approved_module 15_mechanical installation in buildings_july 09

7/26/2019 APPROVED_Module 15_Mechanical Installation in Buildings_July 09

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STANDARDSPECIFICATIONS FOR

CONSTRUCTION WORKS

2008

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Introduction

The Standard Specification is published in a series of 21 stand-alone modules each addressing

single distinct areas of the construction process. This stand-alone module 15 addresses the main

aspects of mechanical installation in buildings in general.

The purpose of the MoW STANDARD SPECIFICATIONS FOR CONSTRUCTION is to provide the

design professional with a guide for accepted construction practices for Ministry of Works projects.

As an aid to the designer, these Standard Specifications are provided for the inclusion in proposed

development projects for ease, efficiency and cost savings.

The Standard Specifications are not intended to limit the design responsibility of the design

professional. However, they establish a minimum acceptable criterion and/or quality for use within

Ministry of Works projects.

The design professional may increase the requirements of an item contained in the Standard

Specifications to meet job requirements, but when this is done, there should be no reference for

that item on the drawings to the Ministry of Works Standard Specifications and a new specification

should be included with the drawings or project contract documents.

The design professional must review all Standard Specifications to be sure that they are adequate

for the proposed project based on the job site conditions; the design professional is solely

responsible for the designs submitted under his seal.

In order to keep design standards current with changing regulations and improved construction

materials and practices this section will be updated and maintained by the concerned authorities of

the Ministry of Works. Prior to starting a new project, the design professional should contact the

concerned Directorate of the Ministry of Works to verify that he/she has the latest document

revisions.


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Module List

ModuleNo Module Title

1 Guidance and General Specifications

2 Concrete

3 Earthworks

4 Glass and Glazing

5 Joinery and Carpentry

6 Ironmongery

7 Internal Finishes including Thermal Insulation

8 Painting and Decorating (Internal & External)

9 Metalwork

10 Roofing

11 Structural Steel (and Coatings)

12 Structural Timber

13 Masonry

14 Plumbing and Sanitary

15 Mechanical Installation in Buildings

16 Electrical Installation

17 Sewerage, Pipelines and Pipe work

18 Sewerage M&E Works

19 Roadworks

20 Landscaping

21 Dredging, Reclamation and Shoreline Protection


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Table of Contents

CLAUSE DESCRIPTION PAGE

Introduction 1

Module List 2

Table of Contents 3

Foreword 5

1.

PART 1 MATERIALS 6

1.1 Source Approvals 6

1.2 Product Delivery, Storage and Handling 23

2.

PART 2 METHODOLOGY AND WORKMANSHIP 25

2.1 Installation and Testing. 25

2.2 Off-Site Testing of Components.. 25

2.3 Installation Management.. 26

2.4 Site Testing of Pipe Work and Ductwork... 27

2.5 Earth Bonding 27

2.6 'As installed' Drawings.. 27

2.7 Identification of Services.. 28

2.8 Refrigerant Handling. 28

2.9

Refrigerant Pipe Work.. 29

2.10 Testing of Refrigerant Plant. 30

2.11 Commissioning.. 30

3. PART 3 SUMMARY 33

3.1 Requirements for Type Approvals.. 34

3.2 Table of Requirements for Type Approval. 36

3.3 Requirements for Product Delivery, Storage and Handling 38

3.4 Requirements for Methodology and Workmanship.. 40

3.5 Requirements for Completion and Handover 43

3.6 Reference Documents.. 45

4. PART 4 FIRE SUPPRESSION SYSTEMS 52

4.1 General 52

4.2 High-Pressure CO2Fire Suppression System.. 55

4.3 Total Flooding Fire Suppression System.. 57


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4.4 Low-Pressure CO2Fire Suppression System.. 66

4.5 INERGEN Fire Suppression System. 76

4.6 Wet Chemical Kitchen Fire Suppression System 87

4.7 Execution 90

4.8 Standards References.. 91

5. PART 5 WATER-BASED FIRE SUPPRESSION

AND SPRINKLER SYSTEMS 92

5.1 General 92

5.2 Product Requirements.. 93

5.3 Execution.. 104

5.4 Standards References 106

Abbreviations 107


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Foreword

This specification provides the basis for mechanical installation in buildings. It relates to the

manufacture, works testing, supply, delivery to site, installation, site testing, commissioning and

performance testing of mechanical services systems including air-conditioning, for buildings. It

includes provision for the supply of 'As Installed' drawings and Maintenance and Operation

documents. This specification defines the standards of equipment and work normally required.

This specification must be read in its entirety, as it is structured in order of work-flow, which means

that items or activities appear in several places in the specification corresponding to the

progression of the construction process.

For larger or more complex or specialist projects, a project-specific Particular Specification for

mechanical installation may also be provided.

Absence of clauses for materials and methods does not necessarily signify that they can not be

used. Proposals for use of innovative methods and materials are encouraged and are subject to

review and approval by the Client.

Where the word approved is used in this specification, this means that the Client or Engineer has

been consulted and has confirmed that the item or procedure is acceptable in the specific context

for which approval has been requested.


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1. PART 1 MATERIALS

1.1 Source Approvals

The work shall comprise all the equipment materials and labour necessary to form a

completed installation and such testing and commissioning described in this specification

and such other activity as may be required to deliver an effective working installation to

the satisfaction of the Engineer.

This section relates to the manufacture, works testing, supply, delivery to site, installation,site testing, commissioning and performance testing of mechanical services systemsincluding air-conditioning, for buildings. It includes provision for the supply of 'As Installed'drawings and Maintenance and Operation documents. This specification defines thestandards of equipment and work normally required.

1.1.1 Water Heating

1.1.1.1 General

Materials, plant, equipment and components shall comply with the standards required by

the Particular Specification. The system design shall cover the water heating equipment,whether central plant or localised heating equipment, as well as the distribution pipe workand supports, ancillary components including valves and insulation, and the outlets andterminal components.

The water heating system shall comply with:

BS 6880:Parts 13 Code of Practice for low temperature hot water heating systemsof output greater than 45 kW or,

BS EN 12828 Heating systems in buildings. Design for water-based heatingsystems.

BS EN 12831 Heating systems in buildings. Method for calculation of the designheat load.

BS EN 14336 Heating systems in buildings. Installation and commissioning of water

based heating systems.

The controls shall comply with:

BS EN 12098: Part 1 Controls for heating systems. Outside temperaturecompensated control equipment for hot water heating systems.

BS EN 12098: Part 2 Controls for heating systems. Optimum start-stop controlequipment for hot water heating systems.

1.1.2 Boilers

Boilers intended for use in hydronic systems are available in a wide range of types,constructions and output ranges, and suitable for use with different fuels. Many standardsand codes of practice relate to boilers, covering their construction, the combustionequipment required for each type of fuel, and their installation and commissioning,including:

BS 5258: Part 1 Safety of gas domestic appliances. Specifications for centralheating boilers and circulators.

BS EN 297 Gas-fired central heating boilers. Type B11 and B11 BS boilers liftedwith atmospheric burners of nominal heat input not exceeding 70 kW.

BS EN 303: Part 6 Heating boilers. Heating boilers with forced draught burners.Specific requirements for the domestic hot water operation of combination boilerswith atomising oil burners of nominal heat input not exceeding 70 kW.


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BS EN 625 Gas-fired central heating boilers. Specific requirements for the domestichot water operation of combination boilers of nominal heat input not exceeding70 Kw.

Common types of boiler include:

Sectional boilers made from cast iron or steel, conforming to BS 779 Specification

for cast iron boilers for central heating and indirect hot water supply (rated output44 kW and above). Welded steel and reverse flow boilers, conforming to BS 855 Specification for

welded steel boilers for central heating and indirect hot water supply (rated output44 kW to 3 MW).

Steel shell and fire-tube boilers, conforming to BS 2790 Specification for design andmanufacture of shell boilers of welded construction.

1.1.3 Condensing Boilers

Where condensing boilers are specified, adequate provision shall be included for theeffective and safe removal of condensate. Institution of Gas Engineers UtilisationProcedure 10 gives detailed guidance on suitable materials for condensate pipes. Thereturn water temperature of the system shall be sufficiently low to allow the boiler to

operate in condensing mode. The fuel supply shall be suitable for condensing boilers,with sufficiently low sulphur content.

1.1.4 Gas Burners

Gas boilers are available in a large range of types and sizes for use with both natural gasand liquefied petroleum gas (LPG). Installations shall comply with BS 6798 Specificationfor installation of gas-fired boilers of rated input not exceeding 70 kW net.

Appliance standards deal not only with construction but also cover efficiency andemissions to the atmosphere. Automatic gas burners shall comply with BS 5885: Part 1Automatic gas burners Specification for burners with input rating 60kW and above.

1.1.5 Oil Burners

Oil fired systems shall comply with BS 5410: Part 1 Code of practice for oil firing.Installations up to 45 kW output capacity for space heating and hot water supplypurposes, or with BS 5410: Part 2 Installations of 45 kW and above capacity for spaceheating, hot water and steam supply purposes. Storage shall comply with BS 799: Part 5Oil burning equipment. Specification for oil storage tanks.

Further guidance on oil fired burners is provided by the Oil Firing Technical Associationfor the Petroleum Industry (OFTEC) in Oil Fired Appliance Standard OFS A100 (2000).Oil fired burners should satisfy the requirements of BS EN 304 Heating boilers. Testcode for heating boilers for atomizing oil burners.

1.1.6 Flues and Chimneys

Flues and chimneys shall comply with BS 5854 Code of practice for flues and fluestructures in buildings and with BS EN 1443 Chimneys. General requirements.

Flues for gas appliances shall comply with BS 5440 Installation and maintenance of fluesand ventilation for gas appliances of rated input not exceeding 70 kW net (1st, 2nd and3rd family gases):

Part 1: Specification for installation of gas appliances to chimneys and formaintenance of chimneys;


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Part 2: Specification for installation and maintenance of ventilation for gasappliances.

Where appropriate they shall also comply with the requirements of BS EN 13216: Part 1Chimneys. Test methods for system chimneys. General test methods or BS EN 1859Chimneys. Metal chimneys. Test methods.

Flues and chimneys shall be constructed using materials suitable for the application, andcomply with the relevant standards, which may include:

BS 4076 Specifications for steel chimneys. BS EN 1856 Chimneys. Requirements for metal chimneys Part 1 Systems

chimney products, Part 2 Metal liners and connecting flue pipes. BS 835 Specification for asbestos-cement flue pipes and fittings, heavy quality.

BS 715 Specification for metal flue boxes for gas-fired appliances not exceeding 20kW.

Free standing chimneys shall satisfy the requirements of BS EN 13084: Part 6 Free-standing chimneys. Steel liners. Design and execution.

1.1.7 Pumps

Centrifugal pumps shall be used to provide the necessary circulation in hydronic systems.The pump characteristics, including flow rates, pressure and frictional resistance shall bespecified in the particular specification and the contractor shall provide evidence thatpump performance meets the design requirements, according to BS EN 1151: Part 1Pumps. Rotodynamic pumps. Circulation pumps having a rated power input notexceeding 200 W for heating installations and domestic hot water installations. Non-automatic circulation pumps, requirements, testing, marking.

1.1.8 Pipe work, Valves and Ancillaries (for systems other than refrigeration systems)

Mild steel pipe work shall comply with BS EN 10255 Non-alloy steel tubes suitable forwelding and threading. Technical delivery conditions.

Copper pipe work shall comply with BS EN 1057 Copper and copper alloys. Seamless,round copper tubes for water and gas in sanitary and heating applications. Fittings shallcomply with BS EN 1254 (various parts) Copper and copper alloys plumbing fittings.

Plastics pipe work shall comply with BS 7291 Thermoplastic pipes and associatedfittings for hot and cold water for domestic purposes and heating installations in buildings(4 parts).

1.1.9 Heating Coil

Heating Coils shall comply with BS 5141: Part 2 Specification for air heating and coolingcoils. Method of testing for rating of heating coils. or with BS EN 1216 Heat exchangers.Forced circulation air-cooling and air-heating coils. Test procedures for establishing theperformance.

1.1.10 Packaged Air Conditioning Units with Domestic Hot Water Production Facilities

Packaged air conditioning units may be used to supply hot water, as specified in;

BS EN 255: Part 3 Air conditioners, liquid chilling packages and heat pumps withelectrically driven compressors. Heating mode Testing and requirements for markingfor sanitary hot water units.


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BS EN 14511: Part 4 Air conditioners, liquid chilling packages and heat pumps withelectrically driven compressors for space heating and cooling. Requirements.

1.1.11 Expansion Vessels

Expansion vessels shall comply with:

BS EN 13831 Closed expansion vessels with built-in diaphragm for installation inwater.

BS 7074: Part 1 Application, selection and installation of expansion vessels andancillary equipment for sealed water systems. Code of practice for domestic heatingand hot water supply.

BS 7074: Part 2 Application, selection and installation of expansion vessels andancillary equipment for sealed water systems. Code of practice for low and mediumtemperature hot water heating systems.

1.1.12 Calorifier

Calorifiers shall comply with BS 853: Specification for vessels for use in heatingsystems, Part 1 Calorifiers and storage vessels for central heating and hot water supplyand Part 2 Tubular heat exchangers and storage vessels for buildings and industrial

services.

1.1.13 Water Treatment

Water used in the primary circuit of a hydronic hot water system shall be treated tominimise scaling, corrosion, deposition and biological activity. Treatment shall complywith:

BS 2486 Recommendation for treatment of water for steam boilers and waterheaters.

BS 7593 Code of practice for treatment of water in domestic hot water centralheating systems.

HVCA TR13 Water Treatment BSRIA Technical Note.

1.1.14 Ventilation

Ventilation equipment shall comply with the standards specified in the detailed design. Itshall be supplied with documentary evidence of compliance with the standards, issued byan approved laboratory or testing body.

Naturally ventilated spaces shall be designed to comply with the requirements of BS 5925Code of practice for ventilation principles and designing for natural ventilation.

Ventilation systems and the related works shall comply as appropriate with the variousspecifications listed below.

1.1.14.1 Air Terminal Devices

BS EN 1751 Ventilation for buildings. Air terminal devices. Aerodynamic testing ofdampers and valves.

BS EN 12238 Ventilation for buildings. Air terminal devices. Aerodynamic testingand rating for mixed flow application.

BS EN 13030 Ventilation for buildings. Terminals. Performance testing of louverssubject to simulated rain.

BS EN 13181 Ventilation for buildings. Terminals. Performance testing of louverssubject to simulated sand.


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Grilles shall be made of steel, aluminium or PVC as indicated in the particularspecification or drawings. Diffusers shall be made of steel or aluminium. The steeldiffuser shall be protected against corrosion

1.1.14.2 Ductwork and Ancillary Components

BS EN 12097 Ventilation for buildings. Requirements for ductwork components to

facilitate maintenance of ductwork systems. BS EN 12236 Ventilation for buildings. Ductwork hangers and supports.

Requirement for strength. BS EN 12237 Ventilation for buildings. Ductwork, Strength and leakage of circular

sheet metal ducts. BS EN 13403 Ventilation for buildings. Non metallic ducts. Ductwork made from

insulation duct boards.

1.1.14.3 Fans

BS ISO 5801, BS 848: Part 1 Industrial fans. Performance testing using standardizedairways.

1.1.14.4 Filters

BS EN 779 Particulate air filters for general ventilation. Determination of the filtrationperformance.

BS 3928 Method for sodium flame test for air filters (other than for air supply to I.C.engines and compressors).

BS EN 1822 High efficiency air filters (HEPA and ULPA):

o Part 1 Classification, performance testing, marking;o Part 2 Aerosol production, measuring equipment, particle counting statistics;o Part 3 Testing flat sheet filter media;o Part 4 Determining leakage of filter element (scan method);o Part 5 Determining the efficiency of filter element.

1.1.14.5 Fan Coil Units

BS 4856: Methods for testing and rating fan coil units, unit heaters and unit coolers:

Part 1 Thermal and volumetric performance for heating duties; without additionalducting;

Part 2 Thermal and volumetric performance for cooling duties; without additionalducting;

Part 3 Thermal and volumetric performance for heating and cooling duties; withadditional ducting;

Part 4 Determination of sound power levels of fan coil units, unit heaters and unitcoolers using reverberating rooms.

1.1.14.6 Fire Dampers

The fire damper shall have at least the same standard of fire resistance as wall or floorthrough which the duct passes. It shall have a fire resistance rating of 2 hours. A singledamper having a fire resistance rating of 4 hours shall be certified by Civil Defence.

Fire dampers shall satisfy the requirements of:

BS EN 1366: Part 2 Fire resistance tests for service installations. Fire dampers. BS ISO 10294: Part 5 Fire-resistance tests. Fire dampers for air distribution

systems. Intumescent fire dampers.


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1.1.14.7 Residential Systems

BS EN 13141: Parts 14 & 6 Ventilation for buildings. Performance testing ofcomponents/products residential ventilation.

BS EN 14134 Ventilation for buildings. Performance testing and installation checksof residential ventilation system.

1.1.14.8 Kitchen Ventilation

BS EN 60335: Part 231 Specification for safety of household and similar electricalappliances. Particular requirements. Range Hood.

BS EN 61591 Household range hoods. Methods for measuring performance.

1.1.15 Air Conditioning

1.1.15.1 Refrigeration Plant

Refrigeration plant shall satisfy the requirements of BS EN 378 Refrigerating systemsand heat pumps Safety and environmental requirements.

Part 1: Basic requirements, definitions, classification and selection criteria Part 2: Design, construction, testing, marking and documentation Part 3: Installation, site and personal protection Part 4: Operation, maintenance, repair and recovery

And shall also satisfy the requirements of the Institute of Refrigeration Safety Code forRefrigerating Systems Utilizing Groups A1 & A2 Refrigerants, the Safety Code forRefrigerating Systems Utilizing Group A3 Refrigerants (Flammable) and the AmmoniaCode of Practice.

Reference should also be made to the Guidelines for the use of HydrocarbonRefrigerants in Static Refrigeration and Air Conditioning Systems, published by The AirConditioning and Refrigeration Industry Board (ACRIB) February 2001.

BS EN 809 Pumps and pump units for liquid. Common safety requirements. BS 14511: Parts 14 Air conditioners, liquid chilling packages and heat pumps with

electrically driven compressors for space heating and cooling. BS EN 13711: Part 1 Compressor and condensing units for refrigeration.

Performance testing and test methods. Refrigerant compressors.

BS EN 13215 Condensing units for refrigeration. Rating conditions, tolerances andpresentation of manufacturers performance data.

BS EN 14511: Parts 14 Air conditioners, liquid chilling packages and heat pumpswith electrically driven compressors for space heating and cooling.

The Air Conditioning works and its related activities shall also conform to the standardslisted in the following sections:

1.1.15.2 Fire Safety Requirements

BS 9999 Code of practice for fire safety in the design, management and use ofbuildings.

BS ISO 10294: Parts 14 Fire-resistance tests. Fire dampers for air distributionsystems.

BS EN 1366: Part 2 Fire resistance tests for service installations. Fire dampers.

1.1.15.3 Cooling Towers


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BS 4485: Part 2 Water cooling towers. Methods for performance testing. BS 4485: Part 3 Water cooling towers. Code of practice for thermal and functional

design. BS EN 13741 Thermal performance acceptance testing of mechanical draught

series wet cooling towers.

1.1.15.4 Air Handling Units

BS EN 1886 Ventilation for buildings. Air handling units. Mechanical performance. BS EN 13053 Ventilation for buildings. Air handling units. Ratings and performance

for units, components and sections. BS 6583 Methods for volumetric testing for rating of fan sections in central station

air handling units (including guidance on rating).

1.1.15.5 Heat Exchangers

BS EN 306 Heat exchangers. Methods of measuring the parameters necessary forestablishing the performance.

BS EN 328 Heat exchangers. Test procedures for establishing the performance offorced convection unit air coolers for refrigeration.

BS EN 1216 Heat exchangers. Forced circulation air cooling and air heating coils.Test procedures for establishing the performance.

BS EN 308 Heat exchangers. Test procedures for establishing the performance ofair to air and flue gases heat recovery devices.

1.1.15.6 Chilled Ceilings and Beams

BS EN 15116 Ventilation in buildings. Chilled beams. Testing and rating of activechilled beams.

BS EN 14518. Ventilation for buildings. Chilled beams. Testing and rating of passivechilled beams.

1.1.16 Lifts and Escalators

1.1.16.1 General

The works and equipment shall be strictly in accordance with the applicable requirementsof the following (with all amendments in force at t ime of tender):

BS 5655: Parts 1, 2, 4, 6, 7, 8, 9, 10, 11 and 12 Lifts and Service Lifts. BS ISO 4190: Part 1 and 2 Lift (US: Elevator) installation.

BS 7255 Code of Practice for Safe Working on Lifts. BS 2655: Parts 1, 4 and 4 Hydraulic Lifts.

BS 7671 IEE Wiring Regulations for Electrical Installations. The requirements of the Local Authorities in connection with the suppression of radio

interference. BS 9999 Code of practice for fire safety in the design, management and use of

buildings. BS EN 81: Parts 1, 2 and 3 Lifts & Service Lifts. BS EN 115 Safety of escalators and moving walks.

BS 7801 Escalators and moving walks. Code of practice for safe working onescalators and moving walks.

Lifts shall fall into 2 categories. These categories are electric traction and hydraulic.

Traction and hydraulic lifts shall be supplied and installed to comply with BS EN 81:Part 2, BS EN 81: Part 3, BS EN 81: Part 70, BS 5655 and other standards as applicable.


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For fire fighting and evacuation lifts comply with BS 5588 and BS EN 81: Part 72.

1.1.16.2 Doors and Entrances

At all landing openings complete entrances shall be provided consisting of frames,architraves, door sills and fascia plates. Frames shall be carried back into well, andsecured to sill and door hangar supports or structure.

Sills shall be one piece with non-slip wearing surface. Sills shall be long enough to retaindoor guides at extremes of travel.

Doors shall be provided with bottom guide shoes to run in the sill slots.

Hangars and headers shall be steel angles bolted to door sill and wall above entrance.

Fascia plates shall be manufactured from reinforced sheet steel, and shall extend fromtop of hangar to sill above.

Fire rating shall be as indicated in the particular specification.

Finish shall be as scheduled in the detailed specification and accompanying drawings

and in agreement with the requirements of the Architect/Interior designer.

1.1.16.3 Door and Entrances Goods Lift

Horizontal collapsible sliding steel shutter doors shall be provided on landing and car.

Totally enclosed box type top tracks shall be provided with ball bearing rollers and trackssunk in floor for guides to run in.

Where required by the particular specification power operated vertical by-parting landingand car doors shall include guide and counterbalance to ensure smooth operation.

Steel angle frames and posts shall be provided for fixing the landing doors, tracks and sillfascia plates.

Fire rating shall be as indicated in the particular specification.

Finish shall be as scheduled in the detailed specification and accompanying drawingsand in agreement with the requirements of the Architect/Interior designer.

Doors shall be hung on hangars running on steel track and guided at bottom by guideshoes sliding smooth threshold grooves.

1.1.16.4 Car and Landing Door Operator for Horizontal Sliding Doors

Motor driven operators shall be provided to open and close car and landing doorssimultaneously when car is at landing. Ensure doors are powered open and closed, andmovement is checked at both limits of travel.

The doors shall automatically open when the car is level at the respective landing andclose after a predetermined time interval has elapsed. Provide a door open button in thecar to reverse the motion and re-open the doors.

Where scheduled, advanced door openers shall be provided so that the doors start toopen as the lift levels at a floor.

The door motors shall be microprocessor controlled, driving the car and landing doorssimultaneously. Levers and door arms are to be designed to achieve smooth operationwithout the use of dashpots. Door speed and operation is to be of the highest quality.


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Door opening, closing and holding times shall be adjustable.

Car doors shall be provided with door nudging feature.

High-speed electronic passenger detector, featuring three dimensional detection zonefields around the leading edges of both car and landing doors, shall be fitted. The

detector shall automatically sense persons entering the detection zone fields and causethe doors to reverse sufficiently for persons to pass through before continuing to close.The detector shall also detect goods trolleys, and so on, to avoid damage to the goods ordoors.

A protective cover shall be provided to avoid damage to the safety edge should the cardoors be hit by goods entering or leaving the lifts.

Vertical-parting doors shall comply with the safety requirements of the appropriatestandard.

1.1.16.5 Lubrication

All bearing points shall be arranged so that they can be lubricated efficiently. Ensure the

whole of the plant works automatically and requires no attention beyond lubrication atrecommended intervals and where grease is used fit a means of lubrication.Provide all oiling holes with covers.

A dipstick shall be fitted to the machine gear box and indicate the normal oil level.Provide a drain plug for the gear box.

1.1.16.6 Testing and Acceptance

The examinations and tests shall be performed as required in the appropriate standardsand complete the appropriate test and examination certificate.

1.1.16.7 Diagrams and Instructions

Copies shall be provided of the schematic circuit diagrams, circuit description andoperation data, wiring schedules and maintenance manual for approval before installationis completed. An encapsulated copy of the schematic circuit diagram shall be mountedpermanently in the machine room, protected from dirt and cleanable.

Schematic circuit diagrams shall show all items in the OFF position with all doors closed(that is, with the equipment completely de-energised), stating this and the position of thecar on the diagram. An alphabetical list shall be included of all items with theirabbreviated title and location on the diagram. The location of coils, the number ofcontacts and whether the contacts are normally opened or closed for relays andcontactors, shall also be shown.

The instructions shall be supplied in A4 size, handbook form. Include the followinginformation:

User maintenance instructions with details of daily routine inspectionrecommendations and general care.

A description of the control equipment including a detailed description of theoperating sequence of the equipment under various conditions of service related tothe schematic circuit drawing.

Adjustment instructions for all items of equipment, including a list of all contactors,relays, resistors and switches giving the circuit reference, the makers reference,rating, resistance, contact pressures and operating and release voltages asappropriate.


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Routine test and servicing instructions for the whole of the installation and orindividual items of equipment. Include a list of the lubricants and dash pot fluidsused.

1.1.16.8 Training

Training shall be provided on completion of the installation to ensure client personnel are

fully acquainted with the correct operation and routine daily and general maintenance ofthe lift. All aspects shall be included of breakdown procedure and the release ofpassengers trapped within the car.

1.1.16.9 Compensating Ropes or Chains

Compensating ropes or chains shall be provided between car and counterweight passinground a pulley. Tension the ropes by gravity and provide a safety switch whereappropriate.

1.1.16.10 Terminal stopping devices

Upper and lower normal stopping devices and upper and lower final stopping devicesshall be fitted, each capable independently of stopping the car and applying the brake

through its own switch. If the lift passes final limit switch it shall be possible to close thecircuit until the lift has moved back by hand into its normal running position.

1.1.16.11 Trailing Cables

Travelling cables shall be provided between the car and the lift well.

Cables shall comply with BS EN 50214 and shall have flame retarding and moistureresisting outer cover. They shall be flexible and suitably suspended to relieve strain in theindividual conductors.

Cables shall be provided with LSF insulation and sheath.

1.1.16.12 Pit Ladders

Pit ladders shall be supplied and installed readily accessible from landing and mountemergency stop switch and light switch adjacent ladder.

1.1.16.13 Lift Car Light Fittings

Main car lighting shall be provided as part of manufacturers standard range incorporating

3-hour non-maintained emergency unit operating from Ni-Cad batteries with trickle

charger.

1.1.16.14 Communications

Communication from the lift car shall be via hands free telephone system activated by the

alarm button. The system shall incorporate battery back-up for mains failure.

1.1.16.15 Alarm Bell

A push button shall be provided on the car control panel to operate a remote audible

alarm, in-car alarm and an indicator on the principal floor.

In the event of a mains power failure, alarms and indicators shall be provided with battery

backup.


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1.1.16.16 Overload Alarm

Audible and visual alarm shall be provided within car utilising a voice synthesiser to aid

visually impaired. This system will include provision in the motor room to turn facility

on/off and adjust volume.

1.1.16.17 Car Fittings and finishes

Where indicated in the design drawings and the particular specification, protective quilts

and hooks or buttons (quilting studs) shall be provided at top of side and rear walls for

hanging a protective quilt.

Car load plate shall clearly indicate car number and location for identification in an

emergency.

Decorative finishes shall be in accordance with the particular specification and the

Architect/Interior Designers requirements.

1.1.16.18 Controls and Priorities

Controls and priorities shall be installed and applied as detailed in the particularspecification.

1.1.16.19 Lift Car Construction

The manufacturer/supplier shall supply car in parts to be assembled in completed shaft.

Adjustable rollers shall be provided on top and bottom of car frame, for cantilever

hydraulic installation.

Ventilation shall be provided to the lift car by means of an extractor fan. Where the

extractor fan is in the car roof, the fan shall be operated by the lighting circuit.

Where applicable on electric traction lifts (high speed > 2.5 m/s), adjustable guide shoesshall be provided on top and bottom of car frame and use adjustable rollers.

1.1.16.20 Car Top Maintenance

Car top controls shall be provided including as follows:

Socket outlet to be RCD protected Car top light to be Fluorescent with 3-hour emergency backup.

1.1.16.21 Trap Doors

Trap doors shall be provided for fire fighting lifts only.

1.1.16.22 Safety Gear

Safety gear shall comply with appropriate standard.

1.1.16.23 Buffers

Buffers shall comply with appropriate standard.

1.1.16.24 Guide Rails

Guide rails shall be provided that extend to the level of the pit f loor.


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A means of lubricating the guide rail, shall be provided, and drip trays to avoid oil spillageon pit floor.

1.1.16.25 Builders Work

At the time of design, following the determination of the quantity, speed, car size and

configuration of lifts the requirements of the lift shaft building works and associated, plantrooms, lifting beams and the such like shall be informed to the Architect and Structuralengineer for incorporation into the building design.

1.1.16.26 Hydraulic Lift

Suspension ropes or chains shall be provided independently of each other, with copies ofmanufacturers test certificates for ropes or chains.

Suspension ropes shall comply with BS EN 12385: Part 5.

A crosshead data plate or dossier shall be provided to show the diameter, number andconstruction of the suspension ropes or chains and the total weight of the completeunlade car.

Car props/stop blocks shall be provided for supporting the lift car during maintenance.

1.1.16.27 Hydraulic Lift Motors

Motors shall be provided that comply with BS 4999, BS 5000, and BS EN 60034 whereapplicable. Design motor for a continuous duty cycle as scheduled.

1.1.16.28 Hydraulic Lift Pump Unit

A pump unit shall be provided comprising three phase motor, oil pump, overload, non-return and lowering valves with reservoir and filters. Operating and control valves shallbe provided on a common manifold block arranged so that all units can be maintained.Valves shall be electronic with temperature compensation for pressure and flowvariations. Lift speed patterns shall be uniform under varying conditions.

Levelling shall maintain the lift car at the landing level within +/- 6 mm under varying loadchanges and times of standing.

A thermostatically operated oil tank heater shall be installed to ensure the lift operatescorrectly during cold conditions.

An oil level indicator shall be provided incorporating an oil level switch or sensor to stopthe motor if a serious leak occurs.

1.1.16.29 Hydraulic Lift Ram and Cylinder Assembly

Where included in the design drawings, an indirect side acting purpose built assemblyshall be installed, carried in a fabricated steel framework, incorporating roller guide, with

replaceable tyres/rollers, running between the tee-section guides and including a 2:1multiplying sheave.

Where included in the design drawings, a purpose built direct acting assembly shall bearranged to support the car.

The complete assembly shall be located and secured in the pit and treat the cylinder withtwo coats of anti-corrosive paint and wrap with overlapping tape.


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Withdrawal of the cylinder shall be possible for a complete external examination andreplaced. The rams and cylinders shall be precision ground seamless steel tube with allnecessary glands and seals.

Mechanical buffers shall be provided to prevent over travel of ram within predeterminedlimits.

1.1.16.30 Electric Traction Lift

A counterweight shall be provided consisting of weights in a structural steel frame withguide shoes and a rigid metal screen around the counterweight to a height of 2.5 mabove pit floor.

For high speed lifts the counterweight shall be provided with compensation ropes/chains.Weights and screen shall be painted yellow as a warning indication.

1.1.16.31 Suspension Electric Lifts

Suspension ropes shall be provided in accordance with BS EN 12385: Part 5independent of each other and include copies of manufacturers test certificates for ropeand the number of suspension ropes as required and method of roping shall be asmanufacturers standard.

A crosshead data plate or dossier shall be provided to show the diameter, number andconstruction of the suspension ropes and the total weight of the complete unlade car.

1.1.16.32 Rope Anchorages

Car rope anchorages shall permit equalisation of tension, and an anti-twist device shallbe fitted where necessary.

1.1.16.33 Sheaves and Pulleys

Diverter and overhead pulleys shall be provided together with supporting steelwork.Sheaves shall be manufactured from cast iron machined and grooved for the diameter ofropes used.

Sheaves and pulleys shall be arranged to avoid ropes touching and limit noise in shaft.

1.1.16.34 Traction Lift Machines

Worm geared traction type winding machinery shall be provided with Variable VoltageVariable Frequency drive, motor, brake, gearbox and driving sheave mounted on a castiron or steel bed-plate.

For speeds above 2.5 m/sec gearless winding machine shall have thyristor control, AC orDC motor, brake and sheave mounted on cast iron or steel bed-plate and hand windinggear with a brake lifting device, ensuring that the brake cannot be left in the liftedposition.

Up and Down labels shall be provided to indicate direction of winding on machine, andhand winding floor indication audible and visual (with battery back-up) and project-specific instructions for hand winding adjacent the winding position.

Motors shall comply with BS 4999, BS 5000, and BS EN 60034, where applicable, anddesigned for continuous duty cycle as scheduled.


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1.1.16.35 Escalators and Travellators

The design of the escalator/travelators shall be such that no major repairs shall benecessary for a minimum period of 20 years from the date of the Engineers acceptance,and shall be suited for a minimum duty of 12 hours per day, 7 days per week with a loadfactor as detailed under BS EN 115 Clause 3.90.4 (b).

The design of the escalator/travelators shall give consideration to fire prevention, theelimination of dust and dirt traps, and easy access for cleaning and routine maintenance,which shall not require the removal of panels on the passenger side of theescalator/travelator. Provision shall be made for the sprinkler system within theescalator/travelator.

Each escalator/travelator shall be a self-contained unit consisting of truss, tracks, stepdrive units, steps, step chains, comb plates, hand rails, driving machine, controller, safetydevices, balustrades, and all other parts required to provide a completeescalator/travelator.

The basic loading and safety factors shall be as those laid down in BS EN 115 as aminimum.

A hand winding device must be provided complying with the requirements of BS EN 115.A manually operated brake release lever must be provided in order to ensure movementof the step band in the event of an emergency and loss of power to the driving machine.Due consideration shall be given to the omission of the hand winding device subject toan acceptable risk assessment by the vertical transportation sub contractor.

The escalator/travelators shall operate with the minimum noise and vibration. The noiselevel shall not exceed 55 dB(A) 1.7 m above the step band under normal workingcondition.

1.1.16.36 Truss

The truss shall be welded construction designed to the basic loading and safety factorgiven in accordance with BS EN 115.

The underside of the truss shall be covered by an oil tight welded soffit.

The truss supports shall be provided with anti-vibration pads to prevent vibration andnoise being transmitted to the building structure if the escalator/travelator rests on thesteel beam supports.

1.1.16.37 Track System

A continuous track system for the step and chain wheels shall be used constructed fromrolled steel shapes. All track surfaces shall be straight and smooth and all joints, wherepossible, shall be diagonal on the actual running surface. The track supplied should begalvanised.

The chain wheel tracks shall be adjustable at the main drive and tension carriage so that

the step chain may be set tangential to the sprocket pitch line in both the upper andlower sides of the sprockets.

1.1.16.38 Main Drive Shaft

The main drive shaft shall be of high quality steel providing adequate torsion stiffnesswith welded plate flanges at each side to support the step chain sprockets and handraildrive sprockets. Ensure that parts of the unit are coupled together rigidly for transmittingtorque from one to the other.


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1.1.16.39 Tension Carriage

The tension carriage shall be designed and constructed to maintain correct tensioning ofthe step chains.

Each side of the tension carriage shall be provided with a spring loaded tension device.

1.1.16.40 Step Chains

Two main step chains shall be supplied connected through solid axles of precisionmatched lengths, manufactured from high quality steel links, pins, bushes and rollers.The chains shall be designed to suit the basic loading and safety factor, relative to thevertical rise of each escalator with a minimum safety factor of 5.

The bearings shall be life lubricated and specially sealed. The life time of the chainrollers shall be a minimum of 100,000 hours.

1.1.16.41 Steps/Treads

The steps shall be accurately formed as a one piece aluminium die casting to suit thebasic loads and safety factor.

The geometry and dimensions of the steps shall conform to BS EN 115 and shallincorporate cleared risers.

The steps shall conform to the static and dynamic test requirements of BS EN 115.

1.1.16.42 Handrail and Handrail Drive

A moving handrail shall be provided on each side of the escalator/travelator balustrade.The handrail shall be constructed of rubber or hypalon and fabric plies enclosing steelcord reinforcement to eliminate elongation of the handrail. There shall be only onefactory-made vulcanised joint in each handrail.

The hand rail drive shall be of the friction type, synchronous with the steps and providedwith a tension device to compensate for any stretching which may occur. Examination of

the hand rail drive mechanism shall be by removal of the skirting panels at the upperlanding or adjustable at the bottom of the machine.

Where there is a maximum 5% variation between the hand rail and step speed then adetection device shall immediately stop the escalator/travelator within the limits definedin BS EN 115.

At each hand rail entry an automatic safety guide shall be fitted which will stop theescalator/travelator in the event of an object being drawn in the entry, to prevent theobject becoming trapped. The design of the device shall minimise the likelihood of injuryin the event of the finger trapping.

All sheaves shall be fitted with lifetime greased bearings.

The speed of the handrail shall coincide with the speed of the steps within the limits of0% to + 2%.

The handrail entries and exit points at the balustrade newel ends shall to be providedwith close fitting guards to avoid finger traps. The lower edge of the handrail entry pointshall not be less than 100 mm above the floor level and be designed to avoid trapping ofobjects between the floor and moving handrail.

The whole of the handrail design shall ensure the longest possible life of the handrailwith the minimum of friction. The colour shall be black.


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1.1.16.43 Comb Plates

A comb plate shall be fitted at the upper level and lower landing.

The combs shall be easily removable, in sections and the comb plates shall be readilyadjustable to provide the clearances specified in BS EN 115. Tools shall be provided in a

readily accessible location for removal of the comb plate sections. Adjacent areas to thecomb plates shall be of a high wear/slip resistant nature.

The combs shall be designed with rupture points to prevent serious accidents shouldentrapment occur.

Guides shall be provided on both sides of the step at each landing to ensure the stepsenter the comb plate accurately guided.

The comb plates shall be fitted with a safety device such that the machine willautomatically stop in the event of items being trapped in the comb plates.

1.1.16.44 Guards

All exposed chains and moving parts shall be provided with safety guards as required.

1.1.16.45 Drive Machine

Each escalator/travelator shall be driven by a hypoid helical geared machine, suitable forthe operation in the environmental conditions and installed inside the top machinerycompartment. A multi-strand roller chain shall be provided as the drive between themachine and the main drive shaft. The machine shall be movable with easy access tothe fastening screws to keep the main drive chain in the correct tension.

There shall be access for maintenance, hand winding and manual brake release whichmust comply with BS EN 115.

1.1.16.46 Motor

Each escalator/travelator shall be provided with a motor designed and rated to meet thespecified duty, cycle, load, speed, starting and running torques for the individual rises.

The motors shall be single speed AC induction type with Class B insulation minimumwith IP 55 protection and assisted starting must be provided on motor sizes above7.5 kW.

1.1.16.47 Controller

The controller shall consist of a totally enclosed cabinet of non combustible materials.

The cabinet shall be provided with lockable doors, sealed against the ingress of waterand dust. The protection shall be to IP 54 minimum.

The cabinet shall contain all necessary contactors, relays and components to ensureefficient starting, stopping and reversing of the drive motor, brake applications and theoperation of functional safety circuits, including motor overload protection devices.

All circuits shall be adequately protected by approved type fuses and a phasefailure/reversal relay shall be incorporated in the protective circuits. An earth stud shallbe provided at a suitable location in each controller. All metal frames, door covers,armouring, trunking and controller components at earth potential shall be earthed.


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1.1.16.48 Machine Brake

The drive machine shall be fitted with an electro mechanical service brake operating onthe high speed shaft of the motor. The brake shall be held off electrically and springapplied to a fail safe condition. The operation of a safety switch or stop button shallapply the brake.

The brake shall be capable of arresting a loaded escalator/travelator operating at acontract speed. Determination of the brake and stopping distances shall be in accordwith BS EN 115.

Provision shall be made to release the brake by hand, but it must be impossible to lockthe brake off in the released position.

The brake shall automatically stop the escalator/travelator when the power supply isinterrupted for any cause or by any of the safety devices being activated, and it shall holdthe escalator/travelator stationary under the full load conditions (100% carrying capacity).

1.1.16.49 Auxiliary Brake

An electro-mechanical operated auxiliary brake shall be fitted to the main drive shaftwhere necessary to comply with BS EN 115. The brake shall operate each time theescalator/travelator is brought to a stop following the operation of the safety devices,over speed, fault reversal, or main drive chain breakage.

The applied brake forced shall be sufficient to enable the escalator/travelator to be safelyused as a fixed stair in an emergency.

1.1.16.50 Safety Devices

The following safety devices shall be incorporated in each escalator/travelator. Theoperation of any of these devices shall cause the escalator/travelator to stop and theoperational brake to be applied.

Non reversal device Broken step chain detector

Step and chain wheel control contact Handrail entry obstruction device

Comb plate safety device Step up thrust control contact at each landing Drive motor overload Phase failure relay Hand winding and brake release facilities Emergency stop buttons at top and bottom ends Hand rail entry switches Double row skirt bus guards Neck guards where relevant Anti climbing guards Inspection control buttons

Hand rail speed detector Guarding in accordance with pure regulations End barrier guards

1.1.16.51 Stop Switches

A stop switch shall be provided within the machine compartment. The switch shalldisconnect the power supply to the motor and through application of the brake bring theescalator/travelator to rest.


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Emergency stop switches shall be located at the upper and lower landings adjacent tothe start switches. The location shall be accessible whilst not prone to accidental trippingor misuse.

1.1.16.52 Start Switches

Starting shall be carried out by key operated buttons or switches located at the upper

and lower landings.

1.1.16.53 Operational Panel

An operation panel shall be provided at the upper landing which will indicate on a displaypanel when a stop switch has been activated or when a handrail entry device has beentripped. It shall also provide the facility to operate the escalator/travelator lighting.

The control panel shall be capable of shutting down on receipt of a fire alarm signal.

1.1.16.54 Notices and Signs

Notices and signs provided for each escalator/travelator shall be of a durable materialplaced in a conspicuous position, written clearly in legible characters or pictograph formcomplying with BS EN 115 and BS 5378.

1.1.16.55 Wiring

All wiring shall be LSF insulated and oil resistant. All cables have to be carefully fastenedwithin the escalator/travelator truss in order to avoid contact with moving parts.

Carry out the wiring from the main intake of the supply to the machine rooms.

1.1.16.56 Balustrade

All escalator/travelators shall be delivered with 1,100 mm-high balustrades consisting ofdeck covers, handrail guides interior panels and skirt panels.

The skirt panels are to be from stainless steel, covered in low friction material. Ensure

stiffness in accord with BS EN 115.

The interior panels shall be of 10 mm thick fully heat strengthened clear safety glass toBS 6206 with joints vertical to the handrails. The handrail will run on a guide rail mountedcentrally on the balustrade interior panel.

The skirting shall be fitted with a brush deflector to reduce the risk of accident by trappingbetween the skirt and step.

1.1.16.57 BMS Interface

230 V-rated volt-free normally closed contacts shall be provided in the control panel tooperation on common failure/fault.

1.2 Product Delivery, Storage and Handling

1.2.1 Delivery

Delivery of all materials brought to the site shall be recorded by means of deliverysheets.


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Large plant items and items of large monetary value shall be delivered by themanufacturer or supplier in proprietary crates/packaging using vehicles intended for thepurpose.

The Engineer shall be notified in advance of such large plant items arriving at site toenable inspection of the status of equipment and packaging at time of receipt.

1.2.2 Delivery Documentation

Delivery sheets shall include the manufacturer's name, model and type number and fulldetails of duty and rating for all items of plant including control equipment, as well as thedate of delivery, inspection details and the name of person accepting the delivery.

All relevant accompanying documentation shall be included with the equipment at thetime of delivery and appropriate checks shall be made ensuring that the documentationcorresponds to the delivered items.

For factory assembled and packaged units of refrigeration plant, pressure and leak testresults as specified by BS EN 378 shall be supplied.

These records shall be maintained on site and shall be available for review by theEngineer if requested.

1.2.3 Off-Site Storage Prior to Delivery

Where the Contractor obtains material early, for example for financial benefits of earlypurchasing, but chooses to store the items off site in his own premises the abovestatements apply both to the initial delivery to the off-site premises and subsequentdelivery to the site.

1.2.4 Handling

All materials entering the site shall be handled at all times in a safe manner betweendelivery to site stores or from stores to location of final installation.

Handling of all materials shall in all instances be in accordance with the manufacturersrecommendations. All material delivered to site should be accompanied by the relevantmanufacturers data referring to the handling of the item.

Particular importance shall be given to the handling of large plant items and largemonetary value items. Any damage caused during handling of material and plant on siteshall be reported to the engineer at the earliest possible time.

The contractor shall ensure that all plant required to move material and equipment isavailable on site at the time needed.

1.2.5 Storage and Protection

The location and size of site stores shall be agreed in advance of site mobilisation. The

size of any internal storage shall be adequate for the quantities of equipment requiringinternal storage, and shall be decided on the basis of the planned schedule of sitedeliveries.

Storage of material shall be in accordance with the requirements of the manufacturer.

Particular importance shall be given to items requiring stable climatic conditions(temperature, humidity and sunlight) to ensure that they are not damaged between timeof supply from the manufacturer and the time at which they are to be installed.


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Where required certain parts of equipment may have to be installed at a later date thanthe bulk of the equipment, for example UPS batteries may be installed later than thecabinet ensuring that air conditioning is working prior to their installation.

Storage of material will be in 3 categories which shall include:

Internal storage Internal storage in climatic controlled environment

External storage

Whilst in storage, the Contractor is obliged to ensure the protection of material. Thisincludes security of such material and also the physical protection.

Any such items of equipment delivered to site in crates or containers should remain in itspackaging until the time if installation, the crates or containers should be opened tocheck the equipment upon arrival at the site but then re-sealed to prevent damage fromoccurring whilst in storage.

24-hour security shall be provided to guard stores of equipment containing high-valueitems.

2. PART 2 METHODOLOGY AND WORKMANSHIP

2.1 Installation and Testing

The installation(s) shall comply with all relevant legislative requirements of the Kingdomof Bahrain.

The installation shall comply with any special regulations issued by any relevant authorityof the Kingdom of Bahrain.

Unless specified to the contrary by any special requirements of the Electricity Directorateor Gas Authority, electrical works shall comply with BS 7671: 2001 (Requirements forelectrical installations, The IEE Wiring Regulations. (Seventeenth Edition)), and gas

installations shall comply with the requirements of The Institution of Gas EngineersUtilization Procedures (IGE/UP).

2.2 Off-Site Testing of Components

Where British Standards stipulate testing of items of equipment to demonstratecompliance, these shall be carried out at the manufacturer's works or elsewhere asappropriate. In all cases, test certificates shall be submitted in duplicate to the Engineerand be included in the Record Documents. In certain cases, where appropriate, type testcertificates will be accepted as indicated.

Test certificates shall serve as a record that the item referred to has been shown undertest to meet the requirements of this Specification and/or British Standards as applicableand shall be dated, numbered and clearly referenced to the item tested by means of

serial, chassis, or other manufacturer's reference number permanently marked in aconspicuous position.

Where an individual inspection or test takes place at the manufacturer's works, arepresentative of the Contractor shall normally be required to be present.

Tests shall be made at the Contractor's or Supplier's premises, on samples of materialsand components to be installed in the Works in any manner deemed necessary by theEngineer to ensure conformity with this Specification. The results of such tests shall in noway relieve the Contractor of his responsibilities to ensure that all materials and


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components used in the Works are entirely suitable for the applications and conditions ofoperation.

All control panels shall be checked at the manufacturer's works and certified to complywith the Particular Specification prior to despatch. Functional checks shall also be carriedout at the manufacturer's works to ensure that all inter-locking and sequencing is inaccordance with the performance requirements. Test jumpers, where fitted, shall be

removed at the end of the checking. Documentary evidence of compliance with shortcircuit ratings shall also be provided.

2.3 Installation Management

Guidance on appropriate arrangements for the management of the building servicesinstallation is given in BSRIA Applications Guide 11/98: Project Management Handbookfor Building Services.

Lifting beams shall be provided above heavy plant items, for use for maintenance andrepair.

2.3.1 Access and Provision of Space in Plant Rooms

The Contractor shall ensure the provision of adequate access in and around the site forinstallation, maintenance and deliveries for all services.

The arrangements shall be incorporated in the Contractors method statements.

The installed layout of plant systems should permit adequate access for maintenanceand commissioning and should be consistent with manufacturers guidelines.

2.3.2 Ductwork and Ventilation Systems Installation

Ductwork shall be installed in accordance with the requirements and procedures set outin the HVCA specifications:

Specification for Sheet Metal Ductwork Low, Medium & High Pressure/Velocity Air

Systems DW144 (1998) (supersedes DW 142) Standard for Kitchen Ventilation Systems DW172 (2005) Specification for Plastics Ductwork DW154 (2000)

2.3.3 Pipe Work Installation

Pipe work installation shall comply with the guidance set out in the following HVCAtechnical reports, unless agreed otherwise with the Engineer.

TR5 Welding of Carbon Steel Pipe workTR6 Guide to Good Practice Site Pressure Testing of Pipe workTR11 Guide to the Use of Plastic Pipe workTR15 Gas Safety ChecklistTR16 Modular Prefabrication Guidance Notes

TR20 Installation & Testing of Pipe work Systems

Standard guidance should be followed regarding the provision of maintenanceequipment on all systems, such as drain points, isolating valves and access panels.

There shall be sufficient drain points so that the system can be drained within areasonable period.


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2.4 Site Testing of Pipe Work and Ductwork

The Contractor shall be responsible for site testing of static systems in order to ensuresafe operating conditions consistent with design performance. Site testing shall includeinspection and testing of welding and brazing, pressure testing for soundness ofhydraulic systems and air leakage testing of ductwork systems.

Unless otherwise indicated, fuel, water (other than treated water) and electricitynecessary for the operation of the plant during site testing will be provided free of cost bythe Contractor.

After completion of pipe work cleaning operations and before the application of thermalor acoustic insulation, each water distribution system shall be charged with clean waterand then subjected to a hydraulic test of 1.5 times the working pressure. There shall beno loss of pressure during a period of not less than 30 minutes. To suit particularinstallations, hydraulic test(s) shall be carried out on the complete system or in sectionsas directed by or agreed with the Engineer. Where sectional testing is adopted, a finalhydraulic test will be necessary. Any items of equipment set to operate at or below thetest pressure shall be isolated or removed prior to the application of this test. Oncompletion of testing and cleaning operations, systems shall be protected againstinternal corrosion until the water treatment plant is put into service.

Medium and high pressure/velocity ductwork systems shall be tested for air leakage inaccordance with HVCA Specification DW/142 using method described in HVCApublication DW/143. Low pressure/velocity ductwork systems shall be tested for airleakage by the same methods where indicated.

Installations or sections of air or water distribution systems which will be embedded inthe structure or concealed in permanently sealed ducts, trenches, roof spaces, and soon, shall, in addition to the above specified tests, be individually tested as they areinstalled and before being embedded or concealed.

Vibration transmission-break equipment shall be thoroughly checked for correctinstallation and alignment, and shall be statically tested to ensure that suspensionsand/or connections operate as intended.

The Contractor shall be responsible for correcting any unacceptable vibration apparentduring plant operation.

Wiring terminations to control equipment shall be checked for compliance with the wiringdiagrams, and for interlocking with other equipment. Any faults shall be rectified unlessassociated with wiring carried out under a separate Contract in which case they shall berecorded and the details passed to the Engineer for action.

2.5 Earth Bonding

Bonding of all extraneous conductive parts of the installation (including metallic pipework, Ductwork, insulation cladding, and so on) shall be carried out in accordance withBS 7671 and BS 7430: Code of practice for earthing.

2.6 'As Installed' Drawings

The Contractor shall provide 'As Installed' drawings in the number, format and mediaspecified in the Particular Specification.

Unless otherwise indicated, the drawings shall show the following:

the complete installation including the sizes and routes of all ductwork and pipework,

the location and identification number of all dampers,


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the location and identification number of all terminal units, fan coil units, grilles,registers and diffusers,

the location and identification number of each pipe work isolating, regulating andcontrol valve according to the labelling and circuit control diagram(s) required by theSpecification,

the location and identification of services buried within the structure or underground,

The manufacturer's name, model and type number and full details of duty and rating

for all items of plant including control equipment.

Each drawing shall include the name of the site, section of the Works, the title of theinstallation, the date of completion of the Works, the contract number and the name ofthe Contractor, and shall clearly show the words 'AS INSTALLED'.

During the course of the Works the Contractor shall maintain a fully detailed record of allchanges from the tender drawings to facilitate easy and accurate preparation of the 'AsInstalled' drawings and to ensure that these drawings are in all respects a true record ofthe installation. The symbols used for individual 'As Installed' drawings shall be identifiedon each drawing.

2.7 Identification of Services

Pipe work and ductwork service installations shall be identified by colour band codeand/or symbols in accordance with BS 1710, and/or HVCA DW 144.

All pipe work shall be identified by colour bands at least 25 mm wide. All ductwork shallbe identified by colour triangles with a side length of at least 150 mm. The bands ortriangles shall be spaced and located to permit ready identification of the services,particularly adjacent to equipment positions, at all valves, at service junctions, at wallpenetrations and at all changes of direction.

In addition, all pipe work and ductwork in plant rooms and service areas shall be indeliblyand legibly marked with black or white letters and arrows, to show the type of service andthe direction of fluid flow. Lettering shall be 50 mm in height or of pipe nominal borewhere this is smaller. All water storage vessels shall be properly labelled in accordancewith the requirements of the Particular Specification.

Services shall be shown as follows:

Chilled water CHW Cooling water CLW Supply air SA Return or re-circulated air RA Fresh air FA Exhaust air EA

The letters F and R shall be added to pumped distribution to show flow and returnrespectively. All symbols shall conform to the legend on the 'As Installed' drawings andplant room valve charts.

2.8 Refrigerant Handling

The guidance given in HVCA publication RAC/70 Guide to Good Practice - Commercialand Light Industrial Refrigeration Non-statutory standard for designers, specifies,contractors and end users of commercial refrigerating systems shall be followedwherever possible. This document also gives guidance on the safe handling ofrefrigerants and the REFCOM Scheme.

Mechanical vapour compression refrigeration plant shall use hydrogenated CFCs (HCFC)or hydro fluorocarbons (HFC) or any other refrigerant having zero Ozone Depletion


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Potential (ODP). Refrigerants R11 and R12 shall not be offered for any new cooling plantinstallations.

The refrigerant used shall be fully compatible with all materials within the completerefrigeration system with which the refrigerant will come into contact.

The plant shall be charged with lubricant and shall be provided with a holding charge of

refrigerant or inert gas before dispatch from the Works where a full charge is impractical.Where this is the case the procedures for charging outlined in CIBSE CommissioningCode R shall be followed after installation.

Installations shall comply with BS EN 378: Part 14, Refrigerating systems and heatpumps. Safety and environmental requirements.

Where Rll or R12 have to be removed from existing installations, the disposal shall becarried out as required by CECOMAF document GT1-001.

Operatives shall have a Certificate of Achievement for Safe Handling of FluorocarbonRefrigerants showing the registration reference number and date of registration.

2.9 Refrigerant Pipe Work

To minimise the possibility of refrigerant losses to atmosphere, pipe work joints shall bekept to a minimum. Wherever possible, brazing or welding is preferable to flared, screwedor flanged connections.

Copper suction, discharge and liquid lines up to 41/8 in (105 mm) outside diameter (O/D)

shall be fabricated from refrigerant quality tube to BS 2871: Part 2, Table 2 materialdesignation C106. Tube shall be fully annealed up to

7/8 in (22 mm) outside diameter

(O/D) only. Tube shall be delivered to site internally degreased and shall be stored inclean and dry conditions with ends sealed until required for installation.

Flared joints in copper piping systems shall only be accepted on equipment accessories.Compression fittings shall only be accepted for feed piping to pressure gauges andsimilar fittings only where these are mounted on instrument or control panels. Brazingshall be carried out in accordance with HVCA/JIB Recommended practice and tests forcompetency. Brazing rods shall be cadmium-free and conform to BS EN 1044.

Steel suction, discharge and liquid lines shall be fabricated from seamless pipe complyingwith BS EN 10216: Part 2 or BS EN 10217:Part 2 material grade 360 minimum orhigher quality. Steel pipe shall be clean and free from all debris, including rust, mill scale,flux and welding scale. Pipe shall be stored in clean dry conditions until required forinstallation. Ingress of dirt and moisture shall be prevented at all times, including duringfixing operations, by sealing or use of end caps.

Joints in steel pipe work shall be welded or flanged. Fabricated mitred or segmentalbends, unless an integral part of equipment design, shall not be used. Screwed jointsshall only be used on equipment accessories with either taper form threads using anapproved sealing compound, or parallel threads associated with machined joint faces anda suitable joint.

Welding shall be carried out in accordance with HVCA/JIB Recommended practice andtests for competency.

Plastics pipe, with compression fittings to BS 864: Part 3 may be used for feed piping topressure gauges and similar fittings only where these are mounted on instrument orcontrol panels. The grades of pipe used shall withstand the test pressure applied and theeffects of refrigerant and oil. Plastic pipe shall not be used for any other refrigerant piping.


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After completion, the refrigerant pipe work shall be subjected to pressure and leakagetests.

2.10 Testing of Refrigerant Plant

Refrigeration equipment assembled on site, including compressors, condensers,evaporators and absorption units shall undergo a strength pressure test and a leakage

pressure test after all piping has been fitted. This test shall be in addition to the strengthpressure test on each unit at completion of manufacture. The required test pressure shallbe between 1.3 and 1.5 times the working system pressure, as shown in the relevantInstitute of Refrigeration Safety Code given below:

The Pressure Equipment Directive, (97/23/EC). Implemented in the UK as thePressure Equipment Regulations 1999.

Safety Code for Refrigerating Systems Utilizing Groups A1 & A2 Refrigerants (1999),Institute of Refrigeration.

Safety Code for Refrigerating Systems Utilizing Group A3 Refrigerants (Flammable)(2001).

Ammonia Code of Practice (2002), Institute of Refrigeration.

Guidelines for the use of Hydrocarbon Refrigerants in Static Refrigeration and Air

Conditioning Systems, published by The Air Conditioning and Refrigeration IndustryBoard (ACRIB) February 2001.

Testing and approval of ventilation and air conditioning systems shall be carried outaccording to the requirements of BS EN 12599 Ventilation for buildings. Testprocedures and measuring methods for handing over installed ventilation and airconditioning systems.

2.11 Commissioning

2.11.1 General

All mechanical, electrical and plumbing services shall be commissioned in accordancewith the procedures set out in CIBSE Commissioning Codes, BSRIA Commissioning

Guides, Commissioning Specialists Association Guidance or other such equivalentreferences, and the various supporting codes and guidance documents specified therein.

A Commissioning Management plan shall be prepared and submitted as one of thescheduled method statements required by Module 01 Clause 6. The CommissioningManagement plan shall include a commissioning specification which describes thedetailed requirements with which the various commissioning services have to comply (thecommissioning work), and specific requirements for system testing. The commissioningspecification shall refer to drawings, schedules and the relevant parts of theCommissioning Codes, guides and other standards. If necessary, specialistcommissioning advice shall be obtained on the commissioning plan.

Commissioningis defined as The advancement of an installation from the state of staticcompletion to full working order to the specified requirements. It includes the setting-to-

work of an installation, the regulation of the system and the fine tuning of the system.

Commissioning Managementis defined as the planning, organisation, co-ordination andcontrol of commissioning activities.

For the purposes of commissioning activity Testingis defined as the measurement andrecording of system parameters to assess specification compliance.

The Contractor shall be responsible for fully commissioning each system.


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The entire commissioning procedure shall be performed to the satisfaction of theEngineer and the Contractor shall demonstrate that the installation of any portion thereof,which has been set to work, complies with the requirements of this Specification.

A Legionella Risk Assessment shall be made on completion of the installation.

Installations subject to the Pressure Systems and Transportable Gas Containers

Regulations shall have a Written Scheme of Inspection prepared by a Competent Person.

Prior to regulation, water pipe systems shall be modified as necessary and in accordancewith good pipe work practice, so that flow rates with all valves fully open are within 50%above the design values.

After all water systems have been regulated, the final settings are to be recorded on theCommissioning Certificates provided.

After the air systems have been regulated, all dampers shall be labelled and quadrantsindelibly marked to show the correct setting. Filters shall be checked and wherenecessary, changed or cleaned. The Engineer shall decide whether a filter change orcleaning is necessary, in accordance with the relevant section of this Specification.

Regulation of a system shall be achieved initially by change of drive pulleys. Any minorregulation may be obtained by adjusting the fan discharge damper. Additional damperswhich may be required for correct air balancing, together with the associated works, shallbe provided.

After all air systems have been regulated, the final settings are to be recorded on theCommissioning Certificates provided.

Building services plant and control systems should be inherently commissionable and thecommissioning requirements shall be identified in the detailed design. Manufacturersshall provide commissioning information as part of the delivery documentation suppliedwith any component or system.

The contractor shall allow sufficient time for the complete commissioning process andensure integration of the commissioning process into the overall programme.

All instruments shall be provided by the Contractor or his Commissioning Specialist, andevidence of the accuracy of the test instruments shall be provided. Test methods shall bedemonstrated to the engineer where required.

The Contractor shall submit to the engineer a schedule detailing the equipment which heor his Commissioning Specialist proposes to use in the testing and commissioning of theservices and the test methods to be employed. This shall form part of the commissioningplan.

Testing and commissioning of major items of proprietary plant or specialist equipmentshall be carried out by the manufacturer's personnel and witnessed by theCommissioning Specialist. The Engineer shall be advised of such activities.

Testing and commissioning will also include any additional accessories or devicesrequired for proper system balancing.

2.11.2 Commissioning of Specialist Equipment

All instruments shall be provided by the Contractor or his Commissioning Specialist, andevidence of the accuracy of the test instruments shall be provided. Test methods shall bedemonstrated to the Engineer where required.


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The Contractor shall ensure that all commissioning work carried out on specialistequipment by the manufacturer's personnel is completed to his satisfaction, to thesatisfaction of the Commissioning Specialist and to the satisfaction of the Engineer.

Testing and commissioning of major items of proprietary plant or specialist equipmentshall be carried out by the manufacturer's personnel and witnessed by theCommissioning Specialist. The Engineer shall be advised of such activities.

The Contractor shall submit to the Engineer a schedule detailing the equipment which heor his Commissioning Specialist proposes to use in the testing and commissioning of theservices and the test methods to be employed.

Pre-operational chemical cleaning of water systems shall be carried out where indicatedusing a specialized agent after the Engineers approval. For chemical cleaningrequirements see Particular Specification and BSRIA Application Guide AG8/91.

Ductwork systems shall be cleaned by blowing out using the supply air fan. No fan shallbe started until cleaning is to commence.

Cleaning shall be completed before the connection of terminal units and fittings.

Duct spigot ends shall be temporarily fitted with securely fixed fine mesh covers to collectairborne particles for disposal as directed by the Engineer.

2.11.3 Commissioning Records

The results of all checks and measurements shall be recorded in writing by thecommissioning engineer as commissioning proceeds, together with any appropriatecommentary. Records of all commissioning activities shall include details of testsundertaken and results achieved. Records shall include calibration certificates for allinstruments used during the commissioning process.

Test results shall be recorded on Commissioning Certificates provided and countersignedby the Engineer.

It is recommended that the format of record sheets should be agreed before testing and

commissioning commences. A pro-forma for these records may be compiled from therelevant Commissioning Code for each particular installation.

Record sheets should be completed once only (that is, not subsequently transcribed bytyping since this can lead to errors being introduced). Where hand written records aresubsequently transcribed into typed format there shall be a formal checking processcarried out to validate their accuracy.

On completion of commissioning, the Contractor shall provide a commissioning reportcontaining documentary evidence that the requirements of the commissioningspecification have been met. This shall accompany the complete set of record sheets forthe commissioning process.

2.11.4 Legionella Risk Assessment

A Legionella Risk Assessment shall be made on completion of the installation, based onCIBSE TM13, Minimising the risk of Legionnaires' disease.

The entire commissioning procedure shall be performed to the satisfaction of theengineer and the Contractor shall demonstrate that the installation of any portion thereof,which has been set to work, complies with the requirements of this Specification.

Note: The commissioning report should indicate that the requirements of thecommissioning specification have been met. A properly annotated copy of the


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commissioning specification, developed contemporaneously with the commissioningworks and referring to the commissioning records should be accepted as acommissioning report.

3. PART 3 SUMMARY

Table 1: Building Services Commissioning: A summary of Codes and Guides

Commissioning Management

CIBSE Commissioning Code MBSRIA Guide to Commissioning ManagementCSA TM/1 Standard Specification for Commissioning and Commissioning ManagementCSA TM/5 Health and Safety Legislation Affecting Commissioning

Specific System Commissioning

SYSTEM & BSRIA GUIDE CSA DocumentsCIBSE CODE

Air (A) Commissioning of Air Systems in

BuildingsCommissioning of HVAC SystemsCommissioning of VAV Systems inBuildings

Boilers (B)Controls (C)Lighting (L)Refrigeration (R)Water (W) Pre-commission cleaning of water systems GN/1 White Water

BalancingCommissioning of pipe work systems GN/2 Automatic

Balancing DevicesCommissioning of Water Systems in GN/3 Variable VolumeBuildings Water Systems

GN/4 Bacteria withinClosed Circuit/ pipe worksystemsTM/9 Water Treatmentand the CommissioningEngineer

Commissioning Matrix

C

ommissioning

C

ode

C

ommissioningPlan

C

ommissioning

S

pecification

T

estingSchedule

C

ommissioning

&

TestingReports

S

ystemH

andover

B

uildingLogbook(or

O

&M

Manuals)

Heating B, C, W

Ventilation A, C, W

Air Conditioning A, C, R, W

Automatic Controls &Building ManagementSystems

C


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3.1 Requirements for Type Approvals

Requirements for type approval, as defined below, are also shown in the following tables.

Supplier Pre-Qualification Documentation

Adequate information of the suppliers organization to allow pre-qualification.

Specialist Contractor Pre-Qualification

Adequate information of the Specialist Contractor organization to allow pre-qualification.

Compliance Statement

Statement or checklist confirming compliance with the Contract.

Certified Type Tested Data

Manufacturers certified type tested data for specific items of equipment or components.

Country of Origin

Country where item of equipment or component is manufactured.

Dimensioned Manufacturers Drawings

Drawings of the item of equipment indicating all critical or major dimensions.

Associated Shop Drawings

Shop drawings showing connecting or interfacing services or equipment demonstratingcorrect location, positioning and adequate provision for maintenance access, operationalneeds and service connections.

Manufacturers Certified Performance Data

Performance data certified by the manufacturers R & D section and is not cataloguedata.

Copy of Third Party Approvals

Any necessary applicable third-party approval documentation such as independenttesting organizations, for example, Fire and Life Safety testing, Underwriters, Laboratory,Loss Prevention Council, British Board of Agreement.

Program of Factory Tests and Proposed Dates

Where applicable, those items of equipment to be factory tested are to be programmedwith agreed dates and suit the construction programme.

List of Projects

A list of pro