cause any part of the louver to become detached
or suffer permanent deflection of more than 1/250th of the span.

BS EN ISO 5135 Acoustics. Determination of sound power levels of noise from air-
terminal devices, dampers and valves by measurement in a
reverberation room
BS EN 13030 Ventilation for buildings. Terminals. Performance testing of
louvres subjected to simulated rain.
BS EN 13181 Performance testing of Louvers subjected to
Part 5
Section 14 - Page 7
Section 15 Air Conditioning Terminal Units
Contents
Section 15 Air Conditioning Terminal Units 1

15.2 Fan coil units 1
15.3 Variable Air Volume Boxes 5
Section 15 Air Conditioning Terminal Units
Casings for all types of unit shall be corrosion resistant and of rigid construction. All components
in contact with the air steam shall be manufactured from non-corrodible materials.
Units shall be selected to achieve the specified noise levels in the areas served or affected by
the units.
Thermal insulation and acoustic linings shall be non-combustible and shall not support bacterial
growth.
15.2 FAN COIL UNITS

Fan coil units shall either be two or four pipe units as indicated on the equipment schedules.
Units shall be horizontal or vertical as indicated. Horizontal units shall be arranged with the filter
and coils on the fan suction side of the unit. Vertical units shall have the coil face and fan
discharge sufficiently separated to ensure adequate development of the air-stream to permit an
even velocity distribution across the coil face.
Units shall be capable of meeting the performance requirements indicated in the equipment
schedules, when operating against the required external air side resistance. Performance
figures shall be in accordance with BS 4856 Parts 1 to 4 as appropriate to the unit selection.
Independently certified thermal, hydraulic, air flow and acoustic data for each type of unit shall
be submitted to the CA before orders are placed. The manufacturer and specific model offered
shall be Eurovent Certified.
Prior to fan coils being ordered sample units shall be provided to CA for approval. The samples
shall be of a size selected by the CA, the selection being representative of the sizes and types
to be supplied. The sample units shall be maintained on site as a benchmark for evaluation of
the units installed.
Units shall be selected to meet the required duty and noise levels when operating at medium
speed unless otherwise stated.
The control valve assemblies shall be pre-wired and pre-plumbed at the manufacturers works
before despatch and shall comprise control valves, pressure tappings, isolating and regulating
valves, drain cocks all as indicated or otherwise stated. The valve arrangement shall be as
detailed elsewhere in the specification. All pipework shall be pressure tested at the factory and
valves shall be capped before delivery.
Provide a flushing bypass on each fan coil unit to enable the chilled water (and heating water
systems if applicable) to be thoroughly flushed clean without passing dirty water through the
coils.
Fan coil units shall be installed in accordance with the manufacturers recommendations for the
particular application. The installation shall prevent the transmission of noise and vibration to the
building or to adjacent services by the use of anti vibration mountings.
Units shall be installed to permit commissioning and maintenance. The installer shall ensure
that casings, false ceilings, suspended floors and other concealment are arranged to permit
these functions to be carried out in a proper and satisfactory manner.
Part 5
Section 15 - Page1
The method of commissioning the units shall be in accordance with CIBSE guidance. The exact
method of commissioning shall be agreed and approved with the CA to suit the particular
installation.
Each fan coil unit is to be complete with a unique identification reference label fitted at the
manufacturers works. The identification reference shall be clearly visible through the wrapping.
The text and method of reference shall be as approved by the CA prior to ordering and shall be
utilised in the record documentation.
Provide access panels for inspection of all moving parts in a safe manner.
Fan coil units shall meet the EMC regulations.
The limiting specific fan power (W/litre s-1) at the design flow rate for fan coil units shall be no
worse than 0.8 (rating weighted average).
Casing
Unless otherwise indicated, casings shall be provided as part of the unit.
Casings shall be corrosion resistant and of rigid construction being adequately stiffened to
prevent drumming, vibration and distortion. Sharpe edges shall be removed and joints sealed
with mastic. Unless otherwise sated all chassis components shall be manufactured from a
minimum of 1.2mm thickness galvanised mild steel. Units in excess of 1000l/s shall be of double
skin construction.
Casings shall be lined with thermal and acoustic insulation to maintain air borne and breakout
noise within the specified limits. Insulation shall be high density being CFC and HFC free with
class O rating and to the required thickness. It shall be securely attached to the unit without
leaving any pockets or un-insulated casing.
Vulnerable chassis components shall be adequately protected during transit, site location and
installation
Access covers shall be provided to allow maintenance access to fans, coils and filters. Covers
shall close onto air-tight seals with retained fixings capable of being easily released and
replaced with the unit in position. Access covers shall be insulated and finished in a similar
manner to the rest of the unit.
Units shall be provided with integral plenum chambers for discharge connections as indicated.
Fresh air supply inlet spigots shall be provided as indicated. Any spigots not used shall be
capped off with a blanking plate.
Filters
Each fan coil unit shall be complete with a cleanable air filter panel, as indicated, located at the
inlet section.
Filters shall be contained in lightweight frames arranged to facilitate replacement. They shall
seal positively against sealing strips fixed to the unit. Filters shall be capable of being removed
without contacting the dirty media. Access to the filter shall be obtained without major
dismantling of the unit, ceiling where applicable or connecting ductwork.
Prior to practical completion all fan coil unit filters shall be cleaned or replaced with new as
applicable. Adequate spare replaceable or cleanable filter media shall be provided to permit
replacement of all filters.
Air filters shall have a performance classification of grade 3 when tested in accordance with BS
EN 779 unless otherwise indicated.
Part 5
Section 15 - Page2
Coils
Unless otherwise indicated, cooling coils and heating coils shall be formed of copper tubes with
aluminium fins and shall have the duties as indicated.
Coil water velocities shall be no greater than 1.5 m/s and air velocities no greater than 2.5 m/s
at the specified speed unless otherwise stated.
Coils shall be selected so that the waterside pressure drop does not exceed 5 kPa on heating
coils or 15 kPa on cooling unless otherwise stated.
Each coil shall be fitted with a manual air vent positioned to eliminate all air from the units. Vents
shall be extended to the unit casing allowing ease access after installation and shall not be
hindered or restricted by the valve sets.
Coils shall be manufactured from seamless copper tube with aluminium fins. Fins to be punched
with die formed collars to afford maximum heat transfer surface area with the tubes. All coils are
to be unhanded and circuited to optimise output but ensure free venting and free draining. The
number of coil rows shall be as required to achieve the required sensible and latent cooling
capacities. Coils shall be a minimum of 4 rows.
Every coil should be leak tested using dry air under water to 20 bar. Every coil to valve
connection should be tested under water
Drain pans shall be one piece and positioned to collect and retain all condensate generated by
the coil and valve assemblies. The bottom of the pan shall be graded in both directions towards
the drain connection. A drain connection shall be provided, capable of adequately discharging
condensate to waste without allowing condensate to collect in pockets or remain as standing
water in the drain pan. Where the connection cannot be taken from the bottom of the pan a
local sump shall be formed in the bottom of the pan and a side outlet drain connection provided.
The entire underside of the drain pan shall be insulated with closed cell insulation material fire
rated Class O. Drain pans shall be fabricated from non-corrosive material or be protected
against corrosion as stated elsewhere.
Drain pans shall be thoroughly cleaned prior to setting the units to work.
Any necessary disturbance of the galvanized finish shall be treated with zinc based surface
treatment.
The operation of condensate pumps (where required) shall be checked by pouring a small
quantity of water into the drip tray prior to setting the units to work.
Fans
Fans shall be directly driven, forward curved, double inlet width (DIDW) centrifugal type and
capable of delivering the required air volume against the external resistance as indicated.
Bearings shall be sealed for life.
The fan layout and suction chamber design shall be arranged to provide as even a velocity
profile as possible across the coil.
Fan motors shall be totally enclosed, external rotor type with standard overload protection and
comply with BS 2048 Part 1, BS 5000 and BS EN 60034.
Each fan shall have its own resiliently mounted motor. The fan and motor unit shall be statically
and dynamically balanced.
Transformers shall be provided as necessary to give the correct electrical supply to the unit
controls
Part 5
Section 15 - Page3
Motors AC
Motors shall be totally enclosed, external rotor, permanent split capacitor type. Power factor
shall be 0.9 or better. Bearings shall be the sealed for life ball race type with a manufacturers
minimum life expectancy of 40,000 hours under typical operating conditions. Overload
protection shall be afforded to each individual motor by an auto resetting thermal contactor.
Motor insulation shall be to class B with the enclosure to IP44 unless stated otherwise.
Electrical supply shall be 230 volts 1 phase 50Hz.
Motors DC
Motors shall be of direct current, electronically commutated type. Each motor shall have an
integral power supply; external power supplies are not acceptable. If filters are required to meet
the harmonic requirements of EN61000-3-2, then these shall be supplied and fully wired by the
fan coil manufacturer. The motor should be insulated to Class B with the enclosure to IP44
Controls
A temperature detector shall control each fan coil unit. The detector shall be provided with
sufficient cable to allow it to be fitted where indicated on the drawings or as agreed with the CA.
Where the detector is fixed to the unit, it shall be on the side remote from the fresh air intake,
and mounted external to the unit in the return air path.
The fan coil and controls package shall be fully wired and tested by the fan coil manufacturer to
an approved wiring diagram by the controls specialists. All components shall be housed in an
adequately sized and ventilated controls enclosure which shall be part of or securely fitted to the
fan coil chassis. Electrical supply shall be via a suitably rated connection mechanism within the
controls enclosure.
Waterside control of the units shall be by three or two port control valves as indicated. Valves
shall be selected to ensure adequate authority and selected to ensure adequate resistance
through the by-pass connection to provide stable control.
Airside control units shall be supplied as purpose designed and constructed units. Integral
dampers shall be provided within the air intake section of the unit to control the passage of air
across the cooling coil, heating coil and by-pass air path. The damper linkage shall be
controlled via an electric or pneumatic actuator, as specified.
Speed Control AC
Fan speed will be affected through a multi tapped unit mounted transformer. As a minimum,
three speeds and three trimming speeds shall be provided which will be selected through a pair
of speed selection switches. These shall be easily accessible. Any relays required to control fan
on/off or fan speed switching shall be fully wired by the fan coil manufacturer and, unless
otherwise stated, shall be supplied by the controls specialist as part of a free issue package.
DC Speed Control
Fan speed shall be achieved through a 0 - 10 VDC signal to the motors. The fan coil
manufacturer shall indicate the input voltage required for achieving the design air volume and
the input voltage required to effect low speed and high speed as defined elsewhere.
Fan coil speed will be controlled as stated by either:

variable DC signal provided via the BMS controller
three stage switch giving three fixed control voltage outputs.
a manual infinitely variable rotary switch giving infinite control voltage outputs for 0 to
10Volts.
Part 5
Section 15 - Page4
Acoustics
Fan coil units shall be selected to meet the specified noise criteria. Ensure that due allowance is
made for the accumulative affect of a number of fan coils operating in the same space.
Tests requested to establish the NR level of individual units shall be conducted at the design
condition for the unit on test. The NR level recorded will be the maximum level of two recordings
taken at 1.5m from the discharge grille and 1.5m from the intake grille.
Unless otherwise indicated the fans shall be selected and set at medium (design) speed
operation to give the specified NR levels.
15.3 VARIABLE AIR VOLUME BOXES

All equipment shall meet the performance criteria as detailed elsewhere.
The design, construction, materials and finishes of all units shall be suitable for the locations,
climatic and operating conditions.
The units shall be suitable for the air application and be suitable for use with the proposed air
flow rates and operating pressure conditions.
Each VAV unit shall be powered and operated by a 230 volt, 1phase, 50 Hz power source
unless otherwise indicated.
All components in contact with the air stream shall be made from non-corrodible materials.
VAV units shall be double skin construction made from 1mm thick galvanised sheet steel
stiffened to prevent drumming, mechanically sealed and gasketed to form a leak proof
construction capable of handling a maximum static pressure of 1500 Pa unless otherwise
stated.
Drilled mild steel lugs shall be provided by the manufacturer where required for fixing.
The boxes shall incorporate integral thermal/acoustic insulation. All thermal/attenuating

materials shall be inherently non-combustible and limit the surface spread of flame to Class 1
when tested in accordance with BS 476: Part 7 and shall not emit toxic or hazardous fumes if
ignited. Non-flammable adhesives shall not be used. Exposed surfaces shall be bonded or
covered to prevent erosion and securely fixed in place. All cut edges shall be sealed to prevent
erosion.
All acoustic/thermal components shall be made from materials with zero ozone depletion
potential (CFC and HCFC free). Submit to the CA, prior to ordering, written confirmation from
the manufacturer(s) that the products to be installed are CFC and HCFC free.
For all thermal/acoustic infill material test evidence must be available and submitted to the CA
showing that the fibres from which the products are made are not classified as a possible
carcinogen as detailed by European Directive 97/69/EC.
Finish of the units shall be galvanised or as otherwise indicated.
Units shall be clean and rust free with a totally unblemished casing finish prior to site delivery.
They shall have adequate packaging to protect from damage whilst stored on site. Each unit
shall be complete with a unique identification reference label fitted at the manufacturers works.
The identification reference shall be clearly visible through the wrapping. The text and method
of reference shall be as agreed with the CA prior to ordering and shall be utilised in the record
documentation.
The control unit, shall consist of a throttling damper or air valve, electric actuator, velocity reset
controller and flow measuring device. The velocity reset controller shall control the air flow to
within 5% of the design value, regardless of change in the static pressure in the duct system.
Part 5
Section 15 - Page5
The controller shall reset the airflow as commanded by the room temperature sensor with the
same accuracy.
Actuators, reset controllers, circuitry, attenuators and distribution boxes shall be provided and
installed at the factory and must be integrated into the unit casing. The control equipment shall
be easily accessible. The controllers shall be of the same manufacturer as the BMS and shall be
fully compatible with the BMS protocol provided.
The controller shall be pre-set at the factory for specified maximum and minimum air flow rates.
A "flow cross" air volume measuring station shall be fitted in the inlet duct to facilitate direct
reading of airflow on site.
A suitably sized access panel shall be provided in the underside of each unit to facilitate
inspection and maintenance of all internal mechanisms and moving parts. Thrusters shall be
readily removable from the units.
All units shall be factory calibrated to the maximum and minimum airflows specified elsewhere.
The operation and accuracy shall be demonstrated at the factory prior to delivery to site.
Maximum permissible air leakage with the outlet blanked off shall be 2% of maximum rated
airflow against an inlet pressure of 1500 Pa on the high pressure inlet unless otherwise stated.
Regulators shall have the specified maximum and minimum volumes, so as to give constant
airflow within a tolerance of 5% over an inlet pressure range of 100 - 1500 Pa.
Each unit shall facilitate adjustment to the airflow limits, calibration and resetting on site. A fully
site re-settable controls calibration chart for setting of airflow on site shall be securely attached
to each unit.
Air inlet and outlet ductwork spigots shall be in accordance with HVCA DW 144 for the
respective pressures.
All units shall be designed and selected so as not to exceed the noise rating indicated when
installed in the areas served and allowing for the cumulative affect of all units operating
together. Units shall be of the type which have reducing sound power levels for induct and
radiated noise as the unit closes down to its minimum air volume rating. The VAV boxes shall be
provided with attenuator modules (from the same manufacturer) were necessary to achieve
specified NR levels.
The units shall be suitable for operating and maintaining the required air volume flow dependent
on the dictates of the control, irrespective of the system inlet pressure.
The VAV unit manufacturer shall supply all necessary controllers, temperature sensors,
transformers etc as indicated.
Ensure the units are supplied with a controls package of the same manufacture as the
BMS/controls system. As indicated the unit set point shall be capable of remote reset via a
reset signal from the BMS
All pre-wiring shall comply with BS 7671.
VAV units shall be installed in accordance with the manufacturers recommendations for the
particular application. The installation shall prevent the transmission of noise and vibration to
the building or to adjacent services.

BS 4856 Methods for testing and rating fan coil units, unit heaters and unit
coolers
BS EN 779 Particulate air filters for general ventilation. Determination of the
Part 5
Section 15 - Page6
filtration performance.
BS 2048 - 1 Specification for dimensions of fractional horse-power motors.
Dimensions for general use.
BS 5000 Rotating electrical machines of particular types or for particular
applications
BS EN 60034 Rotating electrical machines.
Part 5
Section 15 - Page7
Section 16 Refrigeration and Cooling
Contents
Section 16 Refrigeration and Cooling 1
16.1 General 1
16.2 Refrigeration leak detection 2
16.3 Cooling towers 2
16.4 Dry air coolers 3
16.5 Chillers 5
16.6 Refrigerant pipework installation and ancillaries 10
16.7 Refrigeration plant accessories and controls 11
16.8 Chilled water buffer tank 12
Section 16 Refrigeration and Cooling
16.1 GENERAL
All equipment shall meet the performance criteria as detailed elsewhere.
Ensure that the design, construction, materials and finishes of all equipment are suitable for the
location, climatic and operating conditions to which the installation will be exposed.
Ensure that the operating weight of equipment and associated services are acceptable for the
supporting structure.
The noise level from each unit operating at its design duty shall not exceed the criteria stated
elsewhere. Detailed acoustic data shall be submitted to the CA prior to ordering.
Where necessary include for dismantling and rebuilding of plant in position on site
Comply with manufacturers recommendations regarding maintenance and installation

clearances.
Refrigerants used shall be as stated elsewhere. No refrigerant comprising or containing CFC or

HCFCs shall be used. All refrigerants used shall be approved by the CA.
Any refrigerant used shall be fully compatible with all materials comprising the complete
refrigeration system.
Plant shall include all accessories necessary to ensure continuous and reliable automatic
operation.
The design maximum cooling rate shall be achieved at the maximum ambient conditions
indicated. Each unit shall be capable of running continuously at the lowest step of cooling
capacity without any adverse effect. The plant shall be charged with lubricant, and be provided
with a holding charge of refrigerant or inert gas before dispatch from the Works where a full
charge is impractical.
Major components shall be readily accessible for safe maintenance and arranged to facilitate
removal without disturbing other system components. Plant shall be arranged to ensure tube
removal or maintenance is unobstructed.
Where indicated, provision shall be made for remote indication of each alarm condition and for
remote indication of all outputs to a building management system or other control system as
indicated.
An hours-run meters shall be provided to all compressors unless otherwise indicated.
Visual indication of operation of all safety protection devices shall be provided.
Refrigeration equipment shall have a strength pressure test and a leakage pressure test after
manufacture. Tests on the refrigerant side shall be made in accordance with BS 4434. Water-
side pressure tests shall be 1.5 times the working pressure unless otherwise indicated.
Operatives engaged on work to refrigeration systems shall be fully trained and be registered
with the appropriate body.
Part 5
Section 16 Page 1
16.2 REFRIGERATION LEAK DETECTION
Enclosed spaces containing equipment or pipework charged with refrigerant shall be provided
with refrigerant leak detectors. The detection system shall be capable of providing remote
indication of an alarm condition. Where indicated the alarm shall be transmitted to the building
management system or other controls system
As indicated units shall be located within equipment or provided with a remote sensor for
location within equipment.
16.3 COOLING TOWERS

Cooling towers shall be of the type, duty and performance as indicated elsewhere.
Cooling tower installations shall comply with CIBSE TM13 and Health and Safety Executive
publication L8 Legionnaires disease: the control of legionella bacteria in water systems
The entering and leaving water temperatures, water flow rate, and ambient wet-bulb design
temperature shall be as indicated. Tests shall be in accordance with BS 4485.
All parts of the unit shall be accessible for servicing and cleaning with fixed means of suitably
sized personnel access.
A suitably sized water supply, terminating in a hose connection, shall be provided locally to the
units for cleaning purposes.
Unless otherwise indicated cooling towers shall be mounted on a 200mm high channel base
and be complete with anti-vibration mountings as indicated.
Each cooling tower shall have the following connections unless otherwise indicated:
Make-up connection ball valve
Outlet connection
Inlet connection
Drain / side-stream filtration connections
Overflow run to nearest gulley
Balance pipe connection
All necessary joints and bracing in the casing and pond constructions, (including associated
jointing components such as nuts, bolts, etc), shall be made externally such that all internal
surfaces are of smooth finish and free from obstructions. There shall be no internal flanges or
ledges, other than those necessary to support packing material or drift eliminators. All nuts, bolts
and washers shall have corrosion-resistant finishes. Self-tapping screws will not be accepted.
Casings shall be of glass reinforced plastics or stainless steel as indicated. The casing shall
have a treatment to minimise corrosion or decay relevant to the casing material used. The
casing and structure shall be designed to withstand the maximum wind speed.
Tower packing and drift eliminators shall be of plastics materials or glass reinforced plastics as
indicated. Materials shall be resistant to fire, corrosion and deterioration or decomposition due to
condenser water treatment chemicals, polluted air and insect attack. Plastic materials shall be
self extinguishing and be resistant to ultra-violet degradation.
Packing material shall not distort in any way under normal use to cause obstruction to air or
water flow and shall be resistant to organic growth. Packing shall be designed to ensure that
particulate material can drain into the sump for removal. Packing shall be readily cleanable and
fitted in sections, each separately supported to facilitate removal.
The water distribution system shall be easily removed and dismantled for cleaning. Where open
distribution pans or troughs are used, they shall be fitted with fine mesh grids to exclude debris.
Where spray nozzles are used, they shall be of non-ferrous material, easily removable for
cleaning and shall be protected by a strainer.
Part 5
Section 16 Page 2
Air inlets and outlets shall be arranged to avoid recycling and shall have mesh grids to prevent
ingress of debris. High efficiency drift eliminators shall be provided which limit the drift loss rate
to no more than 0.001% of the water circulation rate. Ensure effective edge sealing of the
eliminators to prevent drift by-pass. Eliminators shall be removable in easily handled sections
with air flow direction indelibly marked on each section. The anticipated level of drift shall be as
indicated.
Sumps shall be sheet steel hot-dip zinc coated after manufacture, sheet steel anti-corrosion
painted, glass reinforced plastics, sheet steel epoxy coated or stainless steel as indicated.
Sumps shall be designed to collect sludge in such a way that facilitates its removal during
cleaning operations. The bottom of the sump shall be sloped towards the drain connection.
The water reservoir shall be shielded from direct sunlight and shall be of sufficient depth above
the outlet connection to prevent air entrainment in the outlet pipe during operation. The sump
capacity shall be sufficient to prevent overflow when the system shuts down. Sumps shall be
fitted with grids of 15mm square mesh to exclude debris from the outlet pipes. An electric
immersion heater, controlled by an adjustable thermostat and a low water level cut-out float
switch, shall be fitted in the water reservoir.
Sumps shall have cold water make-up connection with ball float valve or level control, quick-fill
provision, overflow, drain connection, and outlet pipe with removable strainer and anti-vortex
plate. The relative positions of the cold water make-up and other pipe connections shall be
arranged to avoid creating stagnant water conditions. The drain connection shall be at the
lowest point in the sump and shall be of adequate size to facilitate quick draining of the sump.
A bleed pipe, with stop valve and flow regulating device, shall be provided on each unit from the
water flow pipe. The bleed pipe shall be connected into the water flow pipe above basin water
level and shall be extended to the nearest sump or gulley to discharge through an air break.
Fan casings and impellers shall be made of corrosion-resistant material or be completely

proofed against corrosion after manufacture. Fan motors shall be totally enclosed and
weatherproofed. Drives shall be readily accessible and fully protected against the weather
Fan motors mounted in the moist air-stream of induced-draught units shall be corrosion
resistant. Lubrication shall be possible during operation of fans without component removal and
without the possibility of over lubrication. Fan bearings shall be designed to prevent loss of
lubricant and limit the ingress of dirt and moisture.
Each tower shall be complete with an immersion heater and an integral thermostat, and low
water level cut out switch.
Where the stated noise levels cannot be achieved with standard towers, provide purpose made
attenuators on the inlet and outlet connections to the towers. Attenuators shall be provided by
the cooling tower manufacturer and shall be matched to suit the tower connections. The fan
total resistance and motor requirements shall be recalculated to accommodate the total
pressure drop including attenuators.
Metal parts of coolers shall be bonded to earth. Lightning protection shall be provided where
indicated.
16.4 DRY AIR COOLERS

The duty and performance of the dry air coolers shall be as indicated elsewhere.
The location of dry air cooler(s), relative to the building, shall not impede air flow through the
unit. Where possible unit coils shall be protected from direct sunlight. Airflow through the
unit(s) shall not be restricted by associated water distribution pipework or other services/plant.
Dry air coolers shall be factory assembled, tested, and delivered as a complete package
including all indicated accessories.
Part 5
Section 16 Page 3
Dry cooler assemblies shall be fully accessible for thorough cleaning. The manufacturer shall
provide means and recommend frequency.
Air cooled condensers shall be selected to dissipate the design heat output from the
compressors when operating at or below the ambient temperatures as indicated. The
condensers shall be capable of meeting the required duty without exceeding the specified noise
level requirements as stated elsewhere.
Unit design shall ensure equal air distribution over the full coil surface(s). For multi-fan
arrangements, each fan shall be complete with baffles or separate chambers to eliminate short
circuiting and spinning of de-energised fans.
Heat exchanger materials shall be selected to minimise electrolytic action, suitable for the
operating conditions and local environment.
Unless otherwise indicated condenser coils shall be manufactured from seamless copper tube
expanded into continuous aluminium fins. Fins with minor damage shall be combed straight.
Units with extensive damage to fins will not be accepted. The water circuitry shall be designed
to ensure equal distribution of water to each circuit across the whole face of the coil and the
supply and return headers shall be manufactured from seamless copper tube unless otherwise
indicated.
Coolers mounted externally shall have weatherproof motors. Motors shall comply with the
appropriate clauses of this specification. Motors shall be rated at IP 55 unless otherwise
indicated and have permanently lubricated ball bearings and thermal overload protection.
The units shall discharge air vertically upwards unless protected by integral wind deflectors or
purpose made cases.
The frame supports and casing of the units shall be constructed of material which is either
corrosion resistant or made proof against corrosion after manufacture.
As indicated the complete units shall in addition be painted after manufacture to provide
additional protection in a RAL colour as agreed with the CA.
Cooler coils shall be tested before leaving the manufacturers works. A test certificate shall be
issued for each coil and each coil shall be indelibly marked with details of the test. Each cooler
coil shall be tested at the manufacturers works to a test pressure of 1.5 times the working
pressure or 8 bar gauge pressure whichever is the greater or as otherwise indicated.
Self dealing test points in accordance with this specification shall be provided on the inlet and
outlet connections to each cooler.
Water connections shall be as indicated.
Metal parts of coolers shall be bonded to earth. Lightning protection shall be provided where
indicated.
Unless otherwise indicated each dry cooler shall be provided complete with a control panel,
consisting of a variable speed controller, which alters the speed of the fans to match the heat
rejection. The speed controller shall be regulated by a microprocessor system and have built-in
protection for phase loss or reduced voltage. The microprocessor shall be programmed with the
required set points and control parameters and have a battery back-up to prevent the loss of
strategy should there be loss of mains power. An immersion temperature sensor shall be
provided in the common leaving water pipeline to provide control by varying the fan speeds. The
control panel shall be complete with a door-interlocked mains isolator and an enclosure rated to
IP65 unless otherwise indicated. The control panel shall be capable of interfacing with the
building management system or other controls system providing a common alarm, remote
temperature set-point adjustment and on/off contact.
Part 5
Section 16 Page 4
16.5 CHILLERS
16.5.1 General
The duty and performance of chillers shall be as indicated elsewhere.
Packaged chillers shall be selected to achieve the cooling duty necessary to satisfy the design
requirements when operating under the temperature conditions stated elsewhere.
The design, construction, materials and finishes of all units shall be suitable for the locations,
climatic and operating conditions indicated.
Comply with BS EN 387 and BS 7120.
Rotating and reciprocating components shall be dynamically balanced.
All components shall be readily accessible.
Unless otherwise indicated each unit shall be provided as a fully packaged, factory assembled
and tested unit, constructed on a robust frame and casing.
Refrigerants used shall be as stated elsewhere. No refrigerant comprising or containing CFC or

HCFCs shall be used. All refrigerants used shall be approved by the CA.
Chillers shall be factory finished as indicated to a colour as agreed with the CA.
Each space containing refrigerant equipment shall be provided with refrigerant leakage
detection. Detectors shall be selected to suit the refrigerant in use and be as stated elsewhere.
The main control panel or building management system shall monitor detectors as indicated and
all leakage signals shall be alarmed.
Chillers shall perform within the acoustic requirements as indicated. The acoustic performance
shall be achieved by either selection of equipment to ensure that it performs at a noise level
below that specified, or by the provision of an acoustic protection package to ensure that the
acoustic requirements are achieved. Acoustic data shall be submitted to the CA for approval
prior to ordering.
Anti-vibration mountings shall be supplied and installed to prevent transmission of noise and
vibration to the structure. Chillers shall be supported along their whole length.
Water connections shall be external to the machine and be readily accessible.
Mountings and fittings shall comply with the appropriate section of this specification.
Shell and tube evaporators and condensers shall be provided with a temperature and pressure
gauge and self-sealing combined temperature and pressure test point on each water flow and
return connection.
Each water circuit shall be provided with a flow switch or differential pressure switch to prevent
the machine operating if the flow rates are less than the minimum requirements recommended
by the manufacturer.
Each water connection to the unit shall be provided with a flexible connection as indicated. The
connection shall be capable of withstanding the system operating temperature and pressures
without distortion.
Each chilled water and cooling water return connection shall be provided with a commissioning
set. An isolation valve shall be provided on each flow connection and on each return. Valves
shall comply with the requirements as stated elsewhere.
Pipework and equipment carrying refrigerant shall be insulated. Insulation thickness shall
comply with BS 5422.
Part 5
Section 16 Page 5
Venting of refrigerant to atmosphere will not be allowed during installation, commissioning and
maintenance. Connections shall be provided to allow abstraction of the refrigerant charge into
purpose gas bottles using refrigerant recovery equipment. Each machine shall be provided with
a liquid receiver to hold the full refrigerant charge.
The chiller manufacturer shall start-up, run, test and commission each chiller before despatch
from the factory and during the commissioning period. Factory testing shall include a
demonstration that the chiller is capable of delivering the design duty with the required
temperatures, flow rates and pressure drops at the specified ambient temperatures and acoustic
levels. Units shall be inspected at the factory and the tests witnessed by the CA as indicated
elsewhere.
Prior to machine start-up on site the chilled and condenser water systems shall be
commissioned as indicated elsewhere to ensure that the design water flow rates are being
passed through each machine. Condenser and evaporator pressure drops shall be checked to
ensure that they do not exceed those recommended by the manufacturer. The airflow across
each air-cooled condenser and evaporator shall also be checked.
Commissioning shall be undertaken as indicated elsewhere. On completion the operation and

effectiveness of the chillers shall be checked as part of a system thermal test.
Semi-hermetic and hermetic compressors will only be acceptable on complete factory

assembled refrigeration systems, condensing units or chiller compressor sets provided the units
are fully charged at manufacturers works or complete with holding charge or refrigerant or inert
gas on arrival at site.
Compressor units shall be suitable for continuous and automatic operation and be free of
vibration.
16.5.2 Refrigerant circuits

Unless otherwise stated each multi-compressor machine shall be provided with a minimum of
two independent refrigeration circuits.
Each circuit shall be protected by a pressure relief device on the high- pressure pipework
complying with BS EN 378.
The multiple independent refrigeration circuits shall each include the following components
unless otherwise stated:
Liquid line cut off valve

Liquid line solenoid valve
Dryer filter with replaceable core
Sight glass
Thermal expansion valves with external equaliser
High pressure safety valve
Low pressure safety valve
Discharge and suction pressure control devices
Pressure relief valve.
16.5.3 Controls
Control panels shall be provided for each chiller as an integral part of the package unit.
The panel shall have fully removable or hinged doors. External panels shall be insulated and
weather-proof.
Panels shall contain all starters, operating and safety controls, relays, overload protection and
fuses. The panel shall incorporate a door interlocked mains isolator to shut off all circuits except
the crank case heaters which shall be separately supplied.
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Section 16 Page 6
Panels and panel mounted equipment shall comply with the appropriate sections of this
specification.
A fault indication section shall be provided with alarm lights showing which safety controls have
operated.
The installer and manufacturer shall ensure the panel cable entry points and cable terminations
are suitable for the cable sizes installed.
Unless otherwise indicated the control system shall include:
Multi-step electronic regulation of output capacity

Antifreeze protection with adjustable settings
Automatic compressor start-up sequence rotation
Electronic compressor control and time setting system
Compressor on/off switches
Centralised reset and control following safety device activation
LED indicators for normal operation and safety protection activation
Unless otherwise indicated digital visual display shall include:
Operating times of each compressor

Incoming and outgoing chilled water temperatures
Antifreeze thermostat temperature setting
Unless otherwise indicated push buttons shall be provided for:
Setting antifreeze thermostat

Chilled water temperature setting
Setting temperature difference for checking the terminal head on the chilled water
Where refrigeration machines have separate refrigerant circuits a control panel shall be
provided for each circuit. Each control panel shall be separately isolated. Unless otherwise
indicated the machines shall be served by a single electrical feed. Looping terminals shall be
provided as necessary to permit both panels to be supplied.
For multiple chiller installations, lead machine selection facilities shall be provided. The
necessary multiple machine control systems shall be provided by the chiller manufacturer and
be capable of maintaining a stable flow temperature without hunting.
Flow switches shall be provided factory wired for site installation in the pipework.
The chiller supplier shall provide fully detailed wiring diagrams of the control panels as part of
the record documentation.
Provision shall be made for remote indication of each alarm condition and for remote indication
of all outputs to a building management system or other control system as indicated. Where
indicated the chiller control system shall be fully addressable from the building management
system.
Where necessary an interface unit shall be provided to allow information transfer between the
chillers and the BMS or other control system. The installer, chiller manufacturer and controls
specialist shall liaise to ensure a correct functional and operational interface.
16.5.4 Compressor mountings and fittings

As indicated the following shall be provided:
Oil sumps shall be provided with thermostatically controlled electric heaters that are
arranged to operate when the compressor is at rest. Heaters shall be connected to a
separate electrical supply from the chiller so that it cannot be disconnected by isolation of the
chiller. Warning notices to this effect shall be fitted.
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Section 16 Page 7
Each compressor shall be provided with a suction gas strainer.
Hand reset high and low pressure safety cu-outs with adjustable differential and set point
shall be provided.
Resiliently mounted oil-filled refrigerant pressure gauges of minimum 65mm diameter, fitted
with means of isolation, on suction and discharge with pressure calibrated in kPa and Bar
and saturation temperature for the refrigerant used calibrated in C
Crankcase oil level sight glass
Vibration isolation incorporated in the refrigeration lines of compressors located on anti-
vibration mountings or where refrigerant lines are likely to transmit vibration.
Compressors shall be fitted with stop valves on the refrigerant suction and discharge
connections.
16.5.5 Shell and tube evaporators

Evaporators shall be capable of being re-tubed in position. An evaporator which cannot be re-
tubed in-situ shall be readily removable. The design fouling factor on the water side shall not
be less than 0.00009 m K/W unless otherwise indicated.
End covers shall be manufactured from steel or cast iron as indicated and be removable with
joints and seals positively retained. The tubes shall be of copper, aluminium-brass, or cupro-
nickel as indicated. Tube supports shall be fitted and manufactured of suitable and approved
material and designed to prevent tube vibration.
Water side drain and air venting provisions shall be provided.
The evaporator shall be tested at the manufacturers works. Subsequent to the test, the
manufacturer shall insulate and vapour seal the evaporator in accordance with BS 5422.
Provision shall be made on flooded evaporators for returning oil to the compressor.
Flooded evaporators shall be fitted with a refrigerant level controller.
The refrigerant passages in a direct-expansion water chiller shall ensure that oil present is
always carried through at the lowest stage of capacity reduction.
A hand reset, low temperature thermostat shall be provided on each evaporator to shut the
machine down before freezing can occur.
16.5.6 Water cooled condensers

Shell and tube condensers shall have carbon steel welded shells unless otherwise indicated.
Manually cleanable copper, aluminium-brass or cupro-nickel tubes as indicated and approved
shall be expanded into mild steel tube plates welded to the shell. All tubes shall be adequately
supported and spaced. Condensers shall be capable of being re-tubed in position.
Water end covers shall be manufactured from steel or cast-iron as indicated protected against
corrosion. End covers shall be removable to permit tube inspection, easy cleaning and
replacement. End covers shall be positively retained.
The design fouling factor on the water side shall not be less than 0.00018 m K/W unless
Water-side drain and air venting provisions shall be provided.
Condenser positions shall be so arranged to ensure tube removal or maintenance is

unobstructed.
Unless otherwise indicated, automatic control of the condensing pressure shall be incorporated.
The refrigerant and water spaces shall be pressure tested at the manufacturers works.
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Section 16 Page 8
Where units are to be used for heat recovery they shall be provided, where indicated, with a
double bundle or twin condenser layout. Heat recovery condensers shall be selected to
maintain the required performance with varying cooling water temperatures. Under low load
conditions the temperature of the cooling water return to the unit may approach the design
cooling water flow temperature from the unit.
16.5.7 Centrifugal compressors

Unless otherwise indicated centrifugal compressors shall comprise cast iron casings with radial
impellers, inlet guide vanes and diffusers, driven by a direct coupled motor through a flexible
coupling.
The compressor shall have automatic capacity regulation which will control at any point from
10% to 100% of full duty without inducing a surge condition or vibration. The compressor shall
not be enabled to start unless in the fully unloaded condition. Unless otherwise indicated, the
hot gas bypass or injection system of capacity control will not be accepted.
Units shall be arranged to start only at minimum load condition.
The lubrication system shall be arranged with an interlock to ensure adequate oil pressure at all
bearings before the compressor starts and during the 'coast down' period including conditions
due to power failure.
A replaceable or cleanable filter shall be positioned in the oil delivery pipe.
A hand reset pressure or flow switch shall stop the compressor on a lubrication system failure.
Where an oil cooler is used, it shall be thermostatically controlled.
The oil sump shall have a thermostatically controlled electric heater which operates while the
compressor is at rest.
A manual reset pressure or flow switch shall be provided to stop the compressor should the
lubrication system fail.
16.5.8 Screw compressors

Screw compressors shall be of the oil injection type. Rotary seals shall be provided on the drive
shaft to prevent leakage of refrigerant or oil.
The compressor shall have automatic capacity control equipment which will control at any point
between 10% and 100% of full duty. The compressor shall not be enabled to start unless in the
fully unloaded condition.
A device shall be fitted to prevent the pressure differential across the compressor causing
backward rotation at a normal or emergency stop.
Compressors using oil injection for rotor sealing shall incorporate arrangements to prevent
excessive oil carry-over with refrigerant from the compressor and ensure adequate oil return to
the compressor over the full operating range.
The lubrication system shall be arranged with an interlock or other means to ensure adequate
oil pressure at all bearings before the compressor starts. A manual reset pressure or flow
switch shall stop the compressor on a lubrication system failure. The pipeline from a positive
displacement oil pump shall incorporate a pressure regulating valve to relieve excess oil to the
reservoir.
A replaceable or cleanable filter shall be positioned in the oil delivery pipe.
A thermostatically controlled oil cooling system shall be used to remove heat gained by the oil.
The oil sump shall have a thermostatically controlled electric heater.
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Section 16 Page 9
16.5.9 Reciprocating compressors
Main rotating and reciprocating components shall be statically and dynamically balanced.
Open and semi-hermetic compressors shall have:

Provision for draining oil from the suction manifold into the crankcase and for venting
refrigerant gas (but not oil) in the opposite direction.
A crankcase heater, arranged to operate while the compressor is at rest, with protection
provided to prevent starting before the oil has reached the minimum operating temperature.
All open and semi-hermetic compressors shall have the following as indicated elsewhere:
Removable cylinder liners

Side and/or end covers which will enable servicing or repair of the unit to be carried out in-
situ or local to the installation by virtue of ready removal
A crankshaft-driven oil pump used to force feed lubricant to the main and big end bearings
and the shaft seal. A filter and oil suction strainer incorporated within the oil lubrication
system.
Crankshafts and eccentric shafts of all open or semi-hermetic compressors having an input
power to the compressor in excess of 2.25kW shall run in replaceable bearings.
As indicated, compressors having a refrigeration capacity in excess of 35kW shall have capacity
control by means of either cylinder unloading or speed change and shall be arranged so that
starting is in the unloaded condition.
As indicated, hot gas injection into the refrigerant inlet of the evaporator will be permitted for
capacity control as follows:
on compressors below 35kW refrigeration capacity, or

for compressors above 35kW, equal to the capacity of the final step.
16.6 REFRIGERANT PIPEWORK INSTALLATION AND ANCILLARIES

Copper tubes for refrigerant pipework shall comply with BS EN 12735-1 and shall be suitable for
the refrigerant and oil used. Pipework shall be dry, completely free from scale and internally
degreased.
Where the refrigerant pressure is above the limits for copper pipe then heavy grade mild steel
tube shall be used instead.
Refrigerating system and installation of refrigerant pipework shall comply with BS EN 378.
To minimise the possibility of refrigerant losses to atmosphere, pipework joints shall be kept to a
minimum.
Refrigeration pipework joints shall be brazed or silver soldered. Joints shall be kept to the
absolute minimum. Formed bends shall be used in preference to fittings.
Flared or screwed joints shall only be used with the approval of the CA.
Brazing shall be carried out in accordance with BS EN 14324 by operatives having approved
qualifications in accordance with the necessary standards.
Dry nitrogen shall be passed continuously through the pipework at minimal pressure and at an
adequate velocity during brazing or soldering to eliminate internal oxidation. All excess solder
and flux shall be removed on completion of joints.
Fittings shall be integral ring solder type complying with BS EN 1254 -1.
Connections shall be provided in the high and low pressure sides of each novi system to
facilitate evacuating and charging.
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Section 16 Page 10
Piping and other components which have been prepared and are not to be used immediately
shall be capped and sealed. During installation no component or length of tubing shall be left
un-blanked longer than necessary for installation.
Suction lines shall be sized to provide a minimum practical pressure drop commensurate with
sufficient velocity for oil entrainment.
The suction lines shall be designed to slope back to the compressor to avoid oil logging around
the system.
Where the vertical rise exceeds 3 metres, an oil trap shall be formed in the suction line at the
base of the riser and at 3 metre intervals throughout the length of the riser, or at such intervals
as are recommended by the refrigerant equipment manufacturer.
Where compressors unload, provisions shall be made where necessary to ensure adequate oil
return at all stages of unloading without causing an excessive pressure drop.
Include expansion joints if required to accommodate expansion and contraction. Cold bridging
is to be prevented.
Refrigerant pipework shall be adequately supported with maximum support spacing as follows:
Pipe nominal bore (mm) Spacing (m)

15 to 20 1.0
22 to 54 2.0
54 to 67 3.0
Where the pipework cannot be adequately supported at the stated spacing directly from the
building structure, continuous proprietary channel, angle or tray support systems shall be
provided.
Pipework shall be supported using sheradised steel clips with a rubber or plastic sleeve to
prevent chafing or vibration. The arrangement of pipework and support shall be agreed with the
CA before commencement of the Works.
For refrigeration copper pipework 15 to 28 mm diameter support on continuous plastic coated

cable tray.
Electrical cables shall not be fixed to refrigerant pipework.
The thickness of insulation shall be to BS 5422. Where the indicated thickness in BS 5422
tables is not a commercial size, the nearest larger commercially available thickness shall be
provided.
Liquid refrigerant pipes external to buildings and subject to solar radiation shall either be
shielded or have weatherproofed closed-cell insulation applied, of the correct thickness, with a
reflective or of a light coloured finish.
Discharge pipes likely to cause burns to personnel shall be shielded.
After completion, the refrigerant pipework shall be subjected to pressure and leakage testing as
BS EN 387.
16.7 REFRIGERATION PLANT ACCESSORIES AND CONTROLS

The refrigeration system shall be protected by a pressure relief device unless it is so
constructed that pressure due to fire conditions would be safely relieved anyway. The pressure
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Section 16 Page 11
relief equipment provided shall comply with and the outlet piped to discharge outside the
building.
Each refrigeration system shall be complete with suitable connections for the safe removal of
the complete refrigerant charge.
The operation and safety devices shall be set to ensure safe operation, avoid potential damage
and nuisance tripping. High and low pressure switches are required.
The thermostatic expansion valve shall have the following items preceding it in the refrigerant
liquid line:
solenoid valve
sight glass
refrigerant drier (replaceable)
refrigerant strainer and means of isolation
capped refrigerant charging valve
Where fitted, an evaporator pressure regulating valve shall be protected by a strainer, and an
evaporator pressure gauge shall be provided up-stream of the valve, fitted with means of
isolation.
The condensing unit may be required to start under an exceptionally heavy load condition and
shall either have sufficient motor power available to meet this condition or be fitted with a device
or system which limits the maximum suction pressure.
If the direct expansion evaporator is at a higher level than the compressor it shall operate on a
pump down cycle.
To ensure that no oxides have been formed in the pipelines the CA will select three joints to be
cut out by the installer. Should oxides be found then all pipework shall be replaced at no cost to
the contract. All costs associated with the opening of these joins shall be allowed for by the
installer.
Refrigerant stop valves which incorporate a spindle gland shall be of the back seat type. The
spindle gland shall be serviceable with the valve 'in -situ'.
All refrigerant pipework installations shall be designated, tested and commissioned by the
installer in accordance with all relevant British Standards and Codes of Practice.
16.8 CHILLED WATER BUFFER TANK

Where the chilled water system water content does not comply with the manufacturers
minimum requirements provide a buffer tank to limit the number of starts per hour.

BS 4485 Water cooling towers

BS EN 387 Refrigerating systems and heat pumps Safety and environmental
requirements.
BS 7120 Specification for rating and performance of air to liquid and liquid to
liquid chilling packages
PD 5500 Specification for unfired fusion welded pressure vessels
range -40C to 700C
BS EN 12735-1 Copper and copper alloys. Seamless round copper tubes for air
BS EN 14324 Brazing. Guidance on the application of brazed joints
BS EN 1254 -1 Copper and copper alloys. Plumbing fittings. Fittings with ends for
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Section 16 Page 12
capillary soldering or capillary brazing to copper tubes
ANSI B9.1 Safety code for mechanical refrigeration
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Section 16 Page 13
Section 17 BMS / Controls System
Materials and Workmanship
Contents
Section 17 BMS / Controls System Materials and Workmanship 1
17.1 Standards 1
17.2 Control panels 1
17.3 Field devices 7
17.4 Field controllers 11
17.5 Actuators 14
17.6 Valves 14
17.7 Dampers 15
17.8 Variable speed inverter drives 15
17.9 Control Functions and routines 16
17.10 BMS configuration 20
17.11 System Configurations 21
17.12 Integration with fire detection systems 23
17.13 Operator workstation 24
17.14 Energy metering 27
17.15 Connection to Plant and control equipment 27
17.16 Cabling 28
17.17 Commissioning and testing 29
17.18 Training 32
17.19 Post-handover checks 33
17.20 Documentation 34
Section 17 BMS / Controls System Materials and
Workmanship
17.1 STANDARDS
The controls system shall comply with the following EC Directives:
Low voltage Directive 73/23/EEC and amendments 93/68/EEC

Construction Products Directive 89/106/EEC
General Product Safety Directive 92/59/EEC
Ensure that the controls system/BMS installation complies with BS 7671.
Control panels shall comply with BS EN 60439-1 Low voltage switchgear and control
assemblies.
Electrical supply
Ensure that the controls system/BMS installation is compatible for operation with the electricity
supply.
Electromagnetic Compatibility (EMC)
Ensure that the controls system/BMS installation complies with:
The Electromagnetic Compatibility Regulations 2005 (SI 2005/281).

BS EN 61000-6-1 Electromagnetic Compatibility (EMC).Generic standards. Immunity for
residential, commercial and light industrial environments
BS EN 61000-6-2 Generic standards. Immunity standard for industrial environments.
BS EN 61000-6-3 Electromagnetic Compatibility (EMC).Generic emission standards.
Emission standard for residential, commercial and light industrial environments.
17.2 CONTROL PANELS
17.2.1 General
All grouped controls shall be enclosed in a purpose-made panel. Motor starters and controllers
for mounting in the panel shall comply with BS EN 60947. Panels shall provide the BS EN
60947 degree of protection indicated.
Purpose-made panels shall comply with the requirements for type tested or partially type tested
assemblies contained in BS EN 60439.
Control panels shall be manufactured, equipped, wired and factory tested by the manufacturer
before delivery to site.
Unless otherwise indicated 15% spare back-plate capacity shall be provided. The power
distribution system within panels shall be sized to allow additional switchgear to suit the spare
capacity provision.
All control panels providing electrical supplies to or control of mechanical services plant and
equipment shall be constructed to comply with the latest relevant statutes, regulations and
standards.
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Section 17 Page 1
Clean schematic diagrams shall be provided, contained in a plastic pocket fixed permanently
within each door or within a purpose made housing.
Indicating lamps, instruments and controls shall be, as far as is practicable, of the same
manufacturer and style to provide uniformity of appearance and to facilitate maintenance.
Externally visible equipment shall be flush mounted with minimum projection and fixed securely
to the front of panels.
17.2.2 Construction
Panels shall be designed to be wall mounted (with external fixing lugs) or floor standing as
appropriate and shall be constructed from galvanised steel plate of not less than 2mm
thickness.
Detachable gasketed gland plates for cable/wiring entry shall be provided on all appropriate
elevations.
Surfaces shall be properly prepared before final finishing. All sections of the control panel shall,
prior to assembly, be degreased and chromate etched followed by two coats of primer before
being stove enamelled. The panel external colour shall be as agreed with the CA prior to
manufacturer.
Finished panels shall be without sharp edges and exposed fastenings smooth surfaced. All
exposed screws, bolts and similar fastenings shall be protectively plated.
Panels shall be adequately protected against damage or deterioration during and after delivery
and installation on site until practical completion. Cleaning, making-good and re-spraying shall
be carried out at no cost to the contract.
The maximum height shall be 2200mm, unless otherwise indicated.
Panels wider than 1600mm shall be manufactured in sections unless otherwise indicated. Each
section shall be supplied with fully numbered interconnecting terminals. Sections shall be bolted
and wired together on site after positioning.
Unless otherwise indicated the doors shall be 800mm maximum in width and shall be fitted with
concealed hinges to facilitate the removal of the door panel if required.
A minimum of two doors are to be provided on any panels wider than 800mm. Doors shall be
complete with dust excluding gaskets around their perimeter.
Doors shall be secured by integral handle with provision for locking, such provision being not
more 2 metres above floor level. One key shall fit all locks provided on all panels delivered to
the site.
Panels shall be located so that full and safe access is obtained to itself, other apparatus,
terminals and interconnecting wiring.
Panels shall be drip-proof, dust-proof and vermin proof with a minimum standard of protection to
IP54 for internal units or IP65 for externally mounted panels unless otherwise indicated.
The temperature rise in motor control panels shall not exceed the limits stated in BS EN 60439.
Control panels shall be adequately ventilated and temperature controlled to maintain the internal
operating conditions to ensure satisfactory operation of all panel mounted equipment. As
necessary internal forced cooling, ventilation grilles, internal anti-condensation heaters and
thermostats shall be provided.
Internal lighting and external lap-top shelves shall be provided as appropriate.
Insulating rubber matting of the appropriate voltage grade shall be provided and extend the full
length of the control panel at the front and where, accessible, at the rear.
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Panels not mounted on concrete plinths shall be provided with a purpose made steel plinth to
match the panel. Plinths shall be a minimum of 100mm high unless otherwise indicated.
All panels shall be provided with fixing holes. Large panels or panels exceeding 50kg shall be
provided with detachable lifting eyes.
A power outlet shall be provided inside the panel complete with 30 mA RCD protection.
Equipment shall be shrouded as necessary to prevent accidental contact with live parts.
Form 2 panels shall comprise compartment assemblies complying with Form 2, type 2 of BS EN
60439-1. They shall be partially type tested and provided with a physical vertical delineation
between the power section and the BMS/controls section.
Equipment, busbars and wiring shall be either totally enclosed or protected as required by BS
EN 60439-2 for the class of panel.
Form 4 panels shall comprise cubicle assemblies complying with Form 4, type 2 of BS EN
60439-1. They shall be type tested and constructed to ensure separation of busbars from all
functional units and separation of all functional units from one another. Separation of terminals
for external conductors associated with a functional unit from those of any other functional unit
and the busbars
17.2.3 Electrical isolation

All control panels shall be provided with a door interlock isolator controlling the main incoming
supply. The isolator shall be capable of making and breaking on full load without damage.
Additionally the isolator shall be equipped with auxiliary contacts to isolate any secondary
supplies to the control panel.
All terminals of the isolator (incoming and outgoing) are to be shrouded to prevent accidental
contact.
As indicated the control system only shall be energised whilst the incoming supplies are
isolated. A suitable by-pass fuse shall be fitted with the necessary shrouding and identification.
The panel shall be constructed such that power (400/230V) equipment is located behind the
interlocked isolator door.
Control (extra low voltage) equipment shall be located within a separate section to ensure
segregation from power equipment.
17.2.4 Control panel wiring

Internal power wiring shall be identified by colour code in accordance with BS 7671. Control
circuit and other wiring shall be to BS 6231.
All cables shall be colour coded and numbered using a proprietary marking system comprising
plastic ferrules of the correct size for the cable. Cables shall be identified at both ends and shall
be cross-referenced with the wiring diagram.
All terminals shall be permanently identified by colour coded inserts with black lettering and shall
be cross-referenced with the panel wiring diagram.
Power and control cables shall be terminated using crimp type connectors or other approved
termination devices. Soldered terminations will not be accepted.
Low voltage power and extra low voltage wiring shall be segregated throughout the panel.
Provision shall be made for the earthing of all non-current carrying panel and equipment
metalwork including panel door(s). All necessary electrical bonding shall be provided. A copper
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Section 17 Page 3
earth bar rated for the panel fault current shall be provided for connection of the incoming earth
and the field power circuit protective conductors. Access shall be provided for making
connections to the earthing system.
All internal wiring shall be enclosed within wire-ways. Inter wiring that is required to pass
between the power and control sections of the panel shall be enclosed within separate or
segregated wire-ways to ensure electrical separation of the power and control systems.
Individual terminals shall be provided for each connection entering or leaving the panel and shall
be sized with regard to the type and size of cable taking into account the maximum circuit
loading and length (volt drop).
Terminals for power and control wiring shall be located within their respective panel sections,
where applicable.
Separate terminals shall be provided for the connection of the screening of screened or shielded
cables.
No external wiring will be permitted to extend beyond the incoming/outgoing terminals of the
panel, except those cables which are terminating directly onto BMS outstation devices.
Looms shall be limited in size to permit tracing, identification and replacement of faulty cables.
Busbars where installed, shall be rated to withstand, at any position the full fault level related to
the largest protective fuse that could be used with the main panel isolator. They shall be fully
insulated throughout their length and shall be mounted within a separate labelled enclosure
within the panel.
17.2.5 Internal equipment

A technical summary identifying makes of generic components to be mounted in or on control
panels shall be submitted to the CA for comment prior to manufacturer.
No equipment shall be incorporated into a control panel unless it conforms to the requirements
of the relevant British Standard(s) or carrying the appropriate ASTA BEAB approved mark or
other approved testing standard certificate.
Equipment shall be positioned within the panels to provide a neat and orderly arrangement.
Equipment shall not be fixed to openable doors.
Internal equipment shall be fixed to purpose-made rails or mounting bars. All fixings shall
incorporate shake-proof washers or other vibration resisting fastenings.
All starters, relays etc. shall be of the open type and shall be suitable for DIN rail mounting.
All outgoing power supplies to remote equipment shall be individually protected by HRC fuses or
MCBs as indicated.
Fuses / MCBs shall be grouped and mounted so as to be readily accessible without danger.
All fuses / MCBs shall be identified on a permanently marked fuse chart mounted inside the
panel.
Unless otherwise indicated a minimum of 3 spare fuses for each size and type used shall be
mounted in a suitable carrier within the panel.
Where short circuit ratings are specified documentary evidence of compliance with such
requirements shall be provided.
Overload settings shall be set to suit the load served and the settings recorded in the record
documents.
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17.2.6 Motor starters
All starters shall be by the same manufacturer.
Starters shall incorporate overload and single-phase protection and auxiliary contacts as
required. Starters shall comply with BS EN 60947-4-1 and incorporate overload protection
devices complete with manual reset buttons. Reset buttons shall be fully accessible without
removing the starter cover
Unless otherwise stated starting methods shall be as follows:
Up to and including 5kW direct-on-line

5kW to 37.5 kW star delta or soft start
Above 37.5 kW stator-rotor or auto-transformer or soft start
The Controls Specialist shall consult the manufacturer where necessary to ensure the correct
overload protection.
Starters shall also comply with the specific requirements detailed elsewhere.
Starters shall be of open type for mounting in common cupboard type enclosure with one main
supply isolator for the complete panel, unless otherwise stated.
Any limitation on starting currents, as might be imposed by the Supply Authority, shall be
complied with. Where the indicated starting methods do not satisfy the limitations, a suitable
alternative starter shall be provided as agreed with the CA prior to commencement of the
Works.
17.2.7 Automatic control

For the control of electrical equipment which is not interlocked, an 'ON/OFF' rotary type switch
shall be fitted on the front of the panel for each item of plant.
Where interlocks are required an 'ON/OFF' switch shall be fitted for the master and a 'HAND/
OFF/AUTO' switch shall be fitted for each item of dependent plant. The switch positions shall
be clearly indicated and each switch shall be clearly labelled to show which item of plant it
controls.
Duty/standby plant shall have individual 'HAND/ OFF/AUTO' switches but shall be interlocked to
prevent both items of plant running together.
Control relays shall be of the transistorised plug-in type, with test facility and indication, robust in
construction and mounted on a terminal base with the number of contacts commensurate with
the duty they are to perform.
17.2.8 Indicator lamps

Single lamps shall be of the transformer lamp type or LED type as indicated.
Neon indicators will not be permitted.
Indicating lamps shall generally conform to the following colour code:
Colour Operating status

Red Trip or fault
Yellow(Amber) Alarm / Attention / Caution
Green Equipment running
White(clear) Power available / Condition healthy
Blue Closed
Lamps and holders shall be arranged so that replacement of lamps and cleaning of lenses can
be easily effected.
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Where indicator lamps are not immediately adjacent to their associated switches they shall be
clearly labelled.
A lamp test facility shall be provided on all panels.
The following shall be provided:
Red/yellow/blue phase healthy indication

Panel control circuit healthy indication
Field control circuit healthy indication
17.2.9 Identification and labelling

Wiring shall be adequately colour coded and numbered and indicated on the schematic wiring
diagrams and schedules, using a proprietary cable marking system comprising permanently
fixed plastic ferrules of the correct size for the cable.
All terminals shall be adequately numbered, as indicated on the schematic wiring diagrams.
Hand written numbering shall not be accepted.
All items of internal panel equipment shall be readily identified with clearly visible labels. Such
labelling shall correspond in detail with the panel wiring diagrams.
All labels shall be engraved on white-black-white traffolyte or similar engraving laminate and
shall be fixed by means of 3mm chrome screws or plastic rivets. Unless otherwise indicated
black lettering on white background shall be provided. Warning labels shall have red lettering
on a yellow background. Details of engraved labels shall be provided to the CA for approval
prior to manufacture.
All panels and individual panel sections shall be provided with exterior labels to BS 5499-5
indicating the voltage within the panel and clear warnings of risk and instructions for isolation.
All switches, controls and indicators on control panels shall be labelled as to function and
associated plant.
17.2.10 Local interfaces

Where indicated control panels shall have a fascia mounted keypad and display for local
interrogation, set point alteration and command execution. It shall be possible to communicate
with the entire network from the unit.
Where indicated control panels shall have a fascia mounted socket to allow local interrogation,
set point alteration, and command execution via a portable computer or palm top device.
It shall be possible to communicate with all the controllers located within the associated control
panel. As indicated the Controls Specialist shall provide the portable computer or palm top
device, all necessary software, software licences, and peripheral equipment.
17.2.11 Control panel testing

Control panels shall be fully equipped, wired and tested before delivery to site.
Unless otherwise indicated the following tests and inspections shall be undertaken at the
manufacturers works in the presence of the CA. The control panel manufacturer shall provide
written evidence, including appropriate certification, that the panel has been tested in
accordance with the specification prior to inspection by the CA.
Functional testing including simulation of operation, sequencing, interlocking and automatic

controls
Demonstrating time delays and protection relay setting
Checking all labelling, cable numbering etc and compliance with wiring diagrams and
schematics
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High voltage pressure test of 2kV followed by an insulation test
Demonstrating that all MCBs or fuses are of the correct type and rating
Testing of all transformers for correct polarity and ratio and protection relays for correct
operation.
Demonstrating access to all equipment especially devices requiring adjustment.
Demonstrating access for all incoming cables and for outgoing power and control cables
together with provision of suitable gland plates
Demonstrating compliance with the BS 7671
Demonstrating the provision to maintain the internal environment of the panel
Demonstrating sufficient spare capacity as required by the specification
Visual inspection, to include but not limited to:
i. Neatness and size of cable looms
ii. Tightness of all connections, bolted power connections and bus-bar bolts tightened
to the correct torque.
iii. Segregation of power cabling and switchgear from control cabling and electronic
equipment.
iv. Shrouding of non-isolated equipment, switches, lamps etc
v. Panel metalwork and finish quality
Any other tests required by the CA.
The CA shall be given 10 working days written notice of all testing and inspections unless
Certified schedules detailing all tests and their results shall be submitted to the CA within 5
working days of the tests.
If the control panel is to be left on site for a long period then adequate precautions shall be
taken to ensure that it is protected from dirt, damage and moisture. Sensitive electronic
components shall be removed and stored separately.
On completion of all field wiring to the power section the flash test shall be repeated followed by
an insulation test. All isolators shall be closed and power fuses fitted. Control fuses and other
low voltage equipment fuses shall be removed for the duration of the test to avoid damaging any
extra-low voltage equipment. Flash tests shall be performed for mains powered equipment only.
Before the power is switched on, all new connections into the panel shall be checked and the
interlocks re-checked before the plant is operated.
On completion of the installation, including all field wiring, a complete panel test and inspection
shall be undertaken on-site in the presence of the CA. The tests and inspections shall be as
undertaken at the manufacturers works unless otherwise indicated.
17.3 FIELD DEVICES
17.3.1 General
A schedule of field devices shall be submitted to the CA, cross referenced to the points
schedule and showing the total number and specification of the devices to be supplied. The
information shall include manufacturer, model, range, accuracy, flow characteristics,
working/operating and static pressure ranges.
Sensors shall be selected to have a suitable measuring range and IP rating for their required
application.
Sensors shall be located to achieve representative and accurate readings of the controlled or
monitored medium. The Controls Specialist shall be responsible for the correct output and
positions for sensors. Where sensor positions are indicated the Controls Specialist shall advise
any corrections to the CA at a very early stage of the project.
Sensors shall in all cases be installed in accordance with the manufacturer's instructions.
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Sensors, detectors and associated meters shall have a proven record of precision and reliability
when used with BMS and building services systems.
All devices shall be installed with adequate access and clearance to permit maintenance, testing
and removal of any item. Inspection of all wiring connections shall be possible without removal
of the component.
Each device shall be labelled and the location of concealed devices marked and recorded.
Where a device type is not stated the Controls Specialist shall submit data to the CA for
approval.
All external field devices shall be rated for continuous and accurate operation within their control
limits in the local external environment defined elsewhere in these documents. Where these
sensors rely also on visual reading the visual clarity shall be maintained for the life of the
sensor.
17.3.2 Temperature Sensors

General
Temperature sensors shall comply with the following minimum requirements:
Fluid Temperature range C Sensor accuracy C

Internal Air -10 to +40 0.5
External Air -10 to +60 0.5
Flue gas +30 to +850 3
Chilled water -10 to +30 0.25
Water -10 to +150 0.5
Where a fluid is not identified the error range shall be agreed with the CA.
Drift shall be less than 0.1K per year.
Thermistor sensors shall have a hysteresis error which shall not exceed 0.5%.
Temperature sensors shall be thermistor types unless otherwise indicated. Compensation for
the non-linear characteristic shall be such that the accuracy at range ends shall not exceed 5%
and at the set point 2%.
Sensor ranges shall be chosen so that the range extends to those which might be experienced
under plant fault conditions.
Strap-on temperature sensors shall only be installed in applications as agreed with the CA.
Pipe mounted immersion sensor
The full active length of the sensor shall be immersed in water.

Allow adequate space so that sensors can be removed from their immersion pockets.
Immersion pockets shall be stainless steel and appropriate pressure rating. Pockets shall be
free issued to the Installer for installation in positions as indicated by the Controls Specialist.
Immersion temperature sensors shall be installed into pockets with the facility for removal
without disruption to the system(s). Immersion pockets shall be filled with a heat conducting
compound
Unless otherwise indicated a Binder test point or an additional immersion pocket, adjacent to
the sensor, shall be provided for test purposes
Sensors shall be positioned not less than 12 pipe diameters downstream from a point of
mixing to take account of stratification.
Immersion sensors for air ducts
Sensors for air temperature in ductwork shall be located in positions to most effectively sense
the measured condition.
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The full active portion of the sensor probe shall be exposed to the air flow.
The active portion of the probe shall be located central to the airflow.
A test hole shall be provided adjacent to every sensor with plug when not in use.
Probe-type sensors shall not be used in areas where stratification can occur.
Sensors positioned near to coils shall be shielded against radiative heat transfer.
Return air duct sensors shall be located near to the occupied space to avoid heat gain or
loss and radiant effects influencing readings.
Sensors shall be positioned in an area of representative air flow.
Sensors representing zone temperature should be offset to account for heat gains.
Sensors used for determining the dew-point shall be of material and construction suitable for
use in moist air.
Capillary sensors with probes
The device head must be higher than the sensor probe

The sensor probe should be tilted downwards
The ambient temperature at the device head must always be higher than the temperature to
which the sensor probe is exposed
The sensor element must always point downwards. The capillary should not form a U-shape
The capillary should not be bent too tightly (radius of bend > 50mm)
Frost protection thermostat
Shall be the capillary type and automatically reset unless otherwise indicated and shall be
installed to monitor the full face of the associated heating coil.
A spare capillary loop of 20 cm to enable sensor testing outside the duct/unit
The measuring head and the test loop of the thermostat must be located inside the ductwork
and downstream of the heat exchanger if the ductwork is outdoors or in an unheated space
The capillary should be installed in the air flow, downstream of the first heating coil exposed
to frost. The capillary must be installed diagonal to the heat exchanger pipes or in a
serpentine manner at right angles to the pipes.
Averaging sensor (ducts and air handling units)
Allow a distance of at least 50 mm between any heat exchanger and the sensor
The entire length of an averaging sensor must be fully inside the air-duct
The sensor element must be evenly distributed over the full cross-section and adequately
secured to prevent vibration
The sensor element shall be installed in the air flow, downstream of the eliminator plate
when air washers are used for humidification
Room sensor
Unless otherwise indicated sensors shall be installed at a height of 1.5 m in occupied spaces
and at least 50 cm from any adjacent walls.
A sensor shall be located in an area representative of the entire control zone and located
away from heat sources.
Sensors shall not be located near air currents generated by diffusers or openable windows
and not be exposed to direct solar radiation
External wall locations shall be avoided where possible. Insulated back-plates shall be
provided for external wall locations.
Conduit entry points to the sensor wall box shall be sealed where there is a risk of air from
another zone flowing over the sensor element.
Outdoor air temperature sensors
Sensors shall have protection to IP67 unless otherwise stated.

Shall be complete with a radiation shield.
Sensors shall not be located on facades affected by significant rising heat or facades which
will be heated by solar radiation.
Sensors shall not be located under eaves, above windows, ventilation extracts or subject to
wind influence.
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Ensure accessibility for safe inspection and maintenance.
17.3.3 Humidity sensors

Humidity sensors shall be of good stability and have a humidity range of 10% - 90% with a
sensor accuracy of 5% RH.
Drift shall not exceed 2.5% of the full range per year.
Humidity sensor/stat duct location
The air velocity in the vicinity of the sensor shall not exceed 10 m/s.
Sensors shall not be located in areas where there is no air flow.
A test hole shall be provided downstream of each sensor, plugged off when not in use.
Sensors shall be positioned beyond the spray distance of humidifiers.
Humidity sensor/stat room location
Unless otherwise indicated sensors shall be installed at a height of approximately 1.5 m in

the occupied space and at least 50 cm from adjacent walls or directly adjacent to doors.
Sensors shall no be exposed to direct solar radiation or be located near heat sources and be
protected from airborne contaminants.
Adjacent to the space dry-bulb temperature sensor unless otherwise indicated.
External wall locations shall be avoided except were unavoidable. Insulated back-plates
shall be used for external wall locations.
17.3.4 Air pressure sensors

Unless otherwise stated air pressure sensors shall have a sensor accuracy of 2% of the
reading. Sensors shall be supplied complete with pressure connections and connecting tubes.
Pressure sensors for measuring air at pressures greater than 1 bar shall be rated to meet two
times the maximum pressure and 1.5 - 2 times the working pressure.
DP sensors for measuring air at duct pressure shall have an accuracy of 1% and a resolution of
0.1%. The sensors shall be supplied complete with pressure connections and connecting tubes.
Ensure a steadying zone upstream and downstream of the orifice plate/flow grid.
17.3.5 Differential pressure air switches

Differential pressure switches for fan proving and filter monitoring and sensors for VAV static
pressure control shall be supplied complete with duct connections and PVC connecting tubes of
suitable length. The range and hysteresis adjustments shall be concealed to prevent tampering.
Error shall not exceed 2% of full range after 200ms with a hysteresis of less than 0.4% and
repeatable within 0.25%.
17.3.6 Indoor air quality sensors

CO2 sensors shall have an accuracy of 2% (indicated value).
Indoor air quality (mixed gas) sensors shall detect combinations of pollutant gases.
Duct mounted sensors shall be located in the return air duct from the space as close as possible
to the room extract point(s).
Room mounted sensors shall be located in a representative location at 1.5 to 3 m above the
floor unless otherwise indicated.
17.3.7 Flow velocity/flow rate sensors

Air velocity sensors shall comply with the following minimum requirements.
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Sensor Sensor range Sensor accuracy
Pitot static tube 3 to 80 m/s 2% of reading
3% of reading or 0.1 m/s
Thermo-electric anemometer 0 to 20 m/s
whichever is the greatest
Sensors shall be positioned at an adequate distance from bends, tees, fans and coils such that
the centre line velocity is representative of the average velocity.
Averaging velocity sensors across the duct shall be used where the minimum separation
distance from a flow disruption is not available. The flow grid shall be sized correctly for the
duct dimensions.
17.3.8 Differential pressure switches (liquids)

Differential pressure switches for water applications shall be rated to meet 2 times the static
pressure and/or 4 times the working pressure. All wetted parts shall be stainless steel and
switch housing protection to IP67 standard. The range and hysteresis adjustments shall be
concealed to prevent tampering. The mechanical services installer shall install the differential
pressure switches and connect suitable pressure pipes to service isolating cocks.
Error shall not exceed 2% of full range after 200ms with a hysteresis of less than 0.4% and
repeatable within 0.25%.
17.3.9 Flow meters

Flow meters shall comply with the following minimum requirements:
Meter Meter range Meter accuracy

Fuel flow meter 0 to 10 Hz 3% of reading
Water flow meter >5:1 2% of reading
Electricity meter - 1.5% of reading
Meters shall be complete with suitable pulse contacts.
17.3.10 Thermostats
Error shall not exceed those stated below for a particular type, where a type is not identified the
error shall be agreed with the CA.
Type Error
Bimetallic 5% full range
Liquid expansion 5% full range
Vapour expansion 1.5% full range
Electronic 1% full range
17.3.11 Light level sensors

Outside light sensors shall have a range of 10-2000 lux with an output of 4-20mA and be
mounted in an IP67 enclosure. The sensor shall be mounted in an open position not subject to
shade.
17.4 FIELD CONTROLLERS
17.4.1 General
Field controllers shall comprise distributed intelligence controllers including outstations, unitary
controllers and terminal unit controllers.
All field controllers shall perform all control actions independently of the operator workstation.
The units shall operate with the loss of shared data through the use of default values and final
data reading before the loss of network communications.
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Unless otherwise indicated construct field controller enclosures shall give the following minimum
degree of protection in accordance with BS EN 60529:
Internal plant room applications IP54.

External applications IP65.
Where located inside a control panel protected to IP54 the controller protection shall be
IP41.
Controllers shall be modular construction and designed to allow the removal and replacement of
devices without the need for rewiring of field wiring. Enclosures shall be lockable.
Unless otherwise indicated include provision for a future 20% increase in capacity.
Terminals shall be the screw down clamp-type fixed to purpose made mountings. Terminals
carrying different voltages shall be segregated into groups.
Field controllers shall be suitable for operating normally within the following environmental
ranges unless otherwise indicated:
Temperature 0C to 60C
Relative humidity 10% to 100%
Field controllers shall be protected against the effects of moisture, dust, sand, dirt and gases.
Where controllers are free issued to terminal unit manufacturers the controls specialist shall also
free issue associated interface relays and transformers as required.
Provide internal power back-up as indicated which shall hold the controller memory for a
minimum period of 72 hours and maintain the controllers clock function for a period of two years
unless otherwise stated. The internal power back-up unit shall be easily replaceable. The
interval between battery maintenance inspections shall not be less than 12 months. Battery
monitoring functions shall be as indicated.
External controllers requiring battery back up shall have remote batteries located in an air-
conditioned space. All interconnecting power and battery status monitoring cables shall be
included by the Contractor and installed in accordance with this specification.
Controllers shall have the facility to be fully configured and accessed by a portable computer
and via the operator workstation. Password access shall allow the display of all configuration
details associated with the field controller. Configuration details shall be easily altered by
system operators.
Field controllers shall incorporate a panel mounted operator interface.
The controllers shall include run-time totalling routines to enable run-time for each item of plant
selected. A different maximum run-time for each item of plant shall be allowed together with
interrogation of the controller for a point-by-point summary of run-time totals and limits. An
alarm signal shall be provided when the maximum run-time is reached.
Controllers shall include routines necessary to confirm that specific items of plant are functioning
correctly and this can be performed by monitoring physically separate but functionally related
sensors, switches or transducers. An alarm shall be raised if the expected response has not
been established by a preset time following switching on of plant. The preset time shall be
adjustable. It shall be possible to operate any specified standby plant.
The field controller shall be capable of logging selected hard and soft points and shall have
sufficient memory to log the equivalent of seven days data at 15 minute intervals for 50% of the
total number of physical points unless otherwise stated. Logging frequency and start/stop times
shall be adjustable.
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17.4.2 Controller inputs
The interfaces for field controllers shall be appropriate for gathering data from sensors and
devices.
All inputs shall be scanned at intervals not exceeding 1 second and protected against spurious
out-of-range signals including those caused by contact noise or bounce.
Ensure that errors introduced by the analogue to digital conversion of inputs do not exceed
0.1% of the analogue value.
Analogue input
Variable currents (4-20 mA), variable voltages (0-10V) or variable resistances.

Routines necessary to process analogue inputs shall be resident at the field controller.
Ensure that a minimum and maximum limit value can be defined for each analogue input and
each limit is associated with a configured response.
The field controller shall detect open or closed circuit faults and raise an alarm on the
operator workstation.
Ensure that non-linear inputs can be calibrated / scaled.
It shall be possible to define a relationship between an analogue point threshold value and a
digital point status.
Digital inputs
Derived from volt-free contacts (max 24 volts/20mA). Allow the interface to be selected to
monitor a normally open or normally closed circuit.
Routines necessary to process digital inputs shall be resident at the field controller.
Pulsed inputs
Derived from volt-free contacts (max 24 volts/20mA) at a pulse frequency of up to 32Hz.

Routines necessary to process pulsed inputs shall be resident at the field controller.
The inputs used to monitor fluctuating pulse rate shall have operator adjustable limits.
The field controller shall have the following capabilities:
i. Storage of cumulative totals.

ii. Operator re-set facility of cumulative totals via the workstation.
iii. Facility to combine counts from separate pulsed inputs.
iv. Ability to calculate the number of pulses per unit time through addition and/or subtraction.
v. Ability to compare the number of pulses with preset limits on the basis of total number of
pulses per unit time and the time required for a total number of pulses.
vi. Ability to convert pulsed readings into quantifiable values.
vii. Alarm facility based on a user defined limit being exceeded.
17.4.3 Controller outputs

Controller interface characteristics unless otherwise indicated:
Isolation between controllers and networks shall meet the requirements of pr EN 13646.
Analogue output shall be as variable currents (4-20 mA) or variable voltages (0-10V). It shall
be possible to characterise analogue outputs in order to obtain a near linear response from
the controlled items of plant.
Ensure that digital outputs can be selected as normally closed or normally open.
Errors introduced by the digital to analogue conversion of outputs shall not exceed 0.1% of
the digital value.
In the event of power failure, output devices shall be capable of being driven to their preset,
fully open/closed position.
Field controller interfaces shall be capable of providing control signals to actuators and
switching devices.
Field controllers shall be capable of receiving feedback signals which allow the comparison
between an output signal to a controlled device and its actual condition.
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Routines shall be configurable, such that one or more events maybe enabled in direct
response to any defined logical relationship between the status of a number of physical or
soft-points.
17.4.4 Outstation keypads

As indicated these shall be provided by either the use of a portable device such as a laptop PC
or palmtop CE device or by a fixed keypad located at each outstation facia mounted on the
associated mechanical service panel.
As indicated a number of Palmtop CE devices shall be provided, there shall be a minimum of

two units supplied. If there are less than five outstations on the system then one unit shall be
provided. The local interface shall provide all the functions available at the central system with
the exception of graphical display.
17.5 ACTUATORS
Actuators shall be selected with adequate force/torque for the required applications.
Actuators and linkages for valves and dampers shall operate smoothly from fully open to fully
closed without binding and with adequate torque to overcome the resistance of the actuator
mechanism and the flow and to provide the specified close off ratings.
Linkages shall be clearly marked with the clamping position such that after maintenance or
replacement the mechanism is able to operate correctly.
Fit actuators with visual position indication.
Actuators shall be suitable for operating normally within the following environmental ranges
unless otherwise indicated:
Temperature 0C to 60C
Relative humidity 10% to 100%
Actuators shall incorporate a disconnection device to allow manual operation of the valve or
damper in the event of actuator failure.
Where indicated include position feedback devices suitable for connection to the BMS.
Actuators shall be protected both electrically and mechanically against the effects of valve or
damper seizure.
Ensure that there is sufficient space so that actuators can be removed for testing and
maintenance. Actuators shall incorporate electronic motor overload protection.
Actuators shall be 24V and accept typical control signal types unless otherwise indicated.
Where line voltage actuators are used, local means of isolation shall be provided.
Actuators shall be protected to the IP rating for their required application.
The Controls Specialist shall fit actuators and required linkages to dampers and control valves.
Actuators shall be supplied complete with all necessary mounting brackets and linkages.
17.6 VALVES
Valve bodies shall be suitable for the medium, the temperature and the operating and test
pressure of the fluid system.
Valves shall have the correct authority without excessive pressure drop and shall pass the
required flow at a pressure drop within the maximum differential pressure rating of the valve.
The control valve sizing method shall be agreed with the CA.
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Ensure system operating pressures, test pressures, pump heads and pressure drops through
heat exchangers and associated pipework are known before control valves are selected.
Unless otherwise indicated select valves to provide an authority of 0.3 to 0.5 for diverting
applications and 0.5 for mixing applications.
Valves shall have port characteristics appropriate for the intended function.
All modulating control valves shall be selected for equal percentage or linear characteristics
according to system type, to provide near linear characteristics between the valve position and
heating/cooling power as delivered to the air or water-based system.
The range-ability of the selected valves shall be large enough to provide stable control under
low load conditions.
Control valves shall be free issued by the controls specialist to the mechanical services installer
for installation. The controls specialist shall instruct on their correct installation allowing for
service and replacement.
Valves shall not be installed with their spindles in the horizontal position or with the actuator at
the bottom.
Unless otherwise stated all two and three port control valves shall be plug and set types with
tight shut-off and having a linear total flow characteristic. Rotary shoe and butterfly type valves
shall not be used.
All modulating actuators shall be low voltage, self stroking and have position indicators and
manual override facilities. Modulating valve actuators shall incorporate positive feed back
monitoring.
Where necessary valve stems shall be supplied fitted with spindle heat barriers, heaters and
shields to prevent actuator over-heating or condensation causing malfunction.
17.7 DAMPERS
Provide visual position indicators on all damper actuators installed so that they are clearly
visible.
Damper characteristics shall be as linear as possible and modulating dampers shall be sized
correctly to give adequate authority.
Actuators shall have end switches for indicating the safe condition/interlock of plant/monitoring
by the BMS (DDC).
Modulating dampers shall incorporate positive feed back monitoring.
17.8 VARIABLE SPEED INVERTER DRIVES

Inverters shall be the pulse width modulation type and shall allow the interfacing requirements
as indicated.
All inverters shall be of the same manufacture and installed fully in accordance with the
manufacturer's recommendations.
Inverters shall provide the following protection functions:
Phase loss detection (both motor and line).

Earth leakage.
Over-voltage fault.
Under-voltage fault.
Over-load/under-load fault.
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Overheat fault.
Stall protection.
Loss of control signal.
Loss of auxiliary control signal.
Over-current protection.
Operation of any of these faults shall cause electronic shutdown without fuse blowing.
Inverters shall have inbuilt RFI and supply harmonic distortion protection.
The inverter enclosure shall be dust and damp proof and shall be protected to the IP rating
suitable for the application in accordance with BS EN 60529. Adequate ventilation for cooling
shall be provided.
Inverters shall have a back lit display and alpha numeric keypad.
Inverters shall be capable of electronic maintenance without the motor being connected.
Where a switch disconnector is installed between an inverter and the associated motor, an early
break connect on the switch-disconnector shall be provided to disable the inverter.
17.9 CONTROL FUNCTIONS AND ROUTINES
17.9.1 Control interlocks

The BMS shall be capable of providing all control interlocks as identified.
17.9.2 Frost protection

Provide frost protection routines to operate plant and pumps in order to protect building services
systems and their components from frost damage.
Unless indicated provide the following two stages of protection:
When the outside temperature falls to the set minimum frost-protection temperature, the
selected pumps shall start and circulation established through pipework systems and their
components. Allow the operator to pre-select which plant is to be started. The automatic
standby plant shall operate on failure of the duty plant.
When the return temperature falls below the pre-set minimum, the full frost-protection facility
shall be initiated. Ensure that for heating systems, the heat source is turned on and operated to
maintain the return flow temperature above the pre-set minimum. Ensure that specified
protective devices activate for other liquid systems.
Provide a facility to allow frost protection to be logged together with data and time.
17.9.3 Building/plant protection

Provide protection routines to operate the plant in order to protect the building fabric and its
contents against the effects of low internal temperatures and of condensation.
If the internal air temperature falls below the pre-set protection temperature, the heating system
and related plant shall be turned on and heat supplied to maintain the air temperature at or
above the protection set-point temperature.
The building/plant protection routine shall override other control functions unless otherwise
indicated.
Protection shall operate whenever the normal heating is switched off.
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17.9.4 Safety interlocks
All safety interlocks shall be hardwired and have precedence over all other control functions.
Safety interlocks shall only be reset manually and locally (not from the operator workstation). All
hardwired safety interlocks shall have corresponding software interlocks to prevent cascading
nuisance alarms.
17.9.5 Fire interlocks

All fire interlocks shall be hard wired. In the event of a fire, all non-essential plant shall be shut
down by a signal generated by the fire alarm unless otherwise stated.
17.9.6 Time schedules

Each field controller shall be capable of enabling plant according to multiple pre-set time
programmes. It shall be possible to schedule each item of plant for a minimum of three
separate switching periods per 24 hours. Separate schedules shall be capable of being defined
for each day of the week.
Time schedules shall be capable of:
Grouped to form global time schedules

Defined on a weekly basis on a single page/screen
Defined 12 months in advance.
Copied from existing schedules
Linked to optimum start/stop control facilities.
Accommodating leap years.
Fixed extensions and contractions (the time schedule shall revert to the normal switching
periods following the extension/contraction period)
Provide:
Time schedule override facility to accommodate holiday periods, etc.
Optimum start/stop over-ride facility for user-defined override days. Optimum start/stop
control shall be enabled following the override period.
Automatic switching between BST and GMT and back.
Operator over-ride facility.
17.9.7 Plant start/stop control

Field controllers shall be capable of starting and stopping plant according to the sequences
indicated including any specific requirements for off position or status of plant items, valves and
dampers, etc.
Field controllers shall be capable of automatically enabling standby plant on failure of duty plant
and automatically report plant failure alarms at the operator workstation. The failure of a flow
switch or other device shall not continuously cycle plant.
If a flow switch fails the operator shall have the option to force either the duty or standby plant to
come on.
Provide the operator with the option to override any start/stop action configured within the field
controllers. When reverting to normal automatic control, ensure that the original program is
automatically reinstated and updated to the correct time.
Provide delayed plant-starting facilities in order to reduce power surges. It shall be possible to
start plant sequentially by adjusting the delay period for each item of plant.
Delayed plant starting shall initiate following power failure/re-instatement and plant shut
down/restart on fire/fireman override.
Provide the operator with a facility to specify minimum on/off cycle times and/or the maximum
number of starts per hour for specified items of plant.
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Provide a plant protection routine that enables the operator to select and automatically run items
of plant for short periods during out of season shut down. Run periods shall be operator
adjustable.
17.9.8 Sequence control

Provide sequence control routines to automatically sequence the operation of multiple items of
plant by monitoring load parameters and efficiently matching the plant to the load.
It shall be possible to define different automatic sequences of control. Provide the operator with
a facility to override the automatic sequence and define an alternative sequence.
Set-point values for each control action shall be variable and adjustable by the operator and
associated alarm limits shall be modified automatically.
The operator shall be capable of adjusting switching control differentials to prevent short cycling.
Routines shall include a facility to operate all plant ancillaries associated with sequence control,
unless these have been specifically excluded.
Routines shall include the facility to proceed with the defined sequence when one of the items of
plant in the sequence is isolated or fails to operate (unless the safety requirements dictate
otherwise). Ensure that failed items of plant are removed from the sequence.
17.9.9 Plant rotation control

The relevant field controllers shall be capable of alternating the lead plant items where duty and
standby equipment is installed. This shall be achieved both by an operator command and on a
time-scheduled basis.
The rotation control shall be capable of being provided on the basis of run hours, elapsed time
and calendar basis.
Provide routines to ensure that when the maximum number of start/stop cycles for a particular
plant is reached then its schedule is automatically modified eg by rotating the standby
equipment or changing the lead machine.
Ensure that each item of plant operated under rotation control can operate at any stage of the
rotation sequence as indicated
The plant rotation control shall accommodate a plant failure condition, in such a way that a failed
item of plant is replaced by the next in the rotation cycle. An alarm condition shall be raised in
response to plant failure.
Rotation control shall be capable of being initiated outside normal operating periods.
17.9.10 Optimum start/stop for heating systems

Provide an optimum-start routine for the heating system to compute the daily minimum pre-heat
period necessary to achieve target comfort conditions at the start of occupation. Provide an
optimum stop routine to compute the earliest time for the heat source to be shut down in order
to retain minimum target comfort conditions in the zone at the end of occupation.
The optimum start/stop routines shall have access to the system real time clock, calendar facility
and time programme to define the occupation periods.
It shall be possible to apply optimum start/stop control both to individual zones and overall plant
operation.
The routines shall operate the heating and ventilation plant as necessary to achieve the required
target conditions, and that the heating and cooling systems do not conflict in any controlled
zone.
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Provide independently adjustable start and stop comfort conditions.
Ensure that weather compensation control can be inhibited during pre-heat periods.
The heating plant shall go into full heating mode with full re-circulation of air (if relevant).
Ensure a return to normal fresh air control following the optimum start period.
Provide the optimum start/stop routines with an automatic self-learning process that seeks to
reduce any error in achieving the target conditions at the target time.
Provide the operator with the facility to adjust the following parameters:
Target temperature for optimum start.
Maximum pre-heat period.
Target temperature for optimum stop.
Minimum space temperature for out-of-hours periods.
Enable/disable the self-adaption function.
Default limit time for handover to the weather compensation routines after the start of
occupation.
The internal and external air temperature sensors associated with the optimiser shall be
positioned correctly in order to provide representative readings.
17.9.11 Optimum start/stop for cooling systems

Provide an optimum-start routine for the cooling system to compute the daily minimum pre-cool
period necessary to achieve target comfort conditions at occupation start time. Provide an
optimum stop routine to compute the earliest time for the cooling system to be shut down in
order to retain minimum comfort conditions in the space at the end of occupation.
The optimum start/stop routines shall have access to the system real-time clock, calendar
facility and time programme to define the occupation periods.
Routines shall be capable of operating the ventilation system for building purging prior to
optimum start of cooling plant.
It shall be possible to apply optimum start/stop control both to individual zones and overall plant
operation.
Provide routines to operate chillers and ventilation plant as necessary to achieve the required
target conditions while ensuring that heating and cooling systems do not conflict in any
controlled zones.
Provide the operator with the facility to adjust the following cooling system optimum start/stop
parameters.
Target temperature for optimum start.

Maximum pre-cool period.
Earliest time for building purging during out of hours period.
Inside and outside temperature limits for building purging.
Separate time/temperature relationships for optimum start and optimum stop.
Minimum space temperature during building purging.
The internal and external air temperature sensors associated with the optimiser shall be
positioned correctly in order to provide representative readings.
17.9.12 Weather compensation

Provide weather compensation routines to control the heating system in relation to external
weather conditions. Provide the operator with the option to adjust temperature and flow-rate
settings for the heating system to re-define the weather compensation.
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Provide automatic adjustment to the weather compensation by comparing measured and
required space temperatures with the outside conditions, and provide the facility to correct the
compensation where a significant difference between the two space temperatures occurs.
Abrupt changes in the heating system performance or space temperature shall not adversely
affect the automatic adaptive compensation process.
Provide a single weather compensation curve for each zone irrespective of the number of
temperature sensors provided in the zone.
The routines shall respond to the reset signals arranged to achieve boost, night set-back and
boiler safety.
Air temperature sensors associated with the compensator shall be positioned correctly in order
to provide representative readings.
17.9.13 Enthalpy
This shall be achieved by comparing the return air temperature and humidity with the fresh
air/external air temperature and humidity, to determine if the fresh air is beneficial to achieve the
design conditions.
17.9.14 Load shedding

As indicated the system shall be capable of monitoring the overall rate of electrical power
consumption and if a pre set demand level is projected to be exceeded, the system shall be
capable of shedding electrical load in a pre-determined manner.
The system shall be capable of as many levels of load priority as are necessary to meet the
requirements as indicated. The order of priority in each level shall be capable of rotation if
required.
Under conditions of partial/total power loss the system shall be able to trim demand in a
controlled manner to match available power from stand-by generator sets.
If load shedding routines are set up the facility to log consumption continuously shall be
provided.
Similarly, the system shall be capable of enabling loads in a controlled sequence to restore
normal operation.
17.9.15 Cascade start

As indicated the control system shall prevent the simultaneous operation of heavy electrical
loads at start up by incorporating time delays between plant start up signals.
17.10 BMS CONFIGURATION
17.10.1 General
Unless otherwise stated the controls system/BMS system shall have the facility to monitor
and/or control the following plant/system functions:
External Conditions - temperature and humidity.

Internal Room Conditions - temperature.
Plant/System Status - run, tripped, fault, alarm, low level, etc.
Plant Time Scheduling - on/off control.
Optimum usage of plant.
Plant cycling "duty sharing".
Energy consumption
Mains failure plant operational routine.
Fire off interlock (for logging purposes).
Archive/trend logging/contingency logging.
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All equipment shall be manufactured such that it shall not generate electrical interference
beyond acceptable limits.
All equipment shall be suitably protected against spikes and harmonics on the incoming
electrical supply and against electromagnetic radiation from site portable radios, etc. Any
equipment limitations shall be stated in the tender.
17.10.2 Point Capability

The points schedule detailed within the tender document is indicative of the monitoring
requirements and control operation of the system.
The Controls Specialist shall produce a points schedule based on the controls and BMS
equipment proposed to be supplied to meet the requirements of the specification. If any points
are omitted state the reasons for so doing.
A schedule of outstations shall be submitted, as part of the tender return documentation,

showing the points connected to each indicating the input/output capacity supplied, and the
spare capacity available for future additions.
The system shall be capable of supporting the type and number of hardware points listed as
indicated and shall support all software points, programming etc necessary for the specified
control sequences.
Each control panel shall be provided with a minimum quantity of 15% surplus of hardware points
of each point type at the time of tender.
The Controls Specialist shall clearly state in the tender return the used and spare point capacity
for each controller.
17.10.3 Password protection

The BMS software shall be protected from unauthorised entry.
Unless otherwise indicated provide, as a minimum, password-protected operator access for the
following levels:
Level 1 Ability to display all point data

Level 2 As level 1 with ability to initiate data logging functions
Level 3 As level 2 with ability to change user-adjustable set points and time schedules
Level 4 As level 3 with ability to change control strategies, schematic/graphics functions and
password assignment.
Password-protected operator access shall be set up for both operator workstations and field
controllers which have an operator interface. A common overall system password set and
procedure shall be provided whether access is gained from operator terminals, portable
terminals or keypads on single or multi-site schemes.
Passwords shall permit at least 6 alpha/numeric characteristics and users shall be able to
change their password/pin numbers at will.
At operator terminals a user logging-on shall be recorded with time and date. Unless otherwise
indicated logging off shall be command or time-out from non-use of the keyboard or mouse with
the event again recorded.
17.11 SYSTEM CONFIGURATIONS
17.11.1 General
The system communications shall allow the full transfer of monitored, logged, alarm, backup
and configuration data between the operator workstation and addressable field controllers.
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The communication protocol selected shall seek to achieve error-free data transfer and shall
include an error detection check, error correction and/or re-try technique. The protocol shall
limit re-transmission and raise an alarm condition on failure.
The available bandwidth shall be sufficient to avoid excessive delays in transmitting data. The
maximum permissible time delay shall not exceed that indicated.
Modems shall comply with BS 6320 and the speed of modems shall be as indicated.
Connections to telecommunication systems shall comply with BS 6701.
Provide an ISDN link if defined unless otherwise indicated.
Field-level protocols shall:
Run on the required communications media

Provide a communications throughput sufficient for the intended application
Provide appropriate network topology options
Allow sufficient maximum physical segment length
Allow sufficient maximum number of nodes for each physical segment and the logical
network
Provide sufficient maximum distance between nodes
Make use of off-the-shelf network devices such as repeaters, bridges and routers
Allow control devices to be powered from the network where indicated.
Ensure that the field-level protocols are compatible with fully developed network configuration
and management tools.
17.11.2 Direct interoperability

Ensure that each of the protocols objects and attributes are consistent with the achievement of
the specified level of direct interoperability.
Ensure that each of the protocols arrangements for physical connection, data packaging,
network management and error detection/correction are the same.
17.11.3 Gateways
Gateways shall:
Transfer the specified maximum number of points

Limit loss of functionality to the level specified
Add functionality where specified
Limit any time delay across the gateway to the maximum indicated
Ensure that the specified contingency and alarm measures in response to a failure of the
gateway are met.
The gateway shall be capable of any modification in response to any future changes relating to
the type and amount of data transferred over it.
The controls specialist shall be responsible for the implementation of any gateways.
If gateways or any other network devices are not indicated but are required to make the network
function correctly they shall be provided.
17.11.4 Communication networks

All addressable control devices shall be addressed over the communication network.
The bandwidth and subsequent speed of communications shall be sufficient to meet the
requirements as indicated.
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No cross corruption of data shall occur when the system shares a communication network with
other IT based systems.
Network testing, identification and documentation shall comply with BS EN 50174.
All network devices shall be compatible with the network and are capable of operating such that
the required throughput of data is achieved.
BMS devices to be directly connected onto the Intranet/Internet shall be TCP/IP compatible.
Where radio communications are employed the radio transmitter/receiver and the BMS
components shall be adequately powered. The lifespan of batteries shall be as indicated.
Radio communications devices and associated BMS components shall be easily accessible to
allow the change of batteries. The attenuation of radio signals shall not hinder effective data
communications.
Mains-born signalling shall comply with the requirements of BS EN 50065-1. Provide the
necessary equipment to ensure that there is no mutual interference between the signalling
system of the electricity utility and mains-borne signalling of the BMS.
17.12 INTEGRATION WITH FIRE DETECTION SYSTEMS

The controls specialist shall liase with the fire alarm specialist and all other relevant parties in
the integration of the systems.
The controls specialist shall be responsible in conjunction with others in obtaining all necessary
approvals from the Civil Defence Authority having jurisdiction.
The fire detection system shall operate autonomously and will not be affected by any failure of
the BMS. The BMS will not be affected by any failure of the fire detection system or fails safe as
appropriate.
The loss of electrical power to the BMS will have no adverse effects on the fire detection
system.
A full cause and effect testing programme shall be developed in conjunction with the fire alarm
specialist and agreed with the CA.
The integrated system shall be fully commissioned.
Provide the display of fire alarm detector status information on the BMS operator workstation as
detailed elsewhere
Provide any specified building graphics/schematics on the BMS operator workstation indicating
the location of fire detector heads or zones, as indicated, along with their respective status.
The fire alarm condition shall automatically display the appropriate building graphic/schematic
along with relevant detector head status or zone status as indicated.
Any time delay in receiving the fire alarm data at the operator workstation shall not exceed the
maximum as stated.
.
Provide fail-safe, hardwired interlocks using volt-free contacts between the BMS field controllers
and items of fire and life safety and general plant as stated elsewhere.
As indicated use relay logic and/or microprocessor-based logic.
Any specified building services control actions shall operate correctly in response to the status
of the fire detection system.
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17.13 OPERATOR WORKSTATION
17.13.1 Operational characteristics

The control of plant shall be independent of the operator workstation. Provide complete system
integrity such that the network of field controllers will continue to fully operate following a failure
of the operator workstation.
No data of a control nature shall be transferred between field controllers via the operator
workstation unless otherwise indicated.
The operator workstation shall communicate with all addressable field controllers. The
appropriate control strategy configuration data shall be capable of being downloaded to all
addressable field controllers.
Provide a means of displaying and modifying each addressable field controllers control
strategy, time schedules and set-points via the operator workstation.
All control strategies and associated control parameters shall be altered via the operator
workstation.
The operator shall be capable of re-scheduling plant operation times. Re-scheduling shall be
capable of being applied globally to a number of items of plant at one or more sites (or one or
more controllers on one site) as selected by the operator.
The operator workstation shall incorporate a data storage management system that warns
against impending on-line storage overflow and allows for data archiving to, and retrieval from,
off-line non-volatile media. The operator shall be prompted at pre-defined intervals to carry out
the data archiving procedure.
It shall be possible to perform a complete backup of the operator workstation comprising control
strategies, set-points and logged data.
Provide an electronic data archival device that uses readily available non-volatile media that is
appropriate for long term storage of system software, configuration data and logged data
(including alarm data). The use of multiple 3.5-inch disks will not be acceptable.
Allow the transfer of data from the system memory and other storage devices to the archive
mediums, and vice versa for the preparation of reports.
The backup data shall be capable of being fully re-loaded and that selected files from the
backup data can be re-loaded.
17.13.2 Processor
The processor speed of each operator workstation shall be adequate to meet the data
processing requirements. Delays in processing system data shall not exceed that indicated. All
necessary power supply and interconnecting leads shall be provided.
17.13.3 Monitor
Unless otherwise indicated provide a 17 flat screen colour monitor complete with adjustments
for display positioning, screen brilliance and contrast.
17.13.4 Keyboard
Provide QWERTY keyboards with full Arabic/English upper/lower case ASCII key-set, numeric
keys and mouse. The keyboard shall also include dedicated, or user defined soft keys, which
initiate the most frequently used functions.
Systems incorporating a touch-screen facility in place of a keyboard shall be provided with a

keyboard connection and associated functionality.
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17.13.5 Printer
Provide an A4 colour printer as indicated. The printer shall be capable of printing:
All monitored and logged data (including graphs of logged data)

All point data (hard and soft)
Graphics, control logic diagrams and plant/building schematics in colour
Alarm data/text and to list any appropriate action to be taken.
Systems help text.
Reports in letter quality format.
The automatic printing of alarm data shall be capable of being switched on/off.
The controls specialist shall provide sufficient paper until practical completion, at which point the
printers shall be reloaded with a fresh supply and the end user issued with two boxes (5000
sheets) of spare paper.
17.13.6 Monitoring and logging functions

All monitored point data shall be displayed at the operator workstation. Analogue, digital and
soft-points shall be displayed simultaneously.
All changes made by the operator (eg set-point changes) shall be logged and identified by both
operator and date/time stamp.
Provide a facility to allow the display, at the operator workstation, of real time data
superimposed on plant schematics with a refresh rate not exceeding 20 seconds unless
Ensure that a minimum of four real time data points can be displayed simultaneously, in the
form of data plots, with a time delay not exceeding 20 seconds.
Provide a facility to allow the monitoring and display, on the same page, of common
criteria/plant functions.
Any hard or soft-point log shall be capable of being displayed and stored on the operator
workstation.
Logs shall be capable of being set up from the operator workstation and logging times and
logging intervals shall be adjustable between 1 second and 24 hours.
The operator workstation shall have sufficient data storage capacity to accommodate the
defined amount of logged data and that the data can be backed up.
Provide a facility to allow the simultaneous display of different logged data. This function shall
be operator adjustable.
Provide a facility to allow the export of logged data to other software packages as indicated.
17.13.7 Graphics
The controls specialist shall include for system graphics print-outs for review by the CA and off-
site demonstration of the graphics before final incorporation into the BMS.
The BMS shall incorporate the facility for a colour graphics package to be installed at the
operators terminal/desktop computer. The system shall be an active graphics presentation and
include the following features unless otherwise indicated:
Provide a software library of plant schematics and symbols, the format/contents shall be
agreed with the CA.
The operator shall be able to select a plant location and associated control panel from a plan
and via a hierarchical set of graphic layouts select a particular plant, point or point attribute.
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A detailed schematic of each plant area or individual plant monitored or controlled by the
system shall be available for viewing and interrogation at the operators terminal. The
schematics shall illustrate the status and analogue values of all points associated with the
selected plant. The value of such points shall be updated while the schematic is displayed to
the user.
Provide a facility to allow the operator to generate additional schematics and symbols.
The system shall accommodate the addition of 20% extra graphics pages.
Provide a facility to allow the operator to modify plant schematics and to generate new ones.
The graphics shall be capable of being displayed in a layered approach (building layout
graphics down to plant subsystems and components). The operator shall be able to modify
the structure of the layered approach.
Graphic selection and use shall be primarily mouse driven. However, the user shall also be
able to access data direct by reference to a point or report name.
Multi-level password protection shall be provided for all interfaces.
Print outs of all system graphics shall display the date, time and external ambient
temperature and humidity conditions.
The operator shall be able to select and modify any point attribute as required.
The operator shall be able to change alarm limits or set points associated with a point or
allow access to the DDC programme code.
17.13.8 Help and assistance

Provide a facility to allow the display of help text covering all operator functions and system fault
conditions.
Provide a facility to allow the display (including a hard copy) of points list (hard and soft-points)
and control strategy logic schematics.
17.13.9 Energy monitoring and targeting software

Provide a facility to allow the direct transfer of recorded energy consumption and external air
temperature readings from the BMS to monitoring and targeting software in an agreed format.
17.13.10 Maintenance management software

As indicated, provide a facility to allow the direct transfer between the BMS and maintenance
management software. The format and scope of the exported data shall be as indicated.
17.13.11 System alarms

System alarms shall meet the following requirements unless otherwise indicated:
Alarms shall be displayed on a rolling basis in chronological order.

The operator shall be able to acknowledge alarms, including muting of audible or flashing
annunciators. A facility shall be provided to silence audible alarms or inhibit flashing
annunciators without performing alarm acknowledgement.
The operator shall be able to alter the limits at which the measured values cause alarms to
be triggered. Alarm limits shall accommodate sliding limits eg set point changes.
Alarms shall be differentiated by means of alarm type and identification.
Alarms shall be prioritised (including a high priority that will be annunciated regardless of
other activity) and a low priority or information status that is only annunciated on demand.
The time taken to receive alarms shall be as indicated.
The reception and acknowledgement of alarms shall take precedence over other operations
and shall not hinder user log-in.
Allow the user to acknowledge alarms individually and on a group basis.
Provide distinction between active alarms whose condition are not cleared and
unacknowledged alarms.
Alarm data shall provide:
i. Condition identity
ii. Condition value
iii. Alarm source
iv. Alarm time and date
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v. Acknowledgement status.
Allow alarms to be automatically redirected to other user interfaces.

Provide sufficient data storage capability for the storage of alarms. Any stored alarm data
shall be analysed in conjunction with other monitored conditions or stored logged data. An
alarm review facility shall be provided.
The operator shall be able to define:
i. The requirement for acknowledgement of alarms

ii. A time programme for annunciation of alarms to different destinations
iii. Text messages associated with alarm conditions.
17.14 ENERGY METERING

As indicated the controls system/BMS shall monitor and record energy consumption data from
all meters as identified elsewhere via pulsed inputs.
The protocol selected for the communications interfaces shall be co-ordinated with the meter
supplier/manufacturers and fully developed, proven and tested off-site prior to installation.
As indicated the BMS shall include the facility to generate, either automatically or via operator
command, daily, weekly, monthly, quarterly or annual reports of energy consumption for
operator selectable times of day, on an individual meter, tenant, floor zone or energy type basis
which can be printed, archived or exported to third party proprietary applications as required.
Reports shall be produced in an agreed Microsoft office format.
17.15 CONNECTION TO PLANT AND CONTROL EQUIPMENT

Provide all devices and terminals necessary to connect the BMS to items of plant and control
equipment.
Take account of any existing services that have to remain in continuous operation. Agree with
the CA the method by which controls system/BMS equipment can be installed without disrupting
the operation of the building services.
Where plant and control equipment are supplied by others, provide the Project Supervisor with
adequate details of installation requirements. Provide this information in time and in sufficient
detail to enable any other installers and their suppliers to incorporate the BMS connection
facilities before delivering their equipment to site.
Where plant is subject to warranty by others, obtain clearances in writing from those concerned
that the proposed connections or modifications do not invalidate the warranties.
Ensure that modifications carried out as a result of the contract are fully documented and do not
affect the satisfactory operation of safety devices connected to any plant or systems affected
directly or indirectly by the controls system/BMS works. Carry out proving tests to the
Ensure that the use of existing relays, contactors, starters and switches as part of the BMS
installation is fully documented.
Provide interlocks as indicated to establish and maintain safe/pre-determined plant conditions

under all modes of operation including loss, reduction and restoration of power.
All safety hardwired interlocks shall be wired to failsafe on loss of power, or on relay coil failure,
or on open circuit.
Unless otherwise indicated all interlocks shall use voltage-free contacts and 24v AC or DC
relays and field wiring.
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Complete all wiring and testing of all hard wired safety interlocks to ensure safe and/or
sequenced operation of the plant before the controls system/BMS is set to work. Arrange
interlocks to prevent unsafe or out of sequence operation of the plant by the BMS.
Ensure that plant does not operate using the BMS until all interlocks have been tested to the
Provide manual control facilities as indicated to enable plant maintenance/facilities staff to

operate essential plant in the event of BMS failure and for routine test purposes. Unless
otherwise stated facilities shall include:
Start/stop operation of the plant

Automatic operation of motorised control devices such as valves and dampers, etc if the
BMS is operating
Manual setting of motorised control devices such as valves and dampers, etc if the BMS has
failed.
The manual control facilities shall not override safety devices or hard-wired interlocks.
The contact materials for volt-free contacts shall be suitable for use in the installation and at the
required voltages and currents. Unless otherwise indicated screw down or locking spade
terminals shall be used for electrical connections to volt-free contacts.
Provide additional contacts for signalling and remote operation purposes from starters as stated
elsewhere.
The controls specialist shall liaise with and obtain all necessary information from the relevant
supplier when additional facilities are to be fitted to control equipment supplied by others.
Connections to packaged plant shall be made within the packaged plant control panel. Fit an
additional enclosure where this is not possible.
17.16 CABLING
All wiring shall be installed in accordance with BS 7671 and the requirements as stated
elsewhere.
The controls specialist shall be responsible for power, control and network communications
wiring. This includes the provision of primary and secondary containment as necessary and
indicated.
Low voltage power, extra low voltage control and network cabling shall be segregated
throughout the installation. Under no circumstances shall power and control / network wiring be
run in the same containment, regardless of the cable types. Control cabling shall be routed
clear of all lighting ballasts and other electromagnetic devices that may damage the integrity of
the control signal. Control system/BMS cabling shall not be mixed with cabling associated with
other services.
The types of cable installed shall not prejudice the operation of the controls system/BMS.
Ensure that the cross-sectional area of cables is sufficient to ensure that sensor circuit
resistance limits are not exceeded.
The method of installation and routing of cables shall not compromise the satisfactory operation
of the controls system/BMS.
All cabling shall be adequately protected from the environment through which it passes to avoid
the possibility of mechanical damage or electromagnetic interference.
Install cabling and conduits associated with sensors in a manner that prevents spurious transfer
of moisture and heat etc from external sources to sensing devices.
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Communications cables as used on a network system shall be shielded twisted pair, with the
shield earthed. The conductor cross sectional area, cable capacitance and length of runs shall
not impair performance or violate the manufacturers recommended network constraints.
Where Ethernet or similar carrier technology is utilised, cables specific to that technology shall
be employed.
All extra low voltage controls system/BMS cables shall be run in screened twisted pair cables
with the shield earthed at one end only.
Cables shall be affixed to tray, drawn into conduit or trunking and protected as agreed with the
CA to suit the various environmental, local and mechanical locations. Cable containment details
shall be as indicated elsewhere.
Cable specifications shall meet the manufacturers requirements, particularly respecting overall
resistance and capacitance limits.
No joints shall be allowed in cables, where these prove necessary the cables shall be joined
using an approved housing, securely fixed and having cable securing clamps. Any such
connecting boxes shall be shown on the record drawings.
All field cables shall be the LSF type.
Power and control cables associated with the operation of life safety plant shall have fire rating
classifications CWZ to BS 6387 and shall be approved by the CA and Building Control prior to
installation.
Field switch disconnectors and junction boxes associated with life safety plant shall be fire rated.
All cables shall have identification sleeves at their terminations which combine the requirements
of BS 7671 with those for specific circuit identification as indicated. The identification shall be
consistent with the relevant wiring diagrams.
Electrical installations shall be undertaken by companies approved by the National Inspection

Council for Electrical Installation Contracting. Test and completion certificates shall be issued
following completion of each section of the installation and for the completed installation.
Use of existing cabling and wire ways
Confirm by testing that any existing means of network communication is of a suitable standard
for satisfactory operation of the BMS. Any tests shall be performed in compliance with EN
50174. Ensure that the potential corruption of data cannot arise.
At the time of tender state in writing whether or not existing cabling is suitable.
17.17 COMMISSIONING AND TESTING
17.17.1 General
Include for carrying out the tests as stated, together with such additional inspections and tests
during the process of manufacturing, installation or otherwise as the CA shall prescribe, to prove
the physical characteristics of all materials and manufactured parts incorporated in the Works,
ensure the overall suitability of all equipment, and to satisfy the requirements of the Local
Authority.
The testing and commissioning shall be co-ordinated with all other trades and shall be
performed in a systematic and methodical manner in accordance with the contract programme.
The Controls Specialist shall ensure satisfactory completion of the testing and commissioning
together with the recording of results.
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Appoint a competent person to supervise the whole of the testing, commissioning, system
proving, system demonstration and instruction of the employers staff.
Include for all expenses, labour, materials, tools, equipment, plant, calibrated instruments and
attendances required for inspections, testing, commissioning and demonstrations of the control
systems.
System commissioning shall be in accordance with CIBSE Commissioning Code C - Automatic

Controls and as indicated elsewhere.
Undertake the following:
Off-site testing and demonstrations

Testing, pre-commissioning checks, commissioning, regulation and setting to work of the
controls systems
Preparation of comprehensive programmes, commissioning plans, schedules and method
statements and procedures supported by risk assessments for the pre-commissioning
checks, setting to work, commissioning, system proving and environmental testing
Provide and submit standard pro-forma for the various requirements for commissioning
records and certification for agreement with the CA prior to commencement on site
Monitor progress against the program of works and provide weekly reports detailing progress
of testing and commissioning activities
Maintain a diary/log of all significant activities and document any faults, snags or queries and
how these were resolved. The diary/log shall be fully noted and available for inspection by
the CA at any time.
Ensure all certification is attained and witnessed as necessary for inclusion in the record
documentation
Provide and submit a report for every test, demonstration, or commissioning activity
witnessed, together with an CAing appraisal on the performance, either on or off-site
As necessary co-ordinate and liaise with the Employers representative
Co-ordinate, give notice and obtain all approvals from the necessary authorities
Provide operator training and demonstrations to the Employers staff or representative
17.17.2 Programme
Within one month of appointment, unless stated otherwise, submit to the CA a preliminary
commissioning programme. The programme shall be of the itemised bar chart format and shall
clearly indicate the proposed approach and all key activities including off site testing, witnessing
etc.
Prior to commencement on site, unless stated otherwise, the installer, controls specialist and
commissioning specialist shall together produce a detailed and final commissioning programme.
This document shall amplify and expand upon the preliminary commissioning programme and
include all necessary detailed method statements and procedures. The programme shall be
fully integrated with all other site activities envisaged to be occurring during the period of
commissioning and shall also indicate all necessary witnessing and acceptance dates.
17.17.3 Reports
Submit to the CA written reports signed by a qualified person to confirm that:
Prior installation - all system designs can be commissioned

Post installation - installations complete and ready for testing and commissioning
Pre-commissioning checks completion of pre-commissioning checks and all off-site testing
Commissioning and testing to demonstrate compliance with specified requirements and
confirm that the controls system has been correctly tested and commissioned and achieving
the specified performance.
The final documentation of reports and completed record sheets shall be compiled into a control
systems commissioning manual for inclusion in the operating and maintenance documentation.
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17.17.4 Instruments for testing and commissioning
All instruments shall be provided by the Controls Specialist.
Submit to the CA a schedule detailing the equipment and instruments to be used in the testing
and commissioning of the controls systems.
Ensure all instruments are correctly calibrated and are marked with a unique reference for
identification. Submit evidence of correct calibration of all instruments used in connection with
commissioning and testing to the CA prior to commencement of the Works. Test methods shall
be demonstrated to the CA where required.
Instrument calibration data and identification shall be included on the respective test record
sheets.
17.17.5 Off-site testing

The Controls Specialist shall include for off-site testing of all control panels, control application
software and user interface software unless otherwise indicated.
The Controls Specialist shall include for all travel and accommodation expenses of the CA
unless otherwise indicated.
The requirements for off-site testing shall be as stated elsewhere.
Testing shall be to the satisfaction of the CA and certificates of all such tests shall be provided
to the CA within 3 days of testing and copies included in the operating and maintenance
documentation. All certificates shall be signed by a competent person and witnessed.
Off-site testing will be required to be repeated on site as directed by the CA.
Ensure that as much pre-commissioning work as possible is perfomed off-site as agreed with
the CA.
17.17.6 System demonstration

The Controls Specialist shall:
Give 10 working days notice to the CA of his intention to undertake the acceptance
demonstrations and witnessing.
Ensure that sufficient on-site resources are available to facilitate the demonstration and
witnessing process.
Submit to the CA a detailed programme of the demonstration and witnessing activities prior
to commencement.
Issue a complete commissioning report to the CA prior to commencement of the
demonstration and witnessing period. The report shall contain the commissioning point-to-
point checklists and details of commissioning values and parameters installed, signed and
dated accordingly. The report shall be revised as necessary on successful completion of the
demonstration.
At the discretion of the CA, and unless otherwise stated, the following shall be demonstrated
and verified in the presence of the CA:
Any operator software and associated graphics

All safety related functions
All plant restarts according to that specified after building failure and local power failure
All power meter data-points to ensure that they match the meters
All optimiser and time clock energising of plant. Demonstration of any optimiser shall include
the switching of all required plant during non occupation period under simulated frost and
internal condensation conditions.
All safety interlocks, overrides and fail-safe conditions. To be operational prior to starting the
plant and demonstrated as agreed with the CA prior to starting plant in BMS auto-mode.
Part 5
Section 17 Page 31
Fault conditions for all critical alarms, safety devices and control interlocks shall be simulated
and proved effective as soon as practical once BMS control mode is selected.
All controls associated with terminal units. Random checks at the discretion of the CA to
demonstrate correct operation of the units including temperature, volume and pressure
checks as necessary.
Sensors to ascertain accuracy within limits. Humidity sensors shall be checked for accuracy
using a wet/dry bulb thermometer.
Fire condition including operation of plant available to the Fire Officer in an emergency
situation.
10%of all points shall be selected by the CA and demonstrated for operation and accuracy.
The CA reserves the right to witness 100% of the points if the failure rate is greater than 5%.
The Controls Specialist shall ensure sufficient man-power, test equipment, consumable
items and portable communications equipment to conduct the demonstration efficiently.
The system security access.
One of several identical items of plant in detail with the others witnessed on a random basis.
The control of critical items of plant.
Dynamic graphics.
Trend graphs will be provided to demonstrate the stable control of the plant. Simulated inputs
will be employed to check stability over the design environmental range.
17.17.7 Electrical services

fittings, complying with the latest edition of the BS 7671, IEE Wiring Regulations with
amendments ruling at the date of tender.
Unless otherwise indicated all tests shall be undertaken in the presence of the CA who shall
have been duly notified. Triplicate copies of test certificates covering all tests carried out on the
completed installation shall be submitted to the CA.
17.18 TRAINING
The Controls Specialist shall provide user training course(s) for the Employers personnel in the
operation, maintenance and programming of the controls system.
The first course will take place after commissioning and prior to handover.
The second course shall take place within 6 months of the handover date tailored to suit the
end-user requirements.
Training will be provided by competent instructors. All associated training equipment required
by the instructors to enable the training to be demonstrated effectively shall be provided.
Submit to the CA for approval a detailed training programme and method statement for the
training of the Employers staff.
Where necessary provide off-site training at the Controls Specialist training facility.
A training manual, together with a comprehensive set of teaching notes and diagrams, shall be
provided for each operative
For all instruction periods maintain training records which shall be submitted to the CA on
completion. All attendee names shall be recorded and signatures obtained from all attendees
confirming they have understood the training given. A schedule of names shall be provided
within the operating and maintenance documentation.
As indicated the training shall include but not be limited to:
Part 5
Section 17 Page 32
Operation of user terminals
use of displays and add or change graphics/ schematic

call up and view point-data from plant schematics and/or points lists
overrides
acknowledge system alarms and setting up alarm routines
Undertaking basic alterations
Time and occupancy programmes

Control set-points
Setting up trend logs
Testing and routine inspection of sensors and actuators

Adding analogue and digital inputs/outputs to the system
Re-load system software/configuration details
Add/modify passwords/monitor system security
Instruction on the procedures for fault-finding, tuning, maintenance, testing and routine
inspection and to assess the nature of faults and extent of remedial action required.
Instruction on the configuration of outstation
Specific system structure including outstations and control strategy overviews.
Back-up of the system and archive logged data.
The controls specialist shall be available for an agreed period as agreed with the CA to assist
the Employer's personnel in the operation of the various systems following practical completion
and occupation of the building.
The Controls Specialist shall provide off-site communications support through a modem
connection during the defects liability period (12 months).
All costs associated with the instruction of the Employers staff and required attendance
following practical completion shall be included in the contract price.
17.19 POST-HANDOVER CHECKS

During the 12 months after practical completion and in consultation with the CA undertake to:
Assess the need for fine tuning of the installations

Ensure the requirements for fine tuning are incorporated in the commissioning specification
Ensure that fine tuning activities are programmed, planned in advance and agreed with the
CA and employer prior to commencement
Ensure that fine tuning activities are planned with regard to the health and safety of
occupants and such that any disturbance to them is minimised
Provide a mechanism by which the Employer can provide feedback on the performance of
the building both before and after fine tuning
Attend meetings as requested by the CA to deal with issues arising from fine-tuning of the
controls system.
The costs for fine-tuning and adjustment of the controls systems during the 12 months after
practical completion shall be included in the contract price.
As agreed with the CA the Controls Specialist shall include the following as part of the post-
handover checks unless otherwise indicated:
Global level checks of:
i. Internal air temperature

ii. Relative humidity
iii. Ventilation
iv. Energy consumption (ensure that the pulse-input counters match the meters)
Part 5
Section 17 Page 33
Control set-points meet the specified requirements.
Control loop settings result in accurate and stable control. Check that all self-learnt
characteristics are valid.
All relevant field controllers communicate properly. Check for correct sharing between
controllers of relevant data and correct inter-controller operation.
Occupant controls work correctly.
Sensors. Check the accuracy and location of any suspect sensors
Actuators. Check that any suspect actuators operate correctly.
Dampers and valves. Check that any suspect dampers and valves are not jammed and that
they operate as intended.
17.20 DOCUMENTATION
The Controls Specialist shall provide the following documentation as part of the overall record
documentation for the project
System documentation will be provided at contract completion and in a format compatible with
the overall project record documentation.
Operation and maintenance manuals
A preliminary copy shall be made available to the CA in sufficient time for comments to be
incorporated.
The operation and maintenance manuals shall include but not limited to:
A written description of plant operation

Control strategy/logic diagrams recording the final version of configuration software installed
Details of system application software configuration
A points list including hard and soft points. All points shall have a unique reference
A description of user adjustable points
Commissioning records and final commissioning report
Detailed data sheets for all control components and equipment
Wiring circuit details including origin, size, route and destination of each cable
Diagrams showing the full diagrammatic (network structures, configuration diagrams, flow
charts, outstations, peripherals etc) and physical layout of the controls system and
components.
Security management and access details
Comprehensive instructions for switching on, daily operation, switching off, isolation, fault
finding and procedures for dealing with emergency conditions
Instructions for any precautionary measures necessary
Instructions for the routine operation of the control system including simple day-to-day
guidance for those operating the control system with limited technical skills
Instructions for servicing and system upkeep
A provision for update and modification
Suppliers and spare parts references, contacts, telephone numbers, and addresses shall be
supplied where relevant.
Software
Two complete sets, unless otherwise indicated, of all software developed by the Controls
Specialist shall be provided for retention by the Employer.
Allowance shall be made to up-date the software as maybe necessary during the one year
defects period.
Obtain on behalf of the end user all appropriate licences, permissions, copyright waivers, rights
of use and the like from the owners of the software rights. Ensure that the end user is properly
registered with the software supplier for support and appropriate updating.
Back-up copies of all system configuration files and master software disks shall be supplied in
an appropriate lockable storage facility. All system and data files shall be current as at the
hand-over date, disks to be suitably identified and directories and files cross-referenced in the
Part 5
Section 17 Page 34
maintenance manuals. In addition to the operating software, each disc will also contain a
complete set of original set points for all conditions. The storage unit and key shall be handed
to the Employer at handover.
A further copy of all master software, system configuration files etc shall be maintained off-site
by the Controls Specialist for a minimum period of three years or as otherwise indicated.
All passwords shall be provided at handover.

BS 6231 Specification for PVC-insulated cables for switchgear and control-

gear wiring
BS 6320 Specification for modems for connection to public switched
telephone networks and speech band private circuits run by certain
public telecommunications operators
BS 6701 Telecommunications equipment and telecommunications cabling.
Specification for installation, operation and maintenance.
BS 7671 Requirements for electrical installations. IEE Wiring Regulations.
BS EN 60947-4-1 Specification for low-voltage switchgear and control -gear.
BS EN 60439 Specification for low-voltage switchgear and control gear
assemblies.
BS EN 60529 Specification for degrees of protection provided by enclosures (IP
code)
BS EN 61000-6-3 Electromagnetic Compatibility (EMC).Generic emission standards.
Emission standard for residential, commercial and light industrial
environments.
BS EN 61000-6-2 Generic standards. Immunity standard for industrial environments.
BS EN 61000-6-1 Electromagnetic Compatibility (EMC).Generic standards. Immunity
for residential, commercial and light industrial environments
Part 5
Section 17 Page 35
Section 18 Electrical works associated
with mechanical services
Contents
Section 18 Electrical works associated with mechanical services 1

18.2 Conduit and trunking 2
18.3 Cable tray and ladders 7
18.4 Fire Barriers 9
18.5 Cables installed directly on the structure 9
18.6 Cables 9
18.7 Local isolation 12
18.8 Electrical accessories 12
18.9 Protective devices 14
18.10 Earthing and bonding 17
Section 18 Electrical works associated with mechanical
services
This section describes the general requirements for wiring systems. Particular requirements
shall be as indicated elsewhere.
The controls specialist shall be responsible for the provision of power and control cabling
between control panels, associated plant and controls equipment as an integral part of the
controls systems/BMS as indicated.
The electrical services installer shall provide the cabling to and be responsible for the
termination of all incoming power supplies to control panels, including power supplies on
packaged equipment where such supplies are not from a mechanical services control panel.
Electrical installation works shall only be carried out by companies approved by the National
Inspection Council for Electrical Installation Contracting.
Cable routes shall be carefully co-ordinated with the routes of other services, particularly other
cable routes. The wiring for the mechanical services installation shall be kept separate from all
other wiring except where approved by the CA. Ensure that the method of installation and
routing of cables does not compromise the satisfactory operation of the BMS.
Cables shall be installed at least 150mm clear of plumbing and mechanical services.
All cabling must be adequately protected from the environment through which it passes to avoid
the possibility of mechanical damage or electromagnetic interference.
Ensure that the types of cable installed do not prejudice satisfactory operation of the BMS and
that the installation and planning comply with the BMS manufacturers recommendations and
the project's electrical specification.
Ensure that the cross-sectional area of cables is sufficient to ensure that sensor circuit
resistance limits are not exceeded.
Ensure that the minimum separation distances between data/analogue signal cables and power
cables as indicated in Clause 18.6 are adhered to.
The controls specialist shall obtain the written approval of the CA and damage caused to the
installation provided by the electrical services installer. The controls specialist shall be solely
responsible for any damage caused to the installation provided by the electrical services
installer.
No claims will be considered due to the need to increase cable sizes to allow for grouping,
whether they are associated with the electrical, mechanical or controls installation.
The electrical installation shall comply with the requirements of BS 7671.
Unless indicated otherwise the controls specialist shall be responsible for the design, supply and
installation of all wire-ways and fixings.
Liaise with equipment suppliers to ensure the sizes and types of cables to be connected to their
equipment can be accommodated.
Part 5
Section 18 Page 1
Conduit and trunking systems shall be erected complete with all accessories connected. Unless
otherwise indicated they shall be offered to the CA for inspection prior to cables being installed.
Cable ties shall not be used to support cables. They shall only be used to secure cables on
horizontal cable tray or for grouping cables within trunking.
Cables shall be delivered on drums and properly protected against mechanical damage. Each
cable drum delivered shall be accompanied by a certificate giving manufacturers name, works
order number and the results of tests made at works.
When lengths are cut from cables, the newly severed ends shall be sealed and remain so until
the ends are terminated.
Where cables of differing voltages are installed in close proximity, cable identification shall be
provided.
Cables shall be installed with particular regard to neatness of appearance, and multiple runs
shall be marshalled so that cables entering or leaving the multiple run shall be kept to a
minimum.
The arrangements for fixing cables shall be of sufficient strength to hold the cables in position
during short circuit conditions.
Straight through joints in cables shall not be permitted without written approval.
Use and install cables only as directed in the appropriate standard or as directed by the
manufacturer in writing.
Lay cables in one length unless otherwise indicated.
Cables shall not be installed in ambient temperatures below that recommended by the
manufacturer.
Use drum stands, drum axles, fair leads, rollers, cable stockings and other equipment as
recommended by the cable manufacturer and as appropriate to the method of installation.
Install cabling and conduits associated with sensors in a manner that prevents spurious transfer
of moisture and heat etc from external sources to sensing devices.
18.2 CONDUIT AND TRUNKING
18.2.1 General
Ensure the entire system is electrically and/or mechanically continuous to BS 7671.
Comply with the requirements of BS 7671 wherever conduit or trunking passes through the
perimeter of a fire compartment (wall, ceiling or floor).
Conduit, trunking and cable tray shall be installed to present a neat appearance, parallel with
other service runs and lines of building construction, except where in screed or in-situ concrete.
Provide provision in conduit and trunking at expansion and settlement joints to allow for
movement of the building structure.
Install conduit, trunking and equipment clear of other services. Measure distances from the
external surface of any insulation. Notify the CA of instances where minimum clearance cannot
be achieved and bond items concerned. Unless otherwise indicated the minimum spacing
between conduit, trunking, equipment and mechanical services, including plumbing, shall be at
least 150mm.
Install conduit and trunking systems to ensure internal condensation does not affect operation of
associated circuits. Provide drainage points in accordance with BS 7671.
Part 5
Section 18 Page 2
18.2.2 Steel conduit
General
Provide conduit systems to BS EN 50086
Use conduit from one manufacturer.
Steel conduit shall comprise heavy grade, welded seam conduit provided with screwed ends.
Dimensions shall comply with BS EN 60423.
Unless otherwise indicated conduit shall be galvanised finish.
All accessories and fittings shall be the same class and finish as the associated conduit system.
No conduit less than 20mm diameter shall be permitted.
All conduit runs shall be agreed with the CA before any work commences.
Surface conduits shall be installed vertically, horizontally or parallel with features of the building.
Conduit shall not be mounted directly on a surface. A minimum spacing of 6mm to the back of
the conduit shall be maintained.
Where conduits cross expansion joints in the building structure, special expansion couplings
shall be used or such other methods as agreed with the CA. Continuity through all such joints
shall be maintained.
Conduit shall be supported at regular intervals not exceeding 1.2m on horizontal runs and 1.5m
on vertical runs and shall be in accordance with the recommendations published by the IEE.
Conduit shall not be under mechanical stress and conduit boxes shall be fixed independently of
conduit. Allowances shall be made for any additional mechanical loading supported by conduit
boxes. Ensure fixings of conduit boxes are suitable to maintain the required protection.
Cut conduit clean and square with axis. Conduit joints shall butt solidly to boxes, couplings, etc
with no exposed threads. Full use shall be made of the total length of threads.
Ensure no indentation or reduction in cross sectional area occurs during installation.
All burrs and sharp edges shall be removed from the ends of conduit after screw threads have
been cut. All dirt, paint, oil etc on the screwed threads of the conduit and accessories shall be
carefully removed immediately prior to installation.
Inspection bends, solid bends, elbows, tees or normal bends shall not be installed.
All bends shall be fabricated on site to suit the conditions using a standard type bending
machine. The radius of any bend shall not be less than four times the outside diameter of the
conduit. Care shall be taken to prevent conduit deformation. Do not apply heat when forming
sets and bends. Conduit sets through walls will not be permitted.
Not more than two right angle bends will be permitted without the interposition of a draw box.
Unless otherwise stated long straight conduit runs shall have draw boxes installed at maximum
intervals of 10 metres.
The number of running joints in conduit shall be kept to a minimum and where installed locknuts
shall be used to secure the sockets.
Conduit runs shall be so arranged that any condensed moisture can drain to the lowest point
and arranged to avoid traps or low level pockets.
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Section 18 Page 3
Where the finish of the conduit is damaged or suffers from the effects of corrosion, the surface
shall be wire brushed and painted with two coats of rust inhibiting paint to the same standard as
the normal surface.
Immediately conduits are fixed in position all exposed threads and bends shall be painted with
two coats of rust inhibiting paint.
Galvanised conduit shall be treated with zinc rich paint.
All conduits shall be maintained in good condition to the satisfaction of the CA throughout the
duration of the Works. Precautions shall be taken to prevent the ingress of silt or moisture into
the conduit system by the use of screwed metal caps and plugs to protect open ends. If fouling
should occur the affected conduit shall immediately be swabbed clean.
Conduits and fittings shall be dry and free from internal burrs and other defects. All conduits
shall be swabbed through before wiring is commenced and cables shall not be drawn into any
section of the system until all conduits and draw boxes for that particular section are fixed in
position.
Where a conduit is exposed to different temperatures, the section of the conduit at the higher
temperature shall be isolated from that at the lower temperature using a conduit or adaptable
box. After wiring the box shall be filled with inert, permanently plastic compound with high
insulation value. The method of isolation shall be agreed with the CA.
Deep boxes or extension rings on standard circular conduit boxes shall be used where
necessary in order to bring the front face of each box flush with the surface of the ceilings and
walls.
Where conduits terminate at a main switch, distribution board, sub switch or other metal clad
accessory, they shall be connected by means of smooth bore male brass bushes, compression
washers and sockets. It shall be arranged to be in good mechanical and electrical contact with
the metal case.
At each distribution board, multi-gang switch control panel etc the conduit provided shall be of
the capacity to accept all cables which could be connected to outgoing ways, whether they are
installed at this stage or in the future.
Where a number of conduits converge they shall terminate in a metal box so as to prevent
bunching.
All draw boxes and junction boxes shall be of ample size to permit cables being drawn in and
out. They shall be manufactured from heavy gauge sheet steel with welded corners and shall
be of square or rectangular pattern. Lids shall be of the same material as the box.
Boxes mounted externally or in damp areas shall be fitted with a rubber gasket between the lid
and the box. External boxes shall be filled with cold plastic compound.
All spare ways in junction boxes, etc left for future extensions shall be fitted with brass stopping
plugs.
Only continuous lengths of cable shall be installed. No cable joints shall be made in the cable
where it resides in the conduit except in conduit boxes where an accessory is to be fixed.
Cables shall be unreeled off cable drums without a helix being formed in the cable and shall be
drawn into the conduit without any resulting stretching or abrasive damage.
Where the installation of cables into conduit is undertaken in sections, then care must be taken
to avoid a helix being formed in the cable.
During installation cables shall not be allowed to lie where they may be damaged.
Part 5
Section 18 Page 4
Concealed conduit
Ensure conduit is not concealed until work has been inspected by the CA.
Concealed conduits shall be securely fixed to prevent movement during building operations.
Fixing shall be by means of purpose made clips or other means so as to ensure there in no
deformation of the conduit.
Conduit buried in concrete shall have at least 35mm depth of cover over its entire length.
Conduit concealed in wall chases shall be covered by plaster and/or rendering to a minimum
depth of at least 12mm depth over its entire length.
Where conduit is buried in the carcass of a building or in the ground, all ends shall be
temporarily plugged to prevent ingress of foreign matter, moisture or water.
Provide temporary protection to conduits until screeds/concrete is laid.
Where conduits are laid in concrete slabs or screeds etc a competent person shall be in
attendance during the concrete pouring operations to ensure that damage to the conduit
installation is avoided.
Conduits in ceiling voids shall be supported independent of the suspended ceilings.
Conduits installed in chases of walls or floors shall be firmly secured by wrought iron pipe hooks
or crampets. The fixings shall be sufficient to maintain the conduit in place. Conduits
mechanically damaged by the installation of crampets will be rejected and shall be replaced.
Conduit buried in the ground shall be wrapped with PVC self adhesive tape, half lapped. The
taping shall extend for a distance of 150mm beyond the point where the conduit emerges from
the ground. Joints in the conduit system shall be made watertight. Buried conduit will not be
allowed.
Ensure that conduit and fittings buried in concrete or behind plaster are protected against
corrosion or electrolytic action.
Equipment connections
Use flexible metallic conduit for final connections to motors or other equipment liable to vibration
or adjustment and to thermostats, motorised valves and similar items mounted in pipelines or
ducts.
Ensure sufficient length between equipment and through type box at the end of the conduit run
(minimum 450mm unless otherwise stated) to allow necessary full range of withdrawal,
adjustment or movement.
Use PVC covered flexible conduit where installed externally, exposed to weather or in any
position where ingress or moisture or condensation may occur.
An earth wire shall be drawn through the length of the flexible conduit. The cable shall be sized
in accordance with BS 7671. The cable shall be connected to the motor earth terminal at one
end and the conduit system at the other.
18.2.3 Cable Trunking

Trunking shall comply with the requirements of BS 4678.
Install trunking in accordance with the manufacturers requirements and in accordance with BS
7671.
Where sizes are not stated they shall be determined to comply with the requirements of BS
7671. Unless otherwise stated allow for 25% additional wiring.
Part 5
Section 18 Page 5
Use trunking of each type from one manufacturer.
All trunking fittings and accessories shall be factory manufactured and finished by the trunking
manufacturer. They shall be of similar construction and finish to the main trunking. Trunking
shall be internally reinforced by cross stays in such a manner that distortion will not occur during
and after the installation of cables.
All site fabricated fittings or special accessories shall be approved by the CA prior to
manufacturer.
Steel cable trunking and lids shall be manufactured from sheet steel with a minimum thickness
of 1.2mm for trunking sizes up to and including 76mm x 76mm and a minimum thickness of
1.6mm for trunking sizes up to and including 228mm x 152mm unless otherwise indicated. The
trunking shall have a removable cover throughout the total length with screw latch fixings.
Trunking shall be arranged to allow safe access to wiring. Covers shall be located on top or
sides of trunking if practicable. Access shall be arranged so covers are on a continuous face
and cables can be laid in throughout the length of the trunking. Notify the CA where either
condition cannot be achieved.
Cut trunking clean and square with axis, prepare ends and remove burrs and sharp edges.
Ensure the inside of trunking is free from anything liable to damage the cables or cause
mechanical damage due to abrasion either during installation or after the covers are installed.
Where trunking is modified or adapted, any damage to the finish shall be made good by painting
with two coats of rust inhibiting paint to the same standard as the normal surface.
No screws, bolts etc shall protrude into the capacity of the trunking.
Connections shall not be made to trunking covers.
All trunking shall be supplied with cable retaining straps at 1m intervals maximum except where
the cover is on the top.
Vertical cable trunking shall be provided with cable pin racks and arranged to avoid any strain
on the cables. They shall be spaced at maximum intervals of 3000mm. Use insulated pins or
insulation sleeved pins on pin racks.
Maintain electrical continuity at each joint by a copper link fixed on the outside of the trunking,
secured by brass nuts, bolts and shake-proof washers.
Where trunking crosses building settlement or expansion joints a trunking joint shall be provided
with slotted fixing holes to permit movement of at least 10mm in both the horizontal and vertical
planes. The earth continuity link shall be braided copper tape not less than 15mm x 2mm thick.
The braid shall be suitable length to allow for the maximum movement of the trunking. Braid
ends shall be folded and swaged solid.
Provide fixed section of lid projecting 75mm either side of fabric where trunking passes through
wall, floor or ceiling.
Where trunking passes through building fire barriers, suitable fire resistant barriers shall be
provided within the trunking. Ensure there is no aperture between the trunking and the structure
through which fire might spread.
Where access points in ceilings etc are provided to trunking ensure the trunking is provided with
a short removable section in the lid.
Fit ends of runs with removable blanking plates.
Metal partitions shall be provided as indicated and as required by BS 7671. Ensure partitions
are electrically continuous with the body of the trunking and the gap between partitions and lids
Part 5
Section 18 Page 6
maintains segregation of circuits. The minimum thickness shall be 1mm unless otherwise
indicated.
Cables shall be unreeled off cable drums without a helix being formed in the cable and shall be
drawn into or placed into the cable trunking without any stretching or abrasive damage.
Where the installation of cables into trunking is undertaken in sections then care must be taken
to avoid a helix being formed in the cable.
During installation cables shall not be allowed to lie where they may be damaged.
Only continuous lengths of cable shall be installed. No cable joints shall be made in the cable
where it resides in the cable trunking.
18.3 CABLE TRAY AND LADDERS
18.3.1 Cable tray

Cables shall be installed on trays or ladders such that each cable runs parallel to its neighbour
and be neatly laid in rows such that as cables leave the tray or ladder they do not cross over
other cables.
Cables leaving trays should either pass through the bottom of the tray through neatly cut holes
with suitable grommets or over the return flange, where the cable shall be supported clear of the
flange. Depending on the size of the slot the tray should be either strengthened or have further
support.
Cables leaving ladder shall pass through the rungs of the ladder. Where they leave over the
edge of the ladder they shall be supported away from the edge.
No more than one layer of cables shall be installed on trays or ladders unless otherwise
approved.
Cables shall be tied to the tray or ladder by plastic cable ties having a minimum size of 5mm
and at such intervals to prevent bowing of the cables. Power cables should be segregated as
far as possible and tied down individually. Other cables having an overall diameter of not more
than 20mm may be embraced by one clip with no more than six cables being so embraced.
Any alternative method of fixing shall be subject to approval.
HV cables shall be installed on separate trays or ladder in order to provide separation from low
voltage and control cables. Instrumentation cabling shall also be installed on separate trays or
ladders where necessary to prevent induced signals
Cable tray shall be heavy-duty perforated metal tray with double edge return and manufactured
from perforated mild steel sheet complying with BS 1449 Part 1.
Unless otherwise indicated cable tray shall have a hot-dip galvanised finish.
Cable tray shall only be cut along a line of plain metal and not through perforations. All cut
edges shall be prepared and treated according to the original finish of the metal. Galvanised
cable tray shall be prepared and treated with a zinc rich paint.
Tees, intersection units and sets shall be purpose made by the manufacturer.
Bends shall be of the same material, thickness and finish as the cable tray and shall an inner
radius of 50mm and a minimum straight length of 100mm at each end.
Tees shall be of the same material, thickness and finish as the cable tray. The distance
between a point of intersection and at the end of the fitting shall be 100mm.
Part 5
Section 18 Page 7
Where special sections are required, the material, thickness and finish shall be as specified for
standard items and agreed with the CA prior to manufacturer.
Holes cut in cable tray for the passage of cables shall be provided with grommets or
alternatively bushed or lined to prevent damage to the cable covering.
Cable tray shall be securely fixed at regular intervals not exceeding 1000mm for trays up to
200mm wide and at 900mm intervals for wider trays. Support shall be adequate to ensure that
there is no sagging of the trays when all the cables are in position. Trays shall be fixed at both
sides of a change of direction at a maximum distance of 150mm from the change.
A minimum clear space of 20mm shall be left behind all cable tray.
Mushroom headed steel roofing bolts and nuts shall be used for the installation and coupling of
trays and/or accessories. The head of any fixing bolt shall be presented to the surface of the
tray on which the cables are to be fixed.
Where tray is installed in the vertical position, cables shall be supported by cable cleats or in the
case of mineral insulated cables, saddles or clips.
The thickness of cable tray and accessories shall comply with the following requirements unless
otherwise stated:
Nominal width Minimum height of Nominal thickness of steel

Application
(mm) up stand (mm) sheet (mm)
100 12 1.5 Internal
150 12 1.5 Internal
225 12 1.5 Internal
300 20 1.5 Internal
450 20 1.5 Internal
600up to and
20 2 Internal
including 900
100 12 2.5 External
150 12 2.5 External
300 20 2.5 External
18.3.2 Cable ladder

Cable ladders shall be fabricated from 1.6mm thick galvanised mild steel unless otherwise
stated. They shall be not less than 300mm wide with 100mm flange depth and shall be
provided in 3m lengths.
Cable ladders fittings and accessories shall be factory formed and be of the same construction
as the ladder. All cut edges shall be prepared and treated according to the original finish of the
metal.
Cable ladders shall be mechanically and electrically continuous throughout. Mushroom headed
bolts shall be used on all joints and for fixing. There shall be not less than two bolts per joint or
fixing. Cable ladder shall not be used as the system earth return path for the electrical
installation.
18.3.3 Installation of cables

Cables on trays or ladder shall be laid in a single layer, leaving 25% of the tray or ladder width
as spare capacity for future use unless otherwise indicated.
Part 5
Section 18 Page 8
Cables installed on cable tray or ladder shall be secured by the use of proprietary ties, each tie
securing cables of only one circuit. Ties shall be spaced at a maximum distance of 600mm and
provided within 100mm of each bend unless otherwise indicated.
Where trays or ladders do not directly support cables, such as on vertical trays or ladders, load
bearing cable cleats or saddles shall be used and securely fixed. All cable cleats, saddles and
straps shall comply with manufacturers recommendations and shall be compatible with the tray
finish and cable sheath.
18.4 FIRE BARRIERS

When cables are routed through floors and fire compartment walls, a system of proprietary fire
barriers having a fire rating equivalent to the fire rating of the structure through which the cables
are passing shall be installed.
The fire barriers shall consist of a metal frame, complete with edge flange.
After installation of the cabling, fire resisting neoprene type inserts and filler blocks shall be
inserted around the cabling and necessary stay plates, compression plates and end packing
units installed. The manufacturers recommended lubricant shall be used when packing the
neoprene inserts and filler blocks into the fire barriers.
18.5 CABLES INSTALLED DIRECTLY ON THE STRUCTURE

Where installed directly onto the structure, cables shall be secured by cable cleats at intervals of
not more than 600mm.
Every cable shall be securely supported throughout its length and at a point not more than
1000mm from its termination and on vertical routes passing through a floor, immediately above
the floor.
18.6 CABLES
18.6.1 General
Power cables shall be selected in accordance with the relevant tables and associated correction
factors in BS 7671.
Cables shall be sized to take account of volt drop, grouping protection and environmental
conditions.
The installer and controls specialist shall ascertain actual cable lengths, include for the actual
lengths in the tender and provide materials accordingly.
Where any cable length varies from that indicated in the tender documents provide calculations
to show that the cable is suitable for the intended load. Similarly if any loads vary from those
envisaged in the tender documents provided calculations to demonstrate that the appropriate
cables will be provided.
All cable routes shall be agreed by the CA before work commences.
Bends in cables shall not be less than those recommended by the cable manufacturer for the
particular type of cable being installed. When the cable is taken off the drum and flaked the
bending radius shall not be less than those stated above.
Cable manufacturers shall be agreed with the CA prior to ordering.
Cables shall not be installed in or through thermal insulation except where they pass through fire
barriers. Any instance where the thickness of the fire barrier exceeds 300mm shall be brought
to the attention of the CA prior to the installation of the cables.
Part 5
Section 18 Page 9
18.6.2 Mineral insulated cables
Cables
Mineral insulated cables shall be manufactured to BS 6207 and be of the grade as indicated.
They shall be LSF unless otherwise indicated.
The manufacturer shall be agreed with the CA prior to ordering.
Unless otherwise indicated the sheath colour shall be orange except for fire alarms circuits
which shall be red.
Where inductive loads are connected using MICC cables, suitable provision shall be made for
surge voltage suppression.
Mineral insulated cables shall be stored in accordance with the manufacturers

recommendations.
Installation
The insulation resistance of cables shall be tested immediately after installation and termination
using either a 1000-volt or 500-volt instrument as appropriate for the cable grade/rating and as
indicated. Further tests shall be carried out not less than 24 hours after the cables have been
sealed. All tests for continuity and insulation resistance shall be in accordance with BS 7671.
Surface cables shall be fixed by means of purpose made PVC covered brass two screw
saddles, spaced at intervals not exceeding 300mm or less if necessary to prevent sagging of the
cables. At bends, boxes and fittings, saddles at each side shall additionally support the cables
where necessary. The PVC covered saddles shall be of the same colour as that of the cable
sheath.
Where cables are grouped cable tray shall be provided unless otherwise agreed with the CA.
The method of grouping shall be agreed prior to installation.
All cable tails shall be clearly marked indicating the phase colour to which to which they are
connected.
Where cables cross expansion joints, they shall be double set across the joint.
Where the cable terminates at a machine or equipment subject to vibration, one complete turn
of the cable shall be made in the run immediately before the cable enters the terminal box or
terminating position. A clear space, minimum 12mm shall be maintained at the point in the loop
where the cable passed over itself. The diameter of the loop shall not be less than that
stipulated by the cable manufacturer in accordance with the minimum bending radius
recommended for the cable size concerned.
Where cables pass through walls or floors or are buried in concrete, plaster or other finishes,
they shall be sleeved by or run in conduit. Provide necessary protection against mechanical
damage.
Cables shall be straightened and dressed using methods and tools recommended by cable
manufacturer.
Jointing
A through joint will only be accepted if a run of cable is of such a length that it exceeds the
maximum to which the cable can be manufactured. Joints shall be made within an adaptable
box, incorporating a fixed based mechanical clamp type connector. The cores of both single
and multi-core cables forming a circuit shall be joined in a common box.
Part 5
Section 18 Page 10
Terminations
All persons employed to make terminations on MICS cables shall have attended a course of
instruction and they shall demonstrate, if so requested, to the CA their ability to make
satisfactory seal prior to commencing work on site.
Mineral insulated cables shall be sealed using screw-on pot type seals incorporating integral
earthing tails. The seals shall be accommodated in brass ring type glands.
Seals shall comprise brass sealing pots, waterproof and oil proof phenolic discs complete with a
suitable number of neoprene insulating sleeves. Seals shall be suitable for temperature ranges
of up to 105C or 302C as required. The insulating sleeves shall be complete with moulded
heads to enable the sleeves to be retained in the phenolic disc. Tails shall be identified by
means of sleeves applied over the neoprene.
Sealing compound and sleeving shall be kept clean when not in use. It shall not be used if it is,
or is suspected to be, contaminated by dirt or moisture.
The ends of MICC cables shall be taken into earthed enclosures. No type of unfixed connector
shall be used.
Final connections for conductors larger than 4mm shall be made by means of cone grip lug
type cable sockets.
The glands of MICC cables shall be connected to fuse switches, distribution boards or
adaptable boxes by locknuts or where space is limited by smooth bore male brass bushes,
compression washers and galvanised sockets for multi-core cables. Non-ferrous sockets and
locknuts shall be used for single core cables. All MICC cable terminations shall be clearly
marked with coloured sleeves.
Terminations on cables having an LSF sheath shall be fitted with a matching LSF shroud
covering the cable gland, and the length of cable from which the sheath has been removed.
18.6.3 Control and communication cables

Control and communications cabling shall be run in fibre optic, twisted pair or multi-core
screened copper cabling as indicated to suit the particular control or BMS installation.
Samples of all control and communications cables shall be submitted to the CA together with
the respective technical specification prior to placing orders.
Control and communication cables shall be protected from mechanical damage by installation in
a conduit or trunking system.
Ensure that any separation and provision of barriers required to prevent pick-up of stray signals
or attenuation of the signal being carried is provided.
Cables shall be installed in accordance with the manufacturers recommendations.
Unless otherwise indicated the minimum separation distances between signal cables and LV
power cables shall be:
Power cable Power cable

Signal cable
Unscreened Armoured steel wire
Plain 150 mm 125 mm
Unscreened
75 mm 50 mm
twisted pair
Screened 0 mm 0 mm
Part 5
Section 18 Page 11
18.7 LOCAL ISOLATION
Rotating equipment and resistive loads shall be provided with local isolation complying with the
requirements of BS 7671.
Isolators shall be fully rated to open or close at the design load of the circuit and give positive
indication of open and closed positions.
Each item of equipment shall be provided with the means to enable it to be locked in the OFF
position.
Enclosures shall be suitable for the environment.
Isolators externally mounted shall be manufactured with a moulded case and provide the
necessary IP rating.
Internally mounted units shall be manufactured from heavy duty cast iron. Isolators shall comply
with BS EN 60947-3 and shall have a minimum protection of IP54 in accordance with BS EN
60947-1 unless otherwise indicated.
Single phase motors and resistive loads up to 3 kW shall be provided with a double pole switch
complying with BS 3676 and BS EN 60669. Switches shall be complete with pilot lamp. Where
they are flush mounted with flexible cables to equipment they shall be provided with a flex outlet
incorporating a cable clamping device.
Larger single phase loads and all three phase loads shall be provided with isolators capable of
isolating all power and control circuits to the equipment protected.
18.8 ELECTRICAL ACCESSORIES
18.8.1 General
All accessories shall be selected to suit the environment in which they are installed.
All accessories for the installation shall be of a common and proprietary manufacture.
Accessories shall be able to withstand the effects of the prospective short circuit current without
damage.
Accessories shall be designed to fix to conduit boxes and shall have plates which overlap the
conduit box for flush installations and plates which match the external dimensions of the conduit
box for surface installations.
Where surface mounted accessories for use in plant rooms and externally are provided with a
purpose made box then these shall be used in lieu of a conduit box.
Any accessories mounted on trunking shall be of the flush mounted type and be provided with
an accessory adapter plate and shroud.
18.8.2 General purpose socket outlets

General purpose socket outlets shall be suitable for operation in single phase a.c circuits up to
250 Volts, be rated at 13 Amperes and be switched or unswitched as indicated.
Pillar terminals shall be provided for the termination of sub circuit cables and be sized to
accommodate three 2.5mm conductors. Terminals shall be manufactured from brass with a
rounded end pinch screw which will adequately terminate from three 2.5mm conductors to a
single 2.5mm conductor.
Where switches are specified the switch contacts shall operate with a snap action and be
controlled by means of a rocker type actuator. Contacts shall have a contact gap and operating
speed such as to prevent the maintenance of an arc during operation.
Part 5
Section 18 Page 12
The manufacturer selected shall offer a comprehensive range of socket outlets and components
to cover a wide spectrum of requirements i.e. metal clad, plastic clad, grid mounted, units for
flush and surface mounting, single and multi gang, indicators, weatherproof and non standard
pin configurations etc.
Fused plug tops shall be moulded from high impact insulating materials with stud terminals and
screw driver driven nuts with captive washers to terminate flexible cables. An insulated cable
restraint shall be provided to secure the flexible cable to the body of the fused plug top.
Plug tops shall be provided un-fused. Plug top fuses shall be provided as detailed elsewhere.
18.8.3 Special purpose socket outlets

Special purpose socket outlets shall be as indicated.
The outlets shall be manufactured from impact resistant materials and designed with an IP
rating suitable for the location in which they are to be installed.
This type of outlet shall be colour coded to suit its voltage and frequency. A plug top shall be
supplied for each socket outlet.
18.8.4 Fused connection units

Fused connection units shall be suitable for operation in single phase ac circuits up to 250 volts,
be rated at 13 Amperes and have the features as indicated.
rounded end pinch screw which will adequately terminate from three 2.5 mm conductors to a
single 2.5 mm conductor.
Where a flex outlet is not specified pillar terminals shall be provided for the termination of
outgoing cables and be sized to accommodate one 2.5 mm conductor. Terminals shall be
manufactured from brass with a rounded end pinch screw.
Where a flex outlet is specified stud terminals and screw driver driven nuts with captive washers
to terminate flexible cables shall be provided together with an insulated cable restraint to secure
the flexible cable to the body of the fused spur unit.
Where switches are specified the switch contacts shall operate with a snap action and be
controlled by means of a rocker type actuator. Contacts shall have a contact gap and operating
speed such as to prevent the maintenance of an arc during operation.
The manufacturer selected shall offer a comprehensive range of fused spur units and
components to cover a wide spectrum of requirements i.e. metal clad, plastic clad, grid
mounted, units for flush and surface mounting units with and without flex outlets and indicators
etc.
18.8.5 Flex outlet plates

Flex outlet plates shall be suitable for operation in single phase ac circuits up to 250 Volts and
be rated to suit the equipment to be connected.
rounded end pinch screw which will adequately terminate from three 2.5 mm conductors to a
single 2.5 mm conductor.
Where a flex outlet is specified stud terminals and screw driver driven nuts with captive washers
to terminate flexible cables shall be provided together with an insulated cable restraint to secure
Part 5
Section 18 Page 13
18.9 PROTECTIVE DEVICES
18.9.1 General
Protective devices shall be of following types:
HRC fuse links and their holders

Fused switch disconnectors
Air circuit breakers
Moulded case circuit breakers
Miniature circuit breakers and residual current devices
Plug top and accessory fuse links
All protective devices shall be of proprietary manufacture.
All the HRC fuse links and holders used throughout the installation shall made by the same
manufacturer and be of the same generic type.
Neutral poles and/or links shall have the same current rating as the phase (i.e. live) poles.
All the air circuit breakers, moulded case circuit breakers and miniature circuit breakers used
throughout the installation shall be made by the same manufacturer.
All the fuse switch disconnection units used throughout the installation shall be made by the
same manufacturer.
All the plug top and accessory fuse links used throughout the installation shall made by the
same manufacturer.
All protection devices shall be selected to suit the ratings of the circuits protected in order that
adequate protection and discrimination is provided.
All air circuit breakers, moulded case circuit breakers, fuse switch disconnection units and
miniature circuit breakers shall comply with the contact clearance criteria for isolators.
Materials and equipment shall comply with the relevant and latest issue of British and European
Standards.
18.9.2 HRC fuses and holders

All HRC fuses shall be of the cartridge type.
The HRC fuse links and holders shall have been type tested and certified by an independent
short circuit testing authority in confirmation of their performance under short circuit conditions
Fuse bridges and bases shall be of non-hygroscopic insulant suitable for the reception of HRC
fuses.
All HRC fuse links shall be fitted with a device to indicate a blown element and be labelled to
indicate the standard to which they are manufactured, their rating and category of duty.
The holder shall comprise a base with incoming and outgoing terminals and a with-drawable
carrier into which the HRC fuse link is fixed. A blown element shall be able to be identified
through the front of the carrier.
The holder and its connections shall be fully shrouded against accidental contact in all positions
of service and be labelled to indicate the current rating and category of duty.
Where indicated, fuse holders shall be fitted with means to enable them to be sealed to prevent
unauthorised interference.
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Section 18 Page 14
Time/current characteristics of all fuses shall be provided when requested by the CA.
18.9.3 Moulded case circuit breakers (MCCB)

Circuit breakers shall be moulded case all insulated pattern conforming to BS EN 60898, BS EN
60439 and BS 5486.
Details of tripping characteristics shall be provided for each type of MCCB. The details shall
include manufacturer's full current discrimination tables showing overload and short-circuit
discrimination.
Certificates shall be provided for each type of MCCB, stating the service and ultimate short-
circuit capacities.
Instantaneous trip settings for MCCB's of 200A and above shall be adjustable over the range
five to ten times rated current as a minimum unless indicated otherwise.
Thermal trip settings shall be adjustable over the range 80% to 100% as a minimum for all
MCCB ratings.
Terminals shall be sized to accommodate the size and type of cable for incoming and outgoing
circuits. MCCB's shall be provided complete with terminal shields.
As indicated, terminals shall be arranged for direct connection to busbars, front or rear as
required by the switchboard design.
All poles of multi-pole circuit-breakers shall be constructed so that contacts open, close and trip
simultaneously. It shall not be possible for one or more poles to be closed while another remains
open and vice-versa.
Operating mechanisms shall be quick-make, quick-break type having operation in which the
speed of operation of the breaker is independent of the operator. Operating mechanisms shall
be trip free such that it is not possible to close or hold in the contacts against a short circuit.
All hand-operated circuit-breakers shall be fitted with rotary action handles. The handles shall be
lockable in both open and closed positions.
Clear indication of the 'ON', 'OFF' and 'TRIPPED' conditions shall be provided not only by the
position of the handle but also by means of a coloured band, or line which shall be visible when
the circuit-breaker is on but not when it is off or tripped. The 'TRIPPED' condition shall be
indicated by the handle assuming a mid-point position between 'ON' and 'OFF'. It shall not be
possible to manually place the handle in the tripped position.
Indication shall be provided to confirm that all main contacts have separated.
Moulded case covers and non-interchangeable trip elements shall be permanently sealed at
works to prevent tampering, but the trip elements may be changed/adjusted and re-sealed on
site by using suitable tools.
All MCCB's shall be of the same manufacture and shall be of the same generic type.
Each pole shall provide inverse time over-current protection and high set instantaneous tripping,
all poles shall trip simultaneously if one detects a fault.
All trip units shall be replaceable.
Tripping mechanisms shall be selective limiting type to obtain discrimination.
All adjustable trips shall be visible and adjustable from the front with the breaker in position.
Adjustments to trip settings shall be made to all poles simultaneously by means of a common
adjustment mechanism.
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Section 18 Page 15
Where thermal trips are used they shall be ambient, temperature compensated, taking account
of the temperature inside the enclosure under continuous full load conditions.
18.9.4 Contactors
Contactors shall be of the air break type. They shall be rated for continuous duty, shall be
category ACS and have a no-load operating cycle of 1 million operations.
All contactors shall be of the block type. Contacts shall be of the self-cleaning type and easily
renewable. The design shall be such as to prevent welding in.
All operating coils of contactors shall be able to operate on the appropriate control system
voltage of the low voltage switchgear.
Each contactor shall be so screened from adjacent units and current carrying parts that it is
possible to carry out maintenance work in complete safety, while other equipment in the panel
remains alive on load.
Means of isolation shall be provided to isolate all primary and secondary circuits to contactors,
but means shall be provided to temporarily reinstate interlocks or other circuit interconnections
with equipment which is required in service whilst the contactor is isolated.
If the fault level for the main low voltage switchgear is higher than that specified for the making
and breaking conditions in the British Standard for co-ordination of short circuit protective
devices and contactors, the manufacturer shall indicate the method and characteristics of
achieving co-ordination.
18.9.5 Miniature circuit breakers

Miniature circuit breakers shall be fixed by means of a screw to provide connection to a busbar
and a sliding catch to enable ease of fixing and replacement. The sub circuit connection shall be
means of a pillar terminal with a clamp tightened by a terminal screw. All live parts shall be
shrouded against accidental contact.
Miniature circuit breakers shall have trip-free mechanisms and be manually operated. It shall not
be possible to hold the contacts closed while a fault persists.
The main contacts shall be single break equipped with shrouds and arc control devices to
obviate the discharge of ionised gases during switching operations. The position of the main
contacts shall be indicated by the operating dolly.
All poles of multi-pole miniature circuit-breakers shall be constructed so that contacts open,
close and trip simultaneously. It shall not be possible for one or more poles to be closed while
another remains open and vice-versa.
The fault rating of the miniature circuit breaker shall be in excess of the prospective short circuit
current and fault duration that may occur with a short circuit across the outgoing terminals at the
point of installation. The short circuit performance of the miniature circuit breaker shall have
been proven by means of tests and certification by a recognised short circuit testing authority.
The protection elements shall include thermal or dashpot operated overload and magnetic short
circuit trips.
All overload elements shall be temperature compensated relative to ambient temperature to

ensure the correct time/current characteristics are maintained through the range of ambient
temperatures that may be experienced in service.
All miniature circuit breakers shall be labelled to indicate the standard to which they are
manufactured their rating and category of duty.
The range of miniature circuit breakers selected shall incorporate a range of accessories that
may be used in conjunction with the miniature circuit breakers to provide additional sub circuit
Part 5
Section 18 Page 16
control. These accessories may provide such features as no-volt detection and switching,
toggling relays, timers etc.
18.9.6 Fuses of plugs and spur units

Fuses for plugs and spur units shall be rated appropriate to the rating of the cable connecting
the equipment being served or the rating of the equipment being served which ever is the
smaller.
18.10 EARTHING AND BONDING
18.10.1 General
Bond in accordance with BS 7430 and BS 7671 to main earth terminal all extraneous conductive
parts of the installation.
Copper earthing leads, bonding leads and circuit protective conductors, shall be sized in
accordance with BS 7671.
Every circuit protective and bonding conductor, other than copper tape or where contained in a
composite cable or flexible cord, shall be protected by LSF or heat resisting insulation as
applicable and shall be identified as required by BS 7671.
Copper earthing or bonding tape run under floors, in ducts or damp locations shall be LSF
sheathed.
All copper earthing tapes shall be fixed by means of a single hole fixing gunmetal type saddle of
the correct size to hold the tape firmly at intervals not greater than 600mm unless otherwise
indicated.
The bonding connections to any gas or water services shall be made as near as practicable to
the point of entry of those services into the building. For insulated services the connection shall
be made to the metalwork on the building premises side of the insulated section. The
connections shall be made with the appropriate pipe clamps and precautions taken to avoid
damage to the pipework.
The earth continuity of metal conduits, metal trunking and metal sheathing or armouring of
cables shall be maintained by efficient bonding. This shall be provided between the conduit,
trunking, cable sheath or armouring, and gland and the metal case of the main switch fuse,
distribution board or other metal clad accessory or appliance at which they terminate.
All metal-clad fittings, accessories, enclosures and metal clad tray shall be sufficiently earthed.
Each conduit installation shall be electrically continuous throughout, forming completely bonded
systems.
Every complete final circuit earth loop impedance comprising conduits, cable sheaths, core
conductors and transformer windings shall be tested.
18.10.2 Methods of earthing

Any metal work that is exposed in an electrical system including exposed metal work in fittings,
must be connected to earth in such a manner as will ensure at all times an immediate discharge
of electrical energy without endangering any personnel or equipment. Earthing shall be in
accordance with BS 7671 and BS 7430. Where these standards differ then the former shall
take precedence.
All exposed or extraneous metal work shall be connected to earth via one or more of the
following methods:
The metallic sheath of the supply cables

An earth continuity conductor carried in the cable
Metallic conduit, trunking or duct containing the wiring
Part 5
Section 18 Page 17
A special conductor or tape run to a suitable earth point
A separate earth wire enclosed in conduit or trunking
18.10.3 Electrical bonding

The electrical continuity of mechanical services ductwork, pipework and equipment together with
drains and vertical stacks shall be ensured by bonding to provide an equipotential with any
simultaneously accessible conductive parts.
The bonding and testing of all equipment within the scope of the mechanical services works
shall be carried out. Tests shall be completed during construction to ensure that where
supplementary bonding conductors are required they shall be installed within the construction
programme and without the need to disturb finishes.
Tests shall verify that any voltages that may occur during fault conditions between items of
mechanical services systems are of such magnitude and duration as not to cause danger.
The connection of mechanical services systems and equipment to the system earth shall be
carried out such that it is required to bond a system to earth at only one point.
Use clamps to BS 951 for bonding of pipes
On completion of the installation, tests shall be completed by the mechanical services installer
to verify compliance with this clause.
Check earth continuity conductors and loop impedance values of existing installation. Report
defects and elements not in accordance with BS 7671 before connecting new or modified
installations to existing supply
18.10.4 Testing
fittings, complying with the latest edition of the IEE Wiring Regulations 16th Edition with
amendments ruling at the date of tender.
All tests shall be made in the presence of the CA who shall have been duly notified of the
installers intentions. The CA will require triplicate copies of test certificates covering all tests
carried out on the completed installation.
The mechanical services installer shall carry out a visual inspection of the installation on
completion.
Further tests shall be undertaken at the end of the defects liability period and all faults found at
the final test not due to fair wear and tear shall be rectified at no cost to the contract.


BS EN 50086 Specification for conduit systems for cable management
BS EN 60423 Conduits for electrical purposes. Outside diameters of conduits for
electrical installations and threads for conduits and fittings
BS EN 50085 Cable trunking and cable ducting systems for electrical installations
BS EN 60529 Specification for degrees of protection provided by enclosures (IP code)
BS 7430 Code of practice for earthing
BS EN 50310 Application of equipotential bonding and earthing in buildings with
information technology equipment
Part 5
Section 18 Page 18
BS 951 Electrical earthing. Clamps for earthing and bonding. Specification.
BS EN 60898 Circuit breakers for over-current protection for household and similar
installations. Circuit breakers for A.C and D.C operation
BS EN 60439 Specification for low voltage switchgear and control-gear assemblies.
BS 5486 Low-voltage switchgear and control-gear assemblies. Specification for
particular requirements of fuseboards
BS 6207 Mineral insulated cables with a rated voltage not exceeding 750 V. Guide
to use.
Part 5
Section 18 Page 19
Section 19 Gas
Contents
Section 19 Gas 1

19.2 Pipes Fittings And Valves 3
19.3 Gas Shut Off Valves 4
19.4 LPG Tanks 5
19.5 Performance and Design Requirements 5
19.6 Gas Control Panel With Built In UPS 6
19.7 LPG Gas Detectors 8
19.8 Testing and purging 8
Section 19 Gas
The installation, materials, workmanship and testing of gas mains and equipment shall be in
accordance with NFPA and the local Civil Defence requirements and regulations.
The scope of work shall include complete design, supply, installation, testing, commissioning,
and handing over of a complete and working LPG system, with Gas Detection System as per
the specification.
By virtue of carrying out complete the design, the Contractor is to assume full responsibility for
the correct functioning of the system and to carry any liability or other insurance or guarantee as
may be necessary to protect all parties in this regard.
The specialist Sub-Contractor shall be responsible for coordination with other trades and
services, and shall provide all materials, labour and supervision, equipment, tools, appliances,
services, etc. for carrying out the following items of work:
LPG storage tanks with all supports, valves and accessories.

LPG distribution pipe work with all valves, supports, controls, etc.
LPG regulation and metering devices.
LPG detection and alarm system.
Painting of all installed items within this section of the Contract.
Identification of all services.
Electrical power and control panels for power supply to equipment including cabling from
panels to respective equipment.
All builders work including breaking and making good of walls, floors, etc., equipment
foundation pads; sleeves; etc.
Hoisting of heavy equipment.
Gas pipework shall be installed only in a position in which it can be used with safety. It shall not
be installed in unventilated ducts, voids or cavity walls. Any external exposed pipework shall be
protected as necessary by a lightning conductor in accordance with current standards.
Where necessary the LPG pipe work may be routed through the building in shafts and ceiling
voids; all such instances the LPG carrier pipe must be enclosed fully in a gas tight protection
pipe (pipe in pipe.)
Pipework shall be cross bonded within the premises with other services in accordance with BS
7671, Electricity at Work Regulations and Gas Safety (Installation & Use) Regulations.
Separate bonding straps shall be fitted to any flexible coupling which does not incorporate a
continuity device. Similar bonding straps shall be fitted across any section of pipework likely to
be removed for maintenance or repair.
Where gas pipework may be subject to temperature change due consideration shall be given to
thermal expansion. Flexible tube, hoses or swivel joints shall not be used for this purpose.
Where connecting to structures which are designed to move, provision for the movement
expected shall be included in the pipework installation. When connecting to equipment which
may vibrate, suitable flexible connections should be fitted to ensure that strain cannot be
transmitted to the gas pipework. Swivel joints should be used for rotational isolation.
Vents from pressure regulators and other safety devices shall be of permanent construction and
be as straight and as short as possible being designed to avoid back pressure. They shall
terminate in a safe place in open air and shall be at least 5m from any possible source of
Part 5
Section 19 - Page 1
ignition and preferably above roof level. Vents from safety shut off systems may be manifolded
together, provided the cross sectional area of the manifold pipe is equal to or greater than the
sum of the cross sectional area of the two largest vents employed.
Any building or room containing a gas installation shall be ventilated to the required standard to
prevent the accumulation of gas from minor gas leaks.
Ducts or voids containing gas pipework shall be ventilated in accordance with specific
requirements of the Gas Safety (Installation and use) Regulations and necessary IGE
recommendations. Such pipework shall not contravene the local Civil Defence Regulations
particularly regarding protected shafts and fire safety requirements. Pipework shall not be
installed in un-ventilated ducts unless it is fully sleeved with one or both ends opening into a
safe area or where the duct is filled with an inert material (eg. washed sand). Gas pipework
shall not be routed through ductwork used for ventilation or within a ceiling void or plenum
forming part of a ventilation system..
Pipework and fittings liable to corrosion shall be protected by suitable coatings and/or sleeving
material. Where a tape wrapping is employed a 50% overlap shall be provided. Site applied
protection of joints should only be applied after testing is complete. Pipework shall be protected
in storage and during construction against corrosion and the ingress of foreign matter.
A gas supply line diagram shall be provided and located adjacent to the primary meter or the
emergency control valve for use in an emergency. Further copies shall be provided in other
relevant locations as determined by the CA. The line diagram shall be provided for any building
where the gas service pipe is 50mm or larger. The line diagram shall be not less than A4 and of
a durable manufacture. It shall indicate the position of all pipes of diameter not less than 25mm
nominal bore, emergency controls, valves, pressure test points, purge points, electrical bonding
and show the location of each gas emergency control valves unless otherwise indicated.
A notice shall be provided at or adjacent to the meter indicating the procedure to be followed in
the event of an escape of gas. The notice shall also be provided at the resetting point
associated with an automatic isolation valve, advising the resetting procedure to be adopted.
Care shall be taken to limit the quantity of foreign material, which may enter the system and is
required to be removed during subsequent flushing and cleaning procedures. All pipework shall
be inspected on delivery to ascertain cleanliness and be stored in a clean dry environment, with
ends covered. All pipework components shall be delivered in suitable protective packaging and
stored in clean covered bins, or bags, prior to use. Particular care shall be taken, when
materials are delivered to the workplace to avoid accidental ingress of material prior to
construction.
Tubes shall be free from burrs, rust, scale, dirt and obstructions before erection. All pipework
and components shall be inspected immediately prior to incorporation into the works and
cleaned where necessary. Millscale, rust, casting sand, swarf etc., shall be removed prior to
assembly. Open ends shall be temporarily capped as the work proceeds. Care shall be
exercised to limit the amount of excess material introduced by jointing methods employed, (i.e.
welding flash, cuttings, silver solder, jointing compounds etc.) and all excess removed as the
installation proceeds.
There shall be no pipeline joints within the thickness of walls or floors. Pipework shall not be
embedded in the structure. Where pipes pass through walls or floors a pipe sleeve shall be built
in, comprising a length of tube of the same material as the pipeline or other equivalent
proprietary purpose made sleeve. The sleeve shall be sufficient in length to finish not less than
3mm and not more than 12mm clear of the finished wall or floor. The sleeve shall be of internal
diameter at least 25mm greater than the OD of the pipe passing through. A greater clearance
may be necessary to accommodate expansion movement and insulation. Where necessary to
effect a noise or fire barrier the space between the pipeline and the sleeve shall be packed with
appropriate material. Pipes passing through external walls, floors and roofs shall be installed
with puddle flanges or sleeves as appropriate and sealed against water, vermin, dust and the
spread of fire.
Part 5
Section 19 - Page 2
No sleeving shall be used that will impair the fire resistance of the structure / fabric of the
building. In areas where floors are washed down, sleeves shall be installed with 100mm
protrusion above the floor finish and the joint between sleeve and floor sealed watertight
Pipework shall be protected from damage whilst being transported, stored, assembled and laid.
Care shall be taken in selecting the underground route for pipework to avoid stress, accidental
damage, contamination and planned future building development. Trenches shall allow for an
adequate depth of cover as detailed in the table below unless otherwise indicated. As dug
material may be re-used provided it is soft in nature. Where ground conditions expose sharp
stone etc the excavation shall be deepened to allow for a sand bed. These protective materials
shall surround the pipe with a minimum thickness of 100mm. The following 200mm of back fill
shall be stone free soil, etc, with the remainder of the back fill graded to avoid sharp objects
penetrating this soft layer. A tracer or marker tape shall be laid at a height of between 250 and
400mm above the crown of the pipe.
Minimum Depth of Cover
Up to 50mm Over 50mm

Location
(nominal bore) (nominal bore)
Roadway 600 750
Grass Verge 600 750
Paved path 600 600
All flexible hoses shall be installed in accordance with the hose manufacturers' instructions. A
manual valve shall be fitted on the inlet to any flexible hose, i.e. the upstream side of a tube or
hose and close to the end. The exception shall be if it is equipped with a self sealing quick
release coupling. All tubes and hoses shall have a minimum operating pressure rating of 350
mbar or three times the operating pressure if greater; at the highest temperature for the
application, unless otherwise stated. Tubes and hoses shall be installed such that movement
takes place in one plane only and torsion or twist strains are avoided.
All pipework shall be identified as stated elsewhere.
Underground valves, siphons or purge points shall be located by a marker plate above ground.
This shall be 150 x 150mm and contain a large letter 'G' with a small letter 'V' (to identify a
valve), 'S' (to identify a siphon) or a 'P' (to identify a purge point) set within the 'G'. A number
adjacent to the 'V', 'S' or 'P' shall indicate the distance in metres from the plate to the valve etc.
location.
19.2 PIPES FITTINGS AND VALVES

This section includes basic design provisions and material specifications for pipe, tubing, pipe
and tubing fittings, valves used to connect container appurtenances with the balance of the LP
Gas system.
LPG filling line shall be seamless carbon steel to API 5L grade B, schedule 80 (suitable for
working pressure up to 30 bar).
Distribution pipe work shall be seamless carbon steel to API 5L grade B, schedule 40
Copper to BS 2871, Table-X., with final connections to equipment in soft copper tubes to BS
2871, Table-X
Pipe joints in steel, brass or copper pipe shall be welded or brazed.
Fittings used with liquid LP Gas or with vapor LP Gas at operating pressures over 125 psig (0.9
MPa gauge) shall be suitable for a working pressure of at least 250 psig (1.7 MPa gauge).
Fittings for use with vapor LP Gas at pressure not exceeding 125 psig (0.9 MPa gauge) shall be
suitable for a working pressure of 125 psig (0.9 MPa gauge).
Part 5
Section 19 - Page 3
Soldering or brazing fills material shall have a melting point exceeding 1,000 F (538 C).
Valves, Other than Container Valves
Pressure containing metal parts of valves (except appliance valves) including manual positive
shut-off valves, excess-flow valves (either manually or automatically operated) used in piping
systems shall be of steel, ductile (nodular) iron, malleable iron or brass. Ductile iron shall meet
the requirements of ANSI/ASTM A 395 or equivalent and malleable iron the requirements of
ANSI/ASTM A 47 or equivalent.
All materials used including valve seat discs, packing, seals and diaphragms shall be resistant
to the action of LP Gas under service conditions.
Valves shall be suitable for the appropriate working pressure as follows:
Valves to be used with liquid LP Gas or with vapour LP Gas at pressures in excess of 125psig
(0.9 MPa gauge), but not to exceed 250 psig (1.7 MPa gauge), shall be suitable for a working
pressure of at least 250 psig (1.7 MPa gauge).
Valves (except appliance valves) to be used with vapour LP Gas at pressures not exceed 125
psig (0.9 MPa gauge) shall be suitable for a working pressure of at least 125 psig (0.9 MPa
gauge).
Valves. Other than Container Valves
Manual shut-off valves, excess-flow check valves and back-flow check valves used in piping
systems shall comply with the provisions for container valves.
Emergency shut-off valves shall be approved and incorporate all of the following means of
closing:
Automatic shut-off through thermal (fire) actuation. When fusible elements are used, they shall
have a melting point not exceeding 250 F (121 C).
19.3 GAS SHUT OFF VALVES

The incoming gas supply shall be complete with emergency shut-off valves as indicated.
The valve shall be located as near as possible to the point of gas service entry into the building.
All valves provided for emergency control shall be fire rated and located so as to be readily
accessible and marked clearly as a Gas Emergency Control.
A solenoid gas shut-off valve, as detailed elsewhere, shall be installed on the incoming gas
supply. The valve shall shut automatically under the following conditions as indicated and be
manually reset:
Gas detected by gas detection sensors in plantrooms or gas meter rooms

Fire detected by electro-thermal links mounted above gas fired plant
Activation of emergency push-buttons located at plantroom exits
Fire alarm activation
Where indicated a solenoid operated gas shut-off valve shall be installed on the incoming gas
supply in plantrooms containing gas fired equipment and be controlled by the fire alarm or gas
detection system as indicated.
Dead weight type fire valves shall be installed on the incoming gas main as indicated. The fire
valve shall be controlled by lock-off push buttons (key re-set), electro-thermal links to each gas
boiler and the fire alarm system as indicated. The valve shall have automatic shut-off on receipt
of a signal from any of the above and be manual re-set.
Part 5
Section 19 - Page 4
Provisions shall be included to allow for testing of the fire alarm system without activating
emergency gas shut off valves.
19.4 LPG TANKS

Basic materials for the steel LPG tanks shall be as follows:
Steel
Shell and plate ASTM A285M, Grade B
Shapes ASTM A36M
Pipe nozzles ASTM A53, Schedule 40, steel pipe
Flanges Standard weight, ANSI B16.5, Class 150, flat faced.
The construction of the LPG tanks must be in accordance with the local Civil Defence
requirements.
19.5 PERFORMANCE AND DESIGN REQUIREMENTS

The LPG tank shall be of the horizontal cylinder type with dished heads and shall be supported
on saddles on concrete bases as specified herein and as indicated on the drawings. The LPG
tank shall be vented and provided with overfill prevention device, overflow fittings, release valve,
feed valves, expansion relief valves, pressure gages, liquid gages and safety valves and will be
used to store LPG gas under pressure. LPG tanks shall be provided with opening for drainage
and cleanout. LPG tank shall conform to the requirements to UL 142.
Portable type LPG tank shall be fabricated in accordance with SSA 61 and tested in accordance
with SSA 62.
The LPG tank capacity and dimension shall be as indicated on the drawing.
Valves for LPG tank shall be in accordance with SSA 119 and tested in accordance with SS
118.
Low pressure regulators for valves of LPG tank shall be in accordance with SSA 121 and tested
in accordance with SSA 120.
Liquefied petroleum gases for household use shall be in accordance with SSA 84 and tested in
accordance with SSA 85.
The welded tank shall be fabricated of steel plate shall be shop fabricated using continuous butt
welded joints.
Nozzles shall be provided in the tank as specified herein with other required accessories.
Nozzles may be fabricated of Schedule 40 steel pipe welded to the LPG tank plates.
Supporting saddles shall be provided with the spacing recommended by the manufacturer.
The saddles shall be fabricated of carbon steel as a part of the LPG tank structure. Saddles
shall be of the size and design required to adequately support the LPG tank and shall have
provisions for anchoring to the concrete base.
Welding fillets shall have full penetration, good fusion, with smooth appearance and shall show
no cracks or undercutting.
Ferrous metal surfaces of welded steel shall be cleaned to remove all projections, weld flush or
splutter. Sharp projections of cut or sheared edges shall be ground to a radius to remove paint
adherence. The use of chipping tools in a manner that produces cuts, burns or other excessive
roughness will not be permitted. Exposed seams at saddles or accessories shall be filled with
Part 5
Section 19 - Page 5
metal filler, finished smooth and cleaned as required to provide a smooth uniform base for
painting.
All ferrous metal surfaces, except stainless steel shall be blast cleaned in the shop in
accordance with the paint manufacturers recommendations. All mill scale, rust and
contaminants shall be completely removed before shop coating is applied.
All ferrous metal surfaces, except stainless steel shall be shop primed and painted an epoxy-
polyamide coating system consisting of a primer, intermediate and topcoat.
Accessories shall include a stainless steel certification plate shall be installed on the side of the
storage LPG tank. At least the following data shall be included on the certification plate.
Name of LPG tank manufacturer

Date of manufacture
Mechanical properties of the structure
Allowable pressure rated
The LPG tank shall be provided with a nameplate to identify the product stored and to warn of
danger of fire.
Provide fixed maximum liquid level gages and variable liquid level gages, one of each per LPG
tank. The fixed maximum liquid level gage shall be provided next to permanent marking on the
LPG tank showing the percentage full that is indicated by that gage. The variable liquid gage
shall be of the slip tube, rotary tube or float tube. The variable liquid gage shall allow for readily
determination of the maximum liquid level in mm or percentage range from empty to full. Gages
that require bleeding of vapors to the atmosphere shall have maximum opening of the bleed
valve no larger than No. 54 drill size.
Provide inert gas-filled temperature gages with range 0oC to 65oC with 1% accuracy and 100
mm diameter dial. Provide ANSI 304 stainless steel cases, copper capillaries and bulbs and
polycarbonate lens.
Provide dry, ASME/ANSI Grade 1A pressure gages, dry type with range 0-700 kPa, 100 mm
diameter dial, ANSI Type 304 stainless steel, copper alloy bourbon, polycarbonate lens.
The concrete bases for the LPG tanks shall be constructed in accordance with the requirements
of the CA, Cast-in-Place Concrete and shall be level and smooth to the tolerances permitted by
the LPG tank manufacturer. The LPG tanks shall be installed in accordance with the
manufacturers recommendations and to the satisfaction of the CA and made ready for the
installation of piping and other appurtenances as indicated on the drawings and specified under
other sections.
Before shipment to the site, the LPG tank shall be shop pressure tested at 1733 kPa air
pressure for one hour and checked for leaks, using a soap solution at all connections and welds.
During testing, connections may be plugged by the installation of temporary blind flanges and
plugs on the outside of the LPG tank. Any leaks or indications of leaks in the LPG tank or
accessory connections shall be repaired by the manufacturer and made completely airtight.
When installation has been completed and all connections have been made, all LPG tank
surfaces, interior and exterior shall be thoroughly cleaned as recommended by the manufacturer
and to the satisfaction of the CA. Abrasive cleaning agents shall not be used.
19.6 GAS CONTROL PANEL WITH BUILT IN UPS

The LP Gas Control panel shall be located in a secure area and be easily accessible in an
emergency.
It shall have a modular design incorporating the input alarm/display for each gas detector.
Each channel shall have an indication for Low Alarm (15% LEL), High Alarm (30% LEL) and
Fault.
Part 5
Section 19 - Page 6
The Main gas supply shall be shut off at 30% LEL.
The system control unit located below the gas control panel and within the same enclosure shall
have the following indications:
AC healthy
DC healthy
Sprinkler on
Gas pressure low
Gas pressure high
Gas valve on
Gas leak
Fire
The panel shall have the following switches:
Sprinkler manually on
Gas manually shut off
Test
Reset
The LEDs on the front panel shall indicate the respective operating status as well as alarms and
faults. The relays shall trigger external devices and transmit information to the BMS.
The relays shall have potential free change over contacts for 240V. This relay can be reset while
gas concentration prevails. The relays operate as follows:
Open circuit: Alarm 1, Alarm 2 and the buzzer relays shall activate as soon as the
respective status is recognized.
Closed circuit: The fault relay shall activate during undisturbed operation, i.e. the relay
is deactivated in case of fault or power failure.
Gas Detectors shall use a pellistor sensor to detect flammable gases and vapours. The sensors
shall be housed in a stainless steel explosion proof housing for the tank area and dust proof for
the other areas.
A sounder cum flasher shall be installed in the vicinity of the gas leak detection panel and
located in a visible area.
MICC or FP 200 cables of at least 1.5 sq. mm shall be used between each gas detector head
and the control panel.
The control unit receives and evaluates the signals from the transmitters in different operating
modes.
Measurements are effected through short averaging. Dangerous gas concentrations shall lead
to Alarm status and malfunctions or exceeding the measuring range should lead to Fault status.
When the detector head senses any gas leak in any zone an indication shall appear on the
control panel.
Standard setting for combustible gases is 15% and 30% LEL (lower explosive limit). Each
transmitter shall have 2 Alarm levels which can be set via external software as follows:
At 15% the green LED for Alarm-1 shall light up and the relay activated. Alarm-1 shall reset
automatically when gas concentration falls below the preset levels.
At 30% the red LED for Alarm-2 shall light up and the relay activated. Alarm-2 shall latch and
shall be manually reset only when gas concentration falls below the preset levels.
Part 5
Section 19 - Page 7
The internal audible indicator and buzzer relays for external alarm signals shall trigger when
Alarm-2 is reached. These should also be latch able and triggered when Alarm- 2 is reached
but can be reset even while the gas concentration prevails.
Malfunction shall be indicated by a fault LED. The control unit should be able to detect and
evaluate faults such as:
Inadequate measuring signal e.g. break in line to transmitter.

Short circuit of line to the transmitter.
Defective sensor element inside the transmitter.
When the measuring range exceeds 100% LEL e.g. due to gas concentration.
After a power failure the alarm signals shall not be accessible for 60 seconds to enable the
transmitter to pick up normal operation thus not activating any false alarms.
When the system is normal the green LED along with the Power on LED shall light up.
The control panel activates the system when the gas concentration reaches Alarm-2 limit, a
signal from the fire alarm panel or the manual operation of the system by the Emergency stop
push button key switch. The system shall continue to operate until the manually operated.
Should the gas line operating pressure drop below the pre-set limit, the pressure switch shall
close the gas solenoid valve automatically.
The sprinkler system shall also be manually operable by the insertion of a special key.
When the test button is activated, all LEDs shall light up and the relays activated. The audible
alarm signal and relay for external alarm are triggered for 2 seconds. On resetting, the unit shall
revert to normal operation.
The gas control panel must be constructed in accordance with Dubai Civil Defence
Requirements and be UL/FM listed.
It is to be complete with built in UPS, solenoid valve assembly, over voltage and over current
protection.
19.7 LPG GAS DETECTORS

Gas Detectors shall have a catalytic sensor for LPG Detection.
Microprocessor based flammable gas detector with auto zeroing procedure and test push
button. It employs a catalytic sensor calibrated to LPG with pre-alarm set at 5% LEL and alarm
threshold set at 10% LEL, audible alarm and output relay. Power supply 12 VDC.
19.8 TESTING AND PURGING

Comply with:
IGE/UP/1 Strength and tightness testing and direct purging of industrial and commercial
natural gas installations
IGE/UP/1A Strength and tightness testing and direct purging of small low pressure industrial
and commercial natural gas installations
BS EN 12327 Gas supply systems. Pressure testing, commissioning and decommissioning
procedures. Functional requirements
These procedures require that new installations are tested on completion. Purging and re-tested
before the insertion of fuel gas.
On existing installations the original pipework shall be tested prior to undertaking any work on
that pipework. Test points shall be fitted at the outlet of any section or plant isolation valve. For
operating pressures up to 350mbar a brass pressure test nipple to BS 4161 may be used. For
higher operating pressures a small bore valve suitably blanked or capped shall be installed.
Part 5
Section 19 - Page 8
Testing and purging of gas pipelines shall be undertaken by qualified and experienced
personnel.
Certificates of strength and tightness testing and direct purging to IGE/UP/1 and IGE/UP/1A
shall be submitted to the CA.
Gas pipelines shall be purged from downstream of the primary meter. Purging of the supply
service pipe and the primary meter shall be carried out by the gas supplier.
Care shall be taken to ensure that no foreign materials are introduced into the system when
filling for test purposes. The fuel source shall be confirmed clean by sampling prior to filling.
Where doubt exists, an alternative source may be required and or an in-line filter installed.

BS 6400 Specification for installation of domestic sized gas meter maximum

rated capacity not exceeding 6m/h (2nd and 3rd family gases). Low
pressure (2nd family gases)
BS 6644 Specification for installation of gas fired hot water boilers of rated
inputs between 70 kW (net) and 1.8 MW (net) (2nd and 3rd family
gases)
BS 6173 Specification for installation of gas-fired catering appliances for use
in all types of catering establishments (2 nd and 3rd family gases)
IGE/UP/1 Strength and tightness testing and direct purging of industrial and
commercial natural gas installations
IGE/UP/1A Strength and tightness testing and direct purging of small low
pressure industrial and commercial natural gas installations
IGE/UP/2 Installation pipework, boosters and compressors
BS EN 12327 Gas supply systems. Pressure testing, commissioning and
decommissioning procedures. Functional requirements
Part 5
Section 19 - Page 9
Section 20 Water Storage
Contents
Section 20 Water Storage 1

20.2 Thermal insulation 2
20.3 Concrete Tanks 2
20.4 One Piece Tanks 2
20.5 Sectional tanks 2
20.6 Level Sensors 3
20.7 Tank Foundations 4
20.8 Tank mountings 4
20.9 Cleaning 4
20.10 Testing 5
Section 20 Water Storage
Cold water storage tanks shall be the type and capacity as indicated.
Tanks shall comply with the requirements of the local municipality, and be fit for purpose for the
storage of cold water for domestic purposes.
Tanks and connections shall comply with:
Municipality Regulations
Water Authority Regulations
CIBSE TM13 Minimising risk of legionnaires disease
HSE L8 Legionnaires disease Control of legionella bacteria in water systems Approved
Code of Practice
BS EN 806
Cistern and tank connections shall be located to ensure adequate circulation of the contents
with outlets from the bottom of the tank, wherever practical. Adequate support shall be provided
to all tank connections, pipe fittings and valves to prevent excessive strain being imposed on the
tank or cistern.
Tanks shall be stored and installed in accordance with manufacturers recommendations.
Ensure adequate protection from damage and ingress of foreign matter to tanks and cisterns
during, storage, erection and commissioning. Tanks and cisterns shall be thoroughly cleaned
prior to testing and commissioning.
The internal surfaces of tanks and cisterns and their covers shall be free from such
imperfections that may inhibit the cleaning of these internal surfaces.
Tanks and cisterns shall be installed to allow internal and external surfaces to be easily
inspected and cleaned.
One-piece and sectional cold water storage tanks shall be in accordance with BS EN 13280 for
the designated class indicated.
Class A one piece cistern or sectional tank for portable water storage
Class B one piece cistern or sectional tank for use in the storing of cold non- portable
water
All tanks and cisterns shall be clearly and durably marked by a waterproof adhesive label with
the information as required by BS EN 13280.
One-piece cistern and sectional tanks shall be provided with a screened air inlet to allow the
escape of air and preserve the integrity of the stored water. The air inlet shall have a screen
with apertures not exceeding 0.65 mm x 0.65 mm intended to prevent the ingress of insects and
particles. The inlet shall be shrouded to alleviate the entry of dust and light, and prevent the
entry of rainwater. The screens shall be non-corrosive material and easily removable for
inspection and cleaning.
A fixing, connection provision or other device shall be provided to allow entry of a vent pipe
through the cover. Such a device shall prevent any displacement or distortion of the cistern of
tank or associate cover due to expansion or other movement of the vent pipe.
Part 5
Section 20 Page 1
Warning pipes and/or overflow pipes shall be provided with a termination assembly for fitting
through the side wall of the one-piece cistern or sectional tank which incorporates a free
draining external watertight housing containing a screen for fitting to the warning pipe. The
screen shall have apertures not exceeding 0.65 mm x 0.65 mm, shall not restrict the full flow
and shall be easily removable for inspection and cleaning.
20.2 THERMAL INSULATION

Unless otherwise indicated tanks shall be thermally insulated to protect against freezing and
against heat gain which would cause the content to rise to a temperature of 26 C or greater.
Insulation materials shall be incorporated as to protect them from the ingress of moisture,
insects or vermin, including those points where connections are made. The materials shall not
contain substances that will support pests or encourage the growth of fungi.
Refer to the thermal insulation section of this specification.
20.3 CONCRETE TANKS

Above or below ground concrete water storage tanks shall be reinforced concrete construction
and shall be of the capacity and dimensions as indicated in the drawings. They shall comply
with the relevant standards of the local authority of jurisdiction.
Tanks shall be complete with the following:
600x600 openings with sealed manhole cover for each valve / accessory.
Manholes with double sealed manhole covers.
Internal stainless steel ladders.
Inlets, outlets, over flows, drains and insect proof vent cowls as required on Drawings.
High and low level controllers, level sensors, level switches and alarms all linked to the BMS.
Internal GRP lining or cementicious waterproof lining to the requirements of the local
authority of jurisdiction and shall be fully potable guaranteed for 25 years.
With watertight hinged cover and locking device.
Necessary perforations (including puddle flanges where required) for the inlet and outlet pipes
shall be provided. Each storage tank shall be equipped with overflow, warning pipes, and vent
pipes, and drain sumps (located directly below the manhole).
20.4 ONE PIECE TANKS

Tanks shall be provided with close fitting lids complying with the Water Regulations. Tanks
holding more than 1000 litres shall be provided with two part lids.
Tanks and lids shall be pre-insulated unless otherwise indicated.
20.5 SECTIONAL TANKS

The tank shall consist of base and side plates all constructed from flanged GRP panels with a
jointing sealant or gasket between. The flanges of all panels shall be internal or external as
indicated.
Where indicated tanks shall be subdivided into two or more compartments by the inclusion of
division plates constructed from GRP sheet panels. Division plates shall be sealed leak tight
and be capable of supporting water on either side to the maximum working depth.
Baffle plates and/or weir plates shall be fitted as indicated. They shall be constructed to
withstand only the additional forces created by the water movement they are designed to
induce, and in the case of weir plates, to withstand any additional force due to any imbalance in
water pressure created by their use.
Internal metallic bracing system members shall be manufactured from stainless steel in
accordance with grade 1.4401 or other appropriate steel selected from Table 3 of EN 1008-3.
Part 5
Section 20 Page 2
External structural supports shall be manufactured from either mild steel encapsulated in GRP
laminate or suitably protected from corrosion or galvanised or from stainless steel. The design
of bracing shall minimise the possibility of bimetallic corrosion.
Fasteners, including bolts, nuts and washers, used outside the tank shall be stainless steel.
Tanks shall be provided with internal and external ladders manufactured to satisfy dimensional
and safety requirements of BS 4211. Internal ladders shall be manufactured from stainless and
external ladders galvanised steel unless otherwise stated.
Tanks shall be provided with a rigid and close fitting cover. The cover shall have a gap of less
0.65 mm and shall be secured or mechanically fixed with an effective seal to ensure the
exclusion of light and the ingress of particles and/or insects and where connections pass
through the cover they shall be sealed. All covers shall be capable of sustaining an imposed
load of 0.6 kN/m or 0.9 kN concentrated load, whichever produces the maximum deflection.
Manholes or access hatches of at least 600mm diameter or side dimension shall be provided in
sectional tanks greater than 1000 litres and designed to prevent the ingress of rainwater, where
external, dust and vermin. Each compartment of the tank shall have one manhole located over
the ball float valve and one to gain access to an internal stainless steel ladder where indicated.
Base panels shall be designed to cope with downward force of a fluctuating static head. Side
panels shall be designed to withstand fluctuating loads applied with rising and falling water
levels. Roof panels shall be manufactured to take the specific point loads exerted by man-traffic.
Purpose designed automated drilling equipment shall be used to accurately drill panel to close
manufacturing tolerances ensuring correct alignment of bolt holes, and to ensure proper joining
and sealing panels. Panel sizes shall be 1.0 x 1.0 metre.
Sectional tanks shall be erected by the tank manufacturer.
20.6 LEVEL SENSORS

All level controllers, level sensors, level switches and alarms shall be provided and installed by
the Contractor.
Each probe shall be of the correct length for its particular application and tank location.
Electrodes shall be polished stainless steel 20mm outside diameter. Electrode holders shall be
weather proof in all respect.
The earthing probes shall be connected and wired to the building earth system.
Each set of electrodes shall be installed inside a 200mm-diameter PVC pipe acting as a wave
barrier.
The level switch set shall be operated with a stepped down voltage at 24V maximum. Stepped
down transformer shall be provided for each set of control probes and shall be installed inside
centralized control cubicles inside pump room.
Provide interface unit at the pump control panel for the levels to be monitored by BMS (refer to
drawing).
The BMS control panel will monitor the following outputs from the location for each Tank.
BMS Tank High Level (O/P)
Whenever the liquid level in the tank reaches a high level, a high level dry contact will be
provided by the contractor at the level controller and monitored by the BMS.
BMS Tank Low Level (O/P)
Part 5
Section 20 Page 3
Whenever the liquid level in the tank reaches a low level, a low level dry contact will be provided
by the contractor at the level controller and monitored by the BMS.
BMS Level Sensing (O/P)
The BMS will monitor the level of liquid in specified tanks via a level sensor provided by the
Contractor. All level controllers will provide a 4-20mA signal to the Contractor. This shall indicate
the volume of water in the tank, directly readable from the BMS head end.
20.7 TANK FOUNDATIONS

The surface of the foundation, whether it is a flat screed concrete, steelwork, support walls or
pillars, shall be flat, level and free from any irregularities. It should not vary more than 2 mm in
any 1mm, or a total of 6 mm in any 6 m, measured laterally or diagonally. Intermittent supports
shall be spaced in accordance with the manufacturers instructions and should continue in one
direction.
Both continuous and discontinuous foundations shall conform to any additional requirements
provided by the manufacturer arising from the design of the cistern or tank.
Install water storage tanks according to manufacturers written instructions and standards
specified.
Excavate to sufficient depth for a minimum of 3 feet (1 m) of earth cover from top of tank to
grade. Allow for cast-in-place, concrete ballast pad, plus 6 inches (150 mm) of sand or pea
gravel between ballast base and tank.
Extend excavation 1 foot (300 mm) around perimeter of tank.
Set tie down eyelets for hold down straps in concrete ballast pad and tie to reinforced steel.
Place 6 inches (150 mm) of clean sand or pea gravel on top of ballast pad.
Set tank on fill materials, install hold down straps, and install pipe connections.
Backfill excavation with clean sand or pea gravel. Tamp back fill to consolidate.
Install filter mat between top of backfill and or pea gravel and earth fill.
The installer shall ensure the tank foundation meets the necessary requirements before the
installation of the tank or cistern.
20.8 TANK MOUNTINGS

Water level indicators shall be provided for each tank compartment to provide visual indication
of the stored water level. Water level indicators shall comprise dial gauges and sensors locally
mounted. Where a BMS system is provided the gauges shall be capable of providing a content
indication to the BMS as indicated. Gauge manufacturers shall be WRAS approved.
Overflow, warning pipes, drains, inlet pipes and balance pipes shall be as indicated and in
accordance with the Water Supply Regulations.
20.9 CLEANING
Disinfect all potable water tanks including concrete water tanks according to the following
method:
A solution of 200-mg/L available chlorine shall be applied directly to the surfaces of all parts of
the storage facility that would be in contact with water when the storage facility is full to the
overflow elevation.
Part 5
Section 20 Page 4
The chorine solution may be applied with suitable brushes or spray equipment. The solution
shall thoroughly coat all surfaces to be treated, including the inlet and outlet piping, and shall be
applied to any separate drain piping such that it will have available chlorine of not less than 10
mg/L when filled with water. Overflow piping need not be disinfected.
The disinfected surfaces shall remain in contact with the strong chlorine solution for at least 30-
min. after which potable water shall be admitted, the drain piping shall be purged of the 10-mg/L
chlorinated water, and the storage facility shall then be filled to its overflow level. Following this
procedure, and subject to satisfactory bacteriological testing and acceptable aesthetic quality,
water may be delivered to the distribution system.
20.10 TESTING
Tanks and cisterns shall be subjected to the tests defined in BS EN 13280.
Leakage tests shall be undertaken on all tanks and cisterns.
When erected a tank shall not show any visible leakage after filling in accordance with the
manufacturers recommendations. The duration of the test shall be for a minimum of 24 hours,
commencing at least 2 hours after the tank has been filled. The test shall be carried out within
10 days of erection unless otherwise stated.
One-piece cistern - The cistern shall be mounted on a flat, level base and filled with water at a
temperature of 5C to 25C to the test water line. Inspection for leaks shall be undertaken after
48 hours.

BS EN 13280 Specification for glass fibre reinforced cisterns of one piece and
sectional construction, for the storage, above ground, of cold water
Specifications for installations inside buildings conveying water for
BS EN 806
human consumption.
BS 4211 Specification for permanently fixed ladders
Part 5
Section 20 Page 5
Section 21 Foul Drainage (Above ground)
Contents
Section 21 Foul Drainage (above ground) 1

21.2 Pipe work protection 2
21.3 Branch soil and waste pipes 2
21.4 Soil and waste traps 3
21.5 Connections to underground services 3
21.6 Pipe work Supports 4
21.7 Soil, waste and vent pipe roof termination 6
21.8 Fire Stopping 6
21.9 Sleeves 7
21.10 Acoustic Insulation 7
21.11 Drainage Sump Pumps 8
Section 21 Foul Drainage (above ground)
The sanitation systems shall be installed to comply with the requirements of BS EN 12056-1 and
BS EN 12056-2 as well as the specific requirements of this specification.
The completed installation shall ensure compliance with the Local Municipality Regulations and
recommendations.
The system shall be installed to effectively convey discharges quickly, quietly and effectively
without nuisance or risk to health. It is essential that foul air is prevented from entering the
building during operation of the system.
Falls and slopes of branch soil and waste pipes shall be to the requirements of BS EN 12056-2.
Ventilation and anti-siphonage pipework shall be installed to be self draining in its entirety.
Pipes shall be installed true to line and to a consistent gradient. All vertical drainage pipework
shall be perpendicular and branches and changes in direction adequately supported.
Obtain all components for all types of pipework from the same manufacturer unless stated
otherwise.
No offsets shall be included in the vertical stacks except where indicated or will occur in the
ventilating section of the stack. The requirement for additional offsets shall be agreed with the
CA.
Access for cleaning and rodding pipes shall be provided to ensure that all parts of the systems
are accessible for such purposes.
As a minimum, an access point shall be provided on each vertical stack at each storey level
(above the highest spill over level of the connected fittings), at changes of direction and
junctions on suspended pipework, and at the upstream end of horizontal branch soil and waste
pipes.
All branch connections to horizontal runs at high level shall be made using 45 degree branches
swept in the direction of flow wherever possible.
Allow for thermal and building movement when jointing and fixing pipework.
Thermal movement shall be accommodated in pipe runs in accordance with the manufacturers
recommendations utilising the correct joints to incorporate thermal movement.
All metallic pipe systems shall be continuity bonded and tested to ensure continuity in
accordance with BS 7671 and as stated elsewhere.
Where plastic pipes with an outside diameter larger than 110mm penetrate fire compartment
walls or floors, a proprietary intumescent fire collar shall be installed on the pipe to maintain the
integrity of the fire barrier.
Any damage to manufacturers paint finishes shall be made good to the manufacturers
recommendations and colour specification.
All floor drains in plant rooms shall have cast iron gratings.
Part 5
Section 21 Page 1
All drainage piping, unless otherwise indicated, shall be pitched at a minimum rate in direction of
flow, in accordance with local Municipality Standards.
The Contractor shall handle fittings into and out of store to job site and they shall be well
protected from damage. After the installation, the fixtures shall be covered by protective crating
with carton cardboard and plastic sheets until handover.
The Contractor shall supply all jointing and fixing materials and seal to structure with
polysulphide sealant and make all connections to water supply services, overflows and waste.
All pipework shall be installed and supported adequately to withstand the pressures experienced
on the high rise stacks. Particular attention shall be paid to anchoring of vertical risers final long
radius bends and vertical stack expansion. The Contractor shall be responsible for obtaining the
pipework manufacturers guidance and recommendations in this regard and installing
accordingly to the CAs approval.
All testing to be carried out in accordance with the local authority requirements and British
Standards
During the progress of the work, test the waste and storm drainage systems to permit general
construction and building in of rough work to proceed.
Provide all apparatus and temporary work for tests. Take all due precautions to prevent
damage to any part of the building.
No caulking of pipe joints to remedy leaks will be permitted except where lead and oakum joints
are used.
Each sections of drainage and roughing piping tested shall have all openings tightly closed with
screw plugs, or equal device, and shall stand without loss of level for a period of four hours
when filled with water to produce at least a 3 meter head at the highest point of the section
tested.
The Contractor shall maintain system until handover and ensure that at handover the systems
are clean and free of blockage.
The Contractor shall offer the complete system to the local authority for testing and inspection
and shall obtain approval from the local authority prior to the handover of the building.
All pipework shall be identified in accordance with BS 1710.
21.2 PIPE WORK PROTECTION

Care shall be taken to prevent the introduction of dirt, debris and rubbish into the system and
open ends of pipework not being worked on shall be protected at all times by means of
proprietary purpose made caps or plugs. Rags or paper shall not be used at any time for this
purpose.
Should adequate protection to prevent ingress of dirt, debris etc into the system not be provided
the CA shall request flow and/or CCTV tests to be undertaken to demonstrate unobstructed flow
within new and existing pipework at no cost to the contract.
Any remedial work necessary to clear blockages or obstructions shall be undertaken at no

additional cost to the contract.
21.3 BRANCH SOIL AND WASTE PIPES

Plastic pipes and fittings shall be to BS EN 1329-1 with solvent weld joints.
All MUPVC pipes where installed in direct contact with concrete shall be wrapped with polythene
tape for protection.
Part 5
Section 21 Page 2
All fittings for pipework shall conform to the relevant BS Specification.
Where purpose fitting is required, they shall also be in accordance with the relevant BS
Standard.
All pipework shall be free from burst, rust and scale and shall be thoroughly cleaned before
erection. Open ends during the progress of work shall be blanked-off with purpose-made metal
or plastic caps and the use of wooden plugs is forbidden. Should any stoppage in the
circulation occur after the various systems have been put into operation, owing to non-
compliance with this requirement, the Contractor shall rectify the matter.
Pipes shall be installed with correct falls for venting and draining and attention shall be paid to
neatness of installation, i.e. groups of pipes shall be accurately spaced and valves, joints, etc.,
symmetrically arranged. Where two or more pipes are visible and change direction together
bends shall be struck from a common radius point. Adequate clearances shall be maintained in
all cases, to allow for the application of the insulation materials and finishing.
The Contractor shall note the restricted space available in certain service ducts and the absolute
necessity to ensure that all pipework is installed in the correct sequence, manner and position to
ensure that operation of all valves and maintenance is possible.
Changes in direction of pipes shall be made with long radius bends or elbows, as far as
practicable. Under no circumstances shall pipes be bent without the use of fittings.
All pipe runs when not installed underground or in duct shall be concealed as far as possible by
careful positioning or shall be chased into walls, laid in screed etc, or as directed by the CA.
All pipework within the fire protected areas must be enclosed to satisfy the Civil Defence
requirements and such enclosures shall be supplied and installed by the Contractor.
Where pipes and floor drains/outlets pass through roof slabs, the Contractor shall leave suitable
openings during casting. The Contractor shall install the pipe, floor drains, etc., taking into
account the water proofing installation method as detailed by the CA.
WC pans are to be connected to soil pipes via BBA or equivalent approved purpose made
connectors. Offset pattern connectors shall not to be used.
Connections must be made without the use of sealants.
Where very high temperature discharges of extended duration are anticipated into waste pipes
plastic pipes and fittings to BS EN 1566-1 shall be used.
21.4 SOIL AND WASTE TRAPS

Sanitary fittings, catering equipment and the like which discharge water to the foul drainage
systems shall each be provided with a plastic trap manufactured in compliance with BS EN 274
to minimise sizes laid out within BS 12056.
Traps shall generally be two-piece swivel types unless specified otherwise elsewhere. Bottle
traps shall not be used on urinals.
21.5 CONNECTIONS TO UNDERGROUND SERVICES

Connections to under building and external drainage systems shall be made using the
manufacturers standard couplings/adapters as recommended to suit the pipe sizes and
materials unless otherwise stated. The above ground installer shall be responsible for the co-
ordination and provision of suitable adapters.
Connect pipework of different materials to a cast iron pipe underground installation using an
appropriate or stepped coupling, to suit the pipework diameters as appropriate.
Part 5
Section 21 Page 3
Connect pipework of different materials to a vitrified clayware pipework underground installation
using Hepworth super sleeve adapters or an approved equivalent.
As indicated connections between pipework of differing materials shall be in accordance with:
Cast iron
Connect cast iron pipework to clay/concrete sockets with bituminised yarn and 1:3 cement: sand
mortar, neatly finished to form a watertight joint.
uPVC
Connect uPVC pipework to cast iron pipework using the appropriate adapters, supplied by the
pipework manufacturer.
Copper
Connect copper pipework to clay/concrete pipework using the appropriate adapters, supplied by
the pipework manufacturer.
Connect copper pipework to cast iron using purpose made copper to iron connectors.
Connect copper pipework to clay/concrete sockets using a caulking bush (brazed on),
bituminized yarn and 1:3 cement: sand mortar, neatly finished to form a watertight joint.
21.6 PIPE WORK SUPPORTS

Fixing screws and nuts and bolts shall be steel with a galvanised or sheradized finish.
Brackets for suspended pipework shall be proprietary steel pipe rings supported on threaded
rod fixed to the slab above or horizontal channel/angle iron suspended on threaded rod fixed to
the slab above with pipes secured to the channel/angle iron with proprietary pipe bracket.
Pipework systems are to be installed and fixed so as to effectively withstand surcharge to 3

metres above ground floor slab level unless otherwise indicated.
Angle brackets shall be installed as necessary on suspended drainage so as to prevent lateral

movement.
Provide hanger rod sizes in accordance with the following schedule:
Pipe Size Rod Size

32mm to 50mm 10mm
65mm to 80mm 15mm
100mm to 125mm 15mm
150mm 20mm
200mm to 300mm 25mm
350mm to 400mm 25mm
450mm 30mm
Provide hangers in accordance with the following schedule:
Hanger Spacing Schedule

Piping Material Pipe Size Maximum Hanger Spacing
UPVC 50mm & larger 1350mm
For flat slab construction only, support hangers from concrete inserts. Furnish, locate and set
such inserts and make sure that such inserts are in place when the concrete is poured.
Construct inserts of malleable iron or pressed steel with space for rods of all sizes. Install all
inserts for pipes 80mm and larger in size with a reinforcing rod 15mm in diameter run through a
slot in the insert specifically provided for this purpose.
For flat slab construction only, if any pipe is to be hung in a space where no inserts have been
provided, drill holes in the slab (subject to the CA prior approval) and provide rods and hanger
Part 5
Section 21 Page 4
attached to an approved fishplate or install double expansion shields connected by a 50mm x
50mm angle, from which the hanger rod is to be suspended. For pipe size 50mm and under,
use single shields but the hanger spacing defined herein before to be reduced to 1.5m. The
carrying capacity and size of each shield to be calculated on the basis of the spacing indicated
above but the minimum size to be 10mm.
Install additional shields of the same size so that the number of hangers are of adequate size to
support the loads which they carry. Shields may be used in flat concrete slabs only.
Regardless of the type of construction (i.e., concrete, concrete-deck-steel or other variations)

take particular care to support all main lines and all large and heavy pipes in an approved
manner, including the furnishing and installation of supplementary steel, if required. Supple-
mentary steel sections are to be mill-rolled.
Submit shop drawings, indicating support methods, point loadings to the building structure and
hanger locations for review sufficiently in advance of concrete pouring schedules to permit
evaluation, critique and any necessary changes to handling and support methods.
Set all inserts for all pipes in ample time to allow concrete work to be performed on scheduled
time.
Hangers may be directly attached to steel beams of building construction, where they occur, if
approved by CA. Smaller pipes may be suspended from crosspieces of pipe or steel angles,
which in turn, are to be securely fastened to building beams. The intention is to provide
supports which, in each case, will be amply strong and rigid for the load, but which will not
weaken or unduly stress the building construction.
Provide approved roller support, floor stands, wall brackets, etc., for all lines running near the
floor or near walls, which can be properly supported or suspended by the floors or walls.
Pipelines near walls may also be hung by hangers carried from approved wall brackets at a
level higher than the pipe.
Do not hang piping from other piping. Support of hangers by means of vertical expansion bolts
is not permitted.
Anchor piping as required to localize expansion or to prevent undue strain on piping and
branches. Anchors to be entirely separate from hangers. All anchor designs to be submitted
flex bellows flanged or screw type for approval and to include piping reactions which respective
anchors are capable of supporting. Provide all indicated or required expansion loops.
All pipes supports shall be of such design and type to allow for the removal of any pipe section
without the necessity of disconnecting other adjacent pipes.
Where pipes pass through walls, floors, etc., the Contractor shall provide pipe sleeves. Sleeves
for MDPE pipes & copper pipes shall be galvanized steel. For pipes, where sleeves are fitted
through floors/wall they shall extend to at least 20mm clear stud out from the finished floor level.
The space between pipe sleeves and the pipe or insulation shall be completely backfilled with
materials having the same fire resistant rating as the walls and floors by the Contractor. Should
multi-services or more than one single pipe be laid through box-out, the space between the
individual pipe sleeves shall be sealed off. The space between the pipe sleeves and the service
pipes shall be back-filled.
Sleeves shall be of sufficient size to allow free movement of pipes and furthermore where pipes
are insulated the sleeves shall be oversized to allow the insulation to be carried through the
sleeves. The Contractor's attention is drawn to the vertical pipe ducts at all floor levels. Where
pipes pass through floors, sleeves shall be provided. The Contractor shall supply sleeves for
setting in walls, floors, etc., and in the shuttering before concrete is poured.
Details of pipes through walls and floors shall be approval by the CA before installation.
Part 5
Section 21 Page 5
21.7 SOIL, WASTE AND VENT PIPE ROOF TERMINATION
Soil and waste vent pipes shall terminate at roof level at least 900mm above the top of and 3m
horizontally from any openable window or air intake. The pipes shall be complete with a
proprietary roofing connector weathering apron and shall be fitted with a plastic guard or cowl.
21.8 FIRE STOPPING

For pipes of OD 50mm passing through a fire compartment structure provide purpose made
fire stop sleeve. Material must be capable of sealing openings around single or multiple pipes
against fire, smoke and toxic gases, and maintaining rating with a thickness no greater than the
structure.
Provide a board material, where required, as per manufacturer's recommendations and as

shown on the Drawings.
Provide a fire stop system consisting of a material, or combination of materials, to retain the
integrity of fire-rated construction to a 2 hour rating unless otherwise stated by maintaining an
effective barrier against the spread of flame, smoke or gases through penetrations in fire-rated
barriers. It shall be used in specific locations as follows:
Penetrations for the passage of piping through fire-rated

vertical barriers (walls and partitions)
horizontal barriers (floor slabs and floor/ceiling assemblies)
vertical service shafts.
Fire stopping materials/systems shall be flexible to allow for normal movement of building
structure and penetrating item(s) without affecting the adhesion or integrity of the system.
Fire stopping materials shall not require hazardous waste disposal of used containers/packages.
Provide fire stopping materials free of solvents which will not experience shrinkage while curing.
Deliver materials to site in original unopened containers or packages bearing the manufacturer's
name, brand designation, product description and U.L. Classification Mark.
Coordinate delivery of materials with scheduled installation date to allow minimum storage time
at job site.
Store materials under cover and protect from weather and damage in compliance with
Comply with recommended procedures, precautions or remedies described in Material Safety

Data Sheets as applicable.
Examine areas and conditions under which work is to be performed and notify the CA in writing
of conditions detrimental to proper and timely completion of the work.
Verify that openings are properly sized and in suitable condition to receive the work of this
section.
Clean substrate of dirt, dust, grease, oil, loose materials, rust or other matter that may affect the
proper fitting or adhesion of the fire stopping materials.
Clean metal and glass surfaces with a non-alcohol solvent.
Install fire stop materials as indicated in accordance with design requirements and
manufacturer's instructions.
Seal all holes or voids made by penetrations to ensure an air, smoke and water-tight seal.
Part 5
Section 21 Page 6
Identify all locations requiring fire stopping and coordinate the work of this section with work
performed under other sections of the Project to provide a uniform system of fire stopping.
Schedule installation of fire stopping after completion of penetrating item installation but prior to
covering or concealing of openings
Do not proceed with installation of fire stop materials when temperatures exceed the
manufacturer's recommended limitations for installation.
Install a pipe duct sleeve with an inside dimension large enough to include the specified
thickness of insulation. The inside diameter of sleeve for an insulated pipe shall be large enough
to include the specified thickness of insulation.
Provide fire stop caulking material between the sleeve and the pipe for the full depth of the
sleeve.
21.9 SLEEVES
Provide sleeves for each pipe passing through walls, partitions, and floors.
Sleeve Materials use 3mm galvanised steel in all applications except those detailed below.
Sleeves for Uninsulated Piping are to be two pipe sizes larger than pipe passing through sleeve
or a minimum of 12mm clearance between inside of sleeve and outside of pipe. Adequate
clearance shall be provided to install fire stopping material.
Sleeves for Insulated Piping are to be of adequate size to accommodate the full thickness of
pipe covering with clearance for packing and caulking. Adequate clearance shall be provided to
install fire stopping.
Sleeve Lengths
Location Sleeve Length

Floor All floor sleeves to extend minimum of 100mm above finished floor
level.
Stair Landing Equal to depth of construction and terminated flush with finished
surfaces.
Walls and Partitions Equal to depth of construction and terminated flush with finished
surfaces.
21.10 ACOUSTIC INSULATION

Provide and install pipe insulation to reduce airborne and impact sound.
All insulated foul drainage pipework shall be labelled to aid identification. Identification shall be
provided at a maximum spacing of 3m.
Unless otherwise indicated, insulation shall comprise 25mm un-faced mineral wool securely
located to the pipework by the use of wire mesh.
As indicated, for sensitive areas a higher rated acoustic insulation shall be provided and shall
comprise 50mm mineral wool having a density of 80-100 kg/m with an outer mass barrier mat
of superficial density of 5 kg/m. Joints between sections of sound reduction mat shall overlap
at least 10mm and be sealed using an approved jointing tape.
As indicated, insulation shall be protected with polyisobutylene (PIB) sheeting. Polyisobutylene

(PIB) sheeting shall have a minimum thickness of 0.8mm and of tensile strength not less than
3.4 MN/m2 lapped on all circumferential and longitudinal joints and sealed using a solvent/cold
welding agent. Points where the PIB sheeting is penetrated due to protrusions shall be sealed
with a suitable sealant to the manufacturer's recommendations. Adhesives and welding agents
used shall as recommended by the Polyisobutylene (PIB) sheeting manufacturer. Under no
Part 5
Section 21 Page 7
circumstances will an alternative adhesive or welding agent be permitted. PIB shall be applied
in accordance with the manufacturer's instructions.
design life.
not pass through the sleeve.
Class O (unassisted by facing material).
21.11 DRAINAGE SUMP PUMPS

Drainage sump pump installations shall comprise duplicate proprietary submersible type
sewage pumps with flameproof electric motors.
The drainage sump pump installation shall include pumps (with quick release couplings), guide
rails, lifting chains, discharge pipework and valves, automatic pump controller, pump control
float switches (start/stop/alarm), wiring between controller and pumps and sump vent pipe.
The pump controller shall comprise heavy gauge robust sheet steel controls cabinet/enclosure,
powder coated, with lockable quick opening door and IP 55 protection. The controls
cabinet/enclosure shall house all controls devices, components, relays, contactors, switches,
warning/indicator lamps, etc and include:

Pump motors protected by miniature circuit breakers
Power on lamp
High water level (visual and audible) alarm indication
Audible alarm muting switch/button
Pump failed alarm indication (visual and audible)
Run/trip indicator lamps per pump
Pump run test buttons/switches
Pump off/manual/auto switches per pump
Tripped VFC per pump
Hours run meters per pump
Remote stop/start facility
Part 5
Section 21 Page 8
Anti frost panel heater.
Each pump controller shall be compatible with and interface with the BMS as indicated.
The installer shall fully liaise and coordinate with the sump pump manufacturer and
BMS/controls specialist to ensure the BMS/controls interface requirements are incorporated.
The installer shall instruct the equipment manufacture to incorporate any reasonable
modifications necessary to achieve the correct BMS/controls interface requirements.
The pump controller shall include volt-free contacts for communication of the following functions
to the BMS/controls as follows:
Power on/fuse failure alarm

Pump run status per pump
Pump trip per pump
High water level alarm

BS EN 12056-1 Gravity drainage systems inside buildings. General and

performance requirements
BS EN 12056-2 Gravity drainage systems inside buildings. Sanitary pipework,
layout and calculation
BS EN 1329-5 Gravity drainage systems inside buildings. Installation and testing,
instructions for operation, maintenance and use.
BS EN 1329-1 Plastics piping systems for soil and waste discharge (low and high
temperature) within the building structure. Unplasticized poly (vinyl
chloride) (PVC-U). Specifications for pipes, fittings and the system.
BS EN 274 Waste fittings for sanitary appliances
Part 4:Non-combustibility test for materials
Part 6:Method of test for fire propagation for products
Part 7:Method of test to determine the classification
of the surface spread of flame of products
Part 11:Method for assessing the heat emission from building
materials
Part 12:Method of test for the ignitability of products by direct flame
impingement
Sixteenth edition
EN ISO 5659-2. Plastics. Smoke generation. Determination of optical density by a
Part 5
Section 21 Page 9
Section 22 Rain Water Drainage (above
ground)
Contents
Section 22 Rain Water Drainage (above ground) 1

22.2 Pipe work protection 2
22.3 Rain Water pipes 2
22.4 Connections to underground services 3
22.5 Pipe work Supports 3
22.6 Rain Water Outlets 5
22.7 Fire Stopping 5
22.8 Sleeves 6
22.9 Thermal Insulation 7
22.10 Acoustic Insulation 7
22.11 Drainage Sump Pumps 8
Section 22 Rain Water Drainage (above ground)
The rainwater systems shall be installed to comply with the requirements of BS EN 12056-
3:2000 as well as the specific requirements of this specification.
The completed installation shall ensure compliance with the local Municipality Regulations and
recommendations.
The system shall be installed to effectively convey rainfall quickly, quietly and effectively without
nuisance or risk to health. It is essential that foul air is prevented from entering the building
during operation of the system.
Falls and slopes of rain water pipes shall be to the requirements of BS EN 12056-2.
Pipes shall be installed true to line and to a consistent gradient. All vertical drainage pipework
shall be perpendicular and branches and changes in direction adequately supported.
Obtain all components for all types of pipework from the same manufacturer unless stated
otherwise.
Access for cleaning and rodding pipes shall be provided to ensure that all parts of the systems
are accessible for such purposes.
As a minimum, an access point shall be provided on each vertical stack at each storey level and
at changes of direction and junctions on suspended pipe work.
All branch connections to horizontal runs at high level shall be made using 45 degree branches
swept in the direction of flow wherever possible.
Allow for thermal and building movement when jointing and fixing pipework.
Thermal movement shall be accommodated in pipe runs in accordance with the manufacturers
recommendations utilising the correct joints to incorporate thermal movement.
Where plastic pipes with an outside diameter larger than 110mm penetrate fire compartment
walls or floors, a proprietary intumescent fire collar shall be installed on the pipe to maintain the
integrity of the fire barrier.
Any damage to manufacturers paint finishes shall be made good to the manufacturers
recommendations and colour specification.
All drainage piping, unless otherwise indicated, shall be pitched at a minimum rate in direction of
flow, in accordance with local Municipality Standards.
The Contractor shall handle fittings into and out of store to job site and they shall be well
protected from damage. After the installation, the fixtures shall be covered by protective crating
with carton cardboard and plastic sheets until handover.
The Contractor shall supply all jointing and fixing materials and seal to structure with
polysulphide sealant and make all connections to water supply services, overflows and waste.
All pipework shall be installed and supported adequately to withstand the pressures experienced
on the high rise stacks. Particular attention shall be paid to anchoring of vertical risers final long
radius bends and vertical stack expansion. The Contractor shall be responsible for obtaining the
Part 5
Section 22 Page 1
pipework manufacturers guidance and recommendations in this regard and installing
accordingly, to the CAs approval.
All testing is to be carried out in accordance with the local authority requirements and British
Standards.
During the progress of the work, test the waste and storm drainage systems to permit general
construction and building in of rough work to proceed.
Provide all apparatus and temporary work for tests. Take all due precautions to prevent
damage to any part of the building.
Each sections of drainage and roughing piping tested shall have all openings tightly closed with
screw plugs, or equal device, and shall stand without loss of level for a period of four hours
when filled with water to produce at least a 3 meter head at the highest point of the section
tested.
The Contractor shall maintain system until handover and ensure that at handover the systems
are clean and free of blockage.
The Contractor shall offer the complete system to the local authority for testing and inspection
and shall obtain approval from the local authority prior to the handover of the building.
All pipework shall be identified in accordance with BS 1710.
22.2 PIPE WORK PROTECTION

Care shall be taken to prevent the introduction of dirt, debris and rubbish into the system and
open ends of pipework not being worked on shall be protected at all times by means of
proprietary purpose made caps or plugs. Rags or paper shall not be used at any time for this
purpose.
Should adequate protection to prevent ingress of dirt, debris etc into the system not be provided
the CA shall request flow and/or CCTV tests to be undertaken to demonstrate unobstructed flow
within new and existing pipework at no cost to the contract.
Any remedial work necessary to clear blockages or obstructions shall be undertaken at no

additional cost to the contract.
22.3 RAIN WATER PIPES

Plastic pipes and fittings shall be to BS EN 1329-1 with solvent weld joints.
All MUPVC pipes where installed in direct contact with concrete shall be wrapped with polythene
tape for protection.
All fittings for pipework shall conform to the relevant BS Specification.
Where purpose fitting is required, they shall also be in accordance with the relevant BS
Standard.
All pipework shall be free from burst, rust and scale and shall be thoroughly cleaned before
erection. Open ends during the progress of work shall be blanked-off with purpose-made metal
or plastic caps and the use of wooden plugs is forbidden. Should any stoppage in the
circulation occur after the various systems have been put into operation, owing to non-
compliance with this requirement, the Contractor shall rectify the matter.
Pipes shall be installed with correct falls for venting and draining and attention shall be paid to
neatness of installation, i.e. groups of pipes shall be accurately spaced and valves, joints, etc.,
symmetrically arranged. Where two or more pipes are visible and change direction together
bends shall be struck from a common radius point. Adequate clearances shall be maintained in
all cases, to allow for the application of the insulation materials and finishing.
Part 5
Section 22 Page 2
The Contractor shall note the restricted space available in certain service ducts and the absolute
necessity to ensure that all pipework is installed in the correct sequence, manner and position to
ensure that operation of all valves and maintenance is possible.
Changes in direction of pipes shall be made with long radius bends or elbows, as far as
practicable. Under no circumstances shall pipes be bent without the use of fittings.
All pipe runs when not installed underground or in duct shall be concealed as far as possible by
careful positioning or shall be chased into walls, laid in screed etc, or as directed by the CA.
All pipework within the fire protected areas must be enclosed to satisfy the local Civil Defence
requirements and such enclosures shall be supplied and installed by the Contractor.
Where pipes and roof outlets pass through roof slabs, the Contractor shall leave suitable
openings during casting. The Contractor shall install the pipe, floor drains, etc., taking into
account the water proofing installation method as detailed by the CA.
Where very high temperature discharges of extended duration are anticipated into waste pipes
plastic pipes and fittings to BS EN 1566-1 shall be used.
22.4 CONNECTIONS TO UNDERGROUND SERVICES

Connections to under building and external drainage systems shall be made using the
manufacturers standard couplings/adapters as recommended to suit the pipe sizes and
materials unless otherwise stated. The above ground installer shall be responsible for the co-
ordination and provision of suitable adapters.
Connect pipework of different materials to a cast iron pipe underground installation using an
appropriate or stepped coupling, to suit the pipework diameters as appropriate.
Connect pipework of different materials to a vitrified clay ware pipework underground installation
using Hepworth super sleeve adapters or an approved equivalent.
As indicated connections between pipework of differing materials shall be in accordance with:
Cast iron
Connect cast iron pipework to clay/concrete sockets with bituminized yarn and 1:3cement: sand
mortar, neatly finished to form a watertight joint.
uPVC
Connect uPVC pipework to cast iron pipework using the appropriate adapters, supplied by the
pipework manufacturer.
Copper
Connect copper pipework to clay/concrete pipework using the appropriate adapters, supplied by
the pipework manufacturer.
Connect copper pipework to cast iron using purpose made copper to iron connectors.
Connect copper pipework to clay/concrete sockets using a caulking bush (brazed on),
bituminized yarn and 1:3cement: sand mortar, neatly finished to form a watertight joint.
22.5 PIPE WORK SUPPORTS

Fixing screws and nuts and bolts shall be steel with a galvanised or sheradized finish.
Brackets for suspended pipework shall be proprietary steel pipe rings supported on threaded
rod fixed to the slab above or horizontal channel/angle iron suspended on threaded rod fixed to
the slab above with pipes secured to the channel/angle iron with proprietary pipe bracket.
Part 5
Section 22 Page 3
Pipework systems are to be installed and fixed so as to effectively withstand surcharge to 3
metres above ground floor slab level unless otherwise indicated.
Angle brackets shall be installed as necessary on suspended drainage so as to prevent lateral

movement.
Provide hanger rod sizes in accordance with the following schedule:
Pipe Size Rod Size

65mm to 80mm 15mm
100mm to 125mm 15mm
150mm 20mm
200mm to 300mm 25mm
350mm to 400mm 25mm
450mm 30mm
Provide hangers in accordance with the following schedule:
Hanger Spacing Schedule

Piping Material Pipe Size Maximum Hanger Spacing
UPVC 50mm & larger 1350mm
For flat slab construction only, support hangers from concrete inserts. Furnish, locate and set
such inserts and make sure that such inserts are in place when the concrete is poured.
Construct inserts of malleable iron or pressed steel with space for rods of all sizes. Install all
inserts for pipes 80mm and larger in size with a reinforcing rod 15mm in diameter run through a
slot in the insert specifically provided for this purpose.
For flat slab construction only, if any pipe is to be hung in a space where no inserts have been
provided, drill holes in the slab (subject to the CA prior approval) and provide rods and hanger
attached to an approved fishplate or install double expansion shields connected by a 50mm x
50mm angle, from which the hanger rod is to be suspended. For pipe size 50mm and under,
use single shields but the hanger spacing defined herein before to be reduced to 1.5m. The
carrying capacity and size of each shield to be calculated on the basis of the spacing indicated
above but the minimum size to be 10mm.
Install additional shields of the same size so that the number of hangers are of adequate size to
support the loads which they carry. Shields may be used in flat concrete slabs only.
Regardless of the type of construction (i.e., concrete, concrete-deck-steel or other variations)

take particular care to support all main lines and all large and heavy pipes in an approved
manner, including the furnishing and installation of supplementary steel, if required. Supple-
mentary steel sections are to be mill-rolled.
Submit shop drawings, indicating support methods, point loadings to the building structure and
hanger locations for review sufficiently in advance of concrete pouring schedules to permit
evaluation, critique and any necessary changes to handling and support methods.
Set all inserts for all pipes in ample time to allow concrete work to be performed on scheduled
time.
Hangers may be directly attached to steel beams of building construction, where they occur, if
approved by CA. Smaller pipes may be suspended from crosspieces of pipe or steel angles,
which in turn, are to be securely fastened to building beams. The intention is to provide
supports which, in each case, will be amply strong and rigid for the load, but which will not
weaken or unduly stress the building construction.
Provide approved roller support, floor stands, wall brackets, etc., for all lines running near the
floor or near walls, which can be properly supported or suspended by the floors or walls.
Pipelines near walls may also be hung by hangers carried from approved wall brackets at a
level higher than the pipe.
Part 5
Section 22 Page 4
Do not hang piping from other piping. Support of hangers by means of vertical expansion bolts
is not permitted.
Anchor piping as required to localize expansion or to prevent undue strain on piping and
branches. Anchors to be entirely separate from hangers. All anchor designs to be submitted
flex bellows flanged or screw type for approval and to include piping reactions which respective
anchors are capable of supporting. Provide all indicated or required expansion loops.
All pipes supports shall be of such design and type to allow for the removal of any pipe section
without the necessity of disconnecting other adjacent pipes.
Where pipes pass through walls, floors, etc., the Contractor shall provide pipe sleeves. Sleeves
for MDPE pipes & copper pipes shall be galvanized steel. For pipes, where sleeves are fitted
through floors/wall they shall extend to at least 20mm clear stud out from the finished floor level.
The space between pipe sleeves and the pipe or insulation shall be completely backfilled with
materials having the same fire resistant rating as the walls and floors by the Contractor. Should
multi-services or more than one single pipe be laid through box-out, the space between the
individual pipe sleeves shall be sealed off. The space between the pipe sleeves and the service
pipes shall be back-filled.
Sleeves shall be of sufficient size to allow free movement of pipes and furthermore where pipes
are insulated the sleeves shall be oversized to allow the insulation to be carried through the
sleeves. The Contractor's attention is drawn to the vertical pipe ducts at all floor levels. Where
pipes pass through floors, sleeves shall be provided. The Contractor shall supply sleeves for
setting in walls, floors, etc., and in the shuttering before concrete is poured.
Details of pipes through walls and floors shall be approval by the CA before installation.
22.6 RAIN WATER OUTLETS

Rainwater outlets on roofs shall be of cast iron construction with dome type cast iron grating &
adequate provision for receiving water proofing materials as specified by the CA.
Rain water outlets shall be set in position at the required openings in the structural slabs.
During casting and after the rainwater outlets are installed, the contractor is to ensure all
measures for making good are applied.
22.7 FIRE STOPPING

Provide fire stop purpose made fire stop sleeve. Material must be capable of sealing openings
around single or multiple pipes against fire, smoke and toxic gases, and maintaining rating with
a thickness no greater than the structure.
Provide a board material, where required, as per manufacturer's recommendations and as

shown on the Drawings.
Provide a fire stop system consisting of a material, or combination of materials, to retain the
integrity of fire-rated construction to a 2 hour rating unless otherwise stated by maintaining an
effective barrier against the spread of flame, smoke or gases through penetrations in fire-rated
barriers. It shall be used in specific locations as follows:
Penetrations for the passage of piping through fire-rated vertical barriers (walls and partitions)
horizontal barriers (floor slabs and floor/ceiling assemblies) and vertical service shafts
Fire stopping materials/systems shall be flexible to allow for normal movement of building
structure and penetrating item(s) without affecting the adhesion or integrity of the system.
Fire stopping materials shall not require hazardous waste disposal of used containers/packages.
Part 5
Section 22 Page 5
Provide fire stopping materials free of solvents which will not experience shrinkage while curing.
Deliver materials to site in original unopened containers or packages bearing the manufacturer's
name, brand designation, product description and U.L. Classification Mark.
Coordinate delivery of materials with scheduled installation date to allow minimum storage time
at job site.
Store materials under cover and protect from weather and damage in compliance with
Comply with recommended procedures, precautions or remedies described in Material Safety

Data Sheets as applicable.
Examine areas and conditions under which work is to be performed and notify the CA in writing
of conditions detrimental to proper and timely completion of the work.
Verify that openings are properly sized and in suitable condition to receive the work of this
section.
Clean substrate of dirt, dust, grease, oil, loose materials, rust or other matter that may affect the
proper fitting or adhesion of the fire stopping materials.
Clean metal and glass surfaces with a non-alcohol solvent.
Install fire stop materials as indicated in accordance with design requirements and
manufacturer's instructions.
Seal all holes or voids made by penetrations to ensure an air, smoke and water-tight seal.
Identify all locations requiring fire stopping and coordinate the work of this section with work
performed under other sections of the Project to provide a uniform system of fire stopping.
Schedule installation of fire stopping after completion of penetrating item installations, but prior
to covering or concealing of openings
Do not proceed with installation of fire stop materials when temperatures exceed the
manufacturer's recommended limitations for installation.
Install a pipe duct sleeve with an inside dimension large enough to include the specified
thickness of insulation. The inside diameter of sleeve for an insulated pipe shall be large enough
to include the specified thickness of insulation.
Provide fire stop caulking material between the sleeve and the pipe for the full depth of the
sleeve.
22.8 SLEEVES
Sleeve Materials use 3mm galvanised steel in all applications except those detailed below.
Sleeves for Uninsulated Piping are to be two pipe sizes larger than pipe passing through sleeve
or a minimum of 12mm clearance between inside of sleeve and outside of pipe. Adequate
clearance shall be provided to install fire stopping material.
Sleeves for Insulated Piping are to be of adequate size to accommodate the full thickness of
pipe covering with clearance for packing and caulking. Adequate clearance shall be provided to
install fire stopping.
Sleeve Lengths
Part 5
Section 22 Page 6
Location Sleeve Length
Floor All floor sleeves to extend minimum of 100mm above
finished floor level.
Stair Landing Equal to depth of construction and terminated flush with
finished surfaces.
Walls and Partitions Equal to depth of construction and terminated flush with
finished surfaces.
22.9 THERMAL INSULATION

To avoid condensation, where rainwater pipe work is installed directly below an external roof
area it is to be insulated for its entire horizontal length and for 500mm of the vertical length in
accordance with the thermal insulation section of this specification.
22.10 ACOUSTIC INSULATION

Provide and install pipe insulation to reduce airborne and impact sound where necessary.
All insulated rainwater drainage pipework shall be labelled to aid identification. Identification
shall be provided at a maximum spacing of 3m.
Unless otherwise indicated, insulation shall comprise 25mm un-faced mineral wool securely
located to the pipework by the use of wire mesh.
As indicated, for sensitive areas a higher rated acoustic insulation shall be provided and shall
comprise 50mm mineral wool having a density of 80-100 kg/m with an outer mass barrier mat
of superficial density of 5 kg/m. Joints between sections of sound reduction mat shall overlap
at least 10mm and be sealed using an approved jointing tape.
As indicated, insulation shall be protected with poly-isobutylene (PIB) sheeting. Poly-

isobutylene (PIB) sheeting shall have a minimum thickness of 0.8mm and of tensile strength not
less than 3.4 MN/m2 lapped on all circumferential and longitudinal joints and sealed using a
solvent/cold welding agent. Points where the PIB sheeting is penetrated due to protrusions
shall be sealed with a suitable sealant to the manufacturer's recommendations. Adhesives and
welding agents used shall as recommended by the Poly-isobutylene (PIB) sheeting
manufacturer. Under no circumstances will an alternative adhesive or welding agent be
permitted. PIB shall be applied in accordance with the manufacturer's instructions.
design life.
not pass through the sleeve.
Class O (unassisted by facing material).
Part 5
Section 22 Page 7
22.11 DRAINAGE SUMP PUMPS

Drainage sump pump installations shall comprise duplicate proprietary submersible type
sewage pumps with flameproof electric motors.
The drainage sump pump installation shall include pumps (with quick release couplings), guide
rails, lifting chains, discharge pipework and valves, automatic pump controller, pump control
float switches (start/stop/alarm), wiring between controller and pumps and sump vent pipe.
The pump controller shall comprise heavy gauge robust sheet steel controls cabinet/enclosure,
powder coated, with lockable quick opening door and IP 55 protection. The controls
cabinet/enclosure shall house all controls devices, components, relays, contactors, switches,
warning/indicator lamps, etc and include:

Pump motors protected by miniature circuit breakers
Power on lamp
High water level (visual and audible) alarm indication
Audible alarm muting switch/button
Pump failed alarm indication (visual and audible)
Run/trip indicator lamps per pump
Pump run test buttons/switches
Pump off/manual/auto switches per pump
Tripped VFC per pump
Hours run meters per pump
Anti frost panel heater.
Each pump controller shall be compatible with and interface with the BMS as indicated.
The installer shall fully liaise and coordinate with the sump pump manufacturer and
BMS/controls specialist to ensure the BMS/controls interface requirements are incorporated.
The installer shall instruct the equipment manufacture to incorporate any reasonable
modifications necessary to achieve the correct BMS/controls interface requirements.
The pump controller shall include volt-free contacts for communication of the following functions
to the BMS/controls as follows:
Power on/fuse failure alarm

Pump run status per pump
Pump trip per pump

BS EN 12056-3 Rainwater gravity drainage systems inside buildings. General and

performance requirements
BS EN 1329-5 Gravity drainage systems inside buildings. Installation and testing,
instructions for operation, maintenance and use.
Part 5
Section 22 Page 8
BS EN 1329-1 Plastics piping systems for rainwater discharge (low and high
Part 4:Non-combustibility test for materials
Part 6:Method of test for fire propagation for products
Part 7:Method of test to determine the classification
of the surface spread of flame of products
Part 11:Method for assessing the heat emission from building
materials
Part 12:Method of test for the ignitability of products by direct flame
impingement
Sixteenth edition
EN ISO 5659-2. Plastics. Smoke generation. Determination of optical density by a
Part 5
Section 22 Page 9
Section 23 Sprinkler Systems
Contents
Section 23 Sprinkler Systems 1

23.2 Sprinkler systems 1
23.3 Hazard classification 6
23.4 Inspection 6
23.5 Testing 7
23.6 Identification signs 7
23.7 Painting 7
Section 23 Sprinkler Systems
Comply with General Requirements and all documents referred to therein.
Provide all labour, materials, products, equipment and services to supply and install sprinkler
systems as indicated on the Drawings and specified in this Section of the Specification in
accordance with NFPA 13 and to the requirements of local civil defence.
The fire protection contractor shall be experienced in the design and installation of fire protection
systems to NFPA standards and shall be an approved contractor by Local Civil Defence
Authority.
Provide all necessary sprinkler heads in accordance with NFPA 13 to achieve a fully sprinklered
building.
Sprinkler system piping shall be sized by hydraulic calculations in accordance with NFPA 13
and a complete set of calculations shall be submitted with the plans for engineers review.
Submit system layout drawings, component shop drawings, specifications and hydraulic
calculations for Consultants review prior to commencing installation.
Submittal data shall be reviewed and incorporate requirements of the local authorities.
Drawings shall be certified correct and bear the contractors engineers certification prior to
submission to the consultant.
Upon completion of the installation, modify the system calculations and submit hydraulic design
data based on as-built system.
Obtain all approvals before proceeding with the work.
Provide certificate of compliance that components are compatible and, where applicable,
certified for intended use by recognised testing agency.
Meet local building and fire regulations, including the most recent issue of the following:
NFPA 13 - Standard for the Installation of Sprinkler Systems
NFPA 14 - Standard for the Installation of Standpipe and Hose Systems
NFPA 20 - Standard for the Installation of Stationary Pumps for Fire Protection
NFPA 22 - Standard for Water tanks for Private Fire Protection
NFPA 24 - Standard for the Installation of Private Fire Service Mains and Their Appurtenances
All components of the sprinkler systems shall be UL listed and labelled.
Perform all tests and provide certification as required by authorities having jurisdiction.
Refer to final Architectural and Interior Designer Reflected Ceiling Plans and co-ordinate
locations of sprinkler head with lighting and other ceiling mounted components. Co-ordinate
sprinkler piping to avoid interference with all other services
23.2 SPRINKLER SYSTEMS

23.2.1 General
Sprinkler systems shall be provided with all accessories as indicated in the drawings and as per
the requirements of the local civil defence and in accordance with NFPA 13.
Part 5
Section 23 Page 1
23.2.2 Pipe and fittings
All pipework, valves and fittings, unless otherwise specified, shall comply with relevant clauses
in the NFPA 13 regulations.
Supply, deliver and install all pipework materials and fittings for the standpipe and hose
systems.
Pipework shall follow the routes and approximate positions indicated on the drawings.
Provide pipe hangers in accordance with NFPA 13.
No joints shall be formed in wall or floor thickness.
All pipe work, fittings and valves shall be free from corrosion, scale and internal obstruction.
Pipe work ends shall be cut square, reamed free from burrs and finished full bore.
Sufficient unions and flanged joints shall be provided to install and dismantle sections of pipe
work, wherever difficulty in dismantling may occur and on straight runs of more than 25m.
Unions or flanges shall be provided at all valves and equipment for easy dismantling.
eliminate undue strains in piping and equipment. Necessary fittings and bends shall be
Care shall be taken in placing unions to allow freedom to spring apart. Unions and flanges shall
not be placed in inaccessible positions. Where pipework is installed in inaccessible places, a
union or flange shall be installed, prior to the pipe passing into the wall or floor. Unions shall
have two bronze conical seats ground in. Long screw connections will not be accepted.
approval.
Changes in diameter of horizontal pipework shall be formed eccentrically.
Prior to any work being "covered up", the Contractor shall request the Engineer's approval to
that part of the installation in question.
Take appropriate means to prevent galvanic action where dissimilar metals are connected.
For working pressures below 20 bar the pipework shall be seamless factory galvanized steel in
accordance with ASTM A 53 grade B schedule 40.
Fittings on 50 mm and below shall be galvanized malleable iron fittings conforming to class 250,
ANSI B16.4 and shall be UL listed, FM approved.
Part 5
Section 23 Page 2
Fittings 65mm and above shall be factory galvanized mechanical roll grooved fittings and shall
be UL listed, FM approved. These shall be class 250 to ANSI B16.9.
For working pressures above 20 bar the pipework shall be seamless factory galvanized steel in
Fittings on 50 mm and below shall be galvanized malleable cast iron fittings conforming to class
300, ANSI B16.3 and shall be UL listed, FM approved.
be UL listed, FM approved. These shall be class 300 to class 16.9.
All valves and fittings used in the pipework system shall not have a pressure rating less than
that of the pipework.
The material shall be subject to approval and must comply with Civil Defence.
UL listed expansion joints shall be provided for all pipework passing through any building
expansion joint and where necessary as specified and shall be designed for use in fire
protection piping systems.
All piping shall be thoroughly cleaned of loose scale, dirt, etc., before installation. During the
course of the installation, all open ends of pipes shall be plugged or capped to prevent ingress
of dirt.
After installation and sealing of joints all piping shall be thoroughly cleaned with clean water
under pressure to the satisfaction of Engineer. Water samples test may be required if the
Engineer is considered as necessary. Water used for this purpose shall be discharged as
directed.
Any temporary pipework and equipment necessary for the above cleaning shall be provided by
the Contractor.
Provide a pressure gauge with an isolation cock with inspectors test plug on top of the each
sprinkler pipe risers.
23.2.3 Valves
Unless otherwise indicated all valves controlling connections to water supplies and sprinkler
systems shall be UL listed and indicating valves and shall be in accordance with NFPA 13.
All valves shall have the name of the manufacturer and working pressure cast or stamped on
body.
All valves shall be selected for the working pressure and test pressure required.
All isolating valves and control valves shall be provided with the proper and efficient operation
and maintenance of the entire systems.
Furnish all valves and accessory material necessary in the piping whether or not shown on
drawings as follows.
All valves shall be packed with an approved packing and threads shall be coated with oil and
graphite. Packing should be replaced when found deteriorated on site.
Part 5
Section 23 Page 3
Plastic or metal plates (rustless) shall be provided to indicate the open/close status as well as
the use of each valve in the pump and tank rooms, and in the town main.
23.2.4 Alarm Check Valves

Provide UL listed alarm check valve for sprinkler systems in accordance with NFPA 13 and with
retarding device of approved design to obviate false alarms due to mains pressure variations
where required and as shown on Drawings.
Alarm check valves shall be complete with Water Motor Alarm Gong, all required auxiliary
valves and drains and with pressure switch for wiring into the building fire alarm system.
Alarm check valves shall be iron body bronze trim for minimum 175psig(12bar) working
pressure complete with electric pressure switches, test and alarm bell connections. Pressure
gauges and all other ancillaries
Provide wiring from alarm check valves to fire alarm panel in accordance with NFPA 72.
23.2.5 Water Motor Alarm

The sprinkler system shall be fitted with an approved water motor alarm, which shall be located
at a distance not exceeding 25m from the alarm valve, and at a height not to exceed 6m above
the alarm valve.
The pipe work and fittings used shall be galvanized and in accordance with NFPA-13.
The pipe work shall be arranged to drain through a fitting having an orifice not exceeding 3 mm
in diameter. The orifice plate may form an integral part of the fitting but shall be manufactured
from a non-ferrous material to prevent the hole from becoming blocked by corrosion or foreign
matter.
A 15 mm test valve shall be installed on the installation side of each alarm valve.
23.2.6 Electric Alarm Pressure Switch

Provide UL listed electric alarm pressure switch in accordance with NFPA 13 and they shall be
mounted on a vertical branch pipe at least 300 mm long.
The pressure switch shall be of the diaphragm bellows operated type, and shall be sufficiently
sensitive to operate when only one sprinkler is discharging. The pressure switch shall be
provided with volt free contracts to facilitate monitoring by a Building Management System, and
wired to the main fire alarm panel.
23.2.7 Automatic Zone Check (Zone Control Valve) Assembly

Provide UL listed/FM approved automatic zone check (zone control valve) assembly for each
sprinkler system zone as required and shown on the drawings in accordance with NFPA 13 and
as per the requirements of local civil defence.
Automatic zone check assembly shall have the followings components;
UL listed and FM approved butterfly valve shall be fitted with factory installed UL listed/FM
approved tamper switch.
UL listed and FM approved check valve.
UL listed and FM approved water flow alarm switch for the size of the pipe in which it is installed
as a paddle type water flow indicator and shall be fixed after the butterfly valve, on the main
supply pipe and before any connection is taken off.
Inspector test and drain connections.
Dial pressure gauges suitable for the water pressures shall be fitted so arranged that it can be
easily removed for testing and checking without shutting down the water supply.
Re-circulating Pump
Part 5
Section 23 Page 4
Vane-type water flow monitoring switch (WFMS).
Electrical box enabling control of motor and monitor of WFMS, local / remote as required.
Wiring from butterfly valve temper switch and water flow alarm switch to the fire alarm panel
shall be in accordance with NFPA 72.
When actuated they shall perform the following:
Test mode actuation: When activated in test mode, the pump shall circulate the water, within the
sprinkler riser, around WFMS to stimulate the flow of one sprinkler head in operation. The
electrical box shall control and monitor, motor and WFMS respectively, as required.
Fire mode actuation: When fire occurs, the sprinkler burst and water starts flowing to control /
extinguish the fire. This leads to flow equal to or more than one sprinkler through the WFMS
actuating it. The fire alarm panel / flow monitoring panel performs monitors / controls required in
the fire condition when the WFMS actuation signal reach them.
They shall have following features in the system:
Insure the testing of WFMS as per the requirements NFPA 25 without activating the fire pump
and opening of test/drain valve.
Installed in such a way that the test shall be conducted from a central control room, through
single push button and the individual WFMS status can be read from main fire alarm panel or
separate flow monitoring panel.
Have the future (contacts and relays) facilitating the connection to BMS, for automatic actuation,
once in 3 months which records the status as required.
23.2.8 OS & Y Gate Valves

OS&Y gate valves shall be UL Listed and shall be fitted to the installation in order to shut the
valve, the spindle must turn clockwise. The hand wheels of all stop valves shall be clearly
marked to indicate which direction the wheel is to be turned to close the valve.
An indication shall also be provided which shows whether the valve is open or shut.
Each main stop valves shall be installed with a tamper / supervisory switch and interconnected
to the building fire alarm system or secured open by a padlock or riveted strap.
Bolted bonnet, outside screw and yoke, wedge gate, iron body, bronze trim with flanged ends,
threaded or grooved ends.
Gate valves to be back seating and suitable for repacking under pressure. Packing to be non-
asbestos
Valves 50 mm (2 in) and smaller, Underwriters Laboratories pattern, bronze to ASTM B61 solid
wedge and screwed ends. OS & Y 1400 Pa (water, oil gas)
Valve 65 mm and larger, Underwriters Laboratories pattern, iron body bronze mounted, OS & Y
solid wedge, flanged ends, 1200 kPa (water, oil, gas).
23.2.9 Drain Pipe

All drain pipe from test valves and drain down points shall discharge over suitable and proper
drain point and shall be discharged over a suitable gully.
Provide drain pipe and fittings in accordance with NFPA 13.
Pipe backflow preventer relief and drain connections to nearest floor drain.
Part 5
Section 23 Page 5
23.2.10 Sprinkler Heads
Provide UL listed / FM Approved sprinkler heads as required and as shown on the drawings in
accordance with NFPA 13.
The sprinkler heads shall be of the spray pattern installed in an upright position or pendant
position as required. Sprinkler in false ceilings shall be concealed to ceiling and to architects
approval.
Finish of sprinklers shall be to the approval of the architect.
The design Criteria for all sprinklers such as K-factor, type and operating temperature shall be
submitted for approval.
The contractor shall supply set of spare sprinkler heads in each type / temperature range and
located in a cabinet in the fire pump room together with sprinkler spanners for use in removing
and installation of the heads in accordance with NFPA 13 and as per the requirements of the
local civil defence.
Where pendant type sprinkler heads are required and shown on the drawings, provide chrome
plated recessed sprinkler heads with chrome plated escutcheons.
Where upright type sprinkler heads are required and shown on the drawings, provide bronze
upright sprinkler heads with bright chrome finish in finished areas an bronze finish in other
areas.
Where concealed type sprinkler heads are required and shown on the drawings, provide
concealed sprinkler heads with cover plate having paint factory finish. Obtain Architect approval
of colours and submit samples.
Where sidewall type sprinkler heads are required and shown on the drawings, provide chrome
plated sidewall sprinkler heads in finished areas and bronze finish in other areas.
Provide high temperature sprinkler heads where required to suit the local civil defence, and
where located in elevator machine rooms, data cupboards, in electrical rooms and near heat
producing equipment. Provide mechanical protection for these locations and which is
acceptable to local authorities having jurisdiction.
Install sprinkler heads symmetrically in ceiling tiles, generally in accordance with Interior Design
reflected ceiling plan drawings. Bring any coverage or code concerns to the attention of the
lead consultant.
Provide guards for sprinkler heads in elevator machine rooms, garbage room, mechanical
rooms, storage rooms and where indicated on Drawings.
Assume full responsibility for protecting sprinkler heads during painting. Replace damaged and
painted components.
Be responsible for necessary modifications to the installation in the event the as-built hydraulic
calculations do not meet the design criteria.
23.3 HAZARD CLASSIFICATION

The area coverage and spacing of sprinkler heads shall be designed and installed as per the
hazard classifications in accordance with NFPA 13 and as shown on the drawings.
23.4 INSPECTION
Do not recess, paint or conceal any work including piping and accessory equipment before it
has been inspected and approved.
Prevent theft of sprinkler systems components. Replace any missing items prior to final
inspection and handover.
Part 5
Section 23 Page 6
Protect all finishes, replace or repair any damaged finishes to the satisfaction of the local
consultant.
23.5 TESTING
Test all sprinkler systems in accordance with NFPA 13.
Carry out any additional tests required by the authorities having jurisdiction.
Perform tests in the presence of each governing authoritys authorised inspector.
Submit certification that systems have been designed and installed in accordance with NFPA 13
and the requirements of the local civil defence.
Perform tests before piping is concealed.
Remove all components which will not withstand test pressure, and replace after tests.
Eliminate leaks, or remove and refit defective parts. Caulking of threaded or welded joints will
not be permitted.
Repeat tests as often as necessary to obtain certification.
23.6 IDENTIFICATION SIGNS

Provide signs, conforming to NFPA 13 requirements and in accordance with the requirements of
local authorities, for each valve and alarm device.
23.7 PAINTING
Paint all exposed sprinkler piping with a suitable primer and top coat(s) in bright red to the
satisfaction of the lead consultant. Obtain agreement from the lead consultant on top coat paint
colour before application.

Documents referred to in this section
NFPA 13 Standard for the Installation of Sprinkler Systems

NFPA 14 Standard for the Installation of Standpipe and Hose
Systems
NFPA 20 Standard for the Installation of Stationary Pumps for Fire
Protection
NFPA 22 Standard for Water tanks for Private Fire Protection
NFPA 24 Standard for the Installation of Private Fire Service Mains
and their Appurtenances.
NFPA 72 Standards for the application, installation, location,
performance and maintenance of fire alarm systems and
their components
Part 5
Section 23 Page 7
Section 23A Pre-Action Sprinkler Systems
Contents
Section 23A Pre-Action Sprinkler Systems 1
23A.1 General requirements 1

23A.2 pre-action Sprinkler systems 1
Section 23A Pre-Action Sprinkler Systems
23A.1 GENERAL REQUIREMENTS
The Fire Protection contractor shall provide all labour, materials, products, equipment and services to
supply and install sprinkler systems as indicated on the Drawings and specified in this Section of the
Specification in accordance with NFPA 13 and to the requirements of local civil defence.
The Fire Protection contractor shall be experienced in the design and installation of fire protection
systems to NFPA standards and shall be an approved contractor by Local Civil
Defence Authority.
Sprinkler system piping shall be sized by hydraulic calculations in accordance with NFPA 13 and a
complete set of calculations shall be submitted with the plans for engineers review.
Submit system layout drawings, component shop drawings, specifications and hydraulic calculations
for Consultants review prior to commencing installation.
Drawings shall be certified correct and bear the contractors engineers certification prior to submission
to the consultant.
Upon completion of the installation, modify the system calculations and submit hydraulic design data
based on as-built system.

NFPA 502 - Standard for Road Tunnels, Bridges, and Other Limited Access Highways
All components of the sprinkler systems shall be UL listed and labelled.
Refer to final Architectural and Interior Designer Reflected Ceiling Plans and co-ordinate locations of
sprinkler head with lighting and other ceiling mounted components. Co-ordinate sprinkler piping to
avoid interference with all other services
23A.2 PRE-ACTION SPRINKLER SYSTEMS
23A.2.1 General
Sprinkler systems shall be provided with all accessories as indicated in the drawings and as per the
requirements of the local civil defence and in accordance with NFPA 13.
23A.2.2 Pipe and fittings
Part 5
Section 23A Page1
All pipework, valves and fittings, unless otherwise specified, shall comply with relevant clauses in the
NFPA 13 regulations.
Supply, deliver and install all pipework materials and fittings for the sprinkler systems.
Pipework, ancillaries, valves and demountable joints shall be installed for convenient and safe routine
maintenance and renewals.
Pipework shall be run in a neat manner and installed plumb, straight, symmetrical and at right angles
to or parallel to adjacent walls.
Sufficient unions and flanged joints shall be provided to install and dismantle sections of pipe work,
wherever difficulty in dismantling may occur and on straight runs of more than 25m.
Connections to coils, pumps, and other equipment shall be made in such a manner as to eliminate
undue strains in piping and equipment. Necessary fittings and bends shall be furnished to avoid
springing of pipes during assembly.
Care shall be taken in placing unions to allow freedom to spring apart. Unions and flanges shall not
be placed in inaccessible positions. Where pipework is installed in inaccessible places, a union or
flange shall be installed, prior to the pipe passing into the wall or floor. Unions shall have two bronze
conical seats ground in. Long screw connections will not be accepted.
approval.
Bends and tees shall be of the easy sweep type, except at air vents, drain points and dead legs where
square tees shall be used.
Prior to any work being "covered up", the Contractor shall request the Engineer's approval to that part
of the installation in question.
Fittings on 50 mm and below shall be galvanized malleable iron fittings conforming to class 250, ANSI
B16.4 or B16.25 and shall be UL listed, FM approved.
Fittings 65mm and above shall be factory galvanized mechanical roll grooved fittings and shall be UL
listed, FM approved. These shall be class 250 to ANSI B16.9.
Part 5
Section 23A Page2
Fittings on 50 mm and below shall be galvanized malleable cast iron fittings conforming to class 300,
Fittings 65mm and above shall be factory galvanized mechanical roll grooved fittings and shall be UL
listed, FM approved. These shall be class 300 to class 16.9.
All valves and fittings used in the pipework system shall not have a pressure rating less than that of
the pipework.
Sleeves which are contained in walls, ceilings or floors which are fire barriers shall be additionally
packed with a non-combustible material for the entire length to form a fire/smoke stop of the required
fire rating.
The material shall be subject to approval and must comply with relevant code & Civil Defence.
UL listed expansion joints shall be provided for all pipework passing through any building expansion
joint and where necessary as specified and shall be designed for use in fire protection piping systems.
All piping shall be thoroughly cleaned of loose scale, dirt, etc., before installation. During the course
of the installation, all open ends of pipes shall be plugged or capped to prevent ingress of dirt.
After installation and sealing of joints all piping shall be thoroughly cleaned with clean water under
pressure to the satisfaction of Engineer. Water samples test may be required if the
Engineer is considered as necessary. Water used for this purpose shall be discharged as directed.
Any temporary pipework and equipment necessary for the above cleaning shall be provided by the
Contractor.
Provide a pressure gauge with an isolation cock with inspectors test plug on top of the each sprinkler
pipe risers.
23A.2.3 Valves
Unless otherwise indicated all valves controlling connections to water supplies and sprinkler systems
shall be UL listed and indicating valves and shall be in accordance with NFPA 13.
All valves shall have the name of the manufacturer and working pressure cast or stamped on body.
All isolating valves and control valves shall be provided with the proper and efficient operation and
maintenance of the entire systems.
Furnish all valves and accessory material necessary in the piping whether or not shown on drawings
as follows.
All valves shall be packed with an approved packing and threads shall be coated with oil and graphite.
Packing should be replaced when found deteriorated on site.
Plastic or metal plates (rustless) shall be provided to indicate the open/close status as well as the use
of each valve in the pump and tank rooms, and in the town main.
23A.2.4 Deluge Valves

The deluge valve shall be automatic in operation from a detection system (combination fixed
temperature and rate of rise heat actuated detector, etc.), a local manual station or a remote manual
station. The valve shall have a water flow switch, alarm test connection, contact for starting fire pump
Part 5
Section 23A Page3
system and de-energizing protected equipment. Provide drain and gages. The deluge valve shall be
capable of being manually tripped.
All trim required for the valve, such as pipe, nipples, valves, check valves, and strainers shall be
included.
23A.2.5 O. S. & Y. Valves

O. S. &Y gate valves shall be UL Listed and shall be fitted to the installation in order to shut the valve,
the spindle must turn clockwise. The hand wheels of all stop valves shall be clearly marked to indicate
which direction the wheel is to be turned to close the valve.
Each main stop valves shall be installed with a tamper / supervisory switch and interconnected to the
building fire alarm system or secured open by a padlock or riveted strap.
asbestos
Valve 65 mm and larger, Underwriters Laboratories pattern, iron body bronze mounted, OS & Y solid
wedge, flanged ends, 1200 kPa (water, oil, gas).
23A.2.6 Air Vents and Drain Valves

UL listed air vents and drain valves shall be provided at high points and low points respectively in all
Pre-Action system piping in accordance with NFPA 13, 11, & 16.
Air vents shall have gunmetal or brass bodies, non-ferrous or stainless steel float and guides, and
non-corrodible valves and seats. Each automatic air vent shall be controlled by a lock-shield valve.
Drain valves shall be connected to the nearest building floor drain or drain point of adequate size.
23A.2.7 Pressure Gauges

Provide UL listed pressure gauges, in accordance with NFPA 13, where indicated on the drawings
and as mentioned below. All gauges shall be provided with snubbers. Gauges shall have 115mm
diameter dial, white coated with black figures and graduations. Shutoff cock shall be provided
between gauge and piping to permit gauge removal while system is under pressure.
Gauges shall have graduation such that at normal working pressure the needle is in the centre of the
field.
Gauge Location:
Inlet and Outlet of Pumps

Mount gauges no higher than 1.5m above finished floor.
All gauges shall be calibrated in kPa to a maximum of not less than 1-1/3 times and not more than 2
times the operating pressure.
23A.2.8 Electric Pressure Alarm Switch

Provide UL listed electric alarm pressure switch in accordance with NFPA 13 and they shall be
mounted on a vertical branch pipe at least 300 mm long.
The pressure switch shall be of the diaphragm bellows operated type, and shall be sufficiently
sensitive to operate when only one sprinkler is discharging. The pressure switch shall be provided
with volt free contracts to facilitate monitoring by a Building Management System, and wired to the
main fire alarm panel.
Part 5
Section 23A Page4
23A.2.9 Alarm and Discharge Action
Cross-zoned Detection System: The Pre-Action sprinkler system shall be automatically actuated by
either verified detection circuits or cross-zoned detection circuits. Combination of
Fixed Temperature & Rate-of-Rise Heat detectors shall be installed at no more than 23 square meters
of coverage per detector (or as per manufacturers / applicable standards requirements).
The detectors shall be alternated throughout the protected area and be compatible on either circuit.
Phase I (General Alarm)
Activation of any single detector in any detection zone shall:

Cause a first-stage alarm (slow pulse horn/strobe).
Energise a lamp on the activated detector and control panel.
Phase II (Pre-Discharge)
Activation of two adjoining (cross-zoned) or any second (verified) detector shall:
Transmit an alarm signal to remote monitoring or building alarm panel
Cause a second-stage (pre-discharge) alarm (fast pulse horn/strobe) to operate.
Operate auxiliary contacts for air conditioning shutdowns and automatic dampers.
Initiate an adjustable time delay
Phase III (Discharge)

Upon completion of the time delay the Pre-Action sprinkler system shall:
Cause discharge (steady horn/strobe) alarm to be activated.
Operate auxiliary contacts for emergency power off all electrical equipment (excluding lighting and
emergency circuits for life safety).
Activate visual alarms at protected area entrance (strobe).
Energise control solenoid for Deluge valve
23A.2.10 Auxiliary Components

Manual Releasing Stations shall be provided at each exit of the protected area and shall when
activated, immediate activation of Solenoid Valve and cause all audible/visual alarms to activate.
Abort Stations shall be provided at each exit of the protected area and shall, when operated, interrupt
the activation of Solenoid Valve and emergency power off function. The Abort Stations shall be
momentary devices (dead-man) requiring constant pressure to maintain contact closure.
Note: Manual Pull Station activation shall override any abort Station. Abort Station operation shall be
per IRI and FM guidelines.
Graphic Annunciator shall be provided at the control panel location. The Graphic Annunciator shall be
provided by the equipment manufacturer in an approved NEMA enclosure with keyed face plate. The
Graphic Annunciator shall display the entire Pre-Action sprinkler system protected area (silk
screened) and shall indicate each heat detector and its proximity.
23A.2.11 Materials and Equipment - Electrical

Materials and equipment shall be of a single manufacturer. Provide materials and equipment from
approved suppliers. The name of the manufacturer and the serial numbers shall appear on all major
components. Locks for all cabinets shall be keyed alike.
All electrical enclosures, trunking and conduits shall be employed in accordance with applicable codes
and intended use and contain only those electrical circuits associated with the fire detection and
control system and shall not contain any circuit that is unrelated to the system.
Unless specifically provided otherwise in each case, all conductors shall be enclosed in steel conduit,
rigid or thin wall as conditions dictate.
Any conduit or trunking exposed to weather or other similar conditions shall be properly sealed and
installed to prevent damage, provisions for draining and/or drying shall be employed.
Part 5
Section 23A Page5
NEMA rating and/or electrically hazardous classifications shall be observed and any equipment or
materials installed must meet or exceed the requirements of service.
Any wiring shall be of the proper size to conduct the circuit current but shall not be smaller than 18
AWG, unless otherwise specified for a given purpose. Wire that has scrapes, nicks, gouges or
crushed insulation shall not be used. The use of aluminium wire is strictly prohibited.
Wire splices shall not be made.

All wire terminations shall be made with crimp terminals unless the device at the termination is
designed for bare wire terminations.
All electrical circuits shall be numerically tagged with suitable devices at its terminating point. All
circuit numbers shall correspond with the installation drawings.
The use of coloured wires is encouraged but not required unless dictated by state or local authorities.
Black coloured wire shall be used exclusively for the identification of the neutral conductor of an
alternating current circuit.
Green/Yellow coloured wire shall be used exclusively for the identification of the earth ground
conductor of an AC or DC circuit.
Primary system voltage shall be 220 VAC, single phase, 50 Hz.
23A.2.12 Control Systems - General

All control systems shall be UL listed or FM approved and be utilised with listed or approved operating
devices and shall be capable of the following features:
Ground fault indication.

Supervised detection circuit(s).
Supervised alarm circuit
Supervised release circuit
Supervised manual pull circuit
Supervised line power circuit
Alarm overrides trouble logic.
Battery standby.
Front panel indicating lamps (LEDs).
Key lock steel enclosure.
Programmable time delay.
Programmable detection logic.
Prioritised trouble logic.
Solid state integrated circuitry.
Lamp test.
23A.2.13 Control Panel

Provide a control system, in addition to the general requirements for control panels, the control
system shall meet the requirements of this section.
The control system shall consist of a power supply, programmable zone actuation with the necessary
number of supervised circuits and auxiliary relays.
The Internal power supply shall operate from 220 VAC, single phase, 50 Hz (1.0/0.5 amp rectified to
24 VDC (2 amp).
The control system shall provide provisions for housing its own set of on-line float charge emergency
batteries within the enclosure.
The control system shall provide two supervised detection (input circuits) programmable for:
Independent-zoning.
Priority-zoning.
Part 5
Section 23A Page6
Cross-zoning
A supervised dedicated manual pull circuit designated for immediate operation of the release circuit
shall be provided.
Abort function (if used) shall be programmed for either immediate release or 10 second delay after
abort and comply with IRI requirements.
A programmable time delay for 10, 15, 30 or 60 seconds shall be provided between verification of a
fire situation and suppression system release.
Battery Supervision shall be provided for condition and placement of the batteries.
Four (4) plug-in relays with two (2) Form C (DPDT) contacts, one relay with Form C (SPDT) rated at
10 amps, 30 VDC and 7.5 amps at 240 VAC shall be provided for auxiliary functions.
Each of the following actions shall cause one for the five relays to transfer:
General alarm.
Pre-discharge alarm.
System discharge.
Assignable general alarm or pre-discharge alarm.
System trouble.
LED indicators shall be provided on the front door to annunciate the following conditions:
Power On (green)
System trouble - (yellow)
Zone 1 alarm - (red) (yellow)
Zone 2 alarm - (Red) (Yellow)
Manual pull/Abort alarm - (Red) (Yellow)
General alarm - (Red) (Yellow)
Pre-discharge alarm - (Red) (Yellow)
System fired - (Red) (Yellow)
Prevent Switch. Furnish each zone with a keyed on/off switch in the face of the control panel to
prevent automatic actuation of the system. In the off mode only operation of the manual pull stations
will cause discharge.
23A.2.14 Heat Detector Combination Fixed Temperature & Rate-of-Rise Type

Refer to Electrical Specification.
23A.2.15 Horns & Strobes

23A.2.16 Manual Call Points

23A.2.17 Abort Switch

The abort switch shall be used where delay is desired between detection and actuation of the fire
suppression system.
This switch shall be a momentary contact dead-man type switch requiring constant pressure to
transfer one set of normally open contacts. Clear operating instructions shall be provided at the abort
switch.
This switch shall be rated at 6 amps at 240 VAC and 1.1 amps at 240 VDC.
The terminal connections shall be of the screw type.
23A.2.18 Hazard classification
Part 5
Section 23A Page7
The area coverage and spacing of Pre-Action Water sprinkler heads shall be designed and installed
as per the hazard classifications in accordance with NFPA 13 & 16, relevant standards and as shown
on the drawings.
23A.2.19 Inspection
Do not recess, paint or conceal any work including piping and accessory equipment before it has
been inspected and approved.
Prevent theft of sprinkler systems components. Replace any missing items prior to final inspection
and handover.
Protect all finishes, replace or repair any damaged finishes to the satisfaction of the local consultant.
23A.2.20 Testing
Pre-Action system test to be carried out in presence of client representative, local fire official, engineer
and a representative of installing contractor to verify the system performance.
Test all system components in accordance with NFPA 13.
Perform tests in the presence of each governing authoritys authorised inspector.
Submit certification that systems have been designed and installed in accordance with NFPA 13
and the requirements of the Local Civil Defence Authority.
Perform tests before piping is concealed.
Remove all components which will not withstand test pressure, and replace after tests.
Eliminate leaks, or remove and refit defective parts. Caulking of threaded or welded joints will not be
permitted.
Repeat tests as often as necessary to obtain certification.
23A.2.21 Identification signs

Provide signs, conforming to NFPA 13 requirements and in accordance with the requirements of local
authorities, for each valve and alarm device.
23A.2.22 Painting
Paint all exposed sprinkler piping with a suitable primer and top coat(s) in bright red to the satisfaction
of the lead consultant. Obtain agreement from the lead consultant on top coat paint colour before
application.
23A.2.23 Referred documents

NFPA 30 Flammable and Combustible Liquids Code
NFPA 20 Standard for the Installation of Stationary Pumps for Fire Protection
NFPA 24 Standard for the Installation of Private Fire Service Mains and their
Appurtenances.
NFPA 72 Standards for the application, installation, location, performance

and maintenance of fire alarm systems and their components
Part 5
Section 23A Page8
Section 24 Standpipe and Hose Systems
Contents
Section 24 Standpipe and Hose Systems 1
24.1 General 1
24.2 Standpipe and hose systems 1
24.3 Portable fire extinguishers 7
24.4 Inspection 8
24.5 Testing 8
24.6 Painting 8
Section 24 Standpipe and Hose Systems
24.1 GENERAL
Provide all labour, materials, products, equipment and services to supply and install standpipe
and hose systems as indicated on the Drawings and specified in this Section of the Specification
in accordance with NFPA 14 and to the requirements of local civil defence.
The fire protection contractor shall be experienced in the design and installation of fire protection
systems to NFPA standards and shall be an approved contractor by Local Civil Defence
Authority.
Standpipe system piping shall be sized by hydraulic calculations in accordance with NFPA 14
and a complete set of calculations shall be submitted with the plans for engineers review.
Submit system layout drawings, component shop drawings, specifications and hydraulic
calculations for Consultants review prior to commencing installation.
Drawings shall be certified correct and bear the contractors engineers certification prior to
submission to the consultant.
Upon completion of the installation, modify the system calculations and submit hydraulic design
data based on as-built system.
NFPA 10 - Standard for Portable Fire Extinguishers

All components of the standpipe and hose systems shall be UL listed and labelled.
Material shall meet current ASTM and ANSI standards.
Confirm fire hose cabinet locations and quantities from both Architectural and Mechanical
Drawings and provide higher count including piping connections. Report any discrepancies to
Consultant prior to bid close.
24.2 STANDPIPE AND HOSE SYSTEMS
24.2.1 General
Standpipe and hose systems shall be provided with all accessories as indicated in the drawings
and as per the requirements of the local civil defence and in accordance with NFPA 14.
Part 5
Section 24 Page 1
24.2.2 Pipe and Fittings
All pipework, valves and fittings, unless otherwise specified, shall comply with relevant clauses
in the NFPA 14 regulations.
Underground piping shall be in accordance with NFPA 24.
Supply, deliver and install all pipework materials and fittings for the standpipe and hose
systems.
Sufficient unions and flanged joints shall be provided to install and dismantle sections of pipe
work, wherever difficulty in dismantling may occur and on straight runs of more than 25m.
eliminate undue strains in piping and equipment. Necessary fittings and bends shall be
Care shall be taken in placing unions to allow freedom to spring apart. Unions and flanges shall
not be placed in inaccessible positions. Where pipework is installed in inaccessible places, a
union or flange shall be installed, prior to the pipe passing into the wall or floor. Unions shall
have two bronze conical seats ground in. Long screw connections will not be accepted.
approval.
Prior to any work being "covered up", the Contractor shall request the Engineer's approval to
that part of the installation in question.
Part 5
Section 24 Page 2
Fittings on 50 mm and below shall be galvanized malleable iron fittings conforming to class 250,
be UL listed, FM approved. These shall be class 250 to ANSI B16.9.
Fittings on 50 mm and below shall be galvanized malleable cast iron fittings conforming to class
300, ANSI B16.3 and shall be UL listed, FM approved.
be UL listed, FM approved. These shall be class 300 to class 16.9.
All valves and fittings used in the pipework system shall not have a pressure rating less than
that of the pipework.
The material shall be subject to approval and must comply with Civil Defence.
UL listed expansion joints shall be provided for all pipework passing through any building
expansion joint and where necessary as specified and shall be designed for use in fire
protection piping systems.
All piping shall be thoroughly cleaned of loose scale, dirt, etc., before installation. During the
course of the installation, all open ends of pipes shall be plugged or capped to prevent ingress
of dirt.
After installation and sealing of joints all piping shall be thoroughly cleaned with clean water
under pressure to the satisfaction of Engineer. Water samples test may be required if the
Engineer is considered as necessary. Water used for this purpose shall be discharged as
directed.
Underground piping supplying the system shall be flushed in accordance with NFPA 24.
Any temporary pipework and equipment necessary for the above cleaning shall be provided by
the Contractor.
24.2.3 Valves
All valves controlling connections to water supplies and standpipes shall be UL listed and
indicating valves and shall be in accordance with NFPA 14.
All valves shall have the name of the manufacturer and working pressure cast or stamped on
body.
All isolating valves and control valves shall be provided with the proper and efficient operation and
maintenance of the entire systems.
Furnish all valves and accessory material necessary in the piping whether or not shown on
drawings as follows.
Part 5
Section 24 Page 3
All valves shall be packed with an approved packing and threads shall be coated with oil and
graphite. Packing should be replaced when found deteriorated on site.
Plastic or metal plates (rustless) shall be provided to indicate the open/close status as well as the
use of each valve in the pump and tank rooms, and in the town main.
24.2.4 Butterfly Valves

Use butterfly valves for riser and zone control valves.
Valves 100 mm and larger, Underwriters Laboratories pattern, iron body, 416 stainless steel
upper and lower stems, bronze disc and copper alloy bearings.
The stem journals will be a multiple seal design providing for completely independent seals.
The stem disc assembly will be such that the need for pins, screws or bolts is not required.
Positive stem retention to be provided to permit removal of handle or actuator while under full
operating pressure
The valve seats to consist of replaceable resilient elastomer.
Valves to be supplied with enclosed worm gear operator and with built-in micro switches for
supervisory monitoring purposes
Valve body to be full-lug pattern to comply with and be compatible with flanges of appropriate
pressure rating. No semi-lug valves are acceptable.
Valve shall have flag indicator and be factory wired for tamper switch installation.
Provide wiring from butterfly valves temper switch to fire alarm panel in accordance with NFPA
72.
24.2.5 OS & Y Gate Valves

OS&Y gate valves shall be UL Listed and shall be fitted to the installation in order to shut the
valve, the spindle must turn clockwise. The hand wheels of all stop valves shall be clearly
marked to indicate which direction the wheel is to be turned to close the valve.
Each main stop valves shall be installed with a tamper / supervisory switch and interconnected
to the building fire alarm system or secured open by a padlock or riveted strap.
asbestos
Valve 65 mm and larger, Underwriters Laboratories pattern, iron body bronze mounted, OS & Y
solid wedge, flanged ends, 1200 kPa (water, oil, gas).
24.2.6 Check Valves

Check valves shall be of materials similar to the gate valves for the appropriate systems in
which they will be installed. All check valves shall be of quick closing type to eliminate the
sudden surge in the pipe line on closing.
Valves 50 mm and smaller, bronze to ASTM B61 designed of both horizontal and vertical
mounting replaceable composition disc, screwed cap and ends, 1400 kPa (water, oil, gas).
Part 5
Section 24 Page 4
Valves 65 mm and larger, iron body, Underwriters Laboratories pattern, bronze mounted,
regrind renew bronze disc and seat ring, bolted cap, designed for either horizontal or vertical
mounting, flanged ends, 1200 kPa (water, oil, gas).
Swing Type: Use for water and low pressure general services: 50 mm and smaller with screwed
bonnet, screwed end; 65mm and larger with bolted bonnet, flanged end or grooved end. Valves
to have renewable bronze seat and disc
Silent Type: Use for standpipe system pumps. Valves to have cast iron body and bronze or
stainless steel trim and to be of the center guide type, with flanged end or grooved end
24.2.7 Air Vents and Drain Valves

UL listed air vents and drain valves shall be provided at high points and low points respectively
in all standpipe piping in accordance with NFPA 14.
Air vents shall have gunmetal or brass bodies, non-ferrous or stainless steel float and guides,
and non-corrodible valves and seats. Each automatic air vent shall be controlled by a lock-shield
valve.
Drain valves shall be connected to the nearest building floor drain or drain point of adequate
size.
24.2.8 Gauges
Provide UL listed pressure gauges, in accordance with NFPA 14, where indicated on the
drawings and as mentioned below. All gauges shall be provided with snubbers. Gauges shall
have 115mm diameter dial, white coated with black figures and graduations. Shutoff cock shall
be provided between gauge and piping to permit gauge removal while system is under pressure.
Gauges shall have graduation such that at normal working pressure the needle is in the center
of the field.
Gauge Location:
Inlet and Outlet of Pumps
Top and bottom of all standpipe risers
Mount gauges no higher than 1.5m above finished floor.
All gauges shall be calibrated in kPa to a maximum of not less than 1-1/3 times and not more
than 2 times the operating pressure.
24.2.9 Waterflow and Supervisory Alarms

UL listed water flow and supervisory alarms shall be provided as required and where mentioned
in the drawings in accordance with NFPA 14.
Alarm and supervisory devices shall be installed in accordance with NFPA 72.
24.2.10 Pressure-Regulating Devices

UL listed pressure regulating devices shall be provided as required and where mentioned in the
drawings in accordance with NFPA 14.
24.2.11 Backflow Preventers

UL listed backflow preventers shall be provided as required and where mentioned in the
drawings in accordance with NFPA 14.
Part 5
Section 24 Page 5
24.2.12 Fire Department Connections
UL listed fire department connections shall be provided complete with clapper valves, female
swivels, cap and chains as required and where mentioned in the drawings in accordance with
NFPA 14 and as per the requirements of local civil defence.
Provide each fire department connection with check valve with automatic ball drip piped to
nearest floor drain.
The inlet connections shall be of suitable type of local fire brigade department / Dubai Civil
Defence / DCA fire station.
Provide identification signage in the required languages and in accordance with NFPA 14 and
as per the requirements of the local fire civil defence.
24.2.13 Hydrants
UL listed / FM approved hydrants shall be provided complete with isolation valve as required
and where mentioned in the drawings in accordance with NFPA 24 and as per the requirements
of local civil defence.
24.2.14 Fire Hose Cabinets

Provide fire hose cabinets complete with valves, hose and accessories as required and where
mentioned in the drawings in accordance with NFPA 14 and as per the requirements of local
civil defence.
Where shown on the drawings, provide steel, recessed, combined cabinets with lacquer finished
door, stainless steel panel, outside lettering and concealed hinges. Finish to be approved by
the lead consultant. Construct lower section of cabinet with removable back panel for access to
space behind.
Where shown on the drawings, provide steel, surface mounted, combined cabinets with lacquer
finished door and panel and outside lettering. Finish to be approved by the lead consultant.
Overall sizes of cabinet shall be as mentioned in the drawings.
Provide lettering on upper cabinet door to read Fire Hose Reel and on the lower cabinet door to
read Fire Department Hose and Extinguishers.
Equip each cabinet with 25 mm chrome plated angle valve, cast or forged brass, with
handwheel. Where indicated on the drawings, instead of the previous valve, provide adjustable
pressure restricting angle valve acceptable to the local authority having jurisdiction. Provide
outlet threads on these valves to match cabinet fore hose.
Locate 25 mm angle valve maximum 1.5 m above floor.
Equip each cabinet with 65 mm chrome plated angle valve, cast or forged brass with
handwheel. Where indicated on the drawings, instead of the previous valve, provide 65 mm
adjustable pressure restricting angle valve acceptable to the local authority having jurisdiction.
Provide outlet complete with spanner wrench and chrome plated forged brass pull-off cap and
chain. Hose threads shall suit local Fire Department connections.
Provide 30 metres long, 25 mm dia. synthetic rubber lined polyester fibre hose, mildew and rot
resistant for the upper cabinet hose reel. Provide adjustable, plastic type combination spray,
solid stream nozzle with shutoff.
Provide hose reel approved by local civil defence.
Provide 30 meters long, 65 mm diameter flat packed fire mans hose with quick connect coupling
and aluminium lever control jet/spray nozzle as indicated on the drawings, all in compliance with
the requirements of the local authorities having jurisdiction.
Part 5
Section 24 Page 6
Provide fire hose complete with reducer couplings, if required, to fit valve, screw threads and
tailpiece.
Equip each fire hose cabinet with one UL listed 5 kg CO2 fire extinguisher and one UL listed 5
kg multipurpose dry chemical extinguisher.
24.2.15 Signs
Provide signs for valves in accordance with NFPA 14 for all main and other system valves
including drain and test connection valves.
Fabricate signs of metal with white letters on red background and suspension chains.
Provide these signs in two languages, Arabic and English in accordance with the requirements
of local authorities having jurisdiction.
24.3 PORTABLE FIRE EXTINGUISHERS

Provide portable fire extinguishers in all areas in accordance with NFPA 10 and in compliance
with local authorities having jurisdiction. Provide the following types of extinguishers in
accordance with the schedule below.
Type 1: Provide in the Mechanical Rooms, UL listed, 5 kg multi purpose dry chemical
extinguishers, stored pressure type having ammonium phosphate base with hose and shutoff
nozzle integral shutoff nozzle labelled by Underwriters Laboratories.
Type 2: Provide in Transformer rooms and all electrical and telephone rooms, UL listed,
chemical dry powder as shown on drawing, insulated handle, hose and horn discharge
assembly, self closing level squeeze grip operation, fully charged, labelled by Underwriters
Laboratories with mounting brackets where required.
Type 3: Provide for other floor areas, UL listed, 5 kg multi purpose dry chemical extinguishers,
complete with wall brackets for future mounting.
Type 4: Provide for Parking areas, UL listed, 5 kg standard dry chemical type, fire extinguishers
complete with mounting bracket.
Type 5: Provide for external plant areas UL listed, 6.8 kg CO2 fire extinguishers complete with
insulated handle, hose and horn discharge assembly, self closing lever squeeze grip operation
and mounting brackets.
Provide extinguisher wall brackets type as recommended by extinguisher manufacturer for non
cabinet mounted fire extinguishers.
Provide recessed steel, extinguisher cabinets with lacquer finished doors, outside lettering and
concealed hinges. Finish to be approved by architect. Exact size of cabinet shall be to suit
extinguisher. Provide lettering on cabinet door to read Extinguisher.
Install portable fire extinguishers in cabinets for finished occupied areas or on brackets.
Provide certification that each extinguisher has been properly charged, including:
Date extinguisher was charged.
Name of person who charged extinguisher and the name of his organisation
Signature of person giving certification, and the name of his organisation
Affix certification to each extinguisher tag provided in this Contract. Provide space for future
service data entry.
Part 5
Section 24 Page 7
24.4 INSPECTION
Do not recess, paint or conceal any work including piping and accessory equipment before it
has been inspected and approved.
Prevent theft of fire hose cabinet components. Replace any missing items prior to final
inspection and handover.
Protect all cabinet finishes, replace or repair any damaged finishes to the satisfaction of the
local consultant.
24.5 TESTING
Test all standpipe and fire hose in accordance with NFPA14.
If impossible to test whole installation in a single operation, subdivide into several zones and
test each zone in the manner prescribed.
Test systems and equipment to hydrostatic and operational pressure as follows:

Fire standpipe system including water supply connections and fire department connections shall
be hydrostatically pressure tested at 345 kPa in excess of normal working pressure, but not less
than 1380 kPa for 2 hours without pressure loss.
Provide certification that installed standpipe and hose system meets all specified standards and
the requirements of all authorities having jurisdiction.
24.6 PAINTING
Paint all exposed standpipe and hose system pipework with a suitable primer and top coat(s) in
Fire mains red to the satisfaction of the lead consultant. Obtain agreement from the lead
consultant on top coat paint color before application.

NFPA 10 Standard for Portable Fire Extinguisher

NFPA 14 Standard for the Installation of Standpipe and Hose Systems
Protection
NFPA 24 Standard for the Installation of Private Fire Service Mains
and their Appurtenances.
NFPA 72 Standards for the application, installation, location,
performance and maintenance of fire alarm systems and
their components
Part 5
Section 24 Page 8
Section 25 Fire Protection pumps
Contents
Section 25 Fire Protection Pumps 1
25.1 General 1
25.2 Horizontal split case centrifugal pumps 1
25.3 Vertical shaft turbine pumps 1
25.4 Jockey pumps 2
25.5 Electric motor driver 2
25.6 Diesel engine driver 2
25.7 Fire pump accessories 2
25.8 Electric motor driven fire pump controller 3
25.9 Diesel engine driven fire pump controller 3
25.10 Jockey pump controller 4
25.11 Fire water tanks 4
25.12 Installation 4
25.13 Testing & Commissioning 5
Section 25 Fire Protection Pumps
25.1 GENERAL
Provide all labour, materials, products, equipment and services to supply and install fire
protection pumps as required and as indicated on the Drawings and specified in this Section of
the Specification in accordance with NFPA 20 and to the requirements of the local civil defence.
Pump, including accessories, shall be UL listed and FM approved, and shall conform to
applicable requirements of:
Local Civil Defence
Provide shop drawings which include drawings showing mounting details of the fire pumps,
motor, diesel engine and controllers, location on the platforms and with respect to the water
tanks and location of the pump suction within the tank.
The fire protection pump shall be a fully automatic unit consisting of electric motor driven pump
to act as duty pump, diesel engine driven pump to act as standby pump and electric motor
driven jockey pump for maintaining the pressure in the system. All the equipments shall be
suitable in all respects for the local climatic conditions.
25.2 HORIZONTAL SPLIT CASE CENTRIFUGAL PUMPS

Provide UL listed / FM approved horizontal split case pumps complete with drivers to the
capacities indicated on drawings in accordance with NFPA 20 and to the requirements of the
Fire pumps shall be capable of furnishing not less that 150% of rated capacity at not less that
65% of rated head. Shut off head shall not exceed 140% of rated head.
Entire Fire pump unit shall be painted to red colour before shipping.
Pump's shaft shall be stainless steel with bronze sleeve.
Bearings shall be replaceable type, bronze.
Provide name plate with all relevant information.
Provide a test valve header assembly complete with hose valves, caps and chains.
25.3 VERTICAL SHAFT TURBINE PUMPS

Provide UL listed / FM approved vertical shaft turbine pumps complete with drivers to the
capacities indicated on drawings in accordance with NFPA 20 and to the requirements of the
Fire pumps shall be capable of furnishing not less that 150% of rated capacity at not less that
65% of rated head. Shut off head shall not exceed 140% of rated head.
Entire Fire pump unit shall be painted to red colour before shipping.
Part 5
Section 25 Page 1
Pump's shaft shall be stainless steel with bronze sleeve.
Bearings shall be replaceable type, bronze.
Provide name plate with all relevant information.
Provide a test valve header assembly complete with hose valves, caps and chains.
25.4 JOCKEY PUMPS

Jockey pump shall be supplied by approved fire pump manufacturer and shall be vertical
multistage, factory assembled and tested for capacity indicated on drawings. Construction of
jockey pump shall be as given below.
Impeller: Stainless steel.
Shaft: Stainless steel.
Casing: Cast iron or stainless steel.
Connections: flanged or threaded.
25.5 ELECTRIC MOTOR DRIVER

Provide NEMA MG1, ODP squirrel cage induction motor in accordance with NFPA 20 and
provide name plate with all relevant information. The Motor shall be UL listed open drip proof,
standard efficiency with 1.15 service factor. The fire pump shall be directly coupled through
flexible coupling to a horizontal electric motor.
The locked rotor current shall not exceed the values specified in NFPA 20.
Terminal and wiring of the motor shall be compatible with controller of the pump.
25.6 DIESEL ENGINE DRIVER

Provide a UL listed and FM approved heat exchanger cooled diesel engine as driver for standby
fire pump in accordance with NFPA 20 and to the requirements of the local civil defence.
The diesel engine shall be equipped with the following standard features:
Manual operation option.
Governor to regulate engine speed within 10%
Over speed shutdown device with manual reset
Battery contactors
Alternator or generator for battery recharging
Heat exchanger cooling system
Raw water cooling line as per NFPA 20
Battery rack and cables
Flexible exhaust connector
Instrument panel with tachometer, oil pressure gauge, temperature gauge, and hour meter
Duel set batteries
Junction box with numbered terminals to correspond with terminals in controller
Fuel tank Double wall
Size of the fuel tank shall be as NFPA 20 requirements.
Fuel system
Exhaust silencer Residential Grade
The exhaust pipe shall be insulated and further protected with hammer finish aluminium
cladding. Exhaust pipe shall be fully insulated and discharge to outside at suitable location and
complete with Air Flap Valve.
The engine shall be of adequate horsepower to be non-overloading at any point on the pump
curve.
25.7 FIRE PUMP ACCESSORIES

Automatic air release valve.
Part 5
Section 25 Page 2
Casing relief valve for electric motor driven pump
Suction and discharge pressure gauges for all pumps
Eccentric tapered suction reducer
Concentric discharge increaser
Flow meter
Main relief valve
Waste cone closed type
25.8 ELECTRIC MOTOR DRIVEN FIRE PUMP CONTROLLER

The electric motor driven fire pump's controller shall be UL listed / FM approved and completely
assembled and tested at the factory for electric motor driven fire pumps, primary resistance
type, with auto transfer switch in accordance with NFPA 20 and have the following features:
Isolating means and circuit breaker
Power on Pilot lamp
Pump running Pilot lamp
Power failure Pilot lamp
Phase reversal Pilot lamp
Pump motor temperature alarm Pilot lamp.
Volt free contacts to fire alarm system for Pump running, Power failure and Phase reversal.
Suitable for manual and automatic operation
Push buttons for starting and stopping the fire pump.
Push button for silencing alarm
Minimum run timer to prevent short cycling
Emergency run mechanical control
Pressure switch
Audible alarm
Voltmeter and ammeter on the front side of the panel.
Controller shall be suitable for wall mounting or freestanding type.
Enclosure of the controller shall meet the requirements of NEMA 12, drip tight terminals of the
controller shall be sized to suit the incoming power cables.
25.9 DIESEL ENGINE DRIVEN FIRE PUMP CONTROLLER

The diesel engine driven fire pump's controller shall be UL listed / FM approved and completely
assembled and tested at the factory for diesel engine driven fire pumps, primary resistance type
in accordance with NFPA 20 and have the following features:
Automatic pilot lamp
Fail to start pilot lamp
Battery failure pilot lamp
Suitable for manual and automatic operation
Push buttons for starting and stopping the fire pump.
Push button for silencing alarm
Pressure switch
Audible alarm
Voltmeter and ammeter on the front side of the panel.
Controller shall be suitable for wall mounting or freestanding type.
Two independent built-in battery chargers with separate AC input fuses or circuit breakers, DC
output fuses or circuit breakers, and charging circuits shall be provided.
The controller shall provide audible and visual indication as well as individual remote contacts
for the following alarm conditions:
Low engine oil pressure
High engine water temperature
Failure to start
Over speed shutdown
Low fuel level
Low pump room temperature
Relief valve discharge
Part 5
Section 25 Page 3
Water level in suction supply below normal
Water level in suction supply near depletion
Battery 1 failure
Battery 2 failure
Battery charger failure
25.10 JOCKEY PUMP CONTROLLER

Provide across-the-line type jockey pump controller UL listed, factory assembled and tested
suitable for combined manual and automatic operation type in accordance with NFPA 20 and
have the following features:
Power on pilot light
Disconnect switch.
Hand-Off-Auto selector switch
Pump running pilot light
Pressure switch
Volt free contacts for fire alarm system for pump running.
25.11 FIRE WATER TANKS

Fire water tanks shall be in accordance with NFPA 22 and for maintenance and safety reasons,
the firewater supply shall be stored in not less than two tanks. The total fire water storage
capacity of both the tanks shall be in accordance with NFPA 13, NFPA 14 and NFPA 20 and as
per the requirements of the local civil defence.
The fire water tanks shall be equipped with;

Level control systems
level alarms (high & low)
On/off feeding valves.
Extruded rubber sealing strip shall be used covering full width of panel flange providing a water
tight seal.
Testing and commissioning shall be in accordance with NFPA 22 and as per the requirements
of the local civil defence.
25.12 INSTALLATION
Install pumps on foundations and arrange to provide access for periodic maintenance.
Follow manufacturers recommendations for installation.
Suction and discharge pipe sizes shall be in accordance with NFPA20.
Wiring from the controller to the motor of main fire pump and jockey pump shall be in steel
conduit or protected from damage and fire.
Piping to pressure switch shall be stainless steel 316.
Install the dual fire pump set with controllers, transfer switch and accessories as a complete
system such that the electric pump starts first automatically on a pressure drop to maintain
system pressure and the diesel pump starts if the electric pump fails for whatever reason.
Provide steel mounting supports for the pumps, motors, pressure vessel and controls.
Install the pumps, motors and control gear on a single platform.
Part 5
Section 25 Page 4
Align the pumps, drives and motors and provide for inspection by a qualified manufacturers
representative before testing.
Comply with all applicable requirements of NFPA20, comply with the requirements of the
authorities having jurisdiction.
Perform all tests required by codes and authorities having jurisdiction.
Provide certification that installation conforms to the requirements of applicable codes and
authorities having jurisdiction.
25.13 TESTING & COMMISSIONING

Perform testing & commissioning in accordance with NFPA 20 and to the requirements of the
Provide services for manufacturers representative for start up and to demonstrate and train
owners representative.
Train owners maintenance personnel on procedures and schedules related to start up,
shutdown, troubleshooting, servicing and preventive maintenance.
Lubricate all bearings.
Start the pump and check the operation the driver of each pump (insure the fire water tank is
filled with water before starting the pump).
Submit all maintenance manuals / catalogues of installed equipment's.


NFPA 14 Standard for the Installation of Standpipe and Hose Systems
Protection
Part 5
Section 25 Page 5
Section 26 Gaseous Fire Suppression:
FM200
Contents
Section 26 Gaseous Fire Suppression: FM200 1
26.1 General 1
26.2 System Description and Operation 1
26.3 Alarm and Discharge Action 2
26.4 Auxiliary Components 2
26.5 Materials and Equipment - Electrical 2
26.6 Equipment and Materials (Mechanical) 3
26.7 Control Panel 6
26.8 Smoke Detector - Ionisation 7
26.9 Smoke Detector - Photoelectric 7
26.10 Horns & Strobes 7
26.11 Manual Call Points 7
26.12 Abort switch 7
26.13 Inert Gas system Arrangement 7
26.14 Testing & Commissioning 8
26.15 Warranty 8
Section 26 Gaseous Fire Suppression: FM200
26.1 GENERAL
Provide all labour, materials, products, equipment and services to supply and install a gaseous
fire suppression system as required on the Drawings and specified in this Section of the
Specification in accordance with NFPA 2001 and to the requirements of the local civil defence.
This installation shall be made in strict accordance with the drawings, specifications and
applicable National Fire Protection Association Standards. All equipment and devices used
shall be listed in both the UL Fire Equipment List and the Factory Mutual Approval Guide.
Design and installation of the fire detection/inert gas suppression system will be in strict
accordance with the following guidelines and regulatory agencies:
NFPA 2001 Clean Agent Fire Extinguishing Systems

NFPA Standards 70, 72A, 72B, 72C & D
Provide comprehensive shop drawings to the approval of the CA.
Furnish all engineering design and materials, for a complete fire detection/inert gas suppression
system, including charged inert gas storage containers, nozzles, control panel, detectors, wiring,
annunciators, alarm and any and all other equipment necessary for a complete operational
system.
Major system components shall be produced by the approved ISO 9002 certified equipment
supplier and shall be installed by a specialist contractor authorised by the approved equipment
supplier.
Contractor shall, as a minimum, provide 24-hour emergency service, 7 days a week and shall
be able to respond to an emergency situation within 2 hours of receiving an emergency trouble
call. In addition, Contractor shall maintain no less than Dh. 5 million liability insurance.
26.2 SYSTEM DESCRIPTION AND OPERATION

The system shall be a total flooding inert gas extinguishing system designed to provide a
uniform concentration of 5.8% inert gas for the protected area.
The amount of inert gas to be provided shall be the amount required to obtain a uniform 5.8%
(minimum) concentration for ten (10) minutes. Take into consideration such factors as
unclosable openings (if any), rundown time of fans, time required for dampers to close (and
requirements for any additional dampers), and any other feature of the facility that could affect
concentration. The design concentration, however, shall be 7.0% (minimum) by volume at
21C.
Cross-zoned or Verified Smoke Detection: The inert gas system shall be automatically actuated
by either verified detection circuits or cross-zoned detection circuits. Smoke detectors shall be
of the ionisation and photoelectric types installed at no more than 7 square meters of coverage
per detector. The detectors shall be alternated throughout the protected area and be
compatible on either circuit.
Part 5
Section 26 Page 1
26.3 ALARM AND DISCHARGE ACTION



Initiate an adjustable time delay (inert gas release).

Upon completion of the time delay the inert gas system shall:

Operate auxiliary contacts for emergency power off all electrical equipment (excluding
lighting and emergency circuits for life safety).
Energise control solenoid for inert gas cylinders releasing gaseous agent into the alarmed
zone only.
26.4 AUXILIARY COMPONENTS

activated, immediately release the inert gas and cause all audible/visual alarms to activate. In
addition, activation of the Manual Releasing stations shall cause immediate shutdown of air and
power circuits.
Abort Stations shall be provided at each exit of the protected area and shall, when operated,
interrupt the discharge of inert gas and emergency power off function. The Abort Stations shall
be momentary devices (dead-man) requiring constant pressure to maintain contact closure.
Note: Manual Pull Station activation shall override any abort Station. Abort Station operation
shall be per IRI and FM guidelines.
Graphic Annunciator shall be provided at the control panel location. The Graphic Annunciator
shall be provided by the equipment manufacturer in an approved NEMA enclosure with keyed
face plate. The Graphic Annunciator shall display the entire inert gas protected area (silk
screened) and shall indicate each smoke detector and its proximity. Smoke detectors, when
activated, will individually annunciate at the graphic Annunciator as follows:
Ceiling Detector: Red LED

Subfloor Detector: Amber LED
26.5 MATERIALS AND EQUIPMENT - ELECTRICAL

Materials and equipment shall be of a single manufacturer. Provide materials and equipment
from approved suppliers. The name of the manufacturer and the serial numbers shall appear on
all major components. Locks for all cabinets shall be keyed alike.
All electrical enclosures, trunking and conduits shall be employed in accordance with applicable
codes and intended use and contain only those electrical circuits associated with the fire
detection and control system and shall not contain any circuit that is unrelated to the system.
Part 5
Section 26 Page 2
Unless specifically provided otherwise in each case, all conductors shall be enclosed in steel
conduit, rigid or thin wall as conditions dictate.
Any conduit or trunking exposed to weather or other similar conditions shall be properly sealed
and installed to prevent damage, provisions for draining and/or drying shall be employed.
NEMA rating and/or electrically hazardous classifications shall be observed and any equipment
or materials installed must meet or exceed the requirements of service.
Any wiring shall be of the proper size to conduct the circuit current but shall not be smaller than
18 AWG, unless otherwise specified for a given purpose. Wire that has scrapes, nicks, gouges
or crushed insulation shall not be used. The use of aluminium wire is strictly prohibited.
The use of coloured wires is encouraged but not required unless dictated by state or local
authorities.
Control Systems - General

All control systems shall be UL listed or FM approved and be utilised with listed or approved
operating devices and shall be capable of the following features:

Battery standby.
Lamp test.
26.6 EQUIPMENT AND MATERIALS (MECHANICAL)
Pipe Material Inert Gas System

Inert gas system piping shall be of non-combustible materials having physical and chemical
characteristics such that its integrity under stress can be predicted with reliability.
As a minimum, piping materials shall be black steel pipe conforming to ASTM A-106A SMLS or
ASTM A-53A.
Part 5
Section 26 Page 3
Under no conditions shall ordinary cast iron pipe, steel pipe conforming to ASTM A-120 or
ASTM A-53/A-120 be used.
Inert gas piping joints shall be suitable for the design conditions and shall be selected with
consideration of joint tightness and mechanical strength.
As a minimum fittings beyond the orifice union shall be black, 136 Kg (300 lb.) class fittings
conforming to ANSI B-16.3. Ordinary cast iron fittings shall not be used.
The system manifold up to the orifice union must be constructed of Schedule 80 piping and 907
or 1360kg forged steel fittings. Distribution piping down stream from the orifice union must be
constructed of a minimum of Schedule 40 piping and 136kg fittings.
All piping shall comply with NFPA-2001.
Piping shall be installed in accordance with good commercial practice to the appropriate codes,
securely supported with UL Listed hangers and arranged with close attention to the design
layout since deviations may alter the design flow performance as calculated.
Piping shall be bracketed within 300 mm of all nozzles.
All piping must be reamed, blown clear and swabbed with appropriate solvent to remove mill
varnish and cutting oils before assembly.
Multi-outlet fittings other than tees shall not be permitted.
Assembly of all joints shall conform to the appropriate standards. Threaded pipe joints shall
utilise teflon tape applied to the male threads only.
Agent
The agent shall be Inert Gas heptafluorpropane, HFC 227 (C 3F7H) supplied under the FM-200
trademark name registered to Great Lakes Chemicals Corporation.
Inert Gas Storage Cylinders

Inert gas cylinder assemblies shall be steel constructed with a standard RED epoxy paint finish.
Each cylinder shall be equipped with a pressure seat type valve and gauge. The system shall
utilise approved pilot valve assemblies. Each valve shall be constructed of forged brass and
shall attach to the cylinder providing a leak tight seal. Each valve shall also include a safety
pressure relief device that provides relief as per CGA test methods.
The size of all cylinders shall be based on computer verified system design requirements.
Tank Bracket
Each inert gas tank shall be furnished with a bracket made from welded steel. The bracket shall
hold the cylinders in a saddle and have a front bracket piece that holds the cylinders in place.
The brackets shall have the ability to add more bracketing or stack cylinders depending on
installation requirements.
Brackets shall be UL/FM Listed for use with inert gas Systems.
Valve Actuators
Inert gas valve actuators shall be of brass construction, stackable design, with swivel
connections to allow removal of actuators for maintenance or testing.
Operation of actuators shall not require replacement of components. NO ELECTRO-

EXPLOSIVE DEVICES may be used to actuate the valve assembly.
Part 5
Section 26 Page 4
Electric actuators shall be of the magnetic latch type or of the continuous duty type for 24 VDC
operation.
UL/FM Listed for use with inert gas.
Discharge Hose / Check Valve

When manfolding, all tank assemblies shall include a flexible discharge hose and check valve
for connection to the manifold inlet.
All hose/check valves shall be UL Listed or FM approved for use with the high flow inert gas
valve.
Discharge Nozzles
Inert gas discharge nozzles shall be of two piece construction sized to provide flow rates in
accordance with system design flow calculations.
A nozzle inlet orifice plate shall be included. The orifice size shall be determined by a
computerised UL Listed flow calculation programme.
Orifice shall be machined in the nozzle body to provide a horizontal discharge pattern based
upon the approved coverage arrangements.
Nozzles shall be permanently marked with the manufacturers part number. The nozzle shall be
threaded directly to the discharge piping without the use of special adapters.
Nozzles shall be UL Listed.
Orifice Union / Nipple Assembly

A manifold orifice union shall be included to reduce pressures in the downstream piping.
System Checkout and Testing

The completed installation shall be inspected by factory authorised personnel and shall include
a full operational text of all components per the equipment manufacturer recommendations
(including agent discharge).
This shall be done in the presence of the Company representative, insuring authority, and the
local authority having jurisdiction.
All mechanical and electrical components shall be tested according to the manufacturers
recommended procedure to verify system integrity.
An inspection shall be provided by the Contractor. Inspection shall include a complete checkout
of the electronic system and certification of cylinder pressure. A written report shall be filed with
the Company.
As-built drawing shall be provided by the Contractor (6 copies) indicating the installed details.
All routing of piping and electrical conduit and accessories shall be noted.
Equipment, installation and maintenance manuals shall be provided in addition to the as-built
drawings.
Part 5
Section 26 Page 5
Prior to final acceptance, the Contractor shall provide operational training in all concepts of the
system to the Companys key personnel. Training shall consist of:
Control system operation.

Trouble procedures.
Abort procedures.
Emergency Procedures.
Safety requirements.
Demonstration of the system (excluding inert gas release).
The quantity of agent shall reflect the actual design quantity of inert gas.
A functional test shall be completed prior to the concentration test consisting of detection,
release, alarm, accessories related to the system, control unit and a review of the tanks, piping,
fittings, hangers and cylinder pressure.
Concentration test shall be provided under the supervision of the Contractors authorised
personnel in the presence of the Companys representative, local authorities and any other
insuring authority.
Inert gas test procedures shall be recommended by the equipment manufacturer and the inert
gas supplier.
The Contractor shall provide a gas analyser capable of automatically recording sampling points.
Concentration recording shall continue until authorities are satisfied with hazard integrity or 10
minutes have elapsed.
The sampling points shall be located at strategic areas but no higher than the highest
combustible contents.
If the test results indicate that the design concentration was not achieved and/or held, the
Contractor shall determine the cause of the failure. After determination of the cause, the system
shall be recharged and again placed in operation. The Contractor shall only be responsible for
retest based on equipment design/failure.
26.7 CONTROL PANEL

The control system shall consist of a power supply, programmable zone actuation with the
necessary number of supervised circuits and auxiliary relays.
The Internal power supply shall operate from 220 VAC, single phase, 50 Hz (1.0/0.5 amp
rectified to 24 VDC (2 amp).
The control system shall provide provisions for housing its own set of on-line float charge
emergency batteries within the enclosure.
Independent-zoning.
Priority-zoning.
Cross-zoning
A supervised dedicated manual pull circuit designated for immediate operation of the release
circuit shall be provided.
Abort function (if used) shall be programmed for either immediate release or 10 second delay
after abort and comply with IRI requirements.
Part 5
Section 26 Page 6
A programmable time delay for 10, 15, 30 or 60 seconds shall be provided between verification
of a fire situation and suppression system release.
Four (4) plug-in relays with two (2) Form C (DPDT) contacts, one relay with Form C (SPDT)
rated at 10 amps, 30 VDC and 7.5 amps at 240 VAC shall be provided for auxiliary functions.
General alarm.
System discharge.
System trouble.
Power On (green)
prevent automatic actuation of the system. In the off mode only operation of the manual pull
stations will cause discharge.
26.8 SMOKE DETECTOR - IONISATION

26.9 SMOKE DETECTOR - PHOTOELECTRIC

26.10 HORNS & STROBES

26.11 MANUAL CALL POINTS

26.12 ABORT SWITCH

The abort switch shall be used where delay is desired between detection and actuation of the
fire suppression system.
transfer one set of normally open contacts. Clear operating instructions shall be provided at the
abort switch.
26.13 INERT GAS SYSTEM ARRANGEMENT

Inert gas fire suppression system shall be of the engineered, permanently piped, fixed nozzle
type.
Part 5
Section 26 Page 7
All agent storage containers shall be centrally located as vertical, free-standing cylinders with
wall mounted or floor mounted retaining brackets. Where multiple cylinders are required for the
same hazard, a common manifold shall be employed.
On multiple cylinder arrangements (discharging into a common hazard), one cylinder shall be
designated as the pilot cylinder and employ both the restorable electric and mechanical manual
actuators. All remaining cylinders shall be pneumatically operated from inert gas discharge of
the pilot cylinder into the manifold.
Manifolded cylinders shall employ a flexible discharge hose to facilitate installation and system
maintenance. Each cylinder on a manifold shall also include an agent check valve installed to
the manifold inlet.
Computerised verification of flow calculations shall be submitted for each inert gas system and
include the following data as a minimum:
Quantity of agent per nozzle.

Type of nozzle.
Pressure at nozzle (kPa).
Nozzle body nominal pipe size (mm).
Number and size of tanks.
Total agent.
Pipe size per pipe section.
Pipe schedule per pipe section.
Number, size and type of fitting per pipe section.
Actual length per pipe section (meters).
Equivalent length per pipe section (meters).
Discharge time (seconds).
Pressure available at the start and end of each pipe section (kPa).
Flow rate per pipe section (l/s).
26.14 TESTING & COMMISSIONING

Perform testing & commissioning in accordance with NFPA 2001 and to the requirements of the
Authority of Jurisdiction.
Provide services for manufacturers representative for start up and to demonstrate and train
owners representative.
Train owners maintenance personnel on procedures and schedules related to start up,
shutdown, troubleshooting, servicing and preventive maintenance.
Submit all maintenance manuals / catalogues of installed equipment's.
26.15 WARRANTY
All inert gas system components furnished under this contract shall be guaranteed against
defect in design, material and workmanship for the full warranty time which is standard with the
manufacturer and/or supplier but not less than one (1) year from the date of system acceptance.
In addition, the installing Contractor must guarantee the system against false actuation or
leakage due to faulty equipment, design or workmanship for a period of one year from final
acceptance. In the event of inert gas leakage or system discharge from any of the above
conditions, the installing Contractor shall completely recharge and recondition the system at no
cost to the Company.
Part 5
Section 26 Page 8
Section 27 Gaseous Fire Suppression:
Inergen
Contents
Section 27 Gaseous Fire Suppression: Inergen 1
27.1 General 1
27.2 System Description and Operation 1
27.3 Alarm and Discharge Action 2
27.4 Auxiliary Components 2
27.5 Materials and Equipment - Electrical 2
27.6 Equipment and Materials (Mechanical) 3
27.8 Smoke Detector - Ionisation 7
27.9 Smoke Detector - Photoelectric 7
27.10 Horns & Strobes 7
27.11 Manual Call Points 7
27.12 Abort switch 7
27.13 Inert Gas system Arrangement 8
27.14 Warranty 8
Section 27 Gaseous Fire Suppression: Inergen
27.1 GENERAL
Provide all labour, materials, products, equipment and services to supply and install an IG-541
INERGEN fire suppression system as indicated on the Drawings and specified in this Section
of the Specification in accordance with NFPA 2001 and to the requirements of the local civil
defence.
Design and installation of the fire detection/inert gas suppression system will be in strict
accordance with the following guidelines and regulatory agencies:
NFPA 2001 Clean Agent Fire Extinguishing Systems

NFPA Standards 70, 72A, 72B, 72C & D
Furnish all engineering design and materials, for a complete fire detection/inert gas suppression
system, including charged inert gas storage containers, nozzles, control panel, detectors, wiring,
annunciators, alarm and any and all other equipment necessary for a complete operational
system.
supplier.
27.2 SYSTEM DESCRIPTION AND OPERATION

The system shall be a total flooding inert gas extinguishing system designed to provide a
uniform concentration of 37.5% inert gas for the protected area.
The amount of inert gas to be provided shall be the amount required to obtain a uniform 37.5%
(minimum) concentration for ten (10) minutes. Take into consideration such factors as
unclosable openings (if any), rundown time of fans, time required for dampers to close (and
requirements for any additional dampers), and any other feature of the facility that could affect
concentration. The design concentration, however, shall be 37.5% (minimum) by volume at 21
C.
Cross-zoned or Verified Smoke Detection: The inert gas system shall be automatically actuated
by either verified detection circuits or cross-zoned detection circuits. Smoke detectors shall be
of the ionisation and photoelectric types installed at no more than 7 square meters of coverage
per detector. The detectors shall be alternated throughout the protected area and be
compatible on either circuit.
Part 5
Section 27 Page 1
27.3 ALARM AND DISCHARGE ACTION



Initiate an adjustable time delay (inert gas release).

Upon completion of the time delay the inert gas system shall:

Operate auxiliary contacts for emergency power off all electrical equipment (excluding
lighting and emergency circuits for life safety).
Energise control solenoid for inert gas cylinders releasing gaseous agent into the alarmed
zone only.
27.4 AUXILIARY COMPONENTS

activated, immediately release the inert gas and cause all audible/visual alarms to activate. In
addition, activation of the Manual Releasing stations shall cause immediate shutdown of air and
power circuits.
Abort Stations shall be provided at each exit of the protected area and shall, when operated,
interrupt the discharge of inert gas and emergency power off function. The Abort Stations shall
be momentary devices (dead-man) requiring constant pressure to maintain contact closure.
Note: Manual Pull Station activation shall override any abort Station. Abort Station operation
shall be per IRI and FM guidelines.
Graphic Annunciator shall be provided at the control panel location. The Graphic Annunciator
shall be provided by the equipment manufacturer in an approved NEMA enclosure with keyed
face plate. The Graphic Annunciator shall display the entire inert gas protected area (silk
screened) and shall indicate each smoke detector and its proximity. Smoke detectors, when
activated, will individually annunciate at the graphic Annunciator as follows:
Ceiling Detector: Red LED

Subfloor Detector: Amber LED
27.5 MATERIALS AND EQUIPMENT - ELECTRICAL

Materials and equipment shall be of a single manufacturer. Provide materials and equipment
from approved suppliers. The name of the manufacturer and the serial numbers shall appear on
all major components. Locks for all cabinets shall be keyed alike.
All electrical enclosures, trunking and conduits shall be employed in accordance with applicable
codes and intended use and contain only those electrical circuits associated with the fire
detection and control system and shall not contain any circuit that is unrelated to the system.
Part 5
Section 27 Page 2
Unless specifically provided otherwise in each case, all conductors shall be enclosed in steel
conduit, rigid or thin wall as conditions dictate.
Any conduit or trunking exposed to weather or other similar conditions shall be properly sealed
and installed to prevent damage, provisions for draining and/or drying shall be employed.
NEMA rating and/or electrically hazardous classifications shall be observed and any equipment
or materials installed must meet or exceed the requirements of service.
Any wiring shall be of the proper size to conduct the circuit current but shall not be smaller than
18 AWG, unless otherwise specified for a given purpose. Wire that has scrapes, nicks, gouges
or crushed insulation shall not be used. The use of aluminium wire is strictly prohibited.
The use of coloured wires is encouraged but not required unless dictated by state or local
authorities.
Control Systems - General

All control systems shall be UL listed or FM approved and be utilised with listed or approved
operating devices and shall be capable of the following features:

Battery standby.
Lamp test.
27.6 EQUIPMENT AND MATERIALS (MECHANICAL)
Pipe Material Inert Gas System

Inert gas system piping shall be of non-combustible materials having physical and chemical
characteristics such that its integrity under stress can be predicted with reliability.
As a minimum, piping materials shall be black steel pipe conforming to ASTM A-106A SMLS or
ASTM A-53A.
Part 5
Section 27 Page 3
Under no conditions shall ordinary cast iron pipe, steel pipe conforming to ASTM A-120 or
ASTM A-53/A-120 be used.
Inert gas piping joints shall be suitable for the design conditions and shall be selected with
consideration of joint tightness and mechanical strength.
As a minimum fittings beyond the orifice union shall be black, 136 Kg (300 lb.) class fittings
conforming to ANSI B-16.3. Ordinary cast iron fittings shall not be used.
The system manifold up to the orifice union must be constructed of Schedule 80 piping and 907
or 1360kg forged steel fittings. Distribution piping down stream from the orifice union must be
constructed of a minimum of Schedule 40 piping and 136kg fittings.
All piping shall comply with NFPA-2001.
Piping shall be installed in accordance with good commercial practice to the appropriate codes,
securely supported with UL Listed hangers and arranged with close attention to the design
layout since deviations may alter the design flow performance as calculated.
Piping shall be bracketed within 300 mm of all nozzles.
All piping must be reamed, blown clear and swabbed with appropriate solvent to remove mill
varnish and cutting oils before assembly.
Multi-outlet fittings other than tees shall not be permitted.
Assembly of all joints shall conform to the appropriate standards. Threaded pipe joints shall
utilise teflon tape applied to the male threads only.
Agent
The agent shall be Inert Gas IG-541, Inergen. The gas shall be a mixture of 52% Nitrogen, 40%
Argon and 8% Carbon Dioxide.
Inert Gas Storage Cylinders

Inert gas cylinder assemblies shall be steel constructed with a standard RED epoxy paint finish.
Each cylinder shall be equipped with a pressure seat type valve and gauge. The system shall
utilise approved pilot valve assemblies. When the systems capacity exceeds 40 cylinders a
second pilot valve shall be provided and used for tank activation. Each valve shall be
constructed of forged brass and shall attach to the cylinder providing a leak tight seal. Each
valve shall also include a safety pressure relief device that provides relief at 1360-1524 kPa as
per CGA test methods.
Filling of the tank assembly shall be by a factory authorised UL Listed filling station. Initial filling
and recharge shall be done in accordance with the manufacturers established procedures and
shall not require replacement components for normal service. The size of all cylinders shall be
based on computer verified system design requirements and shall be 5.8, 7.5 or 10.3 cubic
meter capacity cylinders.
Tank Bracket
Each inert gas tank shall be furnished with a bracket made from welded steel. The bracket shall
hold the cylinders in a saddle and have a front bracket piece that holds the cylinders in place.
The brackets shall have the ability to add more bracketing or stack cylinders depending on
installation requirements.
Brackets shall be UL/FM Listed for use with inert gas Systems.
Part 5
Section 27 Page 4
Valve Actuators
Inert gas valve actuators shall be of brass construction, stackable design, with swivel
connections to allow removal of actuators for maintenance or testing.
Operation of actuators shall not require replacement of components. NO ELECTRO-

EXPLOSIVE DEVICES may be used to actuate the valve assembly.
Electric actuators shall be of the magnetic latch type or of the continuous duty type for 24 VDC
operation.
UL/FM Listed for use with inert gas.
Discharge Hose / Check Valve

When manifolding, all tank assemblies shall include a flexible discharge hose and check valve
for connection to the manifold inlet.
All hose/check valves shall be UL Listed or FM approved for use with the high flow inert gas
valve.
Discharge Nozzles
Inert gas discharge nozzles shall be of two piece construction sized to provide flow rates in
accordance with system design flow calculations.
Nozzles shall be permanently marked with the manufacturers part number. The nozzle shall be
threaded directly to the discharge piping without the use of special adapters.
Nozzles shall be UL Listed.
Orifice Union / Nipple Assembly

A manifold orifice union shall be included to reduce pressures in the downstream piping, rated at
907 or 1360kg Class.
System Checkout and Testing

The completed installation shall be inspected by factory authorised personnel and shall include
a full operational text of all components per the equipment manufacturer recommendations
(including agent discharge).
This shall be done in the presence of the Company representative, insuring authority, and the
local authority having jurisdiction.
All mechanical and electrical components shall be tested according to the manufacturers
recommended procedure to verify system integrity.
An inspection shall be provided by the Contractor. Inspection shall include a complete checkout
of the electronic system and certification of cylinder pressure. A written report shall be filed with
the Company.
Part 5
Section 27 Page 5
As-built drawing shall be provided by the Contractor (6 copies) indicating the installed details.
All routing of piping and electrical conduit and accessories shall be noted.
Equipment, installation and maintenance manuals shall be provided in addition to the as-built
drawings.
Prior to final acceptance, the Contractor shall provide operational training in all concepts of the
system to the Companys key personnel. Training shall consist of:
Control system operation.

Trouble procedures.
Abort procedures.
Emergency Procedures.
Safety requirements.
Demonstration of the system (excluding inert gas release).
The quantity of agent shall reflect the actual design quantity of inert gas.
A functional test shall be completed prior to the concentration test consisting of detection,
release, alarm, accessories related to the system, control unit and a review of the tanks, piping,
fittings, hangers and cylinder pressure.
Concentration test shall be provided under the supervision of the Contractors authorised
personnel in the presence of the Companys representative, local authorities and any other
insuring authority.
Inert gas test procedures shall be recommended by the equipment manufacturer and the inert
gas supplier.
The Contractor shall provide a gas analyser capable of automatically recording sampling points.
Concentration recording shall continue until authorities are satisfied with hazard integrity or 10
minutes have elapsed.
The sampling points shall be located at strategic areas but no higher than the highest
combustible contents.
If the test results indicate that the design concentration was not achieved and/or held, the
Contractor shall determine the cause of the failure. After determination of the cause, the system
shall be recharged and again placed in operation. The Contractor shall only be responsible for
retest based on equipment design/failure.
27.7 CONTROL PANEL

The control system shall consist of a power supply, programmable zone actuation with the
necessary number of supervised circuits and auxiliary relays.
The Internal power supply shall operate from 220 VAC, single phase, 50 Hz (1.0/0.5 amp
rectified to 24 VDC (2 amp).
The control system shall provide provisions for housing its own set of on-line float charge
emergency batteries within the enclosure.
Independent-zoning.
Priority-zoning.
Cross-zoning
Counting Zoning
Part 5
Section 27 Page 6
A supervised dedicated manual pull circuit designated for immediate operation of the release
circuit shall be provided.
Abort function (if used) shall be programmed for either immediate release or 10 second delay
after abort and comply with IRI requirements.
A programmable time delay for 10, 15, 30 or 60 seconds shall be provided between verification
of a fire situation and suppression system release.
Four (4) plug-in relays with two (2) Form C (DPDT) contacts, one relay with Form C (SPDT)
rated at 10 amps, 30 VDC and 7.5 amps at 240 VAC shall be provided for auxiliary functions.
General alarm.
System discharge.
System trouble.
Power On (green)
prevent automatic actuation of the system. In the off mode only operation of the manual pull
stations will cause discharge.
27.8 SMOKE DETECTOR - IONISATION

27.9 SMOKE DETECTOR - PHOTOELECTRIC

27.10 HORNS & STROBES

27.11 MANUAL CALL POINTS

27.12 ABORT SWITCH

The abort switch shall be used where delay is desired between detection and actuation of the
fire suppression system.
transfer one set of normally open contacts. Clear operating instructions shall be provided at the
abort switch.
Part 5
Section 27 Page 7
27.13 INERT GAS SYSTEM ARRANGEMENT

Inert gas fire suppression system shall be of the engineered, permanently piped, fixed nozzle
type.
All agent storage containers shall be centrally located as vertical, free-standing cylinders with
wall mounted or floor mounted retaining brackets. Where multiple cylinders are required for the
same hazard, a common manifold shall be employed.
On multiple cylinder arrangements (discharging into a common hazard), one cylinder shall be
designated as the pilot cylinder and employ both the restorable electric and mechanical manual
actuators. All remaining cylinders shall be pneumatically operated from inert gas discharge of
the pilot cylinder into the manifold.
Manifolded cylinders shall employ a flexible discharge hose to facilitate installation and system
maintenance. Each cylinder on a manifold shall also include an agent check valve installed to
the manifold inlet.
Computerised verification of flow calculations shall be submitted for each inert gas system and
include the following data as a minimum:
Quantity of agent per nozzle.

Type of nozzle.
Pressure at nozzle (kPa).
Nozzle body nominal pipe size (mm).
Number and size of tanks.
Total agent.
Pipe size per pipe section.
Pipe schedule per pipe section.
Number, size and type of fitting per pipe section.
Actual length per pipe section (meters).
Equivalent length per pipe section (meters).
Discharge time (seconds).
Pressure available at the start and end of each pipe section (kPa).
Flow rate per pipe section (l/s).
27.14 WARRANTY
All inert gas system components furnished under this contract shall be guaranteed against
defect in design, material and workmanship for the full warranty time which is standard with the
manufacturer and/or supplier but not less than one (1) year from the date of system acceptance.
In addition, the installing Contractor must guarantee the system against false actuation or
leakage due to faulty equipment, design or workmanship for a period of one year from final
acceptance. In the event of inert gas leakage or system discharge from any of the above
conditions, the installing Contractor shall completely recharge and recondition the system at no
cost to the Company.
Part 5
Section 27 Page 8
SECTION 27A Fire Extinguishers
Contents
Section 27A Fire Extinguishers 3
27A.1 General 3
27A.2 PRODUCTS 3
27A.3 EXECUTION 3
27A.4 Referred documents 4
Section 27A Fire Extinguishers
27A.1 GENERAL
Provide all labour, materials, products, equipment and services to supply and install portable fire
extinguishers as indicated on the Drawings and specified in this Section of the Specification in
accordance with NFPA 10 and to the requirements of Local Civil Defence Authority.
The Fire Protection contractor shall be experienced in the design and installation of fire
protection systems to NFPA standards and shall be an approved contractor by Local Civil
Defence Authority.
Definition. Portable Fire Extinguisher is a portable device, carried or on wheels and operated by
hand, containing an extinguishing agent that can be expelled under pressure for the purpose of
suppressing or extinguishing fire
27A.2 PRODUCTS
All portable Fire Extinguishers shall be UL Listed, FM Approved labelled.
Product Data:
Submit catalogue cuts and technical data on fire extinguishers, including accessories,
components or devices.
Submit Certificates from the manufacturer as evidence that the products meet these
specifications and the referenced standards.
Shop Drawings: Shop drawings shall indicate locations and installation details of fire
extinguishers.
27A.3 EXECUTION
Fire extinguishers shall not be used for the requirements of temporary facilities or for
construction fire protection.
All fire extinguishers complete with monthly inspection tag shall be left in a fully charged
condition and inspected and approved by the local authorities at the completion of the project.
Types of portable fire extinguishers are: DCP (4.5kg), CO2 (4.5kg), and Wet Chemical (6L) as
per NFPA 10 will be provided as indicated and shown on the drawings. All shall conform to fire
rating as recommended by NFPA 10 standards, Local Civil Defence Authority & shall be
electrically tested.
27A.3.1 Submittals
A. Product Data: Submit catalogue cuts and technical data on fire extinguishers, including
accessories, components or devices.
B. Submit Certificates from the manufacturer as evidence that the products meet these
specifications and the referenced standards.
C. Shop Drawings: Shop drawings shall indicate locations and installation details of fire
extinguishers.
2 Part 5
Section 27A Page3
27A.4 REFERRED DOCUMENTS
NFPA 10 Standard for the Portable Fire Extinguishers
2 Part 5
Section 27A Page4
Section 28 Fire Curtains
Contents
Section 28 Fire Curtains 1
28.1 General 1
28.2 Construction 1
28.3 Controls 2
28.4 Power Supply 2
28.5 Operational Monitoring and Addressability 2
28.6 Testing 3
28.7 Installation 3
28.8 Warranty 4
Section 28 Fire Curtains
28.1 GENERAL
Provide all labour, materials, products, equipment and services to supply and install fire curtains
as indicated on the Drawings and specified in this Section of the Specification in accordance
with NFPA 13 and to the requirements of the Authority of Jurisdiction.
Furnish all engineering design and materials for a complete operational system.
supplier.
Coordinate fire curtain location with the architectural design.
Where the fire curtain is part of the fire protection measures associated with auditoria or theatre
stages it is to be hidden from the auditorium and shall be coordinated with the stage curtain in
order that both stage and fire curtain work properly without any interference.
The fire curtain shall resist the passage of flame and smoke between both areas for minimum of
20 minutes.
28.2 CONSTRUCTION
A fire curtain shall be an opening protective assembly labelled by an approved agency or shall
be constructed as follows.
Curtains shall be made of one or more thicknesses of a noncombustible fabric or a fabric with a
noncombustible base material. The fabric shall be permitted to a given coating, provided that the
modified fabric meets the criteria detailed above. Curtain fabric shall have a weight of not less
than 1.3 kg/m2.
Curtain fabric shall have tensile strength requirements of not less than 540 N/m in both the warp
and fill directions.
The fabric shall be reinforced with non corrosive wire intertwined with the base fiber at a rate of
not less than one wire per yarn. Wire shall not be required, and fabric weight shall be permitted
to be less than 1.3 kg/m2 if it can be substantiated by approved tests that it is equivalent in
strength and durability.
Part 5
Section 28 Page 1
All proscenium curtains shall be in the closed position, except during performances, rehearsals,
or similar activities.
28.3 CONTROLS
The system shall have a full Monitoring & Control system with both local and remote monitoring
facilities.
The Monitoring & Control Unit (MCU) is connected to the System via a screened data cable.
This data cable connects all Power Supply Unit/s (PSU) and Motor Control Panel/s (MCP) on a
continuous run.
Each part of the system shall have individual programmable address.
A Monitoring & Control Unit shall continually poll all parts of the System (for faults).
Operation or any System faults shall be displayed and stored in a log.
During normal operation the System shall display date/time. During a fault the display show a
fault log number, smoke barrier address number, nature of the fault and date/time of
occurrence.
The Monitoring & Control Unit shall be a 230v/13amp/50Hz dedicated and maintained fused
spur. It is backed up by a NiCad battery.
The Monitoring & Control Unit shall be used as a direct interface with the Building Management
System (BMS) or Main Fire Alarm Panel (MFAP). This enables control of the smoke barriers
and will alleviate the need for a Zone Control Unit/s.
The Monitoring & Control Unit shall have built in ports for connection to a PC or printer and shall
allow for a PC to be connected locally or remotely via a modem. The PC will graphically display
the set up of the System and its current status. It can also be used to program the system.
28.4 POWER SUPPLY

The Power Supply Unit/s shall be a mains operated unit with 24v battery back up / emergency
power supply.
The period of back up to be determined by the size of the battery ampere, to be nominally 30
60 minutes.
The Power Supply Unit/s will be provided with a 230v/13amp/50Hz dedicated and maintained
fused spur.
The 230v ac input to be transformed internally to provide the smoke curtain system with primary
dc power.
The time delay function, which maintains units in the raised position in the event of a temporary
interruption of power to the System to be nominally 30-60 minutes. Units to operate if alarm is
activated within this period. If the power is not returned, units to power descend to down/default
position after time delay.
28.5 OPERATIONAL MONITORING AND ADDRESSABILITY

The system shall have the following facilities;
Local Monitoring
To Main BMS (by others).
To dedicated Event and Fault Log Recorder.
Remote Monitoring (via modem)
Part 5
Section 28 Page 2
24 hr Monitoring Station.
Dedicated Event and Fault Log Recorder.
Visual Mimic of Actual Site.
Monitored Functions
Individual Curtain.
Curtain in Retracted Position (physical / mechanical monitoring in case Curtains are
obstructed).
Curtains in Fire Operational Position (FOP).
Curtains in neither RP or vice OP, i.e. between positions.
Signal / Alarm Status (with event log).
Primary power and signal supply status.
Open circuit wiring condition.
Communications wiring condition.
Top position sensing and soft / tensioned ascent.
Movement when signaled to fire operational position.
Mains Supply Status.
DC power and signal supply status.
Smoke and Fire Detection.
Sprinkler flow switch initiation.
28.6 TESTING
The complete system shall have full Testing and Certification to BS476 Part 22 1987, Clause 8.
A sample curtain with not less than two vertical seams shall be subjected to the standard fire
test specified in NFPA 251, Standard Methods of Tests of Fire Endurance of Building
Construction and Materials, as applicable to nonbearing walls and partitions for a period of 30
minutes. The curtain shall overlap the furnace edges by a length that is appropriate to seal the
top and sides. It shall have a bottom pocket containing not less than 5 kg/m of batten. The
unexposed surface of the curtain shall not glow, and neither flame nor smoke shall penetrate the
curtain during the test period. Unexposed surface temperature and hose stream test
requirements shall not be applicable to this proscenium fire safety curtain test.
The operational gaps between the edges of barriers and / or the edge of the barrier and the face
of a construction work shall be minimized and comply with the requirements of BS EN 12101-1.
Curtain fabrics shall have a smoke density not to exceed 25 where tested in accordance with
NFPA 255, Standard Method of Test of Surface Burning Characteristics of Building Materials.
The curtain fabric shall be tested in the condition in which it is to be used.
The complete installation of every proscenium curtain shall be subjected to operating tests, and
any theater in which a proscenium curtain is placed shall not be open to public performance until
after the proscenium curtain has been accepted and approved by the authority having
jurisdiction. The curtain shall be automatic-closing without the use of applied power. The curtain
also shall be capable of manual operation.
All proscenium curtains shall be in the closed position, except during performances, rehearsals,
or similar activities.
28.7 INSTALLATION
All moving parts to be contained and protected within the steel roller, Minimum manufactured
deflection characteristics for the roller tube to be 1:600 as per BS6323 Part 5 in order to ensure
minimal deflection over the life span of the system.
Tubes in excess of 5 mtr must have a manufactured deflection of less than 1:600 for anti
deflection characteristics.
Part 5
Section 28 Page 3
Curtains to be contained within 1.2mm galvanized mild steel boxes complete with minimum
2mm galvanized mild steel end cheeks and brackets. Aluminium shall not be utilized except for
cosmetic purposes .as it does not have 600C FR.
The primary bottom bar device to be heavy steel and tested to FR requirements BS EN12101-1
and BS7346 Part 3 1990 as part of a complete assembly.
The manufacture shall submit a proposal for both the bottom bar and the ceiling slot interface.
Such design to ensure that the bottom bar remains straight at all times within the ceiling slot,
and permits addition of additional weight.
All installation and wiring of units to be by contractors own staff. Consideration should be given
to the construction of the building and types of fixings to be used.
Weights of each unit to be submitted with tender application.
Contractors to prove compliance to manufacturers ISO 9001 1994 installation procedures.
28.8 WARRANTY
All components furnished under this contract shall be guaranteed against defect in design,
material and workmanship for the full warranty time which is standard with the manufacturer
and/or supplier but not less than one (1) year from the date of system acceptance. In addition,
the installing Contractor must guarantee the system against false actuation due to faulty
equipment, design or workmanship for a period of one year from final acceptance.
Part 5
Section 28 Page 4
Section 29
Contents
Section 29 1
29.1 General 1
Section 29
29.1 GENERAL
Part 5
Section 25 Page 1
Section 30 Storage, Semi Storage and
Instantaneous Indirect Water Heaters
Contents
Section 30 Storage, Semi Storage and Instantaneous Indirect Water Heaters 1

30.2 Definitions 2
30.3 Construction of storage or semi storage calorifiers to BS 853 2
30.4 Construction of non storage shell and tube calorifiers to BS 853: 3
30.5 Calorifier mountings 4
30.6 De-Stratification pumps 4
30.7 Plate heat exchangers 5
30.8 Installation 6
Section 30 Storage, Semi Storage and Instantaneous
Indirect Water Heaters
Code of Practice
BS EN 806
tank or cistern.
Submit samples, specifications, engineering calculations, catalogue cut sheets, description of

product and installation method in accordance with the Contract Documents. Submissions shall
indicate all dimensions, details of construction, details of installation, relation and connections
with adjoining work.
Submit copies of test reports required to be performed on the proposed products.
Submit a list of installation completed where proposed products were used.
Submit original copies of the pressure test certificates undertaken at works.
Perform Work in accordance with relevant British Standards and industry standard codes.
Make material submittals to the CA for approval before ordering.
Part
Section 30 Page 1
Submit for the approval of the CA method statements for delivery, offloading, positioning and
where applicable site fabrication prior to commencing each of these operations.
Submit for the approval of the CA method statements for the filling, cleaning, flushing, testing,
commissioning and setting to work of the equipment prior to each of these operations.
Do not commence any of these operations until the appropriate method statement has been
approved by the CA.
Warranty and bonds are to be as described in Parts 1 and 2 of this Specification.
All pipes, fittings and valves used in the construction and installation of the systems shall be
constructed of non-dezincifiable materials.
Materials, fittings and construction methods used in water installations shall avoid imparting a
direct taste, odour, colour or turbidity to the water; the releasing of objectionable or toxic
substances of the ability to support microbiological growth (this applies particularly to gaskets,
grommets and insulation).
All equipment is to have suitable Water Research Council acceptance with seals and washers
as listed in the WRc Water Fittings and Materials Directory.
30.2 DEFINITIONS
Direct cylinder - A closed cylindrical vessel with domed ends
Indirect cylinder - A closed cylindrical vessel with domed ends having separate integral means
of heating contents by annular or coil type element.
Combination unit - An indirect/direct cylinder of double or single feed type with attached feed
cistern.
Calorifier - A closed cylindrical vessel having separate integral means of heating contents by 'U'
tube chest type element.
Primary heater - A heater mounted inside the cylinder or calorifier for transfer of heat to stored
water from primary medium.
Capacity - The volume of water storage excluding contents of any primary heater.
Secondary Working head - The vertical distance between bottom of cylinder/calorifiers and
water line of cistern supplying cylinder/calorifiers
30.3 CONSTRUCTION OF STORAGE OR SEMI STORAGE CALORIFIERS TO BS 853

Shall:-
be designed for a flow temperature of 60oC under all load conditions and in such a way that
all water in the calorifier is at 60oC under no draw off conditions.
be horizontal or vertical type (with convex dished ends) with steam or water primary heating
medium, complete with mountings.
have a dished base so sediment can be washed to a centre drain point (vertical type).
comply with BS 853, grade b for shell operating pressures not exceeding 4.5 bar,
temperatures not exceeding 90oc and tube design pressure not exceeding 4.5 bar,
otherwise to BS 3274: type 2.
comply with BS 853 grade a for higher pressures and temperatures.
have copper or copper lined shells.
Part
Section 30 Page 2
have gunmetal chests and brass or gunmetal tube plates except where not in contact with
dhw, in which case the chests can be iron or steel.
have battery tubes of plain or indented solid drawn copper to BS 2871.
have anti-stratification pumps or similar devices to allow the complete contents of the vessel
to be taken to the pasteurisation temperature.
have an adequately sized drain at the lowest point, sized to empty the contents in 30
minutes.
have an adequately sized inspection hatch for cleaning.
have easily removable tube batteries with adequate set-bolts to avoid breaking tube
plate/chest cover joint.
be supported on fabricated feet attached to the shell to enable drainage to be carried out or
on separate cradles or frames with not less than 300mm clearance under the drain valve on
horizontal calorifiers. rubber sheets to be fitted between shell bearing surface and any
separate supports.
be inclined towards the drain valve at the heater battery end at a gradient of not less than
1:60 (horizontal models).
have screwed and/or flanged connections to BS 21 and BS 4504.
be delivered with all connections capped or blanked off.
30.4 CONSTRUCTION OF NON STORAGE SHELL AND TUBE CALORIFIERS TO BS

853:
Shall:-
be horizontal or vertical type (with convex dished ends) with steam or water primary heating
medium, complete with mountings.
comply with BS 853, grade A for shell operating pressures not exceeding 7 bar,
temperatures not exceeding 90oc and tube design pressure not exceeding 17.5 bar,
otherwise to BS 3274: type 2.
have welded mild steel shell to BS 1501, BS EN 10028 and BS EN 10029, complete with
inspection openings or bosses.
Have mild steel chests to BS 1501, BS EN 10028 and BS EN 10029, or alternatively cast
iron to BS 1452 for design pressures not exceeding 10 bar or temperatures not exceeding
200oC.
have tube plates or mild steel to BS 1501, BS EN 10028 and BS 10029.
have battery tubes of solid drawn copper to BS 2871.
have an adequately sized drain at the lowest point, sized to empty the contents.
have easily removable tube batteries with adequate set-bolts to avoid breaking tube
plate/chest cover joint.
be supported on fabricated feet attached to the shell to enable drainage to be carried out or
on separate cradles or frames with not less than 300mm clearance under the drain valve on
horizontal calorifiers. rubber sheets to be fitted between shell bearing surface and any
separate supports.
Part
Section 30 Page 3
have screwed and/or flanged connections to BS 21 and BS 4504.
30.5 CALORIFIER MOUNTINGS

Shall include:-
non return valve on the cold feed and in the return pipe of recirculation systems, the valves
to be within 300mm of the calorifiers.
connections for hot water system controls.
open vent pipe connection, (for open systems), separate from the cold feed pipe.
emptying / drain valve bronze gland pattern with hose union connection and malleable iron
level handle, (fitted at the shell lowest point to ensure complete removal of water content.
stamped, engraved, or cast-metal fixed identification plate clearly showing:-
Manufacturers name and address

Date of manufacture
Hydraulic test pressures
Maximum working pressure
Rated capacity and output
thermometers which shall be calibrated 0oc to 120oc with divisions at 1oC intervals and
numbered at 10oC intervals with bold figures, complete with separate pocket to suit the
immersion position, and casing finish as specified in section 10. Thermometers shall be
mounted half way up vessel and at the top of the vessel.
altitude or pressure gauges which shall be 100mm minimum diameter dial, white faced with
black figured scale, calibrated both in bar and metre head, to approximately twice the
working pressure specified in section 10, complete with lever handle gauge cock and
adjustable red dial pointer set at normal working pressure or head of the system, generally
to comply with BS1780 and casing finished as specified in section 10.
two pressure relief valve which shall be to BS 759, enclosed spring loaded pattern, fitted
with a padlock, and a copper discharge pipe run clear of any insulation, to terminate 150mm
from floor level adjacent to a drain gulley position.
a steam pressure gauge (where required) which shall be 100mm minimum diameter dial,
white faced with black figure scale, calibrated to suit steam chest pressure, complete with U
pattern siphon and level handle gauge cock, generally to comply with BS 1780, and casing
finish as specified in Section 10.
vacuum breaker valve.
30.6 DE-STRATIFICATION PUMPS

Shall:-
be provided with altitude or pressure gauges, fitted in the suction and discharge connections
of each pump.
be installed with isolating valves on suction and discharge connections of each pump.
Valves to be wedge gate type, non rising stem. Up to and including 50mm dia to be copper
alloy (non-dezincifiable) to BS 5154, screwed to BS21, 65mm and above cast iron to BS
5150, flanged to BS 4505.
Part
Section 30 Page 4
be provided with a short makeup pipe for replacement of a pump in series.
Pump assemblies shall be:-
To BS 1394: Part 2 for a power input up to 200 watts. To BS EN 60335-2-51 for a power
input not exceeding 2000 watts, manufactured with stainless steel casings, shafts and
impellers to BS 970 or gunmetal bronze casings and impellers to BS 1400.
Provided with ball or roller bearings sealed for life.
Complete with totally enclosed fan cooled electric motor, as specified in Section 8.
Correctly aligned and balanced.
Subjected to an hydraulic test pressure at the manufacturers works of not less than 1.5
times the maximum pressure, specified in Part D.
Fitted with an engraved of cast-metal identification plate showing:-
Manufacturers name and address

Serial number
Duty and maximum head
Speed
Electrical loading
30.7 PLATE HEAT EXCHANGERS

Shall:-
be mounted on a powder coated mild steel base frame and be complete with control panel
wired to BSEN 60204 Part 1 with BMS interface.
have transfer plates of stainless steel AISI 316.
be gasketed using EPDM gaskets.
be suitable for secondary operating pressures not exceeding 10 bar, temperatures not
exceeding 90oC.
be suitable for primary operating pressures not exceeding 10 bar, temperatures not
exceeding 120oC.
be complete with the following connections and accessories:-
three port control valve and actuator
screwed or flanged connections for primary and secondary connections.
Primary pump
Secondary pump with Grade 304 Stainless steel internals to BS 1449 and IP44 motors with
Class F Insulation.
Drain valve
Safety valve
for European manufacture be CE Marked.
have a control panel comprising the following features:-
Part
Section 30 Page 5
Display showing day, time, secondary flow temperature and status
Remote set point adjustment
Remote enable/disable
Volt free changeover fault contact
Display of alarm / fault messages
Valve output indication
PID secondary temperature control
Time
Dual primary pump with auto changeover, shunt and secondary pump control
High temperature cut out
Low temperature alarm
30.8 INSTALLATION
Before ordering any materials/commencing work verify that building structure associated with
the system is within tolerance and take full account of shape configuration and material
properties of the structure.
Provide flat level concrete base.
Deliver component parts to site, completely identified in accordance with shop and certified
drawings prepared for this work. Store in accordance with manufacturer's instructions, above
ground, properly protected from the weather and construction activities.
All calorifiers, cylinders and plate heat exchangers shall be fabricated at the manufacturers
works.
Before beginning installation in any area, examine all parts of the adjoining work into which
applicable work is to be placed. Should any conditions be found which will prevent the proper
execution of the work, installation shall not proceed in that area until such conditions are
corrected by the contractor.
Provide field quality control in accordance with Parts 1 and 2 of this Specification.
Cleaning installed work to the satisfaction of the CA or Employer.
Remove if necessary for cleaning and reinstate after Work is complete.
Protect work under provisions of Parts 1 and 2 of this Specification.

BS 853-2007-06 Specification for vessels for use in heating systems. Calorifiers and
storage vessels for central heating and hot water supply
BS 3788:1984 Specification for tin coated finish on culinary utensils
BS EN 1057:2006 Copper and copper alloys. Seamless, round copper tubes for water
and gas in sanitary and heating applications
BS 215-1:1970 Specification for aluminium conductors and aluminium conductors,
steel-reinforced for overhead power transmission. Aluminium
stranded conductors
BS EN 1092-2:1997 Flanges and their joints. Circular flanges for pipes, valves, fittings
and accessories, PN designated. Cast iron flanges
BS EN 10028-4:2003 Flat products made of steels for pressure purposes. Nickel alloy
steels with specified low temperature properties
BS EN 10028-7:2000 Flat products made of steels for pressure purposes. Stainless steels
Part
Section 30 Page 6
Section 31 Storage, Semi Storage and
Instantaneous Direct Water Heaters
Contents
Section 31 Storage, Semi Storage and Instantaneous Direct Water Heaters 1

31.2 Electric storage heaters storage above 100 litre 2
31.3 Electric storage heaters storage below 100 litre 3
Section 31 Storage, Semi Storage and Instantaneous
Direct Water Heaters
Code of Practice
BS EN 806
tank or cistern.

Submit a list of installation completed where proposed products were used.
Part 5
Section 31 Page 1
Submit for the approval of the CA method statements for delivery, offloading, positioning and
where applicable site fabrication prior to commencing each of these operations.
Submit for the approval of the CA method statements for the filling, cleaning, flushing, testing,
commissioning and setting to work of the equipment prior to each of these operations.
Do not commence any of these operations until the appropriate method statement has been
approved by the CA.
Warranty and bonds are to be as described in Parts 1 and 2 of this Specification.
All pipes, fittings and valves used in the construction and installation of the systems shall be
constructed of non-dezincifiable materials.
Materials, fittings and construction methods used in water installations shall avoid imparting a
direct taste, odour, colour or turbidity to the water; the releasing of objectionable or toxic
substances of the ability to support microbiological growth (this applies particularly to gaskets,
grommets and insulation).
All equipment is to have suitable Water Research Council acceptance with seals and washers
as listed in the WRc Water Fittings and Materials Directory.
Provide each hot water heater system with a temperature and pressure relief valve piped to
local drain
Comply with manufactures instruction for installations and clearances.
Set supply water temperature for 600C (1400F)
Include documentation of extended warranties with operating and maintenance manuals.
Where water heaters are installed in groups of two or more ensure that the inlet and outlet
piping to individual tanks uses the Equal Flow manifold and piping is arranged for equal flow.
31.2 ELECTRIC STORAGE HEATERS STORAGE ABOVE 100 LITRE

Provide UL listed or British Standard equivalent, lined packaged electric water heater(s).
Provide water heaters as per requirements of Appendix A or approved equivalent. Refer to
Water Heater Schedule for sizes and capacities.
The shell shall be constructed from low carbon steel to BS 1501 -151-430A and lined with
Nickleshield lining not less than 1.6mm thick. The shell thickness and fabrication shall comply
with BS 853:1996 (BS 5500:1997, etc.)
A manhole shall be provided in accordance with relevant BS code.
Secondary connections shall be screwed to BS 21 flanged to BS 4505 for the following

connections:-
Secondary flow and return

Cold feet inlet
The shell shall be fitted with screwed connections for the following mountings (supplied loose for
site assembly):-
Safety valve/pressure temperature relief valve set at pressure defined in the schedules.
100mm diameter dial pressure gauge calibrated in bar and psi c/m gauge cock.
Minimum 20mm dia drain cock with hose union and removable key.
Anti vacuum valve
Low water cut out
150mm high fixed steel legs
Part 5
Section 31 Page 2
The shell shall be fully insulated with 50 mm thick fibreglass mattress of thermal conductivity
0.035w/mk and encapsulated in a 0.5mm thick galvanised and painted sheet steel casing.
Construct the individual heating elements using Incoloysheathed with mechanical seals.
Element watt density shall not exceed 6.2 W/sq.cm (40 watts/sq.in) Install an electronic low
water cut off with a combination high and low pressure sensing device to shut off power on a
low pressure, high pressure and low water conditions.
Provide heaters to accept electric power at 400V, 3 phases, 50 Hertz.
Where tanks are installed in groups of two or more provide factory designed Equal Flow
manifolds.
The water heater is to be fitted with a factory fitted, shell mounted pre-wired control panel with
the following:-
Thermostatic control comprising thermostatic switch for each step with facilities for adjusting the
temperature differential between stages
High temperature safety thermostat mounted on the shell.
Low water cut out mounted on the shell.
Circulating pump interlock
Test buttons
Indicator lamps for all stages and power ON lamp
Solderless power distribution terminal blocks
Built in magnetic contractor with 220V holding coil including 220V transformer, control circuit
switch, fuses, pilot light and externally mounted toggle switch
Fuses for each power circuit
Manual resets for high temperature and low water cut outs, fault indicator lamps.
The control panel shall include BMS interface so all status conditions can be relayed to the BMS
system.
Prior to despatch all controls are to be electrically tested. Flash testing will be at twice the
working voltage (or 2000V) Insulation resistance of individual elements shall not be less than 1
megaohm/
31.3 ELECTRIC STORAGE HEATERS STORAGE BELOW 100 LITRE

Provide UL listed or British standard equivalent, BEAB and WBS approved glass lined,
packaged electric water heaters as per requirements of Appendix A or approved equivalent.
Refer to Water Heater schedule for performance requirements.
Provide heaters with complete CFC-free insulation coverage, finished enamelled steel jacket
and enclosure for contractors and controls.
Provide heater to accept electric power at 220V 1-phase 50 Hz.
Provide the following features and accessories:
Built in magnetic contractors with 220 V holding coil including 220V transformer, control circuit
switch, fuses, element ON pilot light and externally mounted toggle switch
Factory fitted temperature and pressure relief valve.
Replaceable long life alloy sheath element.

Cold water diffuser
Externally adjustable immersion thermostat. 10-700C max lockable in hot or mid-range
position
Magnesium anodes
Heating elements with stainless steel sheathing
High limit control with manual rest
Drain valve.
Part 5
Section 31 Page 3
1 meter of 3-core cable
Where tanks are installed in groups of two or more provide factory designed Equal Flow
manifolds.

BS EN 806-2 : 2005 Specifications for installations inside buildings conveying water for
human consumption. Design
BS EN 13280:2001 Specification for glass fibre reinforced cisterns of one-piece and
sectional construction, for the storage, above ground, of cold water
BS 1501-15-430A Flat products made of steels for pressure purposes. Nickel alloy
BS EN 10028-4:2003 steels with specified low temperature properties
BS 853-2:1996 Specification for vessels for use in heating systems. Tubular heat
exchangers and storage vessels for building and industrial services
BS 4505-2:1990, ISO Digital data transmission. Character structure for start/stop and
1177:1985 synchronous transmission
BS EN 10226-1:2004 Pipe threads where pressure tight joints are made on the threads.
Taper external threads and parallel internal threads. Dimensions,
tolerances and designation
Part 5
Section 31 Page 4
Section 32 Water Softners and Domestic
Water Conditioning
Contents
Section 32 Water Softners and Domestic Water Conditioning 1

32.2 Installation 3
Section 32 Water Softners and Domestic Water
Conditioning
Comply with the General Requirements and all documents referred to therein.
Provide all labour, materials, products, equipment and services to supply and install the Water
Softner and water conditioning system as detailed in the particular specification.
32.1.1 Water Softeners

Provide as indicated a vertical pressure type water softner system complete with pressure
vessel, softening resin, control valve, brine maker, controller and water meter. The system shall
be of an approved design as fabricated by a manufacturer regularly engaged in the production
of water treatment equipment. All equipment and material will be supplied in compliance with the
specifications as intended for a complete and operational system.
A water softener is utilized to remove form scale forming calcium and magnesium ions from the
feed water supply.
The water softener units shall be a duplex ion-exchange water softener sized to meet the
requirements of water flow and water hardness. The regeneration of the water softener by
means of salt brine shall be activated by timer. One unit shall be on stream at all times at each
system, while the other unit is regenerating, so that there is an uninterrupted flow of soft water.
Resin tanks shall be of glass fibre and be provided with access plates to allow filter removal and
replacement. The water softeners shall be provided pre-piped. Water softeners shall be sized
to provide a continuous flow of softened water required by the system. The softener tanks shall
incorporate sufficient side shell height to allow for proper freeboard space above the resin bed
for adequate expansion of the resin during backwash.
Water filters shall be multi media filter, fully automatic packaged type complete with all
necessary pipework, bypass connections, valves, filter media, gauges, drain and automatic
back wash system. All components shall be made of non-corrosive material and suitable
for potable water temperature up to 50C. Filter tank and accessories shall be suitable for
working pressure of 12.0 bars and test pressure of 16 bars.
Filters shall be constructed of fibre glass or mild steel lined with 3 mm thick hypalon rubber
lining internally and with epoxy paint externally or any other non-corrosive material
construction to Engineers approval. The combined bed area of all filters shall be in
accordance with the filtration rate recommended by the manufacturer. However filter
vessel dia shall not be less than the dia shown on the drawings or equipment schedule.
Filters shall be suitable for removal of sediments, rust, dust etc., from potable water
supplies. The filtering media shall be sand or filter-AG (non-hydrous aluminium silicate).
The filter shall be complete with internal distributors, automatic control and valves. The
backwash of the filter shall be fully automatic activated by a time clock. Each filter vessel
shall be provided with pressure gauges at inlet and outlet.
Automatic diaphragm valves shall be installed to control the operating steps. A

hydraulically operated pilot valve shall control the actual opening and closing of the valves.
The filters shall be provided with automatic self adjusting flow controls. This shall ensure
proper flow rate during the operating cycle and shall prevent loss of filter media during
backwash and saves water during the conditioning rinse cycle.
Part 5
Section 32 - Page 1
The filter shall be equipped with an electronic device programmer logic function enable to
program the backwash cycle of the filter at any timer of day. The programmer complete
with soft keyboard and LCD display shall be housed in an IP65 rated cabinet complete
having a transparent cover. During the backwash cycle, the unit under backwash shall
receive the water from one duty pump. The water treatment equipment supplier shall
include for the necessary interfacing from the filter controller and the feed pump control
panel.
The media is a sodium cycle ion exchange resin regenerated with sodium chloride. Gravel is
used at the bottom of the media tank to support the media bed, depending on tank size.
The following minimum requirements should be followed.
Up to 15cu. ft. (cubic feet) of media with a maximum exchange capacity of 450, 000 grains
service flows of up to 44gpm (gallons per minute) Multiple control valves on magnum performa
line.
All valves are fully automatic in that they provide the regeneration cycle at preset times.
Manual regenerations can be initiated when required.

Interlock switch provides for RO shut down during regeneration.
Battery clock backup on the Performa and Magnum control heads.
Tank NSF approved ABS lined fibreglass reinforced plastic (FRP)
Magnum valves Glass filled Noryl
Performa valves Glass filled Noryl
Fleck Valves Brass
The medias used include a polystyrene sodium cycle ion exchange resin and gravel under
bedding (on large tank sizes)
32.1.2 External Softener Piping

Pipe: galvanized, Schedule 40.
Fittings: Malleable iron, or coated cast iron, class 125.
Flanges: Class 125.
Threaded Joints: Shall be made with ends reamed out. Apply bituminous base lubricant or
fluorocarbon resin tape to male threads only.
Brine piping:
Polyvinyl chloride (PVC), Schedule 80 with solvent welded joints
32.1.3 Valves
Ball: Carbon steel body, stainless steel trim, reinforced Teflon seat and seal, full port, threaded
ends.
32.1.4 Pressure Gages

Grade A, 1% accuracy, 110 mm diameter, all metal case, bottom connected.
White dials, black hands, graduated from 0 to 700 kPa and identity labeled.
Provide gages with gage cocks at softener hard water inlet and soft water outlet to show
pressure drop thru softener.
32.1.5 Backflow Preventer

Provide on suction side of water softener serving boilers. Parts shall be made of corrosion-
resistant materials and shall be of heavy duty construction, 850 kPa class minimum. Units shall
operate automatically on line pressure without any manual control or assistance. Failure of any
part vital to prevention of backflow shall be indicated by a continuous discharge for relief valve
opening. Moving parts shall be easily removed and replaced without disconnecting backflow
preventer, shall operate on "reduced pressure" principle and incorporate a zone where pressure
is always less than supply pressure. Pressure differentials shall be maintained by two spring-
Part 5
Section 32 - Page 2
load vertical check valves and one spring-load, diaphragm-actuated, differential pressure relief
valve.
32.1.6 Brine Reuse System

Brine Reuse Tank: Fiberglass, 1200 mm diameter by 2400 mm height, with cover and float
assembly or as project specification.
Slat platform, slat dosage brine well, an automatic brine valve and all necessary fittings for
operation with the water softening system, the system shall consist of a combined brine
measuring and salt storage tank with slat platform.
The brine tank will be equipped with a float operated non-corrosive field serviceable brine float
valve for automatic control of brine withdrawal and fresh water refill.
The brine valve will automatically open to admit brine to the resin tank during education and
close automatically providing positive shut-off to prevent air from entering the system. The brine
valve works with the timed fill feature of the main operating valve controls to admit the correct
volume of fresh water to the brine tank in accordance with the salt dosage setting on the
controls. The brine valve will include float operated safety shut-off valve as a back up to the
timed refill from the main operating valve control to prevent brine tank over flow.
Brine Pump: Cast iron for use with brine, close coupled, and drip proof.
Controls: Timer, test lights and pushbuttons, cast iron diaphragm valves, flow regulator. Timers
shall set recovered brine pumping time, delay time before recovery, and divert brine to recovery
tank.
32.1.7 Flushing and Disinfecting

Flush and disinfect new water lines and softener interiors in accordance with DEWA
requirements.
The maximum operating pressure is 8 bars
For proper serviceability, it is recommended that there be 450mm of space around each tank.
This includes front, back and sides. A minimum of 300mm is required. The tank should be
installed in a firm level area.
The inlet piping should be sized large enough to provide the required water flow for both service
flow and back washing of the tanks with minimum amount of pressure loss.
A drain with suitable capacity for the backwash flow rate of the tanks is required.
Pressure gauges should be installed on the inlet and outlet piping of each tank.
A sample valve should be installed on the inlet and outlet piping of each tank.
It is preferred that the plumbing connections are left to right (i.e. the first pretreatment device is
on the left of the second piece and so on) but can be installed either direction.
Water test kits for hardness tests will be supplied
Pressure gauges for hard water inlet and soft water outlet
Sampling cocks for hard water will be provided
Vacuum breaker for protecting Fiberglass tanks from vacuum will be provided.
32.2 INSTALLATION
32.2.1 Examination
Do not begin installation until all plumbing piping has been installed and tested.
Part 5
Section 32 - Page 3
If plumbing preparation is the responsibility of another installer, notify Engineer of unsatisfactory
preparation before proceeding.
32.2.2 Preparation
Clean all pipe fittings and connections thoroughly prior to installation.
Prepare surfaces using the methods recommended by the manufacturer for achieving the best
result under the specific project conditions.
Locate and position water softener on a flat, level surface before connecting plumbing piping.
32.2.3 Installation
Follow all manufacturers' installation instructions for all products specified in this section.
Install unit vertically on a clean, flat surface.
Follow all BSI and local authority requirements for piping and connections.
The services of a factory authorized representative will be made available to supervise, inspect
and provide operator training as required for initial start-up and system operation.
32.2.4 Protection
Protect all installed products until completion of project.
Repair or replace all damaged products prior to substantial completion.
32.2.5 Instructions
Installation, Operating & Maintenance manuals will be provided. Numbers as per main contract
conditions
Warranty
A single written warranty will be provided from the manufacturer of the water softener system
covering workmanship and materials.

BS 6700 Specification for design, installation, testing & maintenance of

services supply water for domestic use within buildings
BS 21 Specification for pipe threads for tubes and fittings where pressure
pipe threads
BS 3506 Specification for unplasticized PVC pipe for industrial uses
BS EN 10312 Welded stainless steel tubes for the conveyance of aqueous liquids
including water for human consumption. Technical delivery
conditions.
BS EN 1057 Copper and copper alloys. Seamless, round copper tubes for water
and gas in sanitary and heating applications.
BS EN 12201 Plastic piping systems for water supply. Polyethylene (PE)
purposes
BS EN 12450 Copper and copper alloys. Seamless, round copper capillary tube
Part 5
Section 32 - Page 4
Polyethylene (PE).
BS EN 1452 Plastics piping systems for water supply. Unplasticized poly (vinyl
chloride) (PVC-U).
BS EN 1453-1 Plastics piping systems with structured-wall pipes for soil and waste
discharge (low and high temperature) inside buildings Unplasticized
poly(vinyl chloride) (PVC-U). Specification for pipes and fittings.
Part 5
Section 32 - Page 5
Section 33
Section 34 Solar Water Heaters
Contents
Section 34 Solar Water Heaters 1

34.2 Solar hot water thermosiphon systems 1
34.3 Execution 2
34.4 Warranty 3
34.5 Approved manufacturer 3
34.6 Codes and standards 3
34.7 Approved manufacturers 4
Section 34 Solar Water Heaters
Solar Water Heaters shall be the type and capacity as indicated.
Solar Water Heaters shall comply with the requirements of the local municipality, and be fit for
purpose for the storage of hot water for domestic use and where applicable commercial
application purposes.
All connections shall comply with:
Code of Practice
BS 6700 Design And Supply Water Distribution Systems
Australian Standard AS2712
Solar hot water systems shall comply to Australian Standard AS2712 or equivalent to American/
DIN standard, and manufactured under a Quality Assurance System complying to ISO 9001.
Technical design, construction quality and measurement of performance (accelerate ageing,
continuous control) all shall be done as per AS 2712.
Solar Water Heaters shall be stored and installed in accordance with manufacturers
recommendations.
Ensure adequate protection from damage and ingress of foreign matter to solar hot water panel
and interconnecting pipework, storage, erection and commissioning. Solar Panels and pipework
connections shall be thoroughly cleaned prior to testing and commissioning.
Solar Water Heaters shall be installed to allow internal and external surfaces to be easily

34.2 SOLAR HOT WATER THERMOSIPHON SYSTEMS

A Typical Solar Thermal System involves:
Solar Panels and

Storage Tank/s
Definitions
Part 5
Section 34 Page 1
Solar Panels
A nominal aperture area of 2 m2 (approx.) of collector surface shall be provided for every 150
liters of stored water.
Absorber:
A device within a solar collector, which shall absorb solar radiant energy and transfer it as heat
to the fluid, which is in direct contact with it.
The collectors shall be made from two, 25 mm headers & a minimum of 6, 15 mm Risers
between the Headers.
The Absorbers shall be made of 0.7 mm Aluminium and Black powder Coated.
Collector Tray:
The absorber shall lie in a tray with a cover of glass on top. The collector tray shall be made of
0.7 mm marine grade aluminium alloy stable and well insulated with a minimum of 55 mm thick
polyester. This shall withstand high temperatures that might come up over the summer when
there is no hot water consumption (stagnation)
The collector construction shall be sealed from any water ingress.
Glass:
The collector glass shall be tempered, with low iron content and a minimum of 3.0 mm thick.
Glass with minimum iron percentage shall also maximise transmittance of solar radiation
through it and minimize reflection. The glass cover shall protect the absorber plate and to the
insulation under it from weather conditions and protect them from damage.
Storage Tank:
The gained energy out of the sun shall be stored in a storage tank where it can be used at any
time of the day. The storage tank shall be double glazed, Vitreous Enamelled & well insulated in
order to keep hot water inside it hotter for longer periods.
In order to protect the insulation from damage, an outer case of 0.4 mm thick aluminium of
marine grade shall be provided. For those days when there is insufficient solar energy, a
thermostat operated electric booster of 3.6 kW must be provided inside the storage tank. The
booster shall cut in to maintain hot water temperatures round the clock. The booster shall cut-
out again when thermostat set point is reached.
The tank shall be made from 2.5 mm steel and must be suitable for mains pressure. The
storage tank shall be coated or lined from inside with 2 coats of ceramic lining, to prevent
corrosion. It must be able to withstand a working pressure of 850 kPa and shall be tested to
2100 kPa
The storage cylinder shall be fitted with a minimum 20 mm sacrificial Magnesium Anode to be
able to last for a minimum of 5 years.
Where internally mounted tanks are used reference shall be made to the Hot Water cylinder part
of this specification, reference shall also be made to the particular specifications for any
specialities on a specific project.
34.3 EXECUTION
Installation
Solar hot water collectors must be installed on roof with tilt and exposed to direct sun (without
shadowing). They should be tilted towards equator (south direction) with angles between 20-25
C. Single unit or multiple units can be connected together in parallel to cover the desired daily
hot water load.
Part 5
Section 34 Page 2
The system shall also be equipped with all necessary safety devices that guarantee the system
function in a proper way without problems. Such safety devices shall involve cold inlet relief
valve and Pressure & Temperature relief valves. A pressure reduction valve should also be
fitted to maintain the incoming pressure less than 850 kPa. The Pressure & Temperature relief
valve shall be set to relieve water at 1000kPa and/or 99C
The storage tank shall be equipped with all necessary fittings on cold and hot water side, in
order to connect with piping network (by the specialist contractor).
It is the contractors responsibility to ensure that all civil, electrical, mechanical (piping etc) and
all work related to the solar water heater system are done according to the specifications and
manufacturers guidelines. All hot water piping shall be adequately insulated to ensure minimum
heat losses during re-circulation. A hot water circulation pump set (with 24 hrs timer) shall be
provided to ensure continuous hot water availability in the ring main.
It shall be the suppliers responsibility to commission the system. He has also to make sure that
system has been installed in proper way and that the system shall supply hot water at 60C and
above.
34.4 WARRANTY
The complete system shall be supplied with a 5-year comprehensive warranty covering parts
and labour.
34.5 APPROVED MANUFACTURER

Make shall be Edwards, Solahart, SolaFlo (Baxi/Andrews Water Heaters) Australia / Approved
Equivalent
Electric Water Heaters
1 No electric water heater shall be used in with solar water heater for each villa; the water inlet
to the electric water shall be from the outlet of solar water heater.
34.6 CODES AND STANDARDS

Electric water heaters shall be listed to BS 6700 requirement and ASHRAE90.1-1999. All
models are to be certified at 300 PSI test pressure and 150 PSI working pressure.
Capacities: As detailed on the design drawings.
3. Heating element shall be Dual type Screw-in, direct immersion, 4500-watt, 240-volt for
maximum efficiency.
4. Insulation shall be Non-CFC Foam Insulation. The tank shall be surrounded by a thick coat of
non-CFC polyurethane foam to trap heat inside the tank, saving energy.
5. Dip Tube shall be used to Carry cold inlet water deep into the tank to minimize temperature
dilution of hot water.
6. T&P Valve shall be Conveniently located on the side of the tank to facilitate piping to a drain
or external to the building.
7. 3/4 Water Connections: Located on top.
8. Anode Rod: Top-mounted, heavy-duty anode for added tank protection, extending the life of
the tank.
9. Built-In Electric Junction Box: Top-located, convenient junction box, ready for 1/2 or 3/4
conduit.
Part 5
Section 34 Page 3
10. Thermostat/High Limit Control: Combination control allows adjustment of water temperature
while preventing overheat protection.
11. Drain Valve: Child-resistant, corrosion-resistant drain valve.
12. Warranty: 6-years Limited for Tank and Parts
34.7 APPROVED MANUFACTURERS

Make shall be American water heaters, USA or Approved Equivalent

BS ISO 9459-parts 1 to 5 Solar Heating Domestic Water Heating Systems

AS2712 Australian Standard Solar Heating
dimensions)
BS 143 and 1256 Threaded pipe fittings in malleable cast iron and cast
copper alloy
BS EN 10216-1 Seamless steel tubes for pressure purposes. Technical

delivery conditions. Non-alloy steel tubes with specified
room temperature properties.
BS EN 10217-1 Welded steel tubes for pressure purposes. Technical

delivery conditions. Non-alloy steel tubes with specified
room temperature properties.
BS EN 10226 - 1 Pipe threads where pressure tight joins are made on

threads. Taper external threads and parallel internal
threads. Dimensions, tolerances and designation.
BS EN 10253-1 Butt welding pipe fitting. Wrought carbon steel for
general use and without specific inspection requirement
BS EN 10312 Welded stainless steel tubes for the conveyance of

aqueous liquids including water for human consumption.
Technical delivery conditions.
BS EN 1057 Copper and copper alloys. Seamless, round copper

tubes for water and gas in sanitary and heating
applications.
BS EN 1092 Flanges and their joints. Circular flanges for pipes,

valves, fittings and accessories, PN designated.
BS EN 12449 Copper and copper alloys. Seamless, round tubes for

general purposes
BS EN 12450 Copper and copper alloys. Seamless, round copper

capillary tube
Part 5
Section 34 Page 4
BS EN 12735-1 Copper and copper alloys. Seamless copper tubes for

air conditioning and refrigeration. Tubes for piping
systems
BS EN 1453-1 Plastics piping systems with structured-wall pipes for soil

and waste discharge (low and high temperature) inside
buildings Unplasticized poly(vinyl chloride) (PVC-U).
Specification for pipes and fittings.
Part 5
Section 34 Page 5
Section 35 Fuel Storage and Delivery
Systems
Contents
Section 35 Fuel Oil Storage and Delivery Systems 1

35.2 Oil tanks and equipment 1
35.3 Oil handling systems from storage tank to burner 8
35.4 Distillate oil fuel systems (classes C2 and D fuels) 9
35.5 Heated oil fuel systems (classes E, F, G and H) 11
35.6 Trace heating 15
35.7 Thermal insulation of pipelines 18
35.8 Rooftop systems 18
35.9 Size of oil pipelines 18
35.10 Materials and erection of oil pipelines 19
35.11 Testing 19
35.12 Painting and identification 19
Section 35 Fuel Oil Storage and Delivery Systems
Supply, deliver and install all pipework materials and fittings for the pipework services
installation.
35.2 OIL TANKS AND EQUIPMENT
35.2.1 Construction
Storage tanks may be of the following types:
carbon steel (BS 799-5)
pressed steel sectional (BS 799-5 and BS 1564)
medium density polyethylene
glass reinforced plastic (BS 4994)
concrete with impervious oil proof lining.
Where it is not practical to use factory or site welded tanks, sectional or concrete tanks may be
used.
Sectional tanks shall be erected with care under the supervision of the manufacturer.
Concrete tanks shall be designed by specialists in consultation with the engineers responsible
for the layout of the oil firing and storage system. The application of linings impervious to oil,
such as glass or ceramic tiles, steel or special cements, shall be carried out by, or under the
direct and continuous supervision of specialists.
When considering the use of sectional or concrete tanks, account shall be taken of the
temperature conditions of the oil as delivered and stored because of the effects of thermal
expansion.
Tanks constructed of non-metallic materials shall not be used for oils that are required to be
heated.
Riveted construction (e.g. the use of old shell boilers) shall be avoided because of penetration of
oil and eventual leakage at the joints.
NOTE 2 Consideration shall be given to the fitting of a limiting value with very large non-metallic
tanks.
35.2.2 Capacity
The minimum net capacity of oil storage tanks shall be the greater of:
3 weeks supply of oil calculated at the maximum rate of consumption, or

2 weeks supply of oil calculated at the maximum rate of consumption, plus the usual
quantity ordered for one delivery.
Consultation with the oil supplier is advisable before finalizing the minimum net capacity.
When deciding the gross capacity of oil storage tanks, it is important to take note of:
the existing practice of oil suppliers in relation to price variation and quantity delivered at one
time;
the additional volume (dead space) below the fuel take-off required to accommodate sludge
and water at the bottom of the tank;
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the additional volume (ullage) required as a safety allowance against overfilling, thermal
expansion and dumping from rooftop tanks.
the additional volume required to accommodate heating equipment and any other equipment
fitted within the tank.
35.2.3 Choice of number and type of tanks

Number: It is usually preferable to use more than one tank to allow settlement of the contents
after deliveries have been effected. The use of tanks to manufacturers standard sizes may be
cheaper than using specially made tanks.
Multiple tank installations facilitate maintenance as individual tanks may be taken out of service
for cleaning.
Type: Typical factors that shall be taken into account in selecting the type of tank to be installed
are as follows.
Rectangular tanks are generally limited to installations of smaller capacity where available
space imposes restrictions on dimensions. They are liable to contain a large proportion of dead
space.
Horizontal cylindrical tanks are generally limited to medium-capacity installations. They contain
a minimum of dead space and for heated oil they are convenient for the fitting of an outflow
heater.
Vertical cylindrical tanks are generally used for larger-capacity installations and/or where the
ground area is limited. It may be necessary to take account of the wide pressure-head variation
that they impose on the oil burning equipment.
35.2.4 Design and test conditions

Detailed specifications for the design, construction and testing of mild steel oil storage tanks are
given in BS 799-5.
35.2.5 Measurement of contents of oil storage tanks

It is necessary to provide facilities for measuring the quantity of oil in a tank
to determine when a new delivery is necessary;

to determine that the new delivery can be accommodated.
Details of methods of measuring the tank contents are given in BS 799-5.
When cable-operated float gauges are used, water and dust shall be prevented from entering
openings in the tank plates, by using a raised smooth-bore fitting for the cable entry, and by
shrouding the opening.
The cable shall be so arranged that water cannot run along it into the tank.
The oil contents indicator shall be marked O or EMPTY to show when the oil surface is level
with the top of the outflow or level with the foot valve.
Indicators marked in units of volume shall have a litre scale.
To reduce the likelihood of overfilling, scales shall be marked FULL at an oil level a distance
below the top of the tank equivalent to 5 % of the gross tank capacity up to and including 12,000
litres, and to 3 % of the gross tank capacity of tanks above 12000 litres.
A dip stick or tape shall be provided in addition to any other form of oil-level indicator.
Design and test methods for polyethylene tanks are given in OFS T100.
A limiting value with very large non-metallic tanks is required
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35.2.6 Precautions against overfilling
Large multitank installations
contents indicators clearly visible at the filling point;
an overfilling alarm system;
an automatic delivery shut-off device fitted by agreement with the oil supplier.
Where night deliveries are envisaged an adequate standard of illumination of the filling point and
contents indicator, etc. shall be provided.
35.2.7 Filling pipes and connections

Filling pipes and connections shall be in accordance with BS 799-5. Where more than one
grade of oil is being stored in the same installation or building, there shall be a separate filling
terminal for each grade and a label indicating the grade.
A separate filling pipe be provided for each tank. Each tank and each corresponding filling pipe
shall be clearly numbered. If this is not convenient with a multitank installation storing the same
grade of fuel, a common filling line may be used, provided that the following conditions are met.
Independent connections fitted with isolating valves are made between each tank and the
common filling line. These isolating valves shall be readily accessible and shall indicate
whether they are open or closed;
Each tank is clearly numbered and the same number is displayed on or close to the
corresponding oil-level indicator and on the corresponding isolating valve.
Each filling pipe shall be fitted, at the filling point, with a protective cap.
Filling pipes shall be self-draining to the storage tank wherever possible. Where this is not
possible a gate valve shall be provided adjacent to the filling point. Filling pipes for classes F
and G fuel oils containing undrained oil shall be traced and thermally insulated.
Filling pipes shall be installed at a height of approximately 1 m from ground level, protected from
inadvertent mechanical damage and secured against unauthorized interference.
The requirements of local authorities shall be complied with and care taken that the filling
terminal is sited for easy access by delivery vehicles.
Pipes shall be identified in accordance with BS 1710.
35.2.8 Vent pipes

Vent pipes shall comply with the requirements of BS 799-5. Important requirements are that the
vent pipe is free from sharp bends, has a continuous rise and, while being as short as
convenient, terminates in the open air in a position where it cannot be tampered with. Wherever
possible the vent pipe terminal shall be visible from the filling point. The end of the pipe is to be
kept away from any zone in which the discharge of air and vapour might be dangerous or
offensive.
It is preferable that a separate vent pipe is provided for each tank but if the tops of all tanks are
at the same level a common vent pipe may be fitted.
Where of necessity the vent pipe rises to a considerable height, excessive internal pressure on
the tank may result if overfilling occurs. To prevent possible tank failure due to such an
occurrence, a vent-pipe unloading device shall be provided. If an overfill alarm is fitted to the
vent pipe, it shall not restrict the oil flow shall an overfill occur.
35.2.9 Drain valves

The purpose of the drain valve is the removal of water and sludge at regular intervals; it also
provides a facility for draining the dead space below the draw-off point when the tank is emptied
for cleaning.
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Drain valves shall comply with the requirements of BS 799-5.
Drain valves shall be located at the lowest point and be readily accessible for drainage by a
connected hose or into a receptacle.
Provision shall be made to secure drain valves from unauthorized interference.
35.2.10 Multiple storage tanks with return line connections

Where the oil burning system requires the connection of an oil return line to the storage tanks it
is essential that the returned oil always passes back to the tank from which it has been drawn. If
this is not arranged, overflow of the other tanks could occur.
On plants that are not under constant operator supervision and control, an interlocking valve
system or other device on multitank installations is useful to maintain the correct connections
when changing over from one tank to another.
35.2.11 Installation of oil storage tanks

Foundations and/or supports shall be completed before delivery of the oil storage tanks, so that
tanks may be installed without delay. Details of supports, including spacing, etc., are given in BS
799-5.
Supports and foundations shall be designed to accept the loading that would occur if the tank
was completely filled with water.
The bearing capacity of the soil shall be assessed to ensure that it is adequate for the proposed
loads and the foundation shall be designed to ensure correct stability.
Where settlement of foundations is likely to occur, connections to take this into account shall be
fitted.
Sectional oil tanks shall be erected by specialists.
Tanks constructed at suppliers works shall be tested before despatch in accordance with the
method given in BS 799-5 and to suit the pressures that will be imposed in use. Where tanks
are fabricated on site, or where tanks made at works have been altered on site or subjected to
abnormal strain or damage during erection, they shall be tested in accordance with the method
given in BS 799-5 and to suit the pressures that will be imposed in use.
All traces of water, welding debris, scale, and other foreign matter shall be removed from inside
the tank.
Provision shall be made to prevent moisture accumulating between the metal plates of the tank
and the supports on which they rest. Where concrete, brick or steel piers are used to support
the tank, one of the following methods is recommended:
Clean those surfaces of the tank that will come into contact with the supports and apply one
coat of bituminous mastic solution and one thickness of a bitumin-impregnated damp-proof
material. Butter the top surface of the supports thickly with cement mortar in order to allow
for irregularities and lower the treated tank on to the supports.
Clean the tank surfaces facing the supports. Coat the top of the concrete or brick supports
with a thick layer of either bitumen or pitch, which will adhere to the tank when the latter is in
position.
Where tanks are placed directly on foundations, e.g. vertical cylindrical tanks, the foundation
ring of the tank shall be sealed to the foundation with a bitumastic compound. This compound
shall be shaped or sloped upwards from the toe of the foundation ring to the side of the tank
casing, thus allowing rainwater, etc. to drain off quickly and so prevent lodgement of water that
can lead to corrosion at the base of the tank. With large vertical flat-bottomed tanks, the bottom
shall rest on bitumastic-impregnated sand so arranged as to provide uniform support and avoid
tensile stress in the base plate.
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Earthing shall be provided, with adequate electrical conductivity, in accordance with BS 7430.
The stability of tanks when empty shall be taken into account under the following two
circumstances.
Buried tanks may tend to lift under flooded conditions and they shall be suitably anchored.
Above-ground tanks are liable to be affected by wind pressure and shall therefore be suitably
secured to their foundations to allow for this.
35.2.12 Painting and cleaning

Painting and cleaning shall be in accordance with BS 799-5
The external surfaces of tanks shall be thoroughly cleaned and freed from rust, oil or grease and
protected with a suitable rust-inhibiting primer by the manufacturer.
Painting comprising at least two coats of bitumastic paint or other oil-resistant paint shall be
carried out as soon as practicable after manufacture of the tanks; any damage to painted
surfaces shall be made good after erection on site.
Where the painting of the tanks is not the responsibility of the installer, painting requirements
shall be specified to those responsible for this work.
Internal surfaces shall be wire brushed but not painted. The underside of tank roofs of large
vertical cylindrical tanks shall be painted with red oxide or provided with equivalent protection
against condensation.
Before the tank manholes are secured after painting and cleaning, the tanks shall be inspected
and any debris removed.
35.2.13 Heating for oil tanks containing classes E, F, G and H fuels

General: The heaters for oil storage tanks shall be in accordance with BS 799-5. The heating of
oil (classes E, F, G and H) is necessary to maintain a state of fluidity and to raise the
temperature of the oil sufficiently to enable it to flow to the pumps and heaters of the oil burning
equipment. In special cases heating of class D fuel oil may be necessary.
Fuels of classes E to H require storage and handling plant equipped with heating facilities. The
minimum recommended temperatures that may be expected to give satisfactory results with
fuels of each class are given in Bs 799-5 Table 1.
The heating of the oil may be carried out by means of:
whole-tank heating by means of manually or thermostatically controlled steam or hot water

pipe coils or by thermostatically controlled electric immersion heaters inside the tank;
outflow heaters provided with thermostatically controlled steam, water or electrically heated
elements;
method together with partial tank heating similar to method a), particularly for classes F, G
and H fuels.
In addition to technical requirements, initial and running costs for the scheme chosen shall be
considered.
35.2.14 Whole-tank heating only

In cases where a residual grade of oil fuel is to be stored in a tank not fitted with an outflow
heater, i.e. whole-tank heating only, the minimum temperature that shall be maintained within
the tank for each class of oil fuel(ref Table 1). In these cases the use of external thermal
insulation for the tank will generally be required except for class E fuel.
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It is not good practice to store oil fuel at unnecessarily high temperatures and on no account
shall the temperatures specified in Table 1 be exceeded by more than 170C. This is particularly
important for class E fuels.
The following points shall be noted when whole-tank heating is contemplated.

The heat supply for heating the tank contents shall be capable of counteracting tank surface
heat losses plus a margin of between 50 % and 100 % to allow for heating up from cold to
the minimum handling temperature (see line 2, Table 1).
Oil heating coils and connections within the tank shall be constructed of seamless steel tube
and all joints shall be welded.
Coils have to be adequately supported. Steam coils shall be arranged to drain freely.
To minimize the risk of leakage and to facilitate renewal, the pipe coils and their point of
entry and exit to the tank shall pass through oversize flanges or stools, the ends of the coils
being welded to counter-flanges that in turn are bolted to the tank flanges or stools.
BS 2869 class E F G H
Minimum temperature in tank C 10 25 40 45
Minimum temperature for outflow from tank C 10 30 50 55
and for handling
35.2.15 Tanks fitted with outflow heaters only.

The use of tank outflow heaters only is not common practice and may raise difficulties in
maintaining fuel flow within the tank to the outflow heater if applied to storage of fuels of classes
G and H and, in certain cases, class F. This practice is not advisable where the distance from
the outflow point to the farther wall of the tank is more than about 3 m or where the tank is in an
exposed position. Tanks fitted with outflow heaters only do not normally require thermal
insulation.
Outflow heaters shall be capable of raising the temperature of the maximum amount of fuel
required by the burner equipment from the minimum temperature likely to be experienced in
storage to the required flow temperature.
35.2.16 Tank heating combined with outflow heaters

To reduce heat losses from tanks the oil may be stored at a temperature lower than that
required for handling, provided that it will still flow towards an outflow heater that will raise the oil
in its vicinity to the recommended minimum handling temperature. The minimum storage
temperature for the oil shall be in accordance with the recommendations in BS 799-4. This
arrangement is the one found to be generally most satisfactory in practice for classes F, G and
H fuels.
In cases where the distance between the outflow heater and the farthest wall of the tank is not
excessive, provision of heating over only part of the base of the tank may be adequate for
classes F and G to ensure flow to the outflow heater at all times. This shall be so arranged as
also to provide heat in the vicinity of the drain valve to facilitate the periodical draining of water
and sludge. The decision to use partial tank heating will depend on the dimensions of the tank,
the conditions of exposure to which it is subjected and whether or not it is thermally insulated.
Outflow heaters shall be capable of raising the temperature of the maximum amount of fuel
required by the burner equipment, including return oils, from the minimum recommended
storage temperature to the required outflow temperature (see line 2 of Table 1).
35.2.17 Other recommendations for heating for oil tanks

The limits given in 6.6.2, of BS 799-4:1991 for surface heat loading of elements shall not be
exceeded.
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Where high-pressure hot water is the primary heating medium, the use of a heat exchanger is
recommended so that the tank coils or outflow heaters may be fed with low-pressure steam or
low-temperature hot water. If high-temperature hot water is used as the direct heating medium,
the temperature shall not exceed 1750C.
When steam is used, it shall be dry and saturated and at a pressure not exceeding 3.5 bar1).
The use of steam at higher pressure is not recommended as control is easier at lower pressures
and a larger heating surface at a lower temperature is more effective.
When siting oil tanks, account shall be taken of the space required for withdrawal of coils and
outflow heaters.
If the heat supply is by steam or hot water, and is liable to be interrupted for long periods, an
electric immersion heater shall be fitted in the tank or incorporated in the outflow heater. Where
several tanks are installed this need only be provided in one tank.
Electric immersion heaters and thermostats shall be fixed at least 75 mm above the bottom of
the tank to reduce the risk of their becoming immersed in sludge but they shall be below the
level of the outflow to ensure complete immersion at all times. Such heaters shall incorporate a
high-temperature safety cut-out, with manual reset, set at about 10 _C above the operating
temperature.
To avoid fire or explosion hazards due to overheating, heating facilities and their controlling
thermostats shall never be allowed to become exposed when in operation. When a tank is being
emptied, the heat supply shall be discontinued.
Precautions are necessary to prevent any oil contained in condensate or in circulated hot water
from oil heating facilities entering boiler systems.
Any condensate from oil heating coils or heaters shall not be returned to the boiler or feed-water
system because a coil failure could result in contamination of the system.
Condensate shall be run to waste and care taken to ensure that any oil content is trapped and
not discharged to drainage systems or waterways.
If the heating medium is steam at a pressure less than the oil pressure in the heater, it is
desirable to fit a non-return valve in the steam supply line in order to prevent oil being forced
into the line in the event of heater failure.
Where medium- or high-pressure hot water is used as the primary oil heating medium, an
intermediate water/steam or water/water heat exchanger system shall be used so that the oil
heating coils or heaters are fed with low-pressure steam or hot water to eliminate any danger of
oil entering the circulating mains boiler system in the event of accidental leakage.
If it is desirable to provide a condensate recovery system, this shall include means, for which
proprietary devices are available, for detecting trace quantities of oil.
35.2.18 Service tanks

General: Where service tanks are required, the installation has to comply with local regulations
and bye-laws and with the requirements of insurance companies. Any such requirements shall
be ascertained at the design stage.
Service tanks and fittings shall be designed and constructed in accordance with BS 799-5 and
are defined as not exceeding 1000 litres capacity.
A service tank shall be so placed that any escaping oil cannot reach hot surfaces (see section
8).
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An overflow pipe shall be run from the service tank to the top of the main storage tank. If this is
impracticable a separate vent pipe may be run from the service tank to the open air where an
accidental overflow will not increase the fire hazard.
The vent pipe of the service tank fed by gravity shall be carried to a point as high as the top of
the tank supplying it. The overflow or vent pipe shall comply with the requirements of BS 799-5
and shall not be less than 30 mm bore or less than the diameter of the fill line, whichever is
greater.
A fire valve shall be fitted on the outlet pipe of the service tank (see clause 67).
Heating of service tanks: A service tank will require heating in order to maintain the oil
temperature given in Table 1 for the grade used. The heating means shall be generally as
stated previously.
35.2.19 Rooftop tanks

Rooftop tanks may be either service tanks (see clause 30) or storage tanks of total capacity not
exceeding 3 500 litres. All such installations require local authority or other approval at the
design stage.
Rooftop tanks require replenishment by a pumped supply from the ground level storage tank.
The tank shall be provided with a float control to switch off the pump automatically when the oil
reaches a predetermined level.
The method of controlling the filling of the tank may be either manual or automatic by float
control. The method proposed shall receive the prior approval of the local authority.
The rooftop tank has to be equipped with an overflow pipe of adequate size leading back to the
ground level storage tank.
Provision for the dumping of the contents of the rooftop tank in the event of fire or other
emergency and for sufficient extra capacity in the storage tank is required.
Provision for dumping is usually provided by a connection between the base of the tank and the
overflow pipe incorporating an automatic dump valve.
It is essential that the dumping arrangements are actuated by the fire valve system (see clause
67) and also that they isolate the transfer pump from the main storage tank.
35.2.20 Fire precautions

Particular attention is drawn to the need for structural and general fire precautions referred to in
the NFPA & BS 5410-2 Section 7&13.
35.3 OIL HANDLING SYSTEMS FROM STORAGE TANK TO BURNER
35.3.1 General
This section relates to the handling of oil fuel between the outlet of the storage tank and the inlet
to the actual oil burning equipment. It takes into account the pressure and temperature
conditions of the oil fuel at the tank outlet and considers the equipment required for conveying
and conditioning the fuel oil to meet the requirements of the oil burning equipment.
The primary function of a system for handling oil fuel is to transfer oil from storage to the oil
burner at specified conditions of pressure, rate of flow, temperature (and therefore viscosity).
The system shall at all times deliver correctly filtered oil to the burners within the limits of
pressure and temperature required for correct functioning of the equipment. The condition of the
fuel required at the burner shall be stated by the manufacturer.
There can be considerable variety in the choice of system, but correct design, particularly in
respect of pipe size and of pressure and temperature control, is most important if the system is
to function satisfactorily. Distillate grades of fuel (classes C2 and D, BS 2869:1998) are usually
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handled at ambient temperatures (see below), and residual grades (classes E, F, G and H, BS
2869) require to be handled at above ambient temperatures. The salient features of each
system are outlined in distillate fuels and in heated fuels.
In extremely low temperature conditions, the flow properties of class D fuel oil may be affected.
Proper siting and insulation of tanks, pipework and filters may be adequate to provide sufficient
protection to maintain flow. In addition a tank immersion heater capable of maintaining the oil
between 0 _C and 5 _C and pipeline trace heating capable of maintaining the oil between 0_C
and 5 _C will be advisable where continuity of service is essential. The heating equipment shall
be as described earlier.
When deciding upon the route by which fuel is to be transferred from the storage tank to the
burner and its ancillary equipment, care must be taken to minimize the possibility of mechanical
damage to the pipeline by avoiding points at which vehicular or other damage might be
anticipated.
35.4 DISTILLATE OIL FUEL SYSTEMS (CLASSES C2 AND D FUELS)
35.4.1 Gravity supply systems

A gravity supply system is one where the oil will flow directly from the storage or service tank to
the oil burner(s). The outlet from the tank has to be above the level of the inlet to the oil burner
and provide a positive head to the burner at maximum flow and at all depths of oil in the tank.
The maximum and minimum static heads imposed at the burner inlet will depend on the related
depths of oil in the tank according to whether it is full or nearly empty. Either the burner system
has to be capable of accepting these variations in head or the head has to be controlled by
means of a constant-level control device, a pressure reducing valve or an intermediate service
tank between the main tank and the burners.
The oil line shall preferably fall continuously from the tank. Where this is not possible, air vents
shall be provided at high points.
A stop valve shall be fitted at the tank outlet, followed by a first-stage filter (see BS 799-5) in the
supply pipe. A fire valve is to be installed in accordance with the requirements of BS 799-5 (see
also clause 67).
If deemed necessary, an oil cut-off valve, actuated by a sump switch in the boiler house floor or
by other methods of leakage detection, shall be installed.
Where the pipe supplies more than one off-take point or burner, it shall be of such size that any
variation in fuel pressure resulting from changes in the friction head loss does not exceed the
limits of such pressure variation acceptable to the oil burning equipment at all flow rates.
35.4.2 Pump supply systems

General: Because of the relative positions or levels of tanks and burners, it is not always
possible to use a gravity supply system. In such instances, it is necessary to use a pump for
transferring the oil from the tank to the burner. In some installations where the total suction head
does not exceed the suction capability of the pump as advised by the manufacturer it may be
possible to consider the use of the oil burner pump for this purpose.
Use of the oil burner pump (termed a sub-gravity system).
A non-return valve shall be fitted in the suction pipe close to the tank or, if the suction pipe
enters through the top, a foot valve shall be fitted to the end of the pipe. In the latter case
adequate provision for withdrawal shall be made for servicing the foot valve. The draw-off level
of the suction pipe shall allow for a dead space in the bottom of the tank for accumulation of
water and sediment.
Oil surplus to the burner requirements is returned from the burner pump through a return line to
the tank. This line shall terminate at the same level as the draw-off point but away from it so as
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to avoid air entrainment. Return lines from multiple burners may be combined in a single return
pipe of adequate size and valved. In the case of spill-back burners the spill return shall be so
designed that it cannot be shut off inadvertently.
To facilitate priming, the suction pipe shall rise continuously to the burner and a suitable priming
point shall be provided at the high point.
A stop valve shall be fitted at the tank outlet, followed by a first-stage filter (BS 799-5) in the
supply pipe. A fire valve is to be installed in accordance with the requirements of BS 799-5 (see
also clause 67).
Use of transfer pump
A transfer-pump pressurized dead-leg system is one where the oil flows by gravity, or is drawn
by suction from the storage or service tank, to a transfer pump and is then pumped to the oil
burning equipment. The incorporation of a pump will not affect the static head imposed by the oil
in the tank. The maximum static head when the tank is full shall therefore be less than the
maximum permitted inlet pressure at the oil burner. Where the maximum static head is too
great, a constant-level control device, a pressure reducing valve or a service tank shall be
interposed between the storage tank and the pump.
The delivery pressure in the pipe from the pump shall be controlled within the limits required for
the satisfactory operation of the oil burners supplied at all dead-leg flow rates, including zero
flow rate.
This may be achieved by:
a constant-volume pump and a pressure control valve, so that the oil flow in excess of that
required by the oil burners is returned to the pump suction or preferably to the oil tank;
a variable-output pump controlled by a pressure-sensitive device that maintains the pressure
at all required rates of flow.
In all such systems, the provision of a relief valve shall be incorporated.
To facilitate priming, the suction pipe shall rise continuously to the burner and a suitable priming
point shall be provided at the high point.
A stop valve shall be fitted at the tank outlet, followed by a first-stage filter in the supply pipe. A
fire valve is to be installed in accordance with the requirements of BS 799-5 (see also clause
67).
In view of the dependence of the system on the transfer pump and filter, it is normal practice to
install duplicate items.
Pumped ring main systems
In these systems, oil flows by gravity or under suction from a storage or service tank to a pump
and then around a circulatory system. This comprises a flow line up to the last burner served,
and a return line to the pump suction or to the oil tank.
The pressure in the ring main shall be controlled, within the limits required for the satisfactory
operation of the oil burners supplied, at all flow rates and under zero draw-off conditions. This
may be achieved by either:
a pressure control device of suitable size fitted on the downstream side of the last burner
served; or
a vertical loop on the return line to the tank (where the burners only require a low inlet oil
pressure).
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The flow rate of the pumped oil needs to be in excess of burner requirements to ensure that the
correct pressure at the inlet to the burner is maintained satisfactorily by the pressure control
device over the range of flow rate required. Spill-type burners may have special requirements in
this respect.
The burner manufacturer shall be consulted about sizes for the pump and the ring main system.
High points of the ring mains shall be fitted with air vents.
Pressure regulating valves shall be installed with isolating valves and with a bypass valve
incorporating manual control, so that operation of the plant may continue if failure of the
pressure regulating valve occurs.
Pressure gauges shall be fitted at the pump outlet and immediately upstream of the pressure
regulating valve and bypass valve.
A first-stage filter shall be incorporated in the pump suction line. A fire valve shall be installed in
accordance with the requirements of BS 799-5.
A non-return valve needs to be fitted in the ring main return line before it enters the pump
suction or the tank.
Oil suction lines
The total pressure drop in the suction pipe, filters, valves and any other fitting (plus any suction
lift where the lowest level of oil in the supply tanks is below the level of pump suction) at the
maximum flow rate shall be within the maximum suction lift that can be provided by the burner
pump or by the transfer or ring main pump. The maximum suction acceptable at the pump inlet
shall not exceed 40 kPa below atmospheric pressure.
Suction lines shall be as short as possible, with a minimum number of bends to reduce friction
losses. Easy bends shall be used.
To avoid air in-leakage problems, the joints in suction pipework shall have welded joints as far
as possible. When joints are required to be broken, they shall be flanged in preference to
screwed. For use at priming points and isolating of the inlet side of the oil pump, types of valve
designed to eliminate air in-leakage are recommended (e.g. ball valves or lubricated plug
cocks). An appropriate gauge shall be fitted near the pump inlet to check vacuum or pressure
conditions.
35.5 HEATED OIL FUEL SYSTEMS (CLASSES E, F, G AND H)
35.5.1 Use of burner pump only

Normally this layout shall be limited to class E oil because of the problems that can be
experienced in maintaining heavier oils at a suitable viscosity to ensure adequate flow rate
under all conditions of static head of oil in the tank and under all operating conditions and
ambient temperatures.
The use of the burner pump under suction lift conditions for heated oils is not recommended
because of difficulties that may be experienced in providing a reliable supply to the burner under
stop/start conditions.
For spill burners, to avoid overheating of the tank contents, the surplus heated oil shall be
returned to a point in the supply pipe upstream of the burner pump suction and not direct into
the storage tank.
Where this system is used the recommendations in listed below shall be observed.
The static head with the oil tank filled shall not exceed the maximum pressure permitted at the
oil burner equipment.
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Section 35 Page 11
The maximum and minimum static heads imposed at the burner inlet will depend on the related
depths of oil in the tank according to whether it is full or nearly empty. Either the burner system
shall be capable of accepting these variations in head or the head shall be controlled by means
of a constant-level control device, a pressure reducing valve or an intermediate service tank
between the main tank and the burner.
The oil line shall preferably fall continuously from the tank. Where this is not possible, air vents
shall be provided at high points.
A stop valve shall be fitted at the tank outlet, followed by a first-stage filter (see BS 799-5) in the
supply pipe. A fire valve has to be installed in accordance with the requirements of BS 799-5
(see also clause 67).
If deemed necessary, an oil cut-off valve, actuated by a sump switch in the boiler house floor or
by other methods of leakage detection, shall be installed (see clause 66).
Instruments for measuring the oil temperature and pressure adjacent to the oil burning
equipment shall be provided.
35.5.2 Pumped supply systems.

For most heated oils (classes F, G and H) it is advisable to use a pumped system. Each
particular system shall be selected and designed to suit the oil burning equipment employed,
when using the chosen grade of fuel, and taking into account the relative positions and levels of
storage tanks and burners.
35.5.3 Transfer pumps.

The usual arrangement is for heated oil from the tank to flow to the transfer pump, which
transfers the oil to the oil burning equipment.
The drawback of this system is the lack of circulation and the reliance upon trace heating to
maintain temperatures over a shut-down period. A ring main system is therefore preferred
pumped ring.
In some installations, it may be necessary for the transfer pump to provide a suction lift. Suction
lift conditions are not recommended for heated oils: where they are used the recommendations
listed below shall be observed.
A non-return valve shall be fitted to the suction pipe close to the tank. Where, however, the
suction pipe enters the top of the tank (e.g. buried tanks) it shall enter through a suitable
shrouded opening or split manhole to permit withdrawal to inspect the foot valve required in
place of a non-return valve.
The maximum suction demanded at the pump inlet, which shall never exceed 0.4 bar2), to
overcome vertical lift, plus resistance of pipeline, valves, fittings, filters, etc., shall not exceed the
pump makers recommendations when using oil at the specified viscosity.
Delivery pressures from the pump shall be controlled within the limits required for satisfactory
operation of the burner equipment at all flow rates and under no-flow conditions. This may be
achieved by a constant-output pump with a pressure maintaining valve, returning oil in excess of
the flow rates required for combustion by the oil burning equipment; or a variable output pump
controlled by a pressure-sensitive device to maintain pressure at all rates of flow. A relief valve
shall always be fitted to cater for no-flow conditions and any excess pressure due to possible
malfunction.
Surplus oil from the transfer pump has to be returned to the tank and not into the suction line.
Part 5
Section 35 Page 12
The oil pipeline, including all fittings, valves, filters, pumps, etc., shall be covered with thermal
insulation and traced to maintain the required temperatures.
35.5.4 35.2.2 Pumped ring main

From a storage or service tank oil flows by gravity to a ring main pump. A circulatory system
from the ring main pump delivery comprises a flow line up to all sets of burner equipment served
and a return line from the last set to the oil tank or pump suction.
A pressure control device is normally fitted on the down-stream side of the last burner served to
maintain the required supply pressure to all burners under all oil flow rates.
The ring main may incorporate oil heaters to bring the oil supplied to the burners to the required
temperature, and the system can thus cater for oil supply to the burners at temperatures
between oil storage temperature and atomizing temperature.
Sub-circulating loops can be taken from the ring main to feed oil to the burners and to return
excess oil to the return side of the ring main. Burners that do not return excess oil to the return
line may be connected by short dead-legs to the flow side of the ring main.
Selection of ring main flow rate, operating temperature and pressure depends upon the type of
burner served and the grade of oil used and on any heater capacity provided within the burner
arrangement.
The quantity of oil to be circulated depends upon the number of burner take-off points, the
maximum demand at each point, the type of ring main pressure controller selected and the
sensitivity of the burner equipment to pressure fluctuation.
To cover these requirements, it is usual to circulate between one and a half to three times the
maximum consumption rate, but the circulation may need to be greater for some types of
burner, e.g. certain spill-type burners.
This excess volume of circulated oil reduces the pressure fluctuation at the burner take-off
points for varying rates of consumption and allows the pressure regulating valve to operate
correctly under all flow conditions.
The ring main temperature (hence oil viscosity) shall be selected to suit the temperature
required at the entry into the oil burner equipment, allowing suitable margins for control
fluctuations.
The ring main temperature can vary from storage temperature when supplying oil to burners that
have their own full heating equipment up to atomizing temperature when the burners supplied
have no built-in heaters. Higher ring main oil temperatures permit the use of pipework of smaller
diameter. Where low temperatures (high oil viscosities) are involved, the system pressure drops
shall be carefully considered.
In order to avoid vapour pockets where classes F, G and H oils are circulated at elevated
temperatures, the whole of the system shall be operated at a pressure above the vapour
pressure of water at that oil temperature.
To establish the pressure required at the burner, the calculation of resistance through pipes,
fittings, filters, heaters, etc. shall be made for the oil viscosity concerned at the selected oil
temperature, since pressure drop is related to oil viscosity. The pipe sizes chosen depend on
obtaining an acceptable pressure drop round the system when pumping the volume of oil to be
circulated at the selected oil temperature and hence viscosity. Where lower oil pressures are
required at any burner off-take points, these burners can be supplied from the ring either by sub-
circulating loops or by short dead-legs, both fitted with an individual pressure reducing valve.
The amount of the oil flowing through a sub-circulating loop shall be carefully controlled or the
ring main pressure regulating valve may be rendered ineffective due to short-circuited flow. This
Part 5
Section 35 Page 13
control may be effected by use of a secondary pressure regulating valve after the last burner on
the loop or a flow control valve set at a flow that will ensure satisfactory pressure conditions.
Problems can arise after a long shut-down of a ring main system because of excessive pressure
rises due to cold oil.
These problems can be avoided by:
the use of trace heating with continuous circulation of oil;

the use of trace heating without continuous circulation of oil;
complete draining of the system.
If the system is allowed to cool and is then reheated by the trace heating, this can be a very
slow process unless the heater capacity is high. In general it is preferable when possible to
circulate the oil continuously.
If normal circulation is at an elevated temperature, during shut-down periods the temperature

may be reduced to the tank outflow temperature.
Particular care is necessary in determining the size and layout of the suction pipe from the tank,
of the ring main return and of the pump connections.
Where it is evident from the design of the system that a large amount of hot oil is liable to be
returned to the pump suction, the storage tank may not provide an adequate head to prevent the
formation of vapour pockets at the pump entry. The head of oil shall be supplemented by
installing an additional pump in the line from the tank to the ring main pump inlet. Alternatively
the return can be taken back to the tank if the oil temperature is not excessive for this
arrangement.
A permanent vent, connected back to the tank, may in some cases be fitted in the return line to
release any air and vapour pockets.
35.5.5 Recommendations for oil ring main installations

Pipework shall be installed with a slope (1: 100 minimum) so as to be self-draining.
Where practicable, cross-connections shall be provided so that the system can be emptied by
the pump and the oil discharged into the storage tank.
Pockets that could trap air or vapour shall be avoided; if unavoidable, air vents shall be fitted at
all high points. Vents shall consist of either a manually operated cock or an air bottle with
isolating valve and air cock. Alternatively an automatic float-operated air-release vessel with
isolating valve may be fitted. In this case the discharge shall terminate over a receptacle in a
safe position but where it can be observed readily. To be effective such equipment will usually
require lagging and trace heating.
The pressure regulating valve shall be installed as near as possible after the last take-off point;
a valved bypass shall be provided so that operation need not be interrupted if failure of the
pressure regulating valve shall occur.
Pressure regulating valves shall be selected to maintain pressure within the required limits over
the whole range of throughput. The valves shall be located so as to be readily accessible for
adjustment when required.
A pressure gauge shall be fitted on the upstream side of the pressure regulating valve.
Branch lines from ring mains and sub-circulating loops shall be as short as possible and be
provided with isolating valves at the ring main connection. Valves shall be provided as
necessary for purging and draining.
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Section 35 Page 14
All connections from the ring main shall be from the side or bottom of the pipe to avoid
withdrawal of any entrained air bubbles.
All components such as pumps, heaters, oil meters and filters shall be provided with isolating
valves and union or flanged connections to facilitate removal for maintenance.
The oil pipeline, including all fittings, valves, filters, pumps, etc., will need to be traced and
lagged to maintain the required temperatures. The lagging and tracing shall include dead-legs
up to the burner inlet connections otherwise cold-start problems will be experienced.
Relief valves shall be fitted in all positions where a rise in pressure may occur due to a rise in
temperature of oil enclosed within heaters, etc.
Stop valves shall comply with the requirements of BS 799-4.
Fire valves shall comply with the requirements of BS 799-5 and are referred to in clause 67.
Filters shall be fitted in positions accessible for examination and cleaning. First-stage filters shall
be fitted to protect the pump suction; second-stage filters are needed to protect the burner.
First-stage filters shall be duplicated (or be of the duplex type) so that cleaning can be
accomplished without shut-down. Recommended standards of filtration are given in BS 799-4.
The pumps shall be capable of delivering the maximum amount of oil to be circulated and of
operating without undue noise, wear, vibration or leaks from seals, etc. Inlet and outlet
connections shall be fitted with plugged tappings to allow pressure/temperature measurements.
Reciprocating pumps shall be fitted with air bottles to limit pressure fluctuations. Facilities for
charging the bottles are required.
Oil-line heaters may employ steam, water, thermal fluids, electricity or combinations thereof as
the heating media. Consideration shall be given to the provision of electric heating facilities for
use when steam or hot water is not available. Precautions are necessary to prevent any oil
contained in condensate or in circulated hot water from oil heating facilities entering boiler
systems (see also 29.5).
Heaters shall be selected to provide the necessary temperature for the circulated oil; the oil-side
pressure drop will depend on the oil circulation rate as indicated by the manufacturers data.
Heaters shall be thermostatically controlled to maintain the oil fuel at the desired temperature
(see previous) and be fitted with pressure relief valves and thermometers.
Each installation shall be analysed for the effect on plant availability in the event of failure of the
components. This shall be assessed in terms of the time required for repair or replacement of
the affected components. It will generally be found advisable to duplicate such items as pumps,
filters, and oil heaters to ensure continuous operation.
35.6 TRACE HEATING
35.6.1 General
In assessing the requirements in respect of the compensation for heat losses from pipelines,
account shall be taken of the temperature drop (and consequent viscosity increase) that will be
experienced under the most adverse conditions of operation. The most adverse conditions
occur in suction and delivery lines when the oil flow rate is at a minimum or when the plant is
shut down. In these circumstances, tracing will be required if it is possible for the oil in the
pipeline to fall below the minimum recommended pumping temperature. The heat transfer by
the tracing medium to pipelines handling oils at pumping temperature does not require to be
closely controlled. The main requirement is that the heat transfer is adequate for the worst
conditions and yet will not be so excessive at any time as to cause an undue rise in the
temperature of the oil in the pipeline, especially under static conditions (i.e. no-flow conditions).
Part 5
Section 35 Page 15
The necessity for incorporating thermostatic control into the tracing system will depend on the
particular circumstances of the installation but as the temperature control is not critical
thermostatic control is not always required.
In the case of pipelines handling oil at burning temperature (including ring main systems)
compensation of heat loss by tracing shall be provided to avoid the possibility of the oil arriving
at the burner at temperatures significantly below those required. Alternatively, tracing may be a
convenient method of warming up the oil in pipelines after a shut-down period, thus avoiding the
necessity for draining or continuous pumping.
Where steam or hot water tracing is fitted, consideration shall also be given to fitting electric
tracing for use when steam or hot water is not available for this purpose.
When tracing is used to maintain the oil in the pipeline at the correct burning temperature, care
is necessary to ensure that the heat input is regulated accurately by thermostatic control. This
entails careful location of the thermostat to ensure that the temperature measured is truly
representative. In other circumstances, thermostatic control is only necessary where there is a
possibility of overheating the oil in the pipeline.
NOTE All traced pipelines liable to be isolated (i.e. valves shut at each end) shall be fitted with a
pressure relief valve, as excessive pressure may be developed if the contents of the pipe are
heated without room for expansion.
Tracing may be provided for pipelines and for filters, pumps, motors and valves by one or more
of the following means:
steam or hot water pipes clipped on externally;

electric heating cables, tapes or blankets applied externally;
electric induction heating.
35.6.2 Steam or hot water pipes applied externally to oil lines

The tracer line shall be clipped at frequent intervals so that it is in metallic contact with the oil
line while permitting relative movement between the two. The layout shall be arranged so that
steam pipes are self-draining, all off-sets for valves and fittings are horizontal to avoid pockets,
and unavoidable pockets are provided with individual drain points. Adequate provision shall be
made for expansion and anchoring.
Steam traps shall be used for discharging condensate from each drain point. Steam tracer lines
that fall continuously in the direction of steam flow shall be drained every 50 m. The steam
supply shall be arranged at intervals not exceeding 150 m, each section being controlled
independently.
Where accurate control of oil temperature is required (where the oil in the pipeline is to be
controlled to burning temperature) the steam supply shall be regulated automatically by a
thermostat, care being taken to locate the temperature-sensitive element in a representative
position.
The steam supply shall be dry-saturated. Superheated steam shall not be used in tracer lines.
Adequate protection in the form of strainers shall be provided for all steam traps and
thermostatically controlled regulating valves. Where steam traps and strainers will be exposed
to very low temperatures they shall be insulated.
35.6.3 Electric tracing

General: This method of tracing is relatively simple and low in first cost. It is particularly
convenient for starting from cold and for this purpose it may be used in addition to steam or hot
water pipes.
Operating costs for continuous use may be higher than for equivalent steam or hot water
tracing.
Part 5
Section 35 Page 16
Electric tracers shall be applied externally under thermal insulation and may be selected from
several types suitable for the temperatures and conditions of use. There are a number of these
for which full particulars of ratings and instructions for fixing may be obtained from the
manufacturers. It is most important to ensure that the type selected will withstand the
temperatures reached by the conductors, pipes and any other methods of tracing to be
employed on the same pipe.
Examples are:
twin-conductor cable, plastics- or lead-sheathed for lower temperatures; mineral-insulated
metal-sheathed cable either single core, twin core or multicore according to the method of
temperature control heating tapes made up of two single cores with heat-resisting insulation
that are sheathed and spaced apart by a covering material selected according to temperature or
protection required.
35.6.4 Installation recommendations

If single core, the lead and return cables shall be laid together to avoid magnetic loop. If more
than one cable or pair of cables are used for a complete circuit they shall be terminated as far
as possible at a common point permitting the supply from one straight feeder.
The heating cable(s) shall be held in firm contact with the oil pipe by a continuous heat-
insulating tape binder applied in a close spiral round the oil pipe (and the steam or hot water
pipe where fitted). Where two or more heating cables are used, they shall be spaced apart by
the tape. Sharp bends and undue strain on the cables and damage shall be avoided before they
are covered by thermal insulation. Precautions shall be taken to keep cables dry under the pipe
covering.
Where cables cross valves, flanges or other fittings, they shall be protected from damage by
inserting pads of lead strip, or other suitable material, between the cable and any sharp edges.
To facilitate removal of valves or fittings or breaking of joints some slack shall be left in the cable
at such points.
Where it is necessary to accommodate additional cable length (i.e. where the watts required per
metre run are greater than watts/metre run output from the cable) the cable(s) may be spiralled
round or laid in a wavy formation. Some waving of stiff cable will allow for differential expansion.
It is necessary to balance as closely as possible the heat input of tracer cables with the
maximum heat loss of the pipelines and in some cases it may be advisable to zone the tracer
system. Even where thermostatic control is incorporated it is desirable that the balance shall be
maintained. Careful consideration shall be given to the siting of the thermostat. It shall be
located at a point that will ensure that at no portion of the pipeline will the oil fall below the
required temperature.
The tracers shall be terminated with flexible insulated cold leads. Where these leads are not part
of a made-up cable they shall be attached to the conductors in accordance with makers
recommendations. The cold leads shall be connected to the supply cables in a suitable
waterproof junction box.
Pipe joints shall be efficiently bonded across with copper wire as specified in IEE Regulations
for the Electrical Equipment of Buildings, but not less than 7/0.85 mm. The metallic cable sheath
shall be earth-bonded through the electrical installation. The complete pipeline shall be earthed
in the normal way through the electrical installation but if the tanks are far from the boiler house
and the resistance of the pipeline too high, it may be necessary to use a local earth electrode or
to lay an earth continuity conductor along the pipeline.
35.6.5 Electric induction heating

If electric induction heating is considered, specialist suppliers shall be contacted and their
advice and recommendations implemented. Special care is necessary throughout such
installations to avoid loops that may be inadvertently formed with such items as supporting
steelwork.
Part 5
Section 35 Page 17
35.7 THERMAL INSULATION OF PIPELINES
Pipelines including flexible pipes handling oil shall be insulated in accordance with BS 799-4.
Reference may be made to BS 5970. In selecting the type of insulation account shall be taken of
the location of the pipeline and exposure to weather and draughts. The insulation shall be
covered by a suitable material to minimize the absorption of moisture or oil and shall be
protected against mechanical damage. If exposed to the weather the covering shall be
weatherproofed.
The insulation shall be so arranged that flanges or couplings are easily accessible and leakage
readily detectable.
The use of rope-type insulation shall be confined to short lengths of small-bore pipe and flexible
pipes. It shall be protected by a canvas covering sewn on.
Where steam or hot water tracing is used, care shall be taken to avoid impairing the heat
transfer by radiation from the tracing pipe to the oil pipe by accidental filling of the space
between the two pipes with insulating material. Preformed insulating material shall be used
where electrical, steam or hot water tracing is employed.
35.8 ROOFTOP SYSTEMS

These systems incorporate the oil fired equipment at the roof level of the building. The
equipment is supplied either:
from a tank at rooftop level (see previous for requirements), or

directly from ground level storage by means of a pumped oil supply system.
Provision is necessary under emergency conditions to dump the oil contained in the pipework
back to the tank at ground level.
Where rooftop systems are installed additional precautions can be required to prevent damage
due to leakage, e.g. drip-trays.
35.9 SIZE OF OIL PIPELINES

The most economical size of pipeline shall be chosen consistent with obtaining the required
pressure conditions at the burners at all rates of flow. Where the burner pump requires a flooded
suction, the pipe bore selected shall be such that the friction loss does not prevent compliance
with this requirement.
The following factors shall be taken into account when assessing pressure drop.
Viscosity. Pressure drop is directly proportional to viscosity. Assessments shall take into
account the effect of any heat loss from pipelines and the consequent increase in viscosity
as the oil passes through the pipeline.
Flow conditions. Handling systems for fuel oil shall be designed to provide streamline flow
conditions where steady and accurately predictable pressure conditions are essential.
(Velocity of flow not exceeding 2 m/s is generally suitable for viscosities above 18 cSt.)
Turbulent flow conditions shall be avoided as a general rule, but may be acceptable with
transfer or tank filling lines where close control of pressure drop or pressure conditions is not
important.
Flow rate. Pressure drop under streamline flow conditions is directly proportional to the
quantity of oil flowing. The effect of reduced flow rate subsequent to off-take points as
compared with full flow rate throughout the full length of the pipeline when there is no off-take
shall be taken into account to ensure that variation in pressure does not cause excessive
variation of flow through metering devices sensitive to pressure differentials (V-slot metering
valves, etc.). Special attention is necessary in ring main systems or in a gravity system
serving several off-take points.
Part 5
Section 35 Page 18
Equivalent length of pipeline. Pressure drop is directly proportional to the equivalent length of
the pipeline that takes into account friction loss due to valves, bends, filters, fittings, etc.
35.10 MATERIALS AND ERECTION OF OIL PIPELINES

Materials: Materials and joints shall comply with the requirements of BS 799-4. Where pipelines
are welded or screwed and socketed, occasional flanges or unions shall be used to facilitate
dismantling.
Erection: Oil pipelines shall be as short as practicable, with the minimum number of directional
changes.
Easy bends or swept tees shall be used; the use of elbows or square tees shall be avoided.
Pipelines shall be laid with a fall to be self-draining and be supported at intervals that are
sufficiently frequent to avoid sagging.
In outside situations a suitable corrosion-resistant and weatherproof treatment shall be applied.
Where pipelines are required to be located below ground level they shall be laid in concrete
ducts that are adequately drained, readily accessible and provided with removable covers.
When this is not applicable, clean sharp sand or sifted earth shall be used and a suitable
protective coating applied to the pipeline.
35.11 TESTING
The complete pipework installation shall be hydraulically tested after erection and before any
trace heating and thermal insulation is applied. Unless otherwise specified the test pressure
shall be one and a half times working pressure or 7 bar, whichever is the greater. The test
pressure shall be maintained without further purging for not less than 30 min. These are gauge
pressures (i.e. above atmospheric pressure). If any leakage occurs the test shall be repeated
after the leak has been rectified. When testing, care shall be taken to ensure that the pipeline is
completely charged with water and is subsequently thoroughly drained. If there is any possibility
of water being retained, even in small quantities, the test shall be carried out using a light grade
of oil.
Suction lines that may be subjected to sub atmospheric pressure shall be tested under vacuum
so that they hold a pressure below atmospheric of 0.3 bar, i.e. 0.7 bar absolute pressure for 30
min with a loss of not more than 0.03 bar. The test shall cover the whole of the suction line from
the tank draw-off valve to the pump inlet and include all valves and filters incorporated in the
pipeline.
Electrical continuity checks shall be made on electric tracing before fitting the thermal insulation.
A final operational test using oil under operating conditions shall be applied when all thermal
insulation has been completed. This test shall cover the specified conditions of operation
required for the installation and shall be completed to the satisfaction of the purchaser or his
agent.
35.12 PAINTING AND IDENTIFICATION

Oil piping shall be painted in distinctive colours in accordance with the requirements of BS 1710.
A numbered disc or tag shall, where necessary, be affixed to each valve in the system, the
numbers coinciding with those indicated in written working instructions on diagrams or on record
plans.
The installation, materials, workmanship and testing of oil installations shall be in accordance
with NFPA and Local Authority requirements and regulations.
There shall be no pipeline joints within the thickness of walls or floors.
Part 5
Section 35 Page 19
Pipework shall not be embedded in the structure. Where pipes pass through walls or floors a
pipe sleeve shall be built in, comprising a length of tube of the same material as the pipeline or
other equivalent proprietary purpose made sleeve. Pipes passing through external walls, floors
and roofs shall be installed with puddle flanges or sleeves as appropriate and sealed against
water, vermin, dust and the spread of fire.
No sleeving shall be used that will impair the fire resistance of the structure / fabric of the
building.
Dubai Civil Defence Authority

NFPA
Gas Safety (Installation & Use) Regulations
Pressure Equipment Regulations
HSE Approved Codes of Practice and guidance

CIBSE Guide K Electricity in Buildings
BS 143 and 1256 Threaded pipe fittings in malleable cast iron and cast copper alloy
BS 5410-2:1978 Oil Firing Part 2

pipe threads
BS EN 10216-1 Seamless steel tubes for pressure purposes. Technical delivery
conditions. Non-alloy steel tubes with specified room temperature
properties.
properties.
BS EN 10226 - 1 Pipe threads where pressure tight joins are made on threads. Taper
external threads and parallel internal threads. Dimensions,
BS EN 10253-1 Butt welding pipe fitting. Wrought carbon steel for general use and
without specific inspection requirement
conditions.
purposes
BS EN 378 Specification for refrigerating systems and heat pumps. Safety and
environmental requirements.
Part 5
Section 35 Page 20
BS EN 598 Ductile iron pipes, fittings, accessories and their joints for sewerage
applications. Requirements and test method.
evacuation of water from buildings. Requirements, test methods and
quality assurance.
Part 5
Section 35 Page 21
Section 36 Compressed Air
Contents
Section 36 Compressed Air 1

Section 36 Compressed Air
Supply, deliver and install all pipework materials and associated fittings for the compressed air
services installation.
The following assumes that the quality of compressed air required is for tools or instrumentation
only. This document is not to be used for medical compressed air or breathing air installations.
Compressor air intake shall be either external air, protected by sand trap louvre and pre and
final filter or from an adjacent well ventilated and air conditioned room.
Intake from car parks and plantrooms are not acceptable.
The plant and equipment associated with the compressed air installation shall be designed in
accordance with NFPA Regulations, CDA requirements and manufacturers recommendations.
Compressed air pipe work shall be of dual polymer sandwich wall and braided reinforcement
construction of the sizes indicated on the drawings. Controlled flexibility polymer tubes shall be
of the Poly-Tech P-Series as manufactured by Advanced Polymer Technology Inc.
Each branch pipe to compressed air points shall terminate in a standard fitting provided with
chained cover and identity tag.
Fusible plugs shall be fitted as close to compressor outlets as possible to safeguard the
installation in the event of the air temperature reaching the lubricating oil flash point.
Fusible plugs shall also be fitted directly into any receivers which are capable of being isolated
from the safety valve to prevent an explosion in the event of fire.
Safety valves shall be provided to permit air to escape from the system without increasing the
pressure beyond 10% above the blow off pressure when the compressor(s) are delivering their
full output and all other valves are closed.
Safety valves shall be fitted with hand operating easing gear. Where reducing valves are
installed in a system the low pressure, high pressure and any intermediate pressure systems
shall be separately protected by safety valves set to release air as soon as the design pressure
of that part of the system is reached.
A pressure gauge shall be fitted to each air receiver, and at each pressure reducing set.
Plant shall be configured on an N, N+1 or N+N basis as dictated by the application, however,
minimum provision shall be:-
Compressor and after-cooler unit

Air receiver
Duplex filter / separator
Refrigerant dryer unit
Non-return valves, isolation valves, gauges and differential pressure switches.
Plant operating and control system complete with control panel having BMS interface.
Motors shall be in compliance with the Electrical Specification, with the addition of Class F
insulation and Class B temperature rise.
Motors shall be of any type, matched to required load, provided they are suitable for continuous
running on-load and start/stop operation and capable of providing the design outlet pressure.
Part 5
Section 36 Page 1
Be complete with an acoustic shroud to ensure noise limits under full load in the plant room and
adjacent rooms / areas are achieved.
Air receivers shall be manufactured in accordance with BS5169 and/or EN 286.
Filters are to be used both prior to, and after compression. Separators shall be provided to
remove bulk liquid contamination from compressed air and shall comprise:-
A separator / filter providing maximum remaining oil content of 0.5mg/m3 and particle
removal down to 1 micron.
Isolation and safety valves
Filter / Separators shall be rated at the total throughput of the compressor/s and be provided on
a duplex basis.
Dryers shall be of the refrigerant dryer type, cooling and re-heating the air comprising:-
A dryer control / timing mechanism

Isolation and safety valves
A condensate collection system so as not to discharge condensate directly to drain.
Dryers shall be rated at the total throughput of the compressor/s
Relief valves capable of discharging the full throughput of the compressor/s shall be positioned:-
On the delivery pipe downstream of each compressor and upstream of any isolating valve,
non return valve or after cooler.
On each air receiver
Downstream of any pressure regulator
Safety valves shall be:-
Positioned immediately downstream of each line pressure regulator.

Be to BS 1123 and arranged to discharge safely so there is no danger to personnel.
Have a minimum lift pressure of 510kPa.
Automatic Drain Traps shall be:-
Installed for after coolers, air receivers, separators, filters

Electrically or mechanically operated
Provided with auto discharge to a suitable gulley or container via a tundish.
Provided with manual drain valve and a manual bypass.
NRVs shall be fitted:-
Downstream of each compressor discharge before the receiver, but after any flexible delivery
pipe.
After the filter of each dryer.
In the pipeline connecting the plant to the CA distribution pipework.
Shall be of the manual ball type, located:-
On each compressor discharge upstream of the NRV.

Upstream and Downstream of air receivers.
Upstream of auto-drains.
Upstream and downstream of each filter/dryer.
Upstream and downstream of each individual pressure regulator.
Shall comply with BS1780 and be calibrated in bars and be located on:-
Compressor control unit/s, indicating receiver pressure.

Receivers
Part 5
Section 36 Page 2
Downstream of each pressure regulator.
On each dryer
On the CA distribution main in the plantroom.
Upstream and downstream of each final filter.
But shall not:-
Include isolating valve.
All branches shall be taken from the top of the mains.
The system shall be self draining and fitted with drain traps and the necessary isolating and
bypass cocks. Each air receiver shall be fitted with its own drain.
The position of fusible plugs shall be such that their discharge will not cause injury to personnel
or damage to other equipment.
Safety valve outlets shall be positioned such that escaping air will not cause injury to personnel
or damage to equipment.
Underground pipework shall be installed in strict accordance with the manufacturers

recommendations. All underground tee fittings shall be protected with densopol 60 ht bituminous
tape or equivalent. The wrapping shall be applied spirally with 55% overlap excluding the
threaded portion.
The pipe joints shall be similarly wrapped after completion of the pressure test.
On completion of pipe laying, and before concealment, the compressed air pipework shall be
subjected to a test pressure of 1550kPa for 24 hours using air or nitrogen.

BS 5169 : 1992 Specification for fusion welded steel air receivers
BS 1123 : 2006 Fusible plugs for steam boilers and compressed air
applications. Specification
BS EN 837-1 :1998 Fusible plugs for steam boilers and compressed air
applications. Specification
Part 5
Section 36 Page 3
Section 37 Packaged Sewage Pump
Stations
Contents
Section 37 Packaged Sewage Pump Stations 1

37.2 Packaged pumping stations 1
37.3 Installation 5
37.4 Start-Up and testing 5
Section 37 Packaged Sewage Pump Stations
Provide all labour, materials, products, equipment and services to supply and install the
packaged sewage pumping station specified in this section of the specification.
37.2 PACKAGED PUMPING STATIONS

All packaged pump stations shall include the valve assemblies a lever and spring type check
valve and pressure gauge for each pump discharge line. These valves shall be of the same size
as the discharge pipes.
All packaged pumping station units shall incorporate a vent pipe connection.
The packaged foul water station shall be equipped with a minimum of two (2) pumps, each
capable of pumping at a rate equal to the peak design flow. The pumps installed in duplex
pumping stations shall be of equal capacity.
Provide submersible sump pumps as per requirements of this section and suitable for ambient
water temperature but the pump shall be suitable for 100C water.
Foul water sump pumps shall be suitable for handling raw unscreened sewage and foul water
containing dirt, sand, fibres, solids etc. Pumps shall be as manufactured by Flygt or similar and
approved by the engineer.
The pumps shall be submerged in foul water and the Automatic Control panel shall be as
described here and installed outside the foul water sump.
The foul water pump sets shall be self contained fully automatic packaged units, using close
coupled pumps of cast iron construction (including casing, impeller and pump base). The units
shall be complete with duty/standby pumps.
The pumps shall be suitable for "stationery wet" installation i.e. the discharge connection shall
be fixed to the sump floor (with stainless steel fixings) and the pump shall automatically engage
(or disengage) when it is lowered along the guide bar (or raised). All guide bars, guide bar
supports, fixings, lifting chains drop rods for fixing float switches, pipe supports etc. within the
sump shall be stainless steel. The guide bars shall not support any portion of the weight of the
pump. The pump shall be externally pitch epoxy coated.
The discharge connection elbow shall be permanently installed in the wet well along with the
discharge piping.
The pump(s) shall be automatically connected to the discharge connection elbow when lowered
into place, and shall be easily removed for inspection or service. There shall be no need for
personnel to enter pump well. Sealing of the pumping unit to the discharge connection elbow
shall be accomplished by a simple linear downward motion of the pump. A sliding guide bracket
shall be an integral part of the pump unit. The entire weight of the pumping unit shall be guided
by no less than two (2) guide bars and pressed tightly against the discharge connection elbow
with metal-to-metal contact. Sealing of the discharge interface by means of diaphragm, 0-ring,
or other devices will not be acceptable. No portion of the pump shall bear directly on the floor of
the wet well. The pump, with its appurtenances and cable shall be capable of continuous
submergence underwater without loss of watertight integrity.
Part 5
Section 37 Page 1
Pump Construction
Major pump components shall be of gray cast iron, Class 30, with smooth surfaces devoid of
blow holes and other irregularities. All exposed nuts and bolts shall be of stainless
steel 300 series .
All surfaces coming into contact with sewage other than stainless steel or brass, shall be
protected by an approved sewage resistant coating (Tnemec series epoxy or approved equal).
All mating surfaces where watertight sealing is required shall be machined and fitted with rubber
0-rings.
Discharge fitting shall be such that sealing is accomplished by metal-to-metal contact between
machined surfaces. No secondary sealing compounds, rectangular gaskets, elliptical 0-rings,
grease or other devices shall be used.
Cable
The cable entry shall be an integral part of the stator casing.
As a minimum the cable entry shall be comprised of a single cylindrical elastomer grommet,
flanked by washers and a ferrule designed with close tolerance fit against the cable outside
diameter and the entry inside diameter, or shall be triple protected with a compression fitting and
two epoxy potted areas at the power cord entry to the pump.
Motor
Pump motor shall be squirrel-cage, induction, shell type design, housed in a watertight chamber.
The stator winding and stator leads shall be insulated with moisture resistant Class F insulation
which will resist a temperature of l55 degrees C (311 F). The stator shall be dipped and baked
three (3) times in Class F varnish. The motor shall be designed for continuous duty, capable of
sustaining a minimum of ten (10) starts per hour and shall be thermally protected. Each unit
shall be provided with an adequately designed cooling system.
Thermal radiators (cooling fins) integral to the stator housing, shall be adequate to provide the
cooling required by the motor. Water jackets or other devices shall not be necessary for
continuous pumping at sump liquid levels below midpoint of stator housing.
Shaft
The pump shaft shall be of stainless steel 300 or 400 series.

The shaft shall be designed with a constant outside diameter for its entire length and without
machined shoulders for bearings.
Seals
Each pump shall be provided with two separate tandem mechanical rotating shaft seal system.
Seals shall run in an oil reservoir. Seal failure sensors shall be included. Lapped seal faces shall
be hydro dynamically lubricated at a constant rate. The seal units shall contain one (1)
stationary carbon and one (1) positively driven rotating tungsten carbide or ceramic ring. Each
interface shall be held in contact by its own spring system. The seals shall require neither
maintenance nor adjustment, but shall be easily inspected and replaceable. Each pump shall be
provided with an oil chamber for the shaft sealing system. The oil chamber shall be designed to
assure that air is left in the oil chamber, to absorb the expansion of the oil due to temperature
variations. The drain and inspection plug, with positive antileak seal shall be easily accessible
from the outside.
Part 5
Section 37 Page 2
Bearings
The pump shaft shall rotate on two (2) permanently lubricated bearings or continuously
lubricated in an oil bath with a minimum B-10 life expectancy rating. The upper bearing shall be
a single row ball bearing and the lower bearing a two (2) row angular contact ball bearing.
Impeller
The impeller shall be of grey cast iron, Class 30, dynamically balanced, double shrouded non-
clogging design having a long thrulet without acute turns. The impeller shall be capable of
handling solids, fibrous materials, heavy sludge and other matter found in normal sewage
applications. The impeller shall be of a single or two vane design. The pump manufacturer shall,
upon request, furnish mass moment of inertia data for the proposed impeller. The impeller shall
be capable of passing a minimum 3" solid sphere. The fit between the impeller and the shaft
shall be a sliding fit on a key with a impeller nut which can be tightened and locked down with a
set screw or a nylok keeper.
Volute
The volute shall be of single piece design and shall have smooth fluid passages large enough at
all points to pass any size solids, which can pass through the impeller.
Wearing Ring
A wearing ring system shall be installed to provide efficient sealing between the volute and
impeller. The stationary wear ring shall be made of stainless steel or nitrile rubber. The rotating
wear ring shall be made of stainless steel. The wear rings are to be drive fitted to the impeller
and volute inlet.
Power Cord
The electrical power cord shall be water resistant. Cable sizing shall conform to NEC
specifications for pump motors. The pump motor cable, installed, shall be continuous without
splices and shall be suitable for submersible pump application which shall be indicated by a
code or legend permanently embossed on the cable.
The discharge pipe within the sump shall be cast or ductile iron (diameter to suit pump or as
specified on the Drawings) with high solids - high build polyamide cured coal tar epoxy coating
(internally and externally). Dry film thickness of coating to be 300 microns. A flanged
connection shall be provided between the cast/ductile iron pipes and the uPVC Class E or GRP
pressure pipework. The gate valves shall be resiliently seated of ductile iron construction with
internal and external epoxy paint protection. The non-return valve shall be resilient spring
loaded type of ductile iron construction.
The discharge connection size of foul water pumps shall not be less than 50mm diameter and
throughout shall not be less than 76mm diameter. The discharge pipework shall preferably be
arranged such that it crosses the slab above sump vertically in the walkway. The pipe shall be
sleeved where it crosses the floor slab. Discharge piping shall include swing check valve(s) of
the outside lever and spring type, eccentric plug valves(s) or gate valve(s) and all necessary
fittings and tees. Where piping passes through a sleeve, nonshrink grout or other approved
means shall be used to make a watertight joint.
A galvanised steel frame shall be provided around the pipes to protect them from mechanical
damage.
Each foul water pump is for 100% duty (i.e. one of the pumps is duty pump and the other is
standby). However, in the event of excessive flow into the chamber, if the duty pump is unable
to cope the standby pump shall be brought on to assist. Therefore the panel design shall allow
for two pumps working simultaneously.
Part 5
Section 37 Page 3
The foul water pump motor shall be suitable for 380 volts, 3-phase, 50 Hz power supply, have
Class 'F' insulation and IP 68 protection. The foul water pump control panels shall be IP 54
suitable for wall mounting and equipped with anticondensation heater.
Controls
For each pump motor, there shall be included: a combination overload breaker, with manual
reset for dual protection against current overloads and short-circuit protection, overload relay to
be precalibrated to match motor characteristics and factory sealed to insure trip setting is
tamper proof; across-the-line magnetic starter and hand/off/automatic selector switch.
A twenty-four (24) volt control circuit transformer with disconnect circuit breaker and overload
protection shall be included with an automatic, electric alternator for a duplex station (providing
alternating operation of pumps under normal conditions, or in cases of high level, allowing both
pumps to operate simultaneously). A terminal board for connection of level sensors shall be
provided. All items inside or on the panel shall be adequately labeled.
Provisions shall be made to provide the following signals to an autodialer:
Wet well high water alarm

Phase failure or unbalance
Pump motor overload 1 & 2
Pump seal failure 1 & 2
Pump runtime status 1 & 2
Entry alarm
The following items shall be provided with the panel:
IP54 watertight, lockable enclosure with swing out panel allowing access to terminal board.
High Level Alarm
Alarm light with cage protector

Alarm bell
Panel powered contact
Unpowered contact
Condensation heater
Running time meter(s)
Pump run light(s)
Lightning arrestor
Pedestal mounting
Pole mounting bracket
Auto dialer
Provide integral motors with electrical characteristics as specified in electrical section of the
specification provide built-in thermal overload protection.
Provide on/off level control switch for each pump with adjustable levels and level differential.
The make of valves shall be as specified. Due to limited height of tanks the water levels at
which pumps are switched have to be determined accurately. Therefore level switches with
stainless steel drop rods (which act as guides for floats) shall be used. Float switches with
plastic floats and directly connected cables shall not be permitted.
Provide removable steel pit cover plates, bolted and gasketed to the pit rim plate.
High Level Alarm Probe and Light: Alarm probe shall be constructed of stainless steel and other
corrosion resistant materials.
Warning Alarm light shall operate on 240v and shall be actuated by the output relay on the
alarm probe. Warning Alarm light shall be located as shown on drawing.
Part 5
Section 37 Page 4
37.3 INSTALLATION
Packaged pumping stations shall be installed in accordance with the manufacturer's written
instruction. A field representative of the manufacturer shall be made available as and when
required during the installation of the GRP pre packaged pumping station.
All flanges shall be tightened in accordance with the Manufacturer's written instructions using a
torque wrench.
Reinforced concrete used in the construction of slabs and other structures related to the
packaged foul water pump stations shall conform to the applicable sections of the Structural
Specification.
Provide outlet piping from each pump with union or fittings arranged such that the pump can
easily be disconnected for removal and servicing.
Set up the level controls for both pumps to provide lead/lag operation.
Arrange the lag pump start level to be approximately 100 mm (4 in.) above that of the lead
pump. Similarly set the stop level.
Install angle iron pit rim plates during concrete pouring with bolts arranged to accept the pit
cover plate. Install covers and gaskets.
Provide high level alarm through BMS as shown on the control drawing.
Set alarm level switch to activate at approximately 150 mm (6 in.) above lag pump start level.
Where indicated on the schedules, provide power wiring from the emergency power source.
37.4 START-UP AND TESTING

Set up level controls verify alarm signals.
Construction of the panel shall be as detailed previously.
The panel shall incorporate the following:
Panel shall be equipped for each pump with:

-MCB
Starter
Hand/Off/Auto (HOA) switch
Phase Failure Trip.
ELS with audio and visual indications
A cyclic relay and 3 position (P1/P2/, P2/P1 and Auto) Duty selector switch shall also be
provided.
Selected duty pump shall operate independently controlled by float level control switch when
(HOA) switch in 'Auto' position. Duty selection shall be carried out from the duty selector switch.
The standby pump shall assist if required. Where more than one duty pump is specified for a
pump set, the duty pumps shall start with a 15 seconds time delay (adjustable) between each
pump.
A set of four level switches shall be provided to control the operation as under:
Low level switch to stop the pumps.
Level 1 switch to start the duty pump.
Level 2 switch to start "Duty Assist" pump.
Level 3 switch to raise a "high level" alarm.
Pumps shall operate as in (2) above except that duty selection shall be carried out by cyclic
relay and duty selector switch shall be in Auto position.
Part 5
Section 37 Page 5
Pumps shall be capable of operating independently or simultaneously with HOA switch in 'Hand'
position and shall override all control circuits (except overload) so that the selected pump can be
checked for operation.
In the event of duty pump failure, stand-by pump shall automatically operate.
Panel shall have on front door:
Duty selector switch

Hand off auto switch for each pump
Run and trip lamps for each pump
Panel alive lamp
Control circuit breaker fail lamp
Labels for above
Earth leakage indication lamp (30mA)
Hours run meter for each pump
High level alarm lamp.
Where specified, terminals for the following indications to the BMS shall be provided:
Power on
All H.O.A. switches and duty selection switch in auto position
Common fault on panel
Access Hatches
Safety Net
Pump access hatches shall be provided with a rail mounted safety net system for fall through
protection. The safety net shall be designed to slide on guide rails to facilitate entry and
repositioning. Slide rails and hooks shall be constructed of aluminium with stainless steel corner
hooks and eyebolts. Netting material shall be polyester.
Odor Control
The need for odor control shall be evaluated and the provisions for such, if required, approved
by the engineer.
GRP Pipes and Fittings for Pumping Stations and Valve Chambers
Provide pre-packaged GRP foul water pumping stations and valve chambers incorporating all
the requirements of this specification
The GRP pipe and fittings inside pumping stations and chambers shall be for use above ground
with no thrust blocks and shall have sufficient axial strength to resist end thrust, temperature
and bending stresses.
GRP pipe and fittings shall have a minimum pipe stiffness of 10,000 N/m2 and a minimum wall
thickness of 10 mm

BS EN Drain and sewer systems

752-6:1998 outside buildings Part 6 Pumping Stations
BS 143 and 1256 Threaded pipe fittings in malleable cast iron and cast copper alloy
BS 416 Discharge and ventilating pipes and fittings, sand-cast or spun in
Part 5
Section 37 Page 6
cast iron. Specification for spigot and socket systems.
BS 437 Specification for cast iron spigot and socket drain pipes and fittings.
pipe threads
properties.
BS EN 10226 - 1 Pipe threads where pressure tight joins are made on threads. Taper
external threads and parallel internal threads. Dimensions,
BS EN 10253-1 Butt welding pipe fitting. Wrought carbon steel for general use and
without specific inspection requirement
conditions.
purposes
Polyethylene (PE).
BS EN 1452 Plastics piping systems for water supply. Unplasticized poly (vinyl
chloride) (PVC-U).
BS EN 1453-1 Plastics piping systems with structured-wall pipes for soil and waste
discharge (low and high temperature) inside buildings Unplasticized
poly(vinyl chloride) (PVC-U). Specification for pipes and fittings.
BS EN 598 Ductile iron pipes, fittings, accessories and their joints for sewerage
applications. Requirements and test method.
evacuation of water from buildings. Requirements, test methods and
quality assurance.
Part 5
Section 37 Page 7
Section 38 Smoke Ventilators
Contents
Section 38 Smoke Ventilators 1

38.2 Roof Mounted Natural Smoke Ventilators 1
38.3 Construction 1
38.4 Control 2
38.5 Accessories 2
38.6 Type Testing 2
38.7 Fixing 2
38.9 Smoke Curtains 2
Section 38 Smoke Ventilators
Components shall be installed in accordance with manufacturers recommendations.
Electrical bonding terminals shall be provided as necessary to ensure electrical continuity in

accordance BS 7671 (latest edition of the IEE Regulations).
The installer shall be responsible for obtaining all site dimensions and the preparation of
drawings as stated elsewhere.
Full technical details of all equipment, accessories/components to be provided shall be

submitted to the CA for approval.
The installer shall be responsible Party for all necessary inspections and obtaining all approvals
for the systems.
Supply, deliver, off load, store, lift into position and install all smoke ventilation equipment,
fittings, flashings, actuators and materials for the installation
38.2 ROOF MOUNTED NATURAL SMOKE VENTILATORS

The natural smoke ventilators shall be completely factory assembled. The components and
completed assembly shall be manufactured in a facility under a quality assurance scheme
registered to ISO 9002. Manufacturers design shall be quality certified under ISO 9001 and EN
29001.
The Contractor shall prepare and submit for the CAs comment a complete set of calculations,
material submittals, outline and equipment location drawings, detailed layout drawings
secondary support steelwork drawings and builders work drawings co-ordinated with the
architectural and structural steelwork drawings.
Performance, construction and testing of natural smoke ventilators shall be in accordance with
BS7346: Part 1: 1990.
The Contractor shall be responsible for supply and installation of all secondary steelwork
supports and flashing to ensure the roof remains weather tight in accordance with the
requirements of the roofing system.
38.3 CONSTRUCTION
Base assembly shall be press formed and welded double skin mill finished aluminium 1.5mm
thick to BS1470. Base assembly shall be insulated to achieve a minimum U value of 0.56w/ mk.
Sides and ends shall be mill finished aluminium 1.5mm thick to BS1470.
Blades shall be insulated mill finished aluminium 1.2mm thick to BS1470. Minimum U value to
be 0.56w/ mk.
Blade pivot and seals shall be self lubricating nylon and blade seals shall be polypile and brush
pile seals.
Final finish to both base and blades shall be stoved acrylic colour to match roof finish or
cladding.
Part 5
Section 38 Page 1
38.4 CONTROL
Smoke ventilators shall be normally closed and held closed by electrical actuators. Under
emergency operation the actuator shall open through the loss of power to the actuator and the
action of a stainless steel spring. The operation shall be fail safe. As a backup to the normal
actuation, a fusible link set at 90C shall open the louvre should this temperature be attained
irrespective of the operation or not of the electric actuator.
The opening mechanism shall not require to be manually reset upon re-closure of the ventilator.
Preferred actuator voltage shall be 110V.
38.5 ACCESSORIES
The following accessories shall be provided:-
Galvanised 13mm square galvanised steel mesh bird guard in ventilator throat.
Purlin Box
Closure flashing
Fusible link shield
38.6 TYPE TESTING

Type test certification shall be provided for the CAs comment prior to manufacture
demonstrating compliance with the following parameters:-
Aerodynamic efficiency to be no less than 0.70

Results of full scale fire tests
Weatherproof tests in accordance with BS5368, Parts 1, 2 and BS6375 Part 1.
Accelerated life cycle tests of a minimum 30,000 opening and closing operations.
Ventilator ability to withstand wind loads of 3.0kN/ m
38.7 FIXING
The natural smoke ventilators shall be fixed in accordance with the manufacturers
recommendations for fixing into the roof structure.
38.8 CONTROL PANEL

For general construction standards refer to the Electrical Specification.
The Control Panel shall have a lockable outer door to prevent un-authorised access to the
selector switches. This outer door shall have a lamp indicating that the power and control
circuits are live.
The main panel facia behind the outer door shall contain rotary switches and open / close
indication lamps for each smoke ventilator and a door interlocked isolator.
38.9 SMOKE CURTAINS

Where required to limit smoke reservoirs to a maximum of 2000 m smoke curtains shall be
manufactured in a facility under a quality assurance scheme registered to ISO 9002.
Manufacturers design shall be quality certified under ISO 9001 and EN 29001.
Smoke curtains shall be manufactured from a woven glass fibre textile with a weight of 440g/m
tested to BS 476 Part 4 and 7 for non combustibility and spread of flame. Construction,
performance and installation of the smoke curtain shall be in accordance with BS7346, 1990.
Part 5
Section 38 Page 2
The curtain shall be sealed around any breaches in its fabric to ensure integrity is maintained.
Fabric melting temperature shall not be less than 600C.

BS 476 -6 :1989 Fire tests on building materials and structures. Method of test for fire
propagation for products
BS 7671:2001 Requirements for electrical installations. IEE Wiring Regulations.
Sixteenth edition
BS 7346-5:2005 Components for smoke and heat control systems. Functional
recommendations and calculation methods for smoke and heat
exhaust ventilation systems, employing time-dependent design fires.
Code of practice
BS EN 485-2:2007 Aluminium and aluminium alloys. Sheet, strip and plate. Mechanical
properties
BS 5368 Methods of testing windows
BS 6375-1:2004 Performance of windows and doors. Classification for weather
tightness and guidance on selection and specification
Part 5
Section 38 Page 3
Section 39 Coatings and Corrosion
Protection
Contents
Section 39 Coatings and Corrosion Protection 1

39.2 Products / Materials 2
39.3 Paint quality 2
39.4 Heat resistant paint 2
39.5 Matching building services terminals 3
39.6 Affect on performance 3
39.7 Application 3
Section 39 Coatings and Corrosion Protection

Supply, deliver and install all materials plant, equipment and appliances and perform all
necessary operations for the preparation, application and protection of the coatings and
corrosion protection systems described in this section.
This section relates to the on and off site protection of building services plant, equipment and
components.
Submit samples, specifications, catalogue cut sheets, description of product and application
method in accordance with the Contract Documents. Submissions shall indicate all dimensions,
details of construction, details of installation, relation and connections with adjoining work.
Ensure paints used are of quality and type to suit application and that primers have good
adhesion, covering power, rust-inhibiting and grain filling properties; gloss finishing paints are of
machine finish grade having high adhesion and high resistance to solvents, mineral oils, cutting
oils, detergents, chipping and impact damage.
Wherever possible ensure paint finishes applied by component manufacturers are spray
applied.
All paint finishes shall be applied by skilled operatives who have to be trained to apply the
required finishes.
For each type of coating and corrosion protection system prepare and submit for the CA review
and comment a sample or the coating showing each layer of preparation and application.
Do not apply paints where weather, temperature, humidity or other conditions may have a
damaging effect upon finish or paint.
Ensure paint and corrosion protection finishes are suitable for the environment in which they are
sited.
The external environment is hot (up to 50C in the shade), humid (up to 32C saturated and
moisture contents up to 0.030 kg/kg), dusty (up to 70mg/m) and saline. Over 12 hours of
sunshine per day are typical. Surface temperature of the materials being coated may exceed
100C.
Provide warranties and bonds generally in accordance with the main contract. All coatings are to
have a manufacturers guarantee of 10 years to first re-painting
Where particular methods of finish and painting are not specified, ensure following requirements
are met:-
Protect all metal work, plant, equipment, pipelines, ductlines, ancillaries, brackets and
supports against corrosion and oxidization.
Provide ferrous metals, machined or otherwise with protective coatings at manufacturer's

works.
Part 5
Section 39 Page 1
Ensure all items requiring on-site decorative finishes are provided primed to suit base
material and required finish.
Following delivery to site, storage on site and installation make good any damage to finishes, by
cleaning, degreasing and re-furbishing in accordance with the recommendations of the coating
system manufacturers. Do so in accordance with a method statement agreed with the
Consultant.
39.2 PRODUCTS / MATERIALS

Use the following materials as appropriate:-
Solvent borne priming paint to BS 7956 for bare woodwork.
Red Oxide priming paint for bare iron and steelwork.
Zinc Chromate priming paint for bare ferrous and non-ferrous metals.
Calcium Plumbate priming paint to BS 3698 for galvanized steel or composite wood/metal
components.
Undercoating paint for previously primed or painted surfaces before the application of
finishing coats.
Gloss finishing paint for previously primed or painted/undercoated surfaces.
Epoxy resin paint for specialist coatings requiring resistance to acids, alkalis, oils, solvents,
abrasion or high humidity.
Aluminium paint to BS 388 for structural steelwork, storage vessels, heated metallic
surfaces and similar applications where moisture and heat resistant properties are required.
Cold galvanizing paint for making good damage to previously galvanized surfaces and
protection to galvanized materials modified during installation.
Zinc-rich metallic to BS 4652 for bare iron and steelwork where electrical conductivity has to
be assured.
Black tar-based paint to BS 1070 for moisture resistant protection to metal surfaces where
decorating appearance is not important.
Bitumen based coatings for cold application to BS 3416 protection to iron and steel,
particularly pipelines and fittings for use in contact with potable water.
Bitumen based coatings for cold application to BS 6949 not to be used in contact with
potable water.
39.3 PAINT QUALITY

Ensure paints used are of quality and type to suit application and that primers have good
adhesion, covering power, rust-inhibiting and grain filling properties; gloss finishing paints are of
machine finish grade having high adhesion and high resistance to solvents, mineral oils, cutting
oils, detergents, chipping and impact damage.
39.4 HEAT RESISTANT PAINT

Use heat resistant paints for applications to surfaces over 80oC.
Part 5
Section 39 Page 2
39.5 MATCHING BUILDING SERVICES TERMINALS
Where groups of building services terminals in the same location of the same colour (say: white
light fittings, PAVA speakers and air conditioning diffusers in a ceiling) ensure that exactly the
same colour is used for each terminal with the same gloss proportion, so that they all appear the
same.
39.6 AFFECT ON PERFORMANCE

Building services components that could have their performance impaired by painting by any
party other than the manufacturer (e.g. sprinkler heads, sprinkler covers, smoke detectors,
temperature detectors, etc) shall only be painted by the manufacturer unless the manufacturer
agrees otherwise and will warrant the performance of this product.
Building services components that would have their performance impaired by painting shall be
suitably protected by the building services contractor. Any such devices that are painted shall be
replaced before handover of the building and testing and commissioning repeated as required.
39.7 APPLICATION
Before ordering any materials verify site and system conditions.
Before ordering any materials / commencing work verify that building structure associated with
the system is within tolerance and take full account of shape configuration and material
properties of the Structure.
Do not apply paints where weather, temperature, humidity or other conditions may have a
damaging effect upon finish or paint.
Deliver component parts to site, completely identified in accordance with shop and certified
drawings prepared for this work. Store in accordance with manufacturer's instructions, above
ground, properly protected from the weather and construction activities.
Before beginning installation in any area, examine all parts of the adjoining work into which
applicable work is to be placed. Should any conditions be found which will prevent the proper
execution of the work, installation shall not proceed in that area until such conditions are
corrected by the contractor.
Ensure paints are applied in accordance with manufacturers instructions and to BS 6150.
Apply paint evenly and ensure finish shows no excessive brush marks, grinning, runs, sagging,
ropiness or other application defects.
Repair damage to galvanized components due to installation process, ie following cutting,

drilling or welding, by applying 2 no. substantial coats of cold galvanizing paint.
Provide a method statement for the CAs approval for field quality control.
Clean and prepare materials to receive the corrosion protection system in accordance with the
Remove all labels prior to application. Apply the system behind the label position and re-affix the
label once the corrosion protection system is complete and cured.
Protect work in accordance with the requirements of the manufacturer.
Apply a protective coating to all bright-machined parts before despatch from works.
Do not remove protective coatings unless required for installation, testing or commissioning
purposes and in such cases reinstate upon completion.
Part 5
Section 39 Page 3
Repair any damaged protective coating or bright-machined part, or where necessary replace
damaged component.
Use and apply metal coatings in accordance with manufacturers instructions.

Complete where possible all welding, drilling, bending and other work before metal coating.
All sprinkler bulbs shall be protected to prevent paint contamination. Any sprinkler bulb that has
paint on it will be rejected.

The minimum standards for products specified in this section shall be those standards referred
to or relevant BSI standards.
BS 388:1972 Specification for aluminium pigments

BS 1070:1993 Specification for black paint (tar-based)
BS 3416:1991 Specification for bitumen-based coatings for cold
application, suitable for use in contact with potable water
BS 3698:1964 Specification for calcium plumbate priming paints
BS 4652: 1995 Specification for zinc-rich priming paint (organic media)
BS 6150: 2006 Painting of buildings. Code of practice
BS 6949:1991 Specification for bitumen-based coatings for cold application

excluding use in contact with potable water
BS 7956:2000 Specification for primers for woodwork
Part 5
Section 39 Page 4

JD 007 Part 5 Mechanical Specifications R02

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JD 007 Part 5 Mechanical Specifications R02

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REPORT NO 007

CONFIDENTIAL 18 SEPTEMBER 2016

Project no: 37452030

WSP | Parsons Brinckerhoff

Remarks Tender Issue Detailed Design issue Tender issue

Date 05 June 2016 28 August 2016 18 September 2016

Checked by Stuart Moodie Stuart Moodie Stuart Moodie

Authorised by Stuart Moodie Stuart Moodie Stuart Moodie

Project number 37452030 37452030 37452030

File reference 37452030-SM-007 37452030-SM-007-R01 37452030-SM-007-R02

Senior Mechanical Engineer James Devassy

Principal Engineer Public Giovani Tauckoor

Associate Electrical Stuart Moodie

1 Central - Phase 1 A6 WSP | Parsons Brinckerhoff

1 Central - Phase 1 A6 WSP | Parsons Brinckerhoff

1 Central - Phase 1 A6 WSP | Parsons Brinckerhoff

Part 5 Mechanical Services 1

Section 1 Pipework and Fittings 1

1.1 General requirements 1

1.1 GENERAL REQUIREMENTS

No joints shall be formed inside wall constructions or floor slabs.

Changes in the diameter of horizontal pipework shall be formed eccentrically.

Pre-fabricated pipework shall be in accordance with the relevant clauses.

1.2 PROTECTION DURING CONSTRUCTION

Remove all cement adhering to pipework surfaces and brackets.

1.3 PIPEWORK SPACING

Between insulated or un-insulated pipeline and

Between adjacent pipelines

Insulated pipes to adjacent 50 mm

Un-insulated pipes to adjacent 100 mm

Adjacent electrical cables not in 150mm

1.4 STEEL PIPEWORK

1.5 PRE-INSULATED STEEL PIPEWORK LAID IN GROUND

Axial shear strength: min. 0, 12 N/mm2 (MPa)

All pipework joints shall be welded.

Pipes shall be furnished in lengths of 6.00 m or 12.00 m. Tolerance of lengths is 0/+15mm.

Minimum requirements to insulation properties of each pipe size.

Diameter steel pipe Diameter casing pipe Maximum transmission

Installation as described in manufacturers installation manual, covered under Australian

General Conditions of Contract to be referred to and complied with in respect of warranty

ABS pipework shall be manufactured in accordance with BS 5391-1 or to Australian Standards

Measure the pipe and cut clean and square.

The extent of each section tested is to be approved by the CA.

Expansion loops and/or expansion compensators shall be provided as an acceptable means to

Acceptable Manufacturers: Refer to Appendix A Preferred Mechanical equipment suppliers

1.7 GRP PIPEWORK (CONDENSER WATER)

The extent of each section tested is to be approved by the CA.

Expansion loops and/or expansion compensators shall be acceptable means to

1.8 COPPER PIPEWORK (ABOVE GROUND)

Fittings for copper pipework shall be either:

End feed capillary fittings shall not be permitted.

Brass compression fittings shall comply to BS EN 1254-2 or BS 864: Part 2.

1.9 COPPER PIPEWORK (LAID IN GROUND)

1.10 COPPER PIPEWORK (INSTALLED WITHIN SCREED)

1.11 STAINLESS STEEL PIPEWORK

Pipework shall be installed in light gauge stainless steel tube to BS EN 10312.

1.13 GALVANISED MILD STEEL PIPEWORK

All pipework and fittings shall be internally and externally galvanized.

Copper tube to BS EN 1057 - R250/R290

No oils shall be used for lubrication of pipe cutting or fitting insertion.

Pipe supports shall comply with the requirements of the manufacturer.

Connections to equipment items shall be by threaded or flanged press-fit conversion fittings.

All systems shall be leak tested on completion.