Section 35 - Air Conditioning and Mechanic Ventilation System

ELECTRIFIED DOUBLE TRACKING PROJECT BETWEEN RAWANG AND IPOH
Technical Specifications (Infrastructure) – Air Conditionin and Mechanical Ventilation System
SECTION 35 - AIR CONDITIONING AND MECHANIC VENTILATION SYSTEM
35.1 General
1. This section includes the general requirement for materials, workmanship,
design and other items in respect of the Air Conditioning provisions in the
Contract.
2 The Contractor shall be responsible for the due performance of the works
in compliance with these requirements and the Contract.
35.2 Air Cooled Packaged Air Conditioner
1. Scope
This section of the specification details the requirements in respect of

materials, workmanship and other accessories in respect of Air Cooled
Packaged Air Conditioning Units.
2. Casings
(a) The casing shall consist of ¼" angle iron framework, to which are
fixed 18 gauge panels.
(b) The panels shall be cleaned thoroughly and chemically treated

prior to fabrication to ensure that the whole assembly is rust proof.
The whole cabinet shall be prime coated, and finished in two coats
of full gloss finish paint.
(c) The unit shall be completely insulated with ½" to 1" thick
odourless, fireproof, permanent glass fibre material having a
density of at least 2 lb/cu ft.
3. Compressor
(a) The compressor shall be hermatic type or serviceable hermetic

type depending on the size of the unit.
(b) The complete motor and compressor assembly shall be mounted

on vibration isolators.
(c) To reduce noise the hot gas discharge line shall incorporate a hot
gas muffler.
(d) The unit shall incorporate as standard equipment the following:-
i) Compressor unloaders to provide capacity modulation.

ii) Immersion type crankcase beater.
iii) Forced feed lubrication.
Revision: B1 Revised: 1st February 2001 Section: 35 1/32

4. Cooling Coils
(a) The Cooling Coils shall be direct expansion type. The coils shall
be constructed of seamless copper tubing, with either aluminium
or copper fins, mechanically bonded to the tubes.
(b) Cooling Coil shall have two or more rows depending on size of the
unit.
(c) Cooling Coils shall have one refrigerant circuit for units up to and
inclusive of 7½ tons capacity and shall have one expansion valve
only. Larger capacity units have two or more refrigerant circuits,
and each circuit shall have its own expansion valve and solenoid
valve to achieve the required capacity modulation.
5. Condensers (Water Cooled)
(a) The water cooled condenser shall be of shell and finned tube
design.
(b) It shall also incorporate a removable cast iron water header(s) and
the tubes shall be cleanable.
(c) The condenser shall be factory tested to at least 300 psi and shall
be provided with a spring-loaded pressure relief valve set and
sealed to relieve at 300 psi.
6. Condenser (Air Cooled)
1. Where air cooled condensers are used they shall be to the

following specification.
2. Casing
The casings shall be of heavy gauge steel, treated suitably and

made rust-proof, and shall be painted with weatherproof paint.
3. Condenser Coil
(a) The condenser coil shall be constructed of seamless

copper tubing, with either aluminium or copper fins,
mechanically bonded to the tubes.
(b) The coils shall be factory tested and completely dehydrated

under vacuum.
7. Fans
1. Evaporator Fan
(a) The evaporate fan(s) shall be large double width, double

inlet, forward-curved multi-blade fans.

(b) The fan(s) shall be statically and dynamically balanced.
(c) The fan(s) shall be mounted on steel shafts with

permanently lubricated ball bearings.
2. Condenser Fan
(a) The condenser fan(s) shall be either centrifugal or propeller

type depending on size of the units.
(b) The fan(s) shall be direct driven and shall be statically and
dynamically balanced.
(c) The fan(s) shall be mounted on steel shaft with

permanently lubricated ball bearings.
(d) The fans(s) motor shall be weatherproof heavy duty type.
3. Discharge Plenum
(a) The discharge section from the fan shall be suitable for
either ducting or free discharge as shown on the drawings.
(b) Where free discharge is indicated the discharge plenum

shall supplied with either front and side discharge
arrangement or front discharge arrangement only. The
discharge plenum shall also incorporate louvres to enable
the air discharge vertically and horizontally.
(c) In cases where ducted discharge is indicated, provision

shall be made to connect the duct either from the top or the
side, i.e. to give either a vertical or horizontal unit.
8. Controls
(a) All units shall incorporate high and low pressure cut-outs oil
pressure switch, non-recycling control relay.
(b) Temperature controls shall be by means of built-in thermostat and

this shall be located in any easily accessible position. It shall also
have provision for the installation of remote thermostat if
necessary.
9. Filters
(a) Filters shall be suitable for inclined mounting and be so positioned

as to be easily accessible. The filters shall be permanent
cleanable type.
(b) The face velocity across the filter shall not exceed 500 cfm.

10. Drain Pipe
All units shall incorporate a suitable size drain pan, with outlet connection.
The drain pan shall also be insulated with minimum 1" thick fireproof,
permanent insulation.
35.3 Air Distribution System

1. Scope
(a) The section details the requirements in respect of materials,

workmanship, etc. in respect of the Air Distribution System,
consisting of ductwork diffusers, grilles, insulation and all other
accessories to provide a complete system.
(b) The system used is Low/Medium pressure duct system and all
workmanship shall be suitable for this type of installation.
(c) The drawing indicate the general arrangement of the air

distribution system. It is the responsibility of this CONTRACTOR
to check on site, the actual space available and ensure that duct
runs are coordinated with the work of other trades, before
fabrication of the ductwork.
The Contractor shall advise the Consulting Engineers of any

deviations necessary and obtain prior approval.
2. Materials
(a) The ducts shall be fabricated from best quality galvanised steel
sheets. Sheets on which the galvanising peels off on bending will
be rejected.
(b) The recommended gauges of sheet metal types of transverse

joints and bracing to be used, for the various duct sizes are as
listed in Table 3.1 below.
(c) Transverse reinforcing shall be applied on all four sides and tied
together at each corner by reveting, bolting or welding.
(d) All ducts shall be machine bent, free from sharp internal edges
and ensure tightness of seams and corners to minimise leakage.
(e) All ducts sizes shown are clear internal sizes and the dimensions
given in the drawing are 'plane of drawing' first and vertical
dimensions second.
(f) All transitions due to changes in duct size shall be done gradually
and a slope of 1" in 7" is to be used for all transitions.
(g) The ductwork shall be cross braced and reinforced where

necessary to ensure rigidity and freedom from mechanical noise

induced by vibrations.
3. Duct Supports
1. The ductwork shall be supported be means of M.S. angles spaced

at suitable intervals to form a rigid and vibration free support.
TABLE 35.1 - FOR LOW PRESSURE DUCTS
SHEET METAL GAUGES FOR RECTANGULAR DUCT CONSTRUCTION

Max. Size British Type of Transverse Type of Bracing of Duct S.W.G. Joint
Size Sheet Type: Connection:

(Inches): Metal:
Up to 12 24 S. Drive, Pockets or Bar Slips, None

7'10" centres
13 to 24 22 S.Drive, Pocket or Bar Slips, on None

7'10" centres
25 to 30 22 S. Drive, 1" Pocket or 1" Bar 1" x 1" x 1/8" angles

Slips on 7'10" centres 4" from joint
31 to 40 20 Drive, 1" Pocket or 1" Bar Slips 1" x 1" x 1/8" angles
on 7'10" centres 4" from joint
41 to 60 20 1½" Angle Connections, or 1½" 1½" x 1½" x 1/8"

Pocket or 1½" Bar Slips with 1 angles 4 from joint
3/8" x 1/8" bar reinforcing on
7'10" centre
61 to 90 18 1½" Angle Connection or Pocket 1½" x 1½" or 1

diagonal Bar Slips on 3' 9" maxi ½" x 1/8" or 1½”
centres with bar reinforcing angle or 1½" x 1
½" x 1/8" angles 2
from joint
2. The supports shall be spaced as shown in Table 35.2 below :-
Table 35.2
Duct Size Support spacing maximum:

(Longest side):
80" and below 4'- 0" to 5’-0”

48" to 79" 6'- 0" to 7'-0"
12" to 47” 8'- 0" to 9'-0"

3. To provide for adjustment in height, the hangers shall be made of

screwed 3/8" M.S. rods.
4. The hangers shall be fixed to the ceiling by means of suitable in

shear type of fasteners.
4. Elbows And Turning Vanes
(a) Elbows shall in general be long radius type and changes and
reduction in noise and turbulence.
(b) Turning vanes constructed to the Consulting Engineer's approval

shall be provided on all bends to ensure stream line flow.
5. Duct Connection To Fans And Units
(a) All connection of ductwork to fans or Air Handling Unit shall be

made of heavy canvas and the joint shall be made air-tight.
(b) The connection shall be made such that, the renewal of the
canvas connection can be made without dismantling the ductwork.
(c) Where a fire hazard exists, the material used shall conform to the
requirements of the Local Fire or other Authority having
jurisdiction.
6. Dampers
1. Dampers shall be provided on all supply and return (exhaust)

ducts to regulate the volume of air. These shall be installed in the
locations and positions shown on the drawings.
2. Splitter Dampers
These dampers shall be located at the branch connection of a duct

or outlet as shown on the drawings. The damper shall be
constructed of a single blade sheet metal plate hinged at one end.
It shall be rigid and vibrationless in construction and be provided
with a fully adjustable locking quadrant.
3. Butterfly Dampers
This type of dampers shall only be installed in straight duct runs.

The dampers shall be constructed of a single blade sheet metal
plate hinged in the middle. The damper operators shall be
suitable for insulated or non-insulated ducts.
4. Louvre Dampers
These dampers shall be installed in straight duct runs and consist

of a series of splitter or butterfly dampers. The damper shall be
constructed to the following requirements :
i) The frame shall be of iron, enamelled after fabrication. The

whole assembly shall be suitably reinforced to eliminate

any vibrations.
ii) The shafts shall be of adequate M.S. bar.
iii) The bearings shall be oilrite or graphite impregnated

bronze bushes.
iv) The blade shall be constructed of minimum 20 gauge

Galvanised steel sheets.
v) The dampers shall be of the opposed blade type.
vi) All manual dampers shall incorporate an adjustable locking

quadrant of approved manufacture.
vii) All motor operated dampers shall incorporate suitable

means for the addition of damper motors.
5. Fire Dampers
Whenever ducts pass through fire-walls or connect two fire areas

of a building, automatic fire dampers shall be provided, to the
approval of the Local Fire or other Authority in the positions
indicated.
The damper shall be constructed to the following requirements.
i) The plate shall be single or multi-louvred weighted type.
ii) The fire damper shall be operated by a Fusible link set for
the maximum temperature allowed in the particular area.
iii) The Fire Dampers shall lock shut positively and shall be
opened manually. The damper shut or open position shall
be indicated by means of an external indicator.
iv) The Dampers shall have a fire rating of minimum 2 hours.
7. Supply Outlets And Return (Exhaust) Intakes
1. Supply outlets and Return (exhaust) shall be installed in the types

sizes and positions indicated on the drawings.
2. Ceiling diffusers shall be either square, circular or linear type as

shown on the drawings. The outlet shall be of the aspirating type
and be designed to give uniform air flow.
3. For square and circular types of diffusers the outlets shall be

equipped with neck connections to the sizes indicated. It shall
also incorporate combination volume control and equalising
deflector. Provision shall be made to adjust the dampers from
below.

4. Side wall registers shall be of the rectangular type. The vertical

and horizontal louvres shall be adjustable for control and direction
of air flow.
5. Directional volume control dampers shall be provided at the back

of the outlet, to give an even flow across the whole length of the
register.
6. Grilles for exhaust or return air shall be manufacture to the

minimum free area specified in the drawings. Behind each grille
shall be installed a volume control damper, adjustable from the
front.
7. The diffusers, registers and grilles shall be given one coat of rust
preventive primer and given one coat of flat grey enamel. The
final colour shall be enamel to Architect's selection. All the
diffusers, registers and grilles shall be painted matt black, behind
and internally.
8. The linear diffuser for VAV system shall have factory catalogue
performance ratings which conform to CFM, total pressure drop,
throw and drop as designated.
9. The linear diffuser assembly shall be fabricated from 22 gauge

zinc coated steel complete with enamel finish on exposed
surfaces. The diffuser slot shall be manufactured from extruded
aluminium and have baked enamel finish.
10. The internal surfaces of the diffusers shall be automatically and

thermally insulated with minimum ½" fibre glass material treated to
prevent erosion and UL approval meeting NBFU 90A and NFPA
requirements.
11. The linear diffuser shall be suitable for flush mountings in ceiling
with concealed fixing. Exposed screw heads will not be permitted.
8. Flexible Ducts
1. Flexible duct shall be used for connection to diffusers in the low

pressure system as shown on the drawings.
2. The flexible duct shall be of aluminium alloy which has corrosion

resistance quality.
3. The length of flexible duct shall be long enough to provide a

sweeping configuration without undue installation restrictions. It
shall not be too long as to create unnecessary sags or curves.
4. Flexible duct shall be insulated with 2" thick fibre glass similar in
manner to that for rectangular ducts.
5. Factory insulated flexible duct should be supplied. However,

insulation of flexible duct carried out on site may be acceptable if

they are done properly. Approval shall be obtained from the

Consulting Engineer for flexible ducts to be insulated on site.
9. Insulation Of Ductworks
1. The supply and return ductwork shall be insulated with the

insulating materials specified below. Other types of insulation
should only be offered as alternatives; and the basic tender should
offer the insulation specified herein.
2. Ductwork Insulation in Plantroom or Areas Exposed to Physical

Damage. The supply and return air ducts in Air Handling Unit
room, Plantrooms and other areas liable to physical damage shall
be insulated with rigid insulation. The acceptable insulation
materials are cork, onazote or embonit and these shall be to the
following standards.
a) Cork
The insulation shall be 2" thick and the density shall not
exceed 7.7 lb/cu ft. The thermal conductivity shall be 0.24
Btuh/in/sq ft/hr/F at 70oF mean temperature.
All joints shall be sealed with low temperature adhesive or

mastic to ensure a continuous vapour seal. The insulation
shall then be covered with ½" square mesh and plastered
with ½" thickness o hybrid plaster, trowelled to a smooth
finish.
b) Onazote or Embonite
This shall be 2" thick with the density being 6 to 8 lb/cu ft.
The thermal conductivity shall be 0.23 Btu/in/sq.ft/hr/F at
70oF mean temperature. The installation shall be as per
recommendations of the manufactures. To obtain a
continuous vapour seal, all joints shall be sealed with low
temperature adhesive or mastic. The insulation shall be
finished with coats of aluminium bitumastic paint.
3. Ductwork Insulation On Concealed Ducts
a) The supply and return ductwork running inside false

ceilings and other concealed areas shall be insulated with
Fibreglass Flexible Vapour seal duct insulation. The
insulation shall be manufactured in such a manner to
ensure that the insulation remains intact during handling
and fabrication.
b) The duct insulation used shall in general conform to the

requirements listed below:-
i) The thermal conductivity shall be 0.26 Btuh/in/sq

ft/hr/F at 50oF, mean temperature.

ii) For ducts running inside false ceilings below roof,

the thickness of insulation shall be 2".
c) The insulation shall be fixed to the duct by means of

suitable insulation adhesive. All joints shall be lapped
smooth and sealed with 3" wide tape.
d) Factory recommended vapour barrier shall be applied over

the insulation and all joints of the vapour barrier shall be
sealed with 3" wide vapour barrier tape.
4. Internal Insulation of Ductwork for Sound Attenuation
a) In areas where the sound level is to be kept to a minimum

the supply ducts shall be insulated to the extent shown on
the drawings, with semi-rigid duct liner insulation of not less
than 3 lb/cu ft density. The thermal conductivity shall be
0.23 BTUh/in/sq ft/hr/F at 75oF mean temperature.
b) The acoustic lining shall be minimum 1" thick with factory

applied flameproof calico scrim.
c) The insulation shall be fixed to the duct surface with cold

setting adhesive. Galvanised steel angles and strips shall
be used in addition, to secure the insulation permanently.
To prevent erosion, all butt joints in the liner shall have
mechanical protection.
d) In cases where the velocities in the ducts are above 1500

fpm, ½" galvanised square mesh shall be stretched tightly
over the insulation, and secured firmly by means of clips or
pins.
10. Balancing And Testing
1. After complete installation, the Air Distribution System shall be

adjusted and balance to achieve the designed requirements. The
equipment used for balancing shall consist of instruments for
measuring air quantities, static pressure temperature and humidity.
Temperature and humidity shall be recorded on charts, for each
floor or zone as the case may be.
2. Balancing Procedure
The balancing of the Air Distribution System shall in general be

carried out as follows. However, the Contractor could suggest
other methods, which should be capable of giving equivalent
results. Where approved, they shall be adopted accordingly.
i) All ducts and outlet dampers shall be opened fully.
ii) The capacity of the fan shall then be measured. This could
be measured by means of a rotating vane anemometer

placed inside the fan inlet plenum. The capacity of exhaust

fans shall be measured at discharge outlet.
iii) The fan motor input shall be measured.
iv) The air flow at each outlet shall be determined.
v) The outlet and branches shall next be adjusted such that

the outlet deviation is approximately the same percentage
wise as the fan capacity deviation from the total design
quantity.
vi) The fan capacity shall be re-checked and the fan speed or
main trunk damper shall be adjusted to make the fan
capacity equal to the design capacity.
11. Insect Screens and Louvres
Insect screens of the corrosion resistant type shall be provided and fixed
behind all intakes and discharge louvres, grilles and openings where
these occur on the outside of the building. The screens shall be fixed for
easy removal for periodic cleaning and shall be of minimum gauge 22.
All external supply and discharge air louvres shall be of the sizes
indicated on the Drawings and shall be supplied and fixed by the
CONTRACTOR. They shall be suitable for removal and be complete with
suitable corrosion resistant insect screens and shall be constructed of
steel or of aluminium.
35.4 Split System Air Conditioning Units
1. General
Split system air-conditioning unit shall be of the air-cooled type, factory

assembled and furnished complete with wall-mounted/ceiling
exposed/ceiling concealed indoor unit, remote air-cooled condensing unit,
refrigerant piping and all other related controls and accessories.
2. Capacity
The selection of the split system air-conditioning units shall be required to

meet both sensible and total cooling load as specified on the drawings.
The capacity shall have to be suitably derated to take into account any
differences in level between the indoor unit and remote air-cooled
condensing unit and also the length of refrigerant piping involved.
3. Compressors
Compressors shall be of the hermetic rotary type with overload protection. It

shall be internally spring mounted for quiet operation. The compressor motor
shall be interlocked with the condenser fan motor of each unit such that it
may only be run when the condenser fan is operating.

4. Evaporators and Condenser Fans
Evaporator and condenser fans shall be direct driven. The evaporator fan
shall be the centrifugal type and the condenser fan shall be the propeller type
with provisions to eliminate condensate dripping.
5. Evaporator and Condenser Coil
Evaporator coils shall have copper tubing as the primary surface and
aluminium fins for the secondary surface. Condenser coils shall have copper
tubing as the primary surface and copper fins or hydrophilic fins or equivalent
for the secondary surface. They shall be factory tested for leaks. A suitable
metering device shall be provided for the refrigeration system.
6. Filters
Air filters shall be of the reusable type and be efficient for its purpose. They
shall be located so that they can be checked, cleaned and replaced easily.
35.5 Ventilation Fans
1. General
Fans for the air-confitioning and ventilation shall be capable of giving the
specified performance when tested in accordance with B.S.848 and shall
be to UBBL requirements and local authorities approval. Although
estimated values of the resistance to air-flow of items of equipment may
be indicated, this does not relieve the CONTRACTOR of the responsibility
for providing fans capable of delivering the required air volume through
the system.
Each fan shall be capable of continuous operation, having the capacity as

indicated in the Equipment Schedules and/or in the drawings when
operated at the specified speed against the friction in the system.
Installation of Ventilation System (Axial fan/ propeller fan) shall be

completed with electrical and control wiring, high temperature alarm
signal, signal cabling to main fire alarm panel, switches, duct works,
grilles, fire dampers, all supports and accessories etc where required.
Type fan model/brand shall be subject to KTMB approval.
2. Propeller Fans
Propeller fans shall have blades manufactured from epoxy coated

galvanised steel.
The fans shall be window mounted or wall mounted to suit the particular
installations. Wall mounted fans shall be supplied with wall boxes and
wall plates suitable for removal for cleaning or built in the wall where
shown on the Drawings. The fan shall be completed with weatherproof,
flush fitting grilles, draught preventing iris or similar shutters, wire guards,
etc. as specified.

Fan motors shall have IP 55 enclosures.
3. Axial Fans
The fans shall be the tubeaxial, direct driven with aerofoil blades and
manufactured from heavy gauge metal or other approved materials. Fan
motors shall be non overloading over the characteristic curve at the
required rpm to deliver the specified airflows. Fans shall be the bifurcated
type where so specified.
The impellers shall be of steel or other equally approved materials and

shall be accurately balanced after assembly. The blades shall be
fastened to the hub or the blades and hubs shall each be formed in one
piece.
The casings shall be longer than the length of the fan and motor. The
casings shall be of steel, shall have flanged ends and shall incorporate an
inspection door. The fans shall be complete with resilient mountings,
mounting feet or plates, connection spigots, wire guards and dampers.
Silencers shall be included if required to comply with restrictions on noise
levels.
Fans shall be suitable for their particular service, position of fitting and
chosen with respect to corrosion, inflamability or other hazardous
applications and shall not exceed any specified noise levels. Extended
lubricators shall be provided with a suitable size access panel for fans
fitted in a run of ductwork.
Fan speeds shall not exceed 1450 rpm unless specified otherwise. The
fans shall be directly coupled to totally enclosed squirrel-cage induction
motors suitable for either single-phase or three-phase, 50-Hz supply.
35.6 Refrigerant Pipeworks
1. General
The refrigerant pipes shall be routed in an orderly manner along the

partition wall, brickwall or soffit of floor slab without obstructing other
services. The refrigerant pipes shall be housed in white colour metal
trunking of adequate thickness.
2. Material of Pipeworks
The refrigerant pipes shall be copper tubes complying with BS 2871 Part
2 1972.
The pressure rating of copper tubes shall be
Suction Line 1200 kPa

Liquid and Hot Gas Line 2000 kPa
3. Jointing of Copper Pipes

Jointing of copper pipes for air conditioning units of 6 Hp and below shall
not be permitted.
4. Insulation of Refrigerant Pipes
The refrigerant pipes shall be insulated with 15mm thick flexible, close cell
light weight elastometric material. Liquid line and suction line refrigerant
pipe shall not be insulated together.
5. Pipe Supports
Adequate supports shall be provided for refrigerant pipes not housed in

metal trunking. The spacing of supports shall be not be more than 2.0m.
35.7 Condensate Drain Pipes
1. General
The condensate drain pipes shall be routed in an orderly manner along

partition wall, brickwalls and soffit of beam without obstruction to other
services.
The configuration and sizes of the pipeworks shall be as shown on the

drawings.
The horizontal run of the pipework shall be installed with a gradient of not
less than 1/100.
2. Pipe Material and Workmanship
The material of condensate drain pipes shall be PVC.
Where possible, the condensate drain pipes shall be embedded in the

brickwall or apron floor slab.
Thermal insulation is not required for embedded pipes. All exposed

condensate drain pipes shall be insulated with 15mm thick flexible, close
cell light weight elastometric material and shall be housed in white colour
metal trunking of adequate thickness.
The spacing of supports for condensate drain pipes shall not be more
than 2.0m.
35.8 Vibration Isolators
Vibration hangers shall contain a steel spring and 0.3" deflection

neoprene element in series. The neoprene element shall be molded with
a rod isolation bushing that passes through the hanger box.
Spring diameters and hanger box lower hole sizes shall be large enough
to permit the hanger rod to swing thru a 30 o arc before contacting the
hole and short circuiting the spring. Springs shall have a minimum
additional travel to solid equal to 50% of the rated deflection. Submittals
shall include a scale drawing of the hanger showing the 30o capacity.
Hangers shall be type 30N as manufactured by Mason Industries, Inc.

35.9 Duct Mounted Attenuators
1. Description
All sound attenuators shall be manufactured and supplied as complete

packaged units by a recognised manufacturer of noise control equipment
approved by the E.R.
The sound attenuators shall be installed where shown on the mechanical

services drawings, and in accordance with the ductwork specification.
2. Performance
Sound attenuators shall be sized by the CONTRACTOR to ensure that

the sound pressure level at the boundary line does not exceed 55dB(A).
At the specified volume flow rate, sound attenuators shall not exceed the
maximum pressure loss stated on the Drawings.
Performance details of all attenuators shall be submitted for approval by

the E.R. These should include:-
a) The actual length, width (dimension across splitters), height

(dimension parallel to splitters), splitter width and airway width of all
attenuators. If the actual dimensions differ from the nominal
dimensions, the CONTRACTOR shall verify that there is sufficient
space available for the attenuator, and that any necessary duct
transitions are allowed for.
b) The splitter shape for all attenuators, e.g. shape of nose cone and
taper of tail (if any).
c) All acoustical and aerodynamic performance data showing testing

laboratory and relevant testing standards used.
3. Construction
The outer casing shall consist of galvanised sheet steel of minimum

thickness 1.2mm for rectangular sound attenuators, and 1mm for circular
sound attenuators. All seams shall be continuously welded or grooved.
The casing and cells shall have a smooth finish with all edges neatly
butted. Raw edges, fixing straps or screws shall not protrude into the air
stream.
The case shall be suitably braced so as to be completely airtight and free

from drumming or distortion at all pressure up to 1.25kPa.
Rectangular sound attenuators shall be provided with rolled steel angle

end flanges and have adequate intermediate stiffening flanges.
Sound absorbent side panels, splitters and pods shall have acoustic infill
of mineral Rockwool or Fiberglass. The acoustic infill shall be covered by
perforated galvanised sheet steel not less than 1.0mm thick, and between
10% and 40% open area. All splitters shall have a sheet metal nose cone.

All splitters shall be capable of operating at air velocities up to 15m/s

without erosion of infill material. Splitters shall be adequately braced so
they do not sag or bulge and reduce airway width to less than 90% of the
designed dimensions.
4. Installation
Sound attenuators should ideally be installed two duct diameters from any
obstacles such as bends, dampers etc. Where this is not possible,
splitters of rectangular sound attenuators shall be orientated in the same
plane as the bend.
Transformations between ducts and sound attenuators should have a

maximum included angle of 25 degrees.
35.10 Electrical Details
1. General
All electrical works and workmanship on materials covered by this section

shall conform to the best principles of modern engineering practice, be of
first grade quality as to design, manufacture and installation and shall be
complete for satisfactory operation control, maintenance and safety,
under all conditions of services.
The CONTRACTOR shall supply, install and connect all motors,

switchboards, switchgears and all other necessary equipment and
materials except where it is stated in this Specification and/or the
Drawings that materials are to be supplied or works are to be carried out
by others.
The CONTRACTOR shall obtain, fill in and lodge all notices required by
any local authority, public or private, having jurisdiction over the
installation and shall obtain all consent necessary for the various work to
be executed and shall pay all fees in connection herewith.
2. Switchboards
The switchboards shall be of the self-contained, extensible, floor-

mounting and flush-fronted metal cubicle type. They shall house air-
circuit breakers, contactors, starters, relays, fuses, switches, selectors
and isolating switches, fuse distribution boards, meters, busbars,
indicating lamps and switches and all other necessary items of equipment
whether specified hereinafter or not.
The switchboards shall be suitable for indoor service with an ambient

temperture of up to 41oC with 100% relative humidity at maximum
continuous rating without exceeding the maximum temperature permitted
by the relevant B.S. Specification to which reference is made herein for
operation on a 240/415V 3-phase, 50-Hz supply system operating with
solidly earthed neutral.
Each switchboard shall be fabricated from pressed steel sheets of not

less than No.14 BSW gauge in thickness and shall be of rigid construction
with all joints welded.

Doors of switchboards shall also be constructed from pressed steel

sheets of not less than No.14 BSW gauge in thickness and shall be rigidly
reinforced on the inside. Each door shall be provided with a car type
lockable handle and of such construction that the door cannot be opened
unless the isolator switch or handle is first turned to the OFF position
thereby cutting off the electric power supply to the electrical mechanisms
inside the cubicle switchboard. To ensure dust-proof locking
arrangements, felt rubber insert gaskets shall be incorporated in the
frames of the switchboards. The doors shall be fitted on the inside with
shelves for storing of spare cartridge fuses and contactors and electrical
circuit diagrams.
All incoming and outgoing circuits and wirings shall be brought to the
contactors, starters, relays and controllers via insulated terminal strips
mounted within the cubicle. All wirings between terminal strips and
electrical equipment inside the control panels shall be neatly run and
taped in accordance with the requirements of the TNB.
Busbar markings and arrangements connections and grade of copper

shall be in accordance with BS 158, 159, 1433 and 1977. Busbars shall
be air insulated, of high conductivity, hard-drawn copper, rigidly supported
to resist any mechanical force to which they may be subjected under the
specified maximum fault condition of 31MVA.
Whenever possible, busbar drops to secondary and smaller apparatus

shall be made to circular section busbar covered with PVC tubing in
appropriate colour and terminated in concentric lug type, cone grip cable
sockets.
The neutral busbar shall be provided with an adequate number of

terminals including cable lugs, bolts etc. to suit the installations.
Each switchboard panel shall be arranged such that the busbars run
horizontally through each sectionalized length, rigidly mounted on non-
hygroscopic insulators with connections from the busbars to the circuit
breakers and switches effected by means of copper bar or rod securely
clamped to the bars and identified by means of painting or coloured
plastic sleeving to indicate the phase colours.
3. Electrical Wirings
All wirings shall be carried out with PVC cables in fabricated conduits or
mineral insulated copper sheathed (MICS) cables and shall be run strictly
in accordance with the requirements of the TNB. All cables in which links
or abrasions occur shall be rejected and shall be replaced by the
CONTRACTOR at his own expense.
All cables shall be of approved manufacture and shall be of distinguishing

colours for their specified applications.
MICS cables shall be used where specified for wiring to motors and
equipment. Cables shall be neatly run on cable trays in the space under
floor ducts if provided or overhead exposed in the plant rooms or in
suitable trunking whichever is applicable.

Bending radius of cables shall be not less than eight times the overall
cable diameter. The cables shall be terminated at a brass junction box
near the motor or equipment terminal blocks and at earthbar inside the
switchboards. The connection between junction boxes and equipment or
motors shall be made by PVC cables and PVC heavy duty flexible
conduits fitted with approved brass screw type flexible conduit couplings.
Cable from above 6.5 sq.mm. shall be terminated with lug type or grip
cable sockets of approved manufacture.
A steel sleeve shall be provided where the cable passes through a

concrete floor, and shall extend at least 175mm above the floor to afford
mechanical protection to the cable. The sleeve shall be effectively sealed
with bitumen after the cables have been inserted.
Polyvinyl chloride (PVC) cables shall be of the 415V/240V grade and

manufactured to BSS 6004 :1975. PVC insulated cables may be used
where cables are installed in conduit or trunking; but where cables are
installed in plaster, in exposed positions or partly run in conduit and
continued concealed directly in plaster or run on the surface of walls and
ceilings, PVC insulated and sheathed type must be used.
PVC cables shall be installed in rigid conduits fixed to walls, metalworks,

ceilings or buried in the ground. Conduits shall be of class 'B' heavy
gauge, screwed steel type, and together with conduit fittings shall comply
with BBS 31 : 1940. All conduits and fittings shall be galvanised and the
use of water or gas pipe shall be prohibited. Conduits bearing traces of
rust or damage shall not be used.
Conduit sections shall be of sufficiently large and so arranged with draw-

in bones to allow for either an easy draw in or out of any or all the cables,
the total number of which must not exceed the number set out in Table 10
of the latest edition of the IEE Regulations.
All conduits shall be mechanically and electrically continuous throughout

and shall be efficiently earthed with heavy copper wire or tape and screw-
on clips. No conduit shall be less than 20mm outside diameter.
Conduit terminations to loop in boxes shall consist of a screwed socket

and smooth bore bush, but to adaptable boxes, fuse-boards etc.
terminations shall consist of a flanged coupling, lead washers and smooth
bore bush.
Where conduits are exposed to damp situations, or are buried in the

ground they shall be made completely water tight by treating all joints with
red lead.
4. Electric Motors
All motors shall be in accordance with B.S. 5000 Part 99 and B.S. 2757
with Class 'E' insulation to B.S. 2757. Motors shall be continuously rated
(C.M.R. category of B.S. 5000 Part 99) and shall have torque
characteristics as required by their respective duties. Motor enclosures
shall be IP44 unless otherwise specified.
Motor starters shall be in accordance with B.S. 587 and equipped with
overload, single-phasing and under-voltage protection. Where remote

control is required, starters shall be the contactor type with coils wound for
240V 50-Hz supply.
Starters shall be of the following types or as specified in the Drawings.
(a) Fractional horsepower motors shall be 240V, single phase, 50-Hz

squirrel-cage and split phase start.
(b) 1 HP to 3 HP single phase motors shall be squirrel-cage and

capacitors start.
(c) 1 HP to 3 HP three phase motors shall be squirrel-cage and direct

on line start.
(d) 3HP to 10HP motors shall be 415V, three-phase, 50-Hz squirrel-

cage and star-delta start.
(e) 10 HP to 25 HP motors shall be 415V, three-phase, 50-Hz auto-

transformer start.
All starters shall be of automatic type complete with "Start"/"Stop" push

buttons, auxiliary contacts, manual/off/auto selector switch and provision
for remote control as required.
Power factor correction capacitors shall be provided as required to correct

the power factor of all motors over 2 HP in size to 0.85 lagging or better at
all loads. The capacitors shall be installed adjacent to the motors and
complete with necessary protection fuses, discharge resistors and all
wiring and connection.
The rating of motors shall be such that they will not be over loaded at any
points within the range of operation of the equipment connected and shall
be of adequate rating and starting characteristic to allow equipment to be
brought up to speed on starting in a reasonable time.
Bearings shall be of ball or roller or sleeve type as applicable. Terminal

boxes with gasket cover shall be provided suitable for reception of
screwed conduit entry or MICS cable as required.
5. Moulded Case Circuit Breakers (MCCB)
All moulded case circuit breakers shall comply with the requirements of
BS EN60947-2:1992 and shall be of the current limited type. Unless
otherwise stated, the AC rated short-circuit capacity shall be:
o 10kA for standard rated currents up to and including 30 amp.
o 22kA for standard rated currents up to and including 400 amp.
o 45kA for standard rated currents greater than 400 amp.
The MCCB shall incorporate a time delay device to ensure that it will
tolerate harmless transient overload unless this is well in excess of 25%
of its rated value for a sustained period.
The MCCB shall be able to isolate the fault instantaneously for short
circuit current of the order of six to ten times the normal load current.

6. Transformer Rectifier Units
Transformer rectifier units shall provide a stabilized output of 50V D.C.

within a range of + 5% at all conditions of loading and variation of input
voltage not exceeding + 6% and variation of supply frequency of between
48 and 52 Hz.
Incoming and outgoing circuits to the unit shall be protected for by fuses.
7. Earthings
Complete earthing systems comprising cables and copper tape necessary

to bond permanently and effectively to earth all non-current-carrying metal
shall be supplied, installed and connected.
All earthings to individual items of equipment shall be looped on to earth

of the incoming electricity supplies to be provided by others.
8. Commissioning Tests
The complete installation or any part thereof shall be tested, both before
and after being connected up.
The CONTRACTOR shall be responsible for all electrical tests at the Site
and shall be represented by a capable and qualified personnel during the
whole of the period required for the tests.
Test certificates of each test and four copies of schedules of the results
shall be submitted by the CONTRACTOR to the E.R.
9. Work To Be Done By CONTRACTOR
The following work associated with the electrical services to the air
conditioning and ventilation systems shall be carried out by the
CONTRACTOR.
o All electrical motors, starters and isolation switches for air

conditioning and ventilation systems.
o Air conditioning switchboards and wirings complete with air-circuit

breakers, fuse switches, remote push buttons and indicating lights.
o Conduit cable trays, cablings and control wirings between the air
conditioning switchboards and the various items of air conditioning
and ventilation equipment.
o All control equipment, control wirings and associated conduit works,

for air conditioning equipment.
o Conduits and wirings, including control switches and fused spur-

outlets for the extractor fans as indicated in the Drawings and the
Specification.
o Conduits for thermostats and/or humidistats.

35.11 Painting And Labelling
1. Painting and Protection
Only the best quality primers and paints shall be used on all equipment,
pipings, fittings, valves, hangers, conduits, framework, duckwork, insulation,
diffusers, grilles, switchboards, etc. and all work exposed to view.
On special materials, such as insulations, the primers and paints shall be as

recommended by the material manufacturer.
Painting shall only be done in suitable weather.
Tarpaulins, sheets and coverings to protect floors, walls, etc. shall be

provided by the CONTRACTOR.
The paint system for steel fabricated items and pipework shall consist of a
lead oxide or zinc chromate primer coat, a undercoat and two finish coats of
gloss paint of an approved colour .
The paint system for galvanised surfaces shall consist of a etching primer, a
zinc chromate primer coat and two finish coats of gloss paint of an approved
colour .
All paint systems shall be from a single manufacturer to ensure compatibility,

follow strictly the recommendations of the manufacturer with no exceptions
being made and be submitted to E.R. for approval.
All unprotected concealed metal work shall be painted with two coats of
bituminous paint.
Exposed insulated surfaces shall first be sealed with an approved pigmented

sealant before any painting.
Surface preparation shall be to the recommendations of the paint

manufacturer and each coat of paint shall be applied by brush to maintain
adequate dry film thickness.
Should any corrosion or signs of faulty painting technique become apparent

during the maintenance and defects liability period, the CONTRACTOR shall
require to remove the defective paint work or component part at his own cost
and retreat and/or repaint it.
2. Colour Scheme
The colour of painting required for various items are as listed below:-
Colours
Registers, diffusers and grilles, To match surroundings as

hangers and supports, housings, instructed

ductwork and insulation
Line or high voltage conduit Bright Yellow
Control circuit (24 volt or less) Black
Fans Jade Green
3. Labels
Directional arrows shall be in black on all visible sides of ducting and pipings
at 2.5m centres and on two visible sides of all pipings at each valve, fitting.
The size of arrows shall be 80mm long on pipes up to and including 50mm
diameter and 150mm long on pipes over 50mm diameter.
The position of all dampers, that is open, normal and shut shall be clearly
labelled.
Ventilation fans and all duplicated equipment shall be numbered and labelled
in 30mm high stencilled letters.
35.12 Testing And Commissioning
1. Testing Equipment
The following calibrated testing equipment shall be made available for the
testing and commissioning of the air conditioning and ventilation system.
 Clip-On Type Volt Meter and Ammeter
 Pressure Gauge Assembly for measurement of compressor suction

and discharge pressure.
 Sling Type oC DB/WB Thermometer.
 Vane anemometer with case
 Sound level meter with 8 octaves band measurement
2. Schedule of Tests
The air conditioning units shall be tested and fine tuned before the
following data are recorded to verify the performance of each equipment.
 Pressure gauge reading at suction and discharge side of the

compressor.
 Voltage of incoming power supply and operating current of the

equipment.
 Room DB and WB Temperature
 Off Coil DB Air Temperature
 Outdoor Air Temperature

Also to be recorded are the observations made on the air conditioning unit
as detailed below:-
 Sign of condensation on indoor unit.
 Sign of condensation on insulated surface of refrigerant pipe.
 Abnormal operating condition at indoor and outdoor unit.
 Sign of clogging at condensate drain pipe.
Any defects identified during testing and commissioning shall be rectified.

Test on the affected air conditioning unit shall be repeated until
acceptable result is obtained.
The quantity of air for ventilation system shall be set within +5% of the
figures given in the Drawings and final setting of air quantities shall be
recorded.
The automatic control operation of air-conditioning and ventilation system

(timer control or duty/standby changeover, etc.) shall also be tested.
3. Format For Recording Test Data
Test procedures and data sheets shall be submitted for approval by the
E.R two weeks before commencement of tests.
All tests and inspection shall be conducted in the presence of the E.R who
shall endorse all test records.
35.13 Service And Maintenance
1. General
The CONTRACTOR shall inspect and service all equipment supplied

under the Contract Work at least once a month.
2. Scope of Work
The scope of work for service and maintenance shall include
 Check the suction and discharge pressure of all split systems, and if
abnormal situation occurs, trace the faults and rectify as necessary.
 Check all pipelines for leaks and rectify as necessary.
 Checking and topping up refrigerant as necessary.
 Checking and cleaning all filters.
 Checking and cleaning evaporator coils and condenser coils.
 Checking and cleaning fan at indoor units and outdoor units.

 Lubricating bearing for fans as necessary.
 Checking and clearing clog in condensate drain pipes.
 Check all motor bearings, and lubricate with grease as necessary.
 Check carbon brushes and slip rings of all motors, and clean as
necessary. Renew carbon brushes as necessary.
 Check safety devices fitted to all motors, and clean, adjust and
lubricate as necessary.
 Inspect and check the routine operation of all electrical starters,

electrical control gears, and ancillary electrical apparatus.
 Clean, adjust and lubricate all bearings, pivots and other moving
parts as necessary.
 Clean or renew electric contactors as necessary.
3. Consumable Materials
All consumable materials including but not limited to refrigerant,

lubricants, electric contact points, carbon brushes, filter, electric fuses,
cotton waste, soap, detergent and other materials required for cleaning
purpose shall be deemed to be included in the Contract Sum.
4. Service and Maintenance Record
All service and maintenance performed shall be recorded on the

maintenance/repair sheet which is to be countersigned by the E.R.
35.14 Operation And Maintenance Manuals
1. General
Two (2) copies of the draft O&M Manual complete with as-built drawings
shall be submitted to the E.R. for approval 2 weeks before handing over
of the installations to the E.R. Upon approval by E.R., four (4) copies of
the hard cover bound O&M Manual shall be submitted to the E.R.
2. Content of O&M Manual
The content of the O&M Manual shall include
 Information on owner and consultant
 Brief description of the installation
 Maintenance procedure for each equipment
 Trouble shooting procedure for each equipment
 Technical specification of each equipment
 List of spare parts (if any)

 List of supplier of major equipment
 Technical information from equipment manufacturer
 Technical catalogues
 Testing and commissioning records
 As-built drawings and electrical circuit diagrams
35.15 Compressed Air System
35.15.1 Air Compressor
1. General description
The Compressor shall be air cooled, oil injected, single stage, positive
displacement rotary screw type, delivering 1500 ltrs/min of free air at 10
bar pressure at the outlet of the compressor. The air flow specification
shall be based on CAGI/Pneurop PN2 CPT C2 air flow measurement
conditions and methodology. The compressor shall be capable of
continuous full flow operation 24 hours/day at rated specified capacities
and pressure. All components are to be mounted on a rigid enclosure with
hinge doors for easy access safety interlocks and vibration isolation pads
for installation on any flat surface capable of supporting the eight of the
compressor shall also be provided .There shall be one point of electrical
input and one point for air discharge for ease of installation.
2. Airend
The compressor airend shall be designed for good efficiency over a

pressure range of 5.5 to 14.5 bars at the outlet of the compressor. rotors
shall be of the energy efficient profile and shall come with matching
housing. The airend is to be supplied via a 3 micron air inlet filter.
3. Bearings
All airend shall come with cylindrical and angular contact bearing capable
of operation up to pressure of 14.0 bar at outlet of compressor.
4. Motor
The motor shall be of the Totally Enclosed Fan Cooled (TEFC), IP54
enclosure type induction motor with a class F insulation and a service
factor of at least 1.5. The motor is to be operated by a 415 volt, three
phase, 50 Hz power source. The motor shall be applied such that only the
rated power is utilised at the specified compressor outlet pressure at full
load.
5. Starter
The compressor package shall include an integral Star-Delta starter

mounted in its own IP54 enclosure. The starter shall be mounted, wired
and tested as part of the complete compressor package prior to shipment.
Wiring schematics should be provided such that a technician with a

minimum rating of wireman issue by the Jabatan Bekalan Elektrik Dan

Gas (JBEG) shall be capable of trouble shooting, service and repair.
6. Controls
The compressor shall include all necessary control for the starting,
capacity control, operating control, and safety control of the unit. The
compressor should come standard with energy efficient DUAL control with
automatic shutdown of the motor on extended idling and automatic restart
after power failure. Optionally, it should be able to support modulation
control, quadro control and RS232/RS485 interface to other external
sequencing and control systems.
The control shall be capable of safety shutdown on the following

conditions:-
 Over temperature
 Main/Fan motor overloading
 Wrong rotation of motors or wrong phasing on incoming supply
The controls shall also provide an accurate indication of the outlet

pressure, airend temperature and operation hours. Additionally, the
controls shall come standard with voltage free contact for external
indication of fault and alarm conditions.
7. Drive Assembly
The motor and compressor airend shall be coupled via belt and pulley
system with integrated automatic belt tensioning device. The drive system
shall be capable of trouble free operation for a minimum of 10000 hours.
The entire assembly shall be vibration isolated from the package.
8. Enclosure
The unit shall come standard totally enclosed in a sound proofed steel
casing with a powder coat finish and hinged doors for easy maintenance
access. All doors should have a mechanical lock and safety interlock to
prevent unauthorised opening while in operation. Compressors should
come with 10 micro filter mats to ensure extended life and sufficient
cooling. The sound level shall not be more than 70 dBA at one meter.
9. Coolant/Lubrication System
The compressor shall utilised a valveless differential pressure flow

lubrication system. The lubrication system shall come standard with all
necessary pressure gauges, relief valves, and other safety components
as necessary to ensure trouble free and safe operation. A thermostatic
control bypass valve shall be provided to maintain the proper operating
temperature of the compressor.
The air cooler shall be efficient enough to provide a compressed air outlet
temperature of below 10oC above ambient conditions.

10. Piping
The compressor shall utilize rigid steel piping capable of safe operation up
to an outlet pressure of 14.0 bars and shall come with Aeroquip leak free
pipe connections for maintenance purposes. Each compressor system,
after manufacturing and assembly, will be 100% inspected and tested to
provide a piping system free of leaks and maintenance.
35.15.2 Receiver Tank
The receiver tank shall a capacity of 1000 liters and shall be designed and
manufactured according to ASME Section VIII Division 1 Boiler and
Pressure Vessel Code. The tank shall have a design/working pressure of
at least 150 psi 910.35 bar) and a test pressure of 300 psi (20.7 bar). The
tank shall be tested and approved by JKKP before delivery and
installation.
35.15.3 Refrigerant Dryer
1. General Description
The dryer shall be of the refrigerant type capable of reducing the

temperature of 1500 ltrs/min of moisture saturated compressed air at 10
bar pressure and 45oC inlet temperature to a pressure dewpoint of 3oC
when operating in an ambient temperature of 35oC.
The dryer shall include precooling and reheating air circuits. The
precooling portion of this air circuit shall lower than inlet air temperature to
the compressed air, thus reducing the required refrigeration wattage. The
reheater portion of the air circuit shall reheat the cool dry air so as to
prevent condensation on the down stream piping. The precooler/reheater
shall be of the tube design that give continued efficiency and minimal
pressure drop.
3. Refrigeration System
The dryer shall include a fully hermetic air-cooled refrigeration

compressor/condenser and liquid refrigerant filter/dryer.
The dryer refrigeration system shall be charged with Refrigerant 22 or

Refrigerant 134A. Refrigerants, such as R12, which are no longer
acceptable to the environmental shall not to be used.
4. Controls and Instrumentation
The dryer shall be equipped with a panel mounted evaporator light to

show refrigerant system operation and a power on light. There shall also
be a temperature display indicating the operating condition of the dryer.

5. Packaging
The dryer shall be enclosed in a powder coated sheet metal enclosure

and shall meet IP54 electrical standards. Access to the internal
components shall be through removable side panels.
Power supply shall be 230 V, 50 Hz., 3 ph.
35.15.4 Automatic Condensate Drains
The system shall come with 1 unit of electronic level sensing condensate
drains for the receiver tank. The condensate drain shall be capable of
handling the condensate flow through the receiver tank. The operating
voltage shall be 230 V, 50Hz., single phase AC supply. The condensate
drains shall come with a alarm led and be equipped with a test feature.
35.15.5 Air Filter
The filter shall have the capability to remove the particle size down to 1
micron and remaining oil contents to 0.5 mg/m3 @ 20oC. The filter
medium shall be manufactured from borosilicate or its equivalent and is
binder free. The maximum working temperature shall be 40oC. The filter
shall be designed to withstand a maximum differential pressure of 5 bar
and provide a sufficiently large surface area to allow high flowrates.
35.15.6 External Compressed Air Pipework
The external compressed air pipework shall be galvanised steel pipe

confirming to BS 1387 grade heavy and suitable for fabrication by use of
screw fittings.
Pipework shall be installed with continuous gradient to facilitate draining,

and be run neatly and parallel to walls and other pipework, and set around
columns and other projections where these occur. All vertical pipes shall
be plumb.
Special precautions shall be taken to prevent dust, dirt or rubbish entering

the open ends of pipework during storage and erection. iron or plastic
caps or plugs shall be used through out, plugs of any other type or
material shall not be permitted under any circumstance.
Any pipework which in the opinion of the E.R shows signs of corrosion,
scale or deterioration of any form shall be remind from site whether
stoned or fixed and shall be replaced without cost to the E.R.

Pipework shall be clean and free from internal obstructions. All butted and
cut ends of tubes provide full unrestricted bone throughout. Any blockage
occury in the pipework system after installation shall be rectified without
any cost to the E.R.
The pipework shall be subjected to a hydrostatic pressure test. The test

pressure shall be 1034 kPa or 1.5 times the working pressure whichever
is greater for a period of 4 hours.
2. Fittings
The fittings for pipes to BS 1387 shall be of malleable iron galvanised type
confirming to BS 143 with BS 21 Standard taper threads.
3. Joints
All cuts ends of pipes shall be at 90 degree to the axis of the tube and
filed smooth and reamed out to their original diameter.
All screwed joints cut onto the ends of tube shall be made with the use of
dies to suit the threads being used. The lengths and depths of thread cut
shall strictly comply with the requirement of the relevant standard to BS
21.
All joints shall be made with P.T.F.E. tape wrapped clockwise round the
male thread of the joint. Other forms of jointing material will only be
accepted with the written approval from the E.R.
All excess jointing material shall be removed after erection and the
exposed threads painted with zinc chromate paint, any damaged area of
the galvanised pipework during erection shall be filled smooth and
painted.
4. Flanges and Unions
In general, flanges and unions shall be installed at the positions shown on

the “approved for construction” drawings and where ever it may be
necessary to facilitate disconnection and/or removal of a section or
individual component from the installed pipework for future maintenance
purposes. Flange bolt holes shall straddle the pipe centre line.
It should be noted that the “approved for construction” drawings may not
necessary indicate the location of all flanges and unions as defined by the
previous paragraph. Therefore it is deemed to be the CONTRACTOR’s
responsibility to provide and install such flanges and
unions as may be required and/or as may be directed by the E.R, so as to

facilitate the correct and satisfactory installation compressed air
pipeworks.
The flanges table shall suit the system working and test pressure and any
items of fixed equipment. Bolting shall be high tensile steel with corrosion
protection finish, and sizes to suit the flange table being used.
Flange joints shall be made with CAF gaskets minimum 1.5mm thick.

Unions shall be installed in the positions previously specified within this

clause for pipe size up to and including 50mm nominal bore.
When using BS1387 pipe, all union shall be of galvanised malleable iron
type confirming to BS143 with BS21 taper thread connections with bronze
seatings commonly referred to as the “Navy Pattern”.
5. Valves
Valves shall be provided at all places for the proper working and
regulation of the systems and are to be suitable for the working and test
pressure for the system on which they are installed.
a) Isolation Valve
Full bore screwed/flanged gate valves shall be provided to isolate all

major components and branches in the compressed air system.
6. Pressure Gauges
Pressure gauges shall be installed to provided continuous monitoring of

the important system gauge pressures.
Selection of pressure dial range shall be based on twice the working

pressure such that the pointer is in vertical position during normal
operation. The scales shown on the dial face shall be in kPa and Psi.
7. Expansion
All pipework shall be installed in such a manner that all expansion is taken
by changes to direction.
All pipework shall be installed with due consideration for expansion and
contraction such that these effects will not damage the pipework and
accessories nor will they put undue strain on the same.
8. Pipe Sleeves
Pipe sleeves shall be supplied and fixed on all pipes passing through
walls, ceiling and floors including all vertical ducts and be of the same
material as the pipe in which they are installed. They shall finish flush with
plaster and/or other finishes.
The sleeves are to be correctly positioned and pipes shall not, after fixing,
be built in solid with masonry material.
All pipe sleeves shall be packed with mineral wool insulation and caulked
with a non-hard setting compound. On external walls only mastic sealant
of at least 12mm shall be applied to totally vapour seal the gap.
Sleeves through floors and walls shall be of sufficient size to allow for
lateral expansion.

9. Supports
The design of supports and hangers shall be approved by the E.R prior to
fabrication, and they shall allow for the free movement of pipes at all
points with the exception of anchors.
All pipework supports, hangers etc. shall be fixed prior to the actual
pipework installation, temporary supports, fixing or other trades work is
satisfactory and shall not be permitted. The setting out of pipe runs and
hole positions SHALL be approved by the E.R prior to drilling or cutting.
The CONTRACTOR shall be provide all necessary materials steel

sections, nuts, bolts, rollers, chairs, sleeves etc. for the fabrication of
suitable supports, sleeves and hangers.
Pipework shall be supported at not more that the following centres:-
Nominal Bore Vertical Horizontal

of Pipe
15 mm 1800 mm 1800 mm
20 mm 2500 mm 2500 mm
25 mm 2500 mm 2500 mm
40 mm 3000 mm 3000 mm
50 mm 3000 mm 3600 mm
80 mm 3600 mm 3600 mm
100 mm 3600 mm 3600 mm
150 mm 3600 mm 3600 mm
Hanger rods shall be of sizes as follows:-
Pipe Size Rod Size
15 mm to 40 mm 9.5 mm
50 mm to 80 mm 12 mm
100 mm 16 mm
150 mm 22 mm

Pipeline mounted equipment shall be provided with additional supports to

eliminate undue stresses on connections and to facilitate removal for
maintenance.
All multiple pipework distribution runs shall be supported from multiple

supports. One such support may be installed at the centres of a larger
bore pipe as indicated above with intermediate single supports built into
walls or ceilings where necessary for smaller bore pipe in order to comply
with the above schedule.
All components of the pipework supports brackets shall be hot dip

galvanised after manufacture or painted.
35.16 Air Curtain
The single-mould casing shall be pulled forward by simply loosening the

top and bottom fixing bolts, for quick and easy inspection of the inner fan
and motor. The ABS resin casing shall be provided for better weather
resistance. The capacity of the air-curtain shall be refered to the relevant
drawings. The type of fan shall be sirocco fan and the operating power
supply shall be single phase.

Section 35 - Air Conditioning and Mechanic Ventilation System

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Section 35 - Air Conditioning and Mechanic Ventilation System

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ELECTRIFIED DOUBLE TRACKING PROJECT BETWEEN RAWANG AND IPOH

Technical Specifications (Infrastructure) – Air Conditionin and Mechanical Ventilation System

SECTION 35 - AIR CONDITIONING AND MECHANIC VENTILATION SYSTEM

35.2 Air Cooled Packaged Air Conditioner

This section of the specification details the requirements in respect of

(b) The panels shall be cleaned thoroughly and chemically treated

(a) The compressor shall be hermatic type or serviceable hermetic

(b) The complete motor and compressor assembly shall be mounted

(d) The unit shall incorporate as standard equipment the following:-

i) Compressor unloaders to provide capacity modulation.

Revision: B1 Revised: 1st February 2001 Section: 35 1/32

5. Condensers (Water Cooled)

6. Condenser (Air Cooled)

1. Where air cooled condensers are used they shall be to the

The casings shall be of heavy gauge steel, treated suitably and

(a) The condenser coil shall be constructed of seamless

(b) The coils shall be factory tested and completely dehydrated

(a) The evaporate fan(s) shall be large double width, double

Revision: B1 Revised: 1st February 2001 Section: 35 2/32

(b) The fan(s) shall be statically and dynamically balanced.

(c) The fan(s) shall be mounted on steel shafts with

(a) The condenser fan(s) shall be either centrifugal or propeller

(c) The fan(s) shall be mounted on steel shaft with

(d) The fans(s) motor shall be weatherproof heavy duty type.

(b) Where free discharge is indicated the discharge plenum

(c) In cases where ducted discharge is indicated, provision

(b) Temperature controls shall be by means of built-in thermostat and

(a) Filters shall be suitable for inclined mounting and be so positioned

Revision: B1 Revised: 1st February 2001 Section: 35 3/32

10. Drain Pipe

35.3 Air Distribution System

(a) The section details the requirements in respect of materials,

(c) The drawing indicate the general arrangement of the air

The Contractor shall advise the Consulting Engineers of any

(b) The recommended gauges of sheet metal types of transverse

(g) The ductwork shall be cross braced and reinforced where

Revision: B1 Revised: 1st February 2001 Section: 35 4/32

necessary to ensure rigidity and freedom from mechanical noise

1. The ductwork shall be supported be means of M.S. angles spaced

TABLE 35.1 - FOR LOW PRESSURE DUCTS

SHEET METAL GAUGES FOR RECTANGULAR DUCT CONSTRUCTION

Size Sheet Type: Connection:

Up to 12 24 S. Drive, Pockets or Bar Slips, None

13 to 24 22 S.Drive, Pocket or Bar Slips, on None

25 to 30 22 S. Drive, 1" Pocket or 1" Bar 1" x 1" x 1/8" angles

41 to 60 20 1½" Angle Connections, or 1½" 1½" x 1½" x 1/8"

61 to 90 18 1½" Angle Connection or Pocket 1½" x 1½" or 1

2. The supports shall be spaced as shown in Table 35.2 below :-

Duct Size Support spacing maximum:

80" and below 4'- 0" to 5’-0”

Revision: B1 Revised: 1st February 2001 Section: 35 5/32

3. To provide for adjustment in height, the hangers shall be made of

4. The hangers shall be fixed to the ceiling by means of suitable in

4. Elbows And Turning Vanes

(b) Turning vanes constructed to the Consulting Engineer's approval

5. Duct Connection To Fans And Units

(a) All connection of ductwork to fans or Air Handling Unit shall be

1. Dampers shall be provided on all supply and return (exhaust)

These dampers shall be located at the branch connection of a duct

This type of dampers shall only be installed in straight duct runs.

These dampers shall be installed in straight duct runs and consist

i) The frame shall be of iron, enamelled after fabrication. The