Specification For Chilled Water Systems

SPECIFICATION FOR CHILLED WATER
SYSTEMS
I:\WATER STANDARD SPECIFICATION\COPY OF ADWEA SPECS DEC 05 ED\ADWEA SS\W-H-SS\W-H-SS-003.DOC
0 02-02-2002 Approved Issue

rev. date Description/issued for prepared authorised
client: ADWEA
project: STANDARD SPECIFICATIONS FOR WATER WORKS
title: SPECIFICATION FOR CHILLED WATER SYSTEMS
tender: project: document: W-H-SS-003 rev: 0 sheet: 1 of: 36

Table of Contents page
1. SCOPE .................................................................................................. 4
2. APPLICABLE STANDARDS AND CODES .......................................... 4
3. CHILLED WATER GENERATION SYSTEM ......................................... 5

3.1 Description .................................................................................. 5
3.2 Design Criteria ............................................................................ 5
3.3 Mode of Operation....................................................................... 5
4. CHILLERS ............................................................................................. 6
4.1 General ....................................................................................... 6
4.2 Evaporator ................................................................................... 6
4.3 Aircooled Condensor ................................................................... 6
4.4 Compressors ............................................................................... 7
4.5 Refrigerant Circuits...................................................................... 7
4.6 Unit Controls ............................................................................... 7
4.7 Chiller Fixing ............................................................................... 8
4.8 Chiller Shipment .......................................................................... 8
4.9 Chiller Commissioning................................................................. 9
5. CHILLED WATER PUMPS.................................................................... 9

5.1 General Requirements ................................................................ 9
5.2 General Construction ................................................................ 10
6. CHILLED WATER PRESSURISATION UNIT ..................................... 10

6.1 Expansion Tank ........................................................................ 10
7. WATER TREATMENT ......................................................................... 11
8. AIR HANDLING UNITS ....................................................................... 11

8.1 Casing Construction .................................................................. 11
8.2 Fan Section ............................................................................... 12
8.3 Cooling Coil Section .................................................................. 13
8.4 Filter Section ............................................................................. 14
8.5 Damper Section ........................................................................ 14
9. FAN COIL UNITS ................................................................................ 15
10. PIPEWORK GENERAL ....................................................................... 16

10.1 Chilled Water Pipe Work ........................................................... 19
10.2 Valves ....................................................................................... 19
10.3 Pressure Gauges ...................................................................... 20
10.4 Thermometers ........................................................................... 20
10.5 Welding ..................................................................................... 21
10.6 Supports .................................................................................... 22
10.7 Pipework Identification .............................................................. 23
Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR CHILLED WATER SYSTEMS

11. THERMAL INSULATION ON PIPEWORK .......................................... 24
11.1 Thermal Insulation – Vapour Barrier Coatings .......................... 24
12. VIBRATION ISOLATION ..................................................................... 25

12.1 Pumps ....................................................................................... 25
12.2 Air Handling Unit Floor Mounted ............................................... 26
12.3 Air Handling Unit Suspended .................................................... 26
12.4 Piping ........................................................................................ 26
12.5 Chiller Plant Vibration Isolation ................................................. 26
13. ANTI-VIBRATION MOUNTING ........................................................... 27

13.1 Caged Spring Mounts................................................................ 27
13.2 Rubber Mattress ........................................................................ 27
13.3 Resilient Hangers ...................................................................... 27
13.4 Rubber or Neoprene Mounts ..................................................... 27
13.5 Plant Bases ............................................................................... 28
14. AUTOMATIC CONTROLS .................................................................. 28

14.1 General ..................................................................................... 28
14.2 Thermostats .............................................................................. 29
14.3 Indicating Thermometers........................................................... 30
14.4 Automatic Control Valves .......................................................... 30
15. TESTING AND COMMISSIONING ...................................................... 31

15.1 Test Instruments ....................................................................... 32
15.2 Pipe Lines Testing Methods ...................................................... 32
15.3 Chilled Water System Commissioning ...................................... 33
16. DESIGN, SHOP AND AS-BUILT DRAWINGS .................................... 33
17. OPERATION AND MAINTENANCE MANUALS ................................. 34
18. SPARES .............................................................................................. 34
19. WARRANTY ........................................................................................ 34
20. QUALITY CONTROL .......................................................................... 35

20.1 Quality Control .......................................................................... 35
20.2 Inspection and Testing .............................................................. 35
21. VENDOR'S DOCUMENTATION.......................................................... 35
22. SCHEDULE OF SUPPLIERS AND MANUFACTURERS.................... 36
23. CROSS REFERENCE BETWEEN SPECIFICATIONS ....................... 36

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1. SCOPE
This specification shall apply to the materials, design, construction, testing and
commissioning of Chilled Water Systems for the Abu Dhabi Water & Electricity Authority.
2. APPLICABLE STANDARDS AND CODES
All works and equipment provided under this contract shall be installed in strict accordance
with local codes, ordinances, rules and regulations of public administrative authorities
including all health and safety related codes.
The current edition at the time of biding of all the publications listed below shall apply, as
applicable.
In case of conflict between this specification and the below mentioned standards then the
more stringent requirements shall be applicable.
Air-conditioning and Refrigeration Institute (ARI)
ARI 410 Forced Circulation Air-Cooling and Air-Heating Coils
American Society for Testing and Materials (ASTM)
ASTM A 53/A 53M Standard Specification for Pipe, Steel, Black and Hot Dipped coated,
Welded and Seamless.
ASTM A 90/A 90M Standard Test Method for Weight of Coating on Zinc-Coated
(Galvanized) Iron or Steel Articles
ASTM B 280 Standard Specification for Seamless Copper Tube for Air Conditioning
and Refrigeration Field Service
ASTM C 552 Standard Specification for Cellular Glass Thermal Insulation
American Society of Heating, Refrigerating, and Air Conditioning Engineer, Inc.

(ASHRAE)
ASHRAE 20 Methods of Testing for Rating Remote Mechanical Draft Air Cooled
Refrigeration Condensing Units
ASHRAE 15 Safety Code for Mechanical Refrigeration
ASHRAE Hand Books
National Electrical Manufactures Association (NEMA)
National Fire Protection Association (NFPA)
NFPA 70 National Electrical Code

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NFPA 90A Standard for the Installation of Air Conditioning and Ventilating
Systems
Rubber Manufactures Association (RMA)
RMA IP-20 Specification for Drives Using Classical Multiple V-Belts, And Sheaves
– Cross Section A, B, C and D.
Underwriters Laboratories, Inc (UL)
UL 181 Factory-Made Air Ducts and Connectors
UL 207 Refrigerant – Containing Components and Accessories, Nonelectrical
UL 1995 Refrigeration and Air-conditioning Condensing and Compressor Units
3. CHILLED WATER GENERATION SYSTEM
3.1 Description
Chilled water will be generated by required number of packaged air cooled liquid chillers,
piped, in parallel. The chilled water will be circulated by circulation pumps backed up by one
standby pump.
3.2 Design Criteria
Chilled water flow temperature = 6º C
Chilled water return temperature = 12º C
Minimum test pressure on pipes = 6 bar
3.3 Mode of Operation
The buildings cooling load will be assessed by a temperature detector located in the main
return header.
The lead chiller shall operate continuously. On demand for more cooling the chiller
sequencer shall start the lag chiller.
On fall in load the chiller sequencer shall shut down the lag chiller.
Lead/lag chillers shall be selectable from the panel. Hours run meters shall be provided for
chillers and chilled water pumps.
In the event of a duty chilled water pump or chiller failing the control system shall
automatically start up the standby pump or chiller.
In the event of loss of system pressure, the chilled water system shall shut down and an
audible alarm shall sound.

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4. CHILLERS
The chillers shall be capable of operating up to an ambient temperature of 55ºC with a

capacity reduction without mechanical failure.
Chilled water flow temperature shall be 6ºC and return temperature shall be 12ºC. Fouling
factor = ARI specified.
The chillers shall be suitable for an electric supply of 415 Volt, 3 phase, 50 Hz.
4.1 General
Units shall be outdoor package which is completely factory assembled piped, wired,
dehydrated and charged with refrigerant. It shall include compressors, evaporators, air
cooled condenser, all mounted on a base for proper support and ease of rigging. Lifting
provisions provided. The only field connections required shall be system water piping and
electrical power supply.
Units are factory run-tested. Units are checked at a factory test stand at typical ambient and
water conditions.
Current draw and control operation are monitored. Units ship with a full operating charge of
refrigerant and oil. Unit shall be suitable for ozone friendly refrigerant.
Chiller is designed, tested and stamped in accordance with BS 5750 Part 1 & ISO 9001.
Construction and ratings shall be in accordance with latest ARI standard 590 and shall
comply with ANSI B9.1 Safety Code, National Electrical Code and ASME Code of U.S.A. Unit
ratings shall be in both imperial and metric system.
4.2 Evaporator
Shell-and-tube design, with two refrigerant circuits each. Consists of steel shell and welded-
on steel tube sheets, seamless internally finned copper tubes mechanically expanded into
grooved tube sheets.
Refrigerant heads of high strength cast steel bolted to the tube sheets.
Maximum operating pressure of water and refrigerant side shall be 14 bar.
Water connections, flanged on all sizes. 10mm thermal insulation of evaporator made of
flexible closed cell polyvinylchloride.
4.3 Aircooled Condensor
Condenser coils shall be with integral sub-cooling circuits. Copper plate fins mechanically
bonded to seamless copper tubes. Condensers shall be factory pressure-tested with air
under at 32 bars air pressure.
Slit or perforated fins will not be accepted.

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Direct-drive vertical discharge condenser fans shall be aluminium and statically and
dynamically balanced. Three-phase condenser-fan motors TEFC class "F" insulation and
Class B rate of rise of temperature with permanently lubricated ball bearings and IP55
protection. All condenser motors must be protected externally by means of sensitive ambient
compensated thermal overload relay located inside the control panel for easy access.
Units shall be provided with automatic head pressure control to permit satisfactory operation
at low ambient air temperatures by cycling condenser fans in response to head pressure
variations.
Condensor coils shall be protected with Heresite or equivalent anticorrosion coating.
4.4 Compressors
Semi-hermetic reciprocating compressors 1500 rpm at 50 Hz with gas cooled motor, multi-
step capacity control and reduced start load. Built-in suction plenum chamber and suction
screens, spring-loaded cylinders, circular, non-flexible suction and discharge valves and
removable cylinder liners. Forged steel crankshaft statically and dynamically balanced, cast
aluminium pistons, high strength heat-treated aluminium connection. Lubrication system
including self-reversing positive feed oil pump, oil strainer, magnetic filters, foam breakers, oil
level sight glass, oil pressure gauge and crankcase heaters.
Part - winding start. Motor protected by sensors in the motor windings.
Internal relief bypass valve set at 30 bar, discharge backseating type service valve.
The compressor power consumption shall not exceed 1.4 KW/TR at full load condition.
4.5 Refrigerant Circuits
Each circuit shall include sight glass, solenoid valve and thermostatic/electronic
expansion valve. Compressor discharge service valve and liquid line shut-off. Refrigerant
circuit factory pressure and leak tested, dehydrated and charged with refrigerant charge.
4.6 Unit Controls
Compressor contactors and unit controls shall be in a water-tight enclosure. Microcomputer

controls provide all control functions including leaving chilled water temperature control,
automatic compressor sequencing, condensor fan sequencing, and anti-recycle functions.
Failure protections include loss of chilled water flow, chiller freezing, compressor running
overcurrent, high motor winding temperature loss of charge, high, low, refrigerant pressure
and oil pressure. Should also include manual pumpdown switch.
Leaving water temperature sensor is factory installed. Control include automatic restart after
a power loss, auto/stop switch, a leaving water temperature set point adjustment, and a digital
display. Display readouts include operating codes, water temperature set point adjustment,
and a digital display. Display readouts include operating codes, water temperature set point,
and diagnostic codes.

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Standard power connections shall include main three-phase power and a single 240-volt,
single-phase connection that handles both controls and the evaporator heater cable
(optional). Unit accepts any of these jobsite supplied contact closures for:
(a) External auto/stop shall be operated from a manual switch or a time clock. In auto, the
unit will be allowed to operate if a load exists.
(b) Chilled water flow interlock – a chilled water pump interlock is required for unit protection,
although a flow switch option (field mounted and factory supplied) must be used for
additional unit flow protection KW demand limit-unit will only be allowed to operate one-
half of compressors.
Automatic lead-lag compressors sequential and automatic restart after power loss features
shall be provided. Compressor cycle counter/hour meters shall be provided.
Power and starting components shall include individual circuit breaker for each compressor.
Circuit breaker for the control circuit, starting contactors, including individual contactors for
each fan motor, solid state compressor sequence start timers, solid state overload protection
in all phases of the compressor and a unit terminal block for field connection to a single
disconnection switch. Panel to be protected against direct sun to avoid temperature rise
inside the control panel.
Multi-refrigerant circuits shall be completely independent of each other and include a factory
insulated suction line, manual liquid line shut-off valve with charging connection, refrigerant
filter/drier with replaceable core, liquid sight glass/moisture indicator, liquid line solenoid
valve, thermal/electric expansion valve, suction and discharge vibration isolators, hot gas
discharge muffler, purge valve and high/low pressure gauges.
During part load operation, the units refrigerant circuits shall be alternatively loaded in steps.
Unit controls shall provide recycling pumpdown protection at all times.
Provision is to be made for connection of all alarms and monitoring functions and control
functions to an external control system.
Unit shall be locked out based on an adjustable outdoor air low ambient temperature set
point.
4.7 Chiller Fixing
The chillers shall be mounted on suitably sized concrete strip plinths. Each chiller shall be
mounted on spring isolators 90% efficient bolted to the concrete plinth by suitably sized cast-
in galvanised bolts.
4.8 Chiller Shipment
The CONTRACTOR shall ensure that chillers are packed to prevent damage during
transportation. The CONTRACTOR shall inform the ADWEA/ENGINEER when the chillers
arrive in the UAE, so that the ADWEA/ENGINEER can be present, if he so wishes, during the

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off loading and subsequent positioning on site. The ADWEA/ENGINEER reserves the right
to reject any chiller which in his opinion have been damaged during shipment.
4.9 Chiller Commissioning
The CONTRACTOR shall include for site commissioning of the chillers by the manufacturer.
After all calibration, adjustment and checking has been completed the CONTRACTOR shall
demonstrate under load the chillers and instruct the owners personnel in the proper operation,
adjustment and maintenance of the chillers. A copy of the commissioning report shall be
bound into the O & M manual.
5. CHILLED WATER PUMPS
5.1 General Requirements
Estimated pump duties are given on the drawings but it is the CONTRACTOR's responsibility
to re-calculate duties on his installation drawings and selected pipeline equipment, and to
provide pumps capable of delivering the required water quantity and pressure, and operating
satisfactorily under the conditions involved.
Chilled water is circulated by 3 no. pumps ( 2 no. working and 1 no. auto standby ) each
capable of handling 50% of the design flow rate. A motorised control valve shall be installed in
the discharge pipeline for each pump. The chiller circuit / pump operation is automatically
controlled from a control system. Differential pressure switches shall be provided for each
pump. In case of failure of one of the duty pumps, control system shall initiate automatic
starting of the standby pump and opening of the respective control valve. Control valve of the
standby / failed pump shall be closed. Hour run meter shall be provided for the pumps.
Circulating pumps generally shall be of the single stage end suction vertical split casing type
direct driven through a flexible coupling by a totally enclosed fan cooled electric motor running
at 1450 rpm, the whole mounted on a cast iron or fabricated mild steel base. The motor shall
be sized to avoid overload at any point on the pump curve.
Closed-coupled or belt-driven pumps will not be permitted unless specified elsewhere.
Anti-vibration protection shall be provided using one of the methods detailed in the
specification, with flexible connections. Pump casings shall be designed for the specified
working pressure and shall be tested 1½ times this pressure and proven tight. Working
pressures are as scheduled in the drawings.
All pumps shall be fully tested at works, with performance characteristics guaranteed in
accordance with BS 5316. Part 1.
Each pump shall be driven at 1450 RPM constant speed by a motor and with a suitable
starter as specified later in this document. Pump brake horsepower at design speed shall
under no condition exceed the nominal motor horsepower.
Each pump shall be guaranteed to circulate not less than the specified quantity of water
against the specified circulating head when operating continuously without producing
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overheating of the motor or bearings, etc., and without producing noise audible anywhere in
the building, outside of the space in which the pumps are installed. Quiet operation is
mandatory.
Certified performance curves shall be submitted for approval for each pump before shipping
from factory.
Pressure gauges as specified elsewhere in this document shall be installed on the suction
and discharge connections of each pump.
5.2 General Construction
Pumps shall normally be constructed with cast iron casing, bronze impeller and stainless steel
shaft running in a pair of pedestal mounted heavy duty sealed-for-life ball bearings.
All pumps shall be fitted with mechanical seals of the self adjusting type, suitable for the
particular operating temperature and pressure.
The exposed motor and pump shafts and the flexible coupling shall be protected by a
galvanised wire mesh guard.
6. CHILLED WATER PRESSURISATION UNIT
Provide and install adjacent to the chilled water circulation pumps an automatic pressurisation
and make-up unit, comprising break tank pressurisation pump, storage vessel, high and low
pressure switches, pressure gauge, safety valve, etc. with expansion vessels with removable
internal rubber diaphragm.
The unit shall be supplied as a complete package, with tank, storage vessel and controls
enclosed in a sheet steel cabinet and mounted along with the expansion vessels on a
stainless steel channel base frame.
The unit shall be suitable for a 240 volts single phase 50 Hz supply.
6.1 Expansion Tank
The expansion tank shall be of at least the size listed in the schedules, or in the documents,
unless a larger size is required for proper functioning of the system.
The tank shall be fabricated from mild steel and shall be galvanized both inside and out after
completion of welding.
The tanks shall be rated for operation at 10 bar in accordance with the pressure test
requirements of a recognized International or National testing agency.
The tank shall have a neoprene rubber diaphragm rated for continuous operation at 10 bar.
The tank shall be complete with all tappings for inlet (which may also be the drain), drain, air
recharge, and pressure relief.

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A spare diaphragm shall be maintained by the CONTRACTOR at site during the maintenance
period and shall be handed over to ADWEA in new condition at the end of the maintenance
period.
7. WATER TREATMENT
All chilled water systems shall be flushed through and treated with the appropriate dosing
chemical in accordance with the Manufacturer's instructions.
The CONTRACTOR shall supply and install in the position indicated on the drawings an
automatic water treatment system consisting of a chemical tank, dosing pump, conductivity
sensor, conductivity meter, controller, injection valve, tubing and similar items for control of
scale and corrosion. A manual dosing pot is to be installed for periodic dosing of bacteria /
algae control agent.
The system shall be flushed out with fresh water, it shall then be refilled and a pre-operational
cleaner added. The system pumps shall then be run for 24 hours (or as recommended by
chemical manufacturer). The system shall be emptied and refilled and the cleaning repeated
until the system water PH is the same as or greater than the supply water.
Upon completion of the pre-commissioning cleaning, the CONTRACTOR shall dose the
system with approved quantities of corrosion inhibitor and bacteria / algae control agent.
8. AIR HANDLING UNITS
The CONTRACTOR shall supply and install on prepared concrete bases the air handling
units detailed on the drawings.
Each AHU plant consists of:
(a) Filter section
(b) Chilled water cooling coil
(c) Supply air fan
8.1 Casing Construction
Units shall be Modular Air Handling Units, utilizing rigid double skinned panels with integral
frame. Panels shall be of 50mm thickness.
Unit dimensions shall be based on standard internationally recognized filter size multiples of
305mm and 610mm.
The unit casework panels shall have staggered assembly to ensure resistance to torsion and
stability of unit operation at all pressures up to 2000 Pa, for either draw-thru or blow-thru.
Each panel shall be totally double skinned using a standard 0.5mm galvanized sheet steel for
both the internal and external surfaces and pre-painted.

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Each panel shall contain a minimum of 50mm thick, fibre glass insulation slabs having a
minimum density of 48 Kg/m3. Insulation shall be held in place both mechanically using studs
and chemically using adhesive on both panels.
Each panel shall have a maximum heat transfer coefficient "U" value of 1.02 W/m2K or 0.87
W/m2K depending on the panel thickness. The minimum sound transmission loss shall be 32
dB.
Each panel shall have its own pre-formed, integral frame complete with galvanized steel
captive nuts for assembly. The panel shall be constructed without welded seams, spot welds
or open leading edges to ensure good corrosion resistance.
The complete assembled casing shall be mounted on a continuous base frame constructed
from galvanized steel.
Access doors or removable panels shall have the same construction as the unit-case work.
Hinges and cam-lock fasteners shall be made from a tough, durable synthetic plastic. Each
door shall have a hollow body rubber edge seal (12mm wide), mechanically bonded to the
door edge.
Weatherproof units for outdoor installation shall utilize galvanized double skinned panels
50mm) with stiffening sections and rubber seals fully integrated into each panel. Sandwich
panel shall be totally enclosed and rot resistant without rough edges giving smooth interior
and exterior surface.
Weatherproof units shall have the panels assembled on a channel base frame. Hot dipped
galvanized sloping roof with 100mm overhang shall cover the entire unit.
Outdoor units handling fresh air shall be provided with galvanized steel or aluminium sand
trap intake louvre having a bird screen. Maximum louvre face velocity for fresh air shall be
2.8 m/s.
The capacity of air handling units shall not be less than that scheduled on drawings. The
units shall be draw-through type.
8.2 Fan Section
The case-work shall be standard panel construction as described in Clause 8.1.
Fan impellers shall be forward curved or backward inclined (aerofoil blades) depending on the
duty required. The fans shall be made of heavy structural material. The wheels shall be of
extruded aluminium. Scrolls and bracing shall be of galvanized steel. All fans shall be
statically and dynamically balanced before mounting in the casing.
Fan scroll shall be constructed from galvanized sheet steel.
The fan and motor mounting frame shall be constructed from galvanized steel. The motor
mounting shall allow easy adjustment of the fan belts and be complete with adjustment bolts.

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The complete fan and motor assembly shall be independently mounted inside the section
casing using anti-vibration isolators. Canvas flexible connections shall be furnished between
the fan outlet and the casing.
Fans and shafts shall operate well below their critical speed. Each shaft assembly shall be
statically and dynamically balanced before shipment from the manufacturer. If any out-of-
balance is apparent on site the ADWEA/ENGINEER reserves the right to require new factory
supplied units to be provided until satisfactory balance is demonstrated.
Fan bearings shall be designed for a life of at least 200,000 hours factory pre-lubricated and
equipped with standard grease fittings with extended lube lines if necessary to terminate
outside the unit. Fan drives shall be rated at 150% of the maximum motor horse power of the
units and shall be equipped with adjustment for belt tension.
System will be constant speed, but with adjustable drive pulleys to give plus or minus 10%
from the rated design speeds.
8.3 Cooling Coil Section
The case-work shall be standard panel construction as described in Clause 8.1.
The cooling coil and drain pan shall be removable as one piece, with the coil mounted inside
the tray. The drain pan shall be galvanized steel, and shall be mounted on slide rails for easy
removal and to ensure that the drain pan does not rest on the unit case-work.
Drain pan shall have a threaded, extended connection piece, sealed to the unit casing with
heavy duty PVC gasket. Drain pans shall be of heavy gauge welded galvanized after
manufacture and shall have drain connections on both sides. Drain pans shall be internally
lined with 25mm of closed cell foamed in place insulation which shall extend upto the top
edges, and 25mm of similar insulation on the outside. In the event that any condensation
problems appear after installation, the CONTRACTOR shall apply greater thickness of
insulation to the underside and edges. This is in addition to any other remedial measures
required by the ADWEA/ENGINEER. Any stacked or double height coils shall have separate
drain pans to reduce carry over, such pans will be piped to the main drain, not into the lower
pan.
Cooling coils shall be fabricated using seamless copper tubes of 5/8 inch diameter expanded
into high efficiency aluminium fins to give a mechanical bond. The copper tubes and
aluminium fins shall be tin plated or bly gold coated against corrosion. Return bends shall be
die formed. Header shall be heavy section seamless copper tubing. All joints shall be silver
brazed. Fittings shall include plugged vent and drain tops for each section.
Coil headers shall be fabricated from copper tube. All coil headers shall have threaded,
extended pipe connections as standard, with heavy duty PVC sealing gaskets where the
connections pass through the casing, rendering the joint air–tight.
The coil casing shall be made from heavy duty 2mm galvanized steel.
All cooling coils shall be tested to 31 bar pressure before installation into the casing.
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Drip eliminators shall be provided at coil face velocity of 3 m/s or above. Eliminators shall be
fabricated of heavy duty plastic. Maximum coil face velocity shall be limited to 2.86 m/s.
o o
The coil shall be designed to operate at 15 bar and 300 F (149 C). The performance shall be
not less than that listed in the schedules. The coil shall be assembled in a galvanized steel
housing which is drilled to meet the adjacent sections of the AHU.
Coils shall have a minimum of 4 rows for recirculation service and 8 rows for fresh air service.
Control valves shall be sized, for the relevant authority, and shall be modulating three way.
Humidifiers if required shall be of the stainless steel dispersion type grid with a floor mounted
individual boiler in a lockable steel cabinet. The steam generator shall be modular, cleanable,
with three phase power and adjustable electrodes. The unit shall incorporate an automatic
drain cycle fully adjustable for 15 minutes to 16 hours with 2 second to 2 minutes dump times.
Control humidistat, high limit, interlocks, etc., will be provided. Control is to modulate from 0 to
100% RH.
8.4 Filter Section
The case-work shall be standard panel construction as described in Clause 8.1
The casing shall contain built-in standard filter frames which accept internationally recognised
filter dimensions (multiples of 610 x 305mm) or as specified in the drawings. The filter frame
shall be bolted directly to the unit casing to ensure full utilization of the cross-sectional area.
Flat filter section insert shall be 50mm panel with a sheet metal edge profile. The media within
the 50mm frame width shall be in 'ZZ' form, additionally supported by wire mesh screen on
both sides. Filters shall be permanent aluminium washable type, maintained by side removal
of channels.
Final filter section shall have high efficiency bag filters, maintained by front withdrawal.
Section shall be of 610mm or 915mm length.
Filter section shall be equipped with removable panels or across doors for replacement and
service of the filters.
8.5 Damper Section
The case-work shall be standard panel construction as described in Clause 8.1
The section shall be fitted with dampers for fresh air and return air (exhaust air also if
needed). Necessary linkage between the motorised dampers shall be provided to ensure
good accurate modulation.
Damper blades shall be mounted in a 1.5 mm galvanized steel frame.

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The horizontally opposed aerofoil shaped damper blades shall be made from either
galvanized steel or aluminium with rubber sealing strip, depending on the leakage rate
required.
For standard galvanized steel blade dampers, the leakage rate shall be 1.9% at a pressure
differential of 1000Pa. For aluminium blade dampers complete with rubber edge seals, the
leakage rate shall be 0.5% at a pressure differential of 1000 Pa.
Blades shall rotate by means of ABS plastic cogs without any additional linkage. The cogs
shall act as both the blade drives as low friction blade bearings.
The damper frame shall be provided with a connection flange for duct work. The damper drive
spindle shall be of square section to ensure positive location for the actuating arm.
Weatherproof units shall have a mixing box with internal dampers and internal
spindle/actuating arm.
9. FAN COIL UNITS
Fan Coil Units shall be ceiling suspended type. Exposed units shall be with decorative cabinet
and made of 1.3mm thick galvanized steel, with 15mm internal fibre glass insulation. The
cabinet of exposed units shall be 1.3mm thick steel panels, primed and baked enamel finish
to a colour indicated by the ADWEA/ENGINEER. Concealed units shall have full casing
enclosing the complete fan/motor assembly and the coil assembly with chilled water coil
headers and U-bends completely concealed from sight within the unit casing. Units shall be
constructed of heavy gauge sheet metal with forward curved direct drive centrifugal fans,
cooling coil with manual air vent, 3-speed motor, washable metallic filter which should be
accessible and at the rear panel of the plenum insulated drain pan to cover control valves.
Motor power supply 240/1/50Hz, with maximum 1400 rpm.
Fan coils shall be two pipe, minimum of four rows of copper coils with fans and filters.
Coils will be A.R.I. rated, at least 15mm OD size copper tube with aluminium fins fitted with
manual air vent, leak tested at 300 psi (20 Bar).
Motor shall be 3 speed tap wound with thermal overload protection. Sleeve bearings with oil
tubes and oil reservoirs shall be provided. The motors shall be permanent split capacitor type.
The fan switch shall be located as directed by ADWEA/ENGINEER and should be capable of
remote operation.
Fans shall be centrifugal, forward curved, statically and dynamically balanced, with wheels
and housings in galvanized steel of at least 1.3mm thickness, or cast aluminium.
Drain pans shall be minimum of 1.3mm thick galvanized steel with 25mm of closed cell
insulation to the sides and bottom. Auxiliary drain pan shall be provided for the valves.

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Where noise criteria are specified elsewhere, the fan coils must also meet these
requirements, and the unit cooling ratings will be determined only at those speeds which
produce noise levels within the acceptable limits.
Control valves shall be line sized, or not more than one size less, and shall be three way,
modulating type.
10. PIPEWORK GENERAL
Pipework shall be installed not closer than 229mm (9") to electrical conduits and lighting and
power cables. Pipes will be spaced in ducts, ceilings, voids and plant areas, such that
adequate access is permitted to any pipe for maintenance or removal without disturbance to
the remaining pipework and other services. All pipework shall be arranged to set round piers
and obstructions and minor modifications shall be made as required by the ENGINEER to
circumvent site difficulties.
Pipes will not be solidly built into walls or plaster. Pipe joints will not be positioned within the
thickness of walls, floors or in any other inaccessible position. Pipes passing through walls
and floors shall be sleeved, where they are exposed to view chrome plated covers shall be
fitted. Pipe shall be arranged to follow the contour of walls or beams or other building
structure lines and all vertical pipework shall be plumb, without offsets and set as close as
possible to any local projections consistent with maintaining adequate clearances for
installation of wall plates or insulation.
Pipework shall be installed so as to give the following minimum clearances between the pipe
(or pipe insulation where specified) and adjacent surfaces as follows :-
Walls 25 mm
Ceilings 100 mm
Finished floor: either above top or skirting 50 mm

or if greater 150 mm
Adjacent pipes, both insulated 25 mm
Adjacent pipes, in trench, both insulated 100 mm
Adjacent pipes, both uninsulated 150 mm
Adjacent pipes, one insulated 75 mm
Insulated pipes to adjacent conduit or trunking 100 mm
Adjacent electrical cables not in conduit or trunking 150 mm
Not, withstanding the above minimum clearances, sufficient space shall be allowed to
facilitate easy application of insulating materials. Pipes shall not be enclosed in a common
insulating covering.

Client ADWEA

Unless otherwise specified or detailed on the drawings or as required by the written approval
of ADWEA/ENGINEER, gradients of pipes will not be less than 1 in 250. Pipework will be
installed with gradients to ensure sufficient air removal, via automatic air vents and drainage
for the whole of the system and parts thereof as required to provide these facilities to the
whole Automatic air vents shall be insulated on top of line size bottles.
Screwed joints shall be clean threaded with the bore reamered to ensure the pipe is free from
burrs or obstructions. Ends of pipes which are threaded to receive screwed joints and fittings
will be screwed in accordance with the relevant British Standard Code of Practice. Thread
depths will be as required by the British Standard and will be taper type.
Couplers, unions and fittings will be screwed up to the reduced depth of the thread, such that
no more than three thread-turns are showing when pulled up tight. All jointing materials shall
be kept to the minimum adequate for the joint and the excess will be removed. The
ADWEA/ENGINEER may request the CONTRACTOR to remove the length of pipe and
fittings involved and replace as specified, at no extra cost, where excessive use of jointing
materials is observed.
Caulking of any joint, screwed, flanged welded or otherwise will not be permitted.
All pipes, valves and fittings and connected equipment shall be thoroughly cleaned of rust,
sand and dust, scale and other foreign matter before erection and before any initial fill of
water for hydraulic testing.
Prior to hydraulic testing ,at a time approved by ADWEA/ENGINEER, all pipework systems
including valves, strainers and fittings will be washed through and thoroughly cleansed. Any
washing through of the systems will be carefully carried out employing the various valves to
isolate sections of the systems and items of equipment to prevent sludge or other foreign
matter being unnecessarily carried into parts of the systems and equipment.
All open ends of pipework left during construction will be covered using purpose made caps
or plugs. The caps or plugs will be of design and material best suited for the size and type of
pipe end. Wood, paper or rag materials will not be permitted.
The CONTRACTOR shall locate and remove any stoppage due to foreign matter or air lock
which is found to impede the flow of fluid, either before or after the systems are in operation.
The CONTRACTOR will bear the cost of making good all pipework supports, insulation,
builders work, building decorations and any other damage caused in locating and rectifying
such defects.
All pipework shall be insulated in accordance with the contract drawings and in positions
indicated on the contract drawings to suit the layout of equipment. Pipework shall be neatly
set round to avoid ductwork, cable trunking, drainage and other services, structural beams
and other obstructions as necessary.
Where installation space permits, long sweep bends will be used in preference to round
elbows. Square elbows will be not be used. All made or set bends will have a large radius as
possible, not less than three times the bore and will be free from deformation of the bore and
tube of any undue thinning of the wall of the tube. Unequal tees shall be used in preference to
Client ADWEA

equal tees with separate reducing fittings. Bushes shall not be used. Unequal tees shall be
eccentric pattern on horizontal pipework, and concentrate on vertical pipework. Segmented,
or "cut-and-shut", or any other site manufactured bends of fittings shall not be installed in any
section of the works.
All pulls and sets will be pulled cold on pipework up to 80mm diameter nominal bore, using a
bending machine with the correct formers for the size of pipe used. Hot forged bends and sets
will not be permitted. In limited cases the ADWEA/ENGINEER will give permission for fire
pulled bends or set heated and formed as one operation. The CONTRACTOR will replace as
required by ADWEA/ENGINEER, any bend or set found burnt or overheated, at no extra cost.
The use of fire or cold pulled bends will not be permitted.
The fittings shall be of the easy sweep or twin elbows pattern. Where such a fitting contains
valves or cocks for drainage or venting, square tees may be used. Integral reinforce welded
branch fittings will be easy sweep pattern. Otherwise all branches will be by fittings and will
easily sweep in the direction of flow with brances over 32mm (1-1/4" each) formed by welding
specially made long sweep branch pieces into the prepared pipe.
Reduction in pipe size other than where the pieces are indicated will be by reducing sockets
or tees. These fittings will be of the eccentric pattern to ensure proper drainage and the
elimination of air pockets. Reducing bushes shall not be permitted.
Increase or decrease in pipe diameters required to suit fittings, take-offs and equipment
connections will be formed using taper pieces, flanged as required with taper reduction
located about the axis of the pipe to facilitate proper flow and to allow proper venting and
draining of the pipes. The angle of the taper of such fabricated tapes pieces will not be
greater than twenty degrees (20o) unless approved otherwise in writing by
ADWEA/ENGINEER.
Pipes shall be erected and provided with flanges or unions as specified herein.
Joints will be formed by flanges or union fittings as indicated or as required by the

CONTRACTOR to the approval of ADWEA/ENGINEER to facilitate erection and dismantling
of any item of plant, equipment or section of pipework. Such joints shall also be provided to
facilitate installation in confined spaces in services shafts, plant areas and false ceiling voids.
Mating flanges will be provided to all flanged valves, expansion joints, pumps, plant and
equipment connections. Flanges will be mild steel on black ferrous pipework.
Pipework will be supplied in random lengths unless otherwise called for, straight and free from
blemish and rust. Ends will be screwed to the correct length where screwed pipe is specified
and the ends will be protected from damage by means of half sockets firmly screwed on.
Black steel tubing will receive one coat of primer protective paint at the manufacturers before
shipment.
Where pipes cross building expansion joints or other movement joints then precautions shall
be taken to accommodate this movement by the arrangement of pipework or suitable fitting to
the ADWEA/ENGINEER approval.

Client ADWEA

Drain pipework will be provided from pumps, air cooling coil drain trays, drip glands etc and
taken to the nearest gully as indicated on the drawings. Drain tundishes will be provided at
each drain boss at the item of equipment.
Each drainpipe size will not be less than 22mm (3/4") or as indicated on the drawings. All
necessary rodding points will be provided in the drain pipework for maintenance and removal
of stoppages. All drain pipe will be carried out in uPVC pipes.
Where metallic drain pipework handles condensate water which would be below the ambient
dewpoint, the pipework shall be insulated with 19mm Armaflex insulation to the drain point to
prevent condensation. Plastic condensation drains shall be uninsulated unless otherwise
indicated.
The ADWEA/ENGINEER may at his discretion ask for the removal of installed pipework for
examination. No extra payment will be made when such removal is called for. If the pipework
is found to have been installed in an unsatisfactory manner, then the complete installation
shall be thoroughly inspected and all unsatisfactory sections shall be removed and re-fixed in
a proper manner.
10.1 Chilled Water Pipe Work
Chilled water pipework greater than 150 dia shall be to BS 3601 or schedule 40 with a black
lacquer finish. But welding fittings shall be to 4504 PN16. Flanges shall be to BS 10. Table
"E".
All other chilled water pipework shall be to BS 1387 'Heavy' or schedule 40 (red band)
seamless with black lacquer finish. But welding fittings and flanges shall be as above.
Screwed fittings shall be malleable iron banded, blackheart type to BS 143 with BS 21 taper
internal and external pipe threads. Joints shall be made with "boss white" paste and best
quality hemp.
10.2 Valves
The CONTRACTOR shall supply and install valves in the locations shown on the drawings
and in accordance with the schedule below :
Schedule of Chilled Water Valves
Function Size Materials
Isolation Up to 50mm Bronze

Isolation 65mm & above Cast iron
Double regulation Up to 50mm Bronze
Double regulation 65mm & above Cast iron
Non return valves Up to 50mm Bronze
Non return valves 65mm & above Cast iron
Drain cocks All sizes Bronze
Manual air cocks All sizes Bronze
Automatic air cocks All sizes Bronze
Client ADWEA

Strainers Up to 50mm Bronze
Strainers 65mm & above Cast iron
Commissioning Sets Up to 50mm Bronze
Commissioning Sets 65mm & above Cast iron
Safety valves Up to 50mm Bronze
Plastic or cylindrical small bore automatic air vents will not be deemed to be equivalent.
10.3 Pressure Gauges
The CONTRACTOR shall supply and install pressure gauges on the flow and return
connection of the chillers and a pressure gauge for each chilled water pump. The gauges for
the Chilled Water pumps shall be fixed to a hard wood gauge board fixed at one end of the
pump base. Where a gauge is fixed to a wall or gauge board, back flange will be provided for
the gauge casing. The gauges shall be piped up so that the following pressure can be
observed, pump suction, pump discharge and pump differential. Pressure connections shall
be taken from the pump casing.
Pressure reading points will be provided at the inlet of each cooling coil for commissioning
purpose.
Pressure gauges shall be Bourdon tube type with 10mm diameter dial with needle pointer,
normal operating pointer, brass casing, bronze cyphone and bronze gauge cock, all suitable
for the working pressure of the system. Each gauge shall be calibrated in Bars from Zero to
twice the working pressure at the point selected, all to ADWEA/ENGINEER approval. All
pressure gauges shall be fully tropicalised and fitted with a red indicating needle set to show
the normal operating position.
Pressure reading points for gauges as specified above and temporary gauges for
commissioning will be installed on the chilled water distribution systems as indicated on the
drawings and typical flow diagrams.
Each point will comprise 15mm welded boss, 15mm nominal diameter isolating valve, and
provided with blanking plug with captive chain.
10.4 Thermometers
The CONTRACTOR shall supply and install indicating stem type thermometers as indicated
on the drawings and specified herein.
Thermometers as specified will be installed adjacent to each pressure gauge point as

specified above.
Thermometers will be of the mercury in glass rigid stem type with brass casing all suitable for
o
the working temperatures of the system. Each thermometer dial will be calibrated 0 C to
o
60 C. All thermometer shall be fully tropicalised. The thermometer stems will be provided with
sheaths for inserting into the thermometer pocket fabricated in the pipe service.

Client ADWEA

Thermometer pockets to receive both permanent thermometers as specified above and
temporary thermometers for commissioning will be installed in the chilled water distribution
system as indicated on the drawings and typical flow diagrams and as specified herein. Each
pocket will be fabricated for insertion with a socket welded to the pipe wall. The socket and
pocket will have internal bore sizes to suit the greased thermometer stem. Each pocket on
vertical pipes will be inserted into the pipe at an angle to contain oil or grease for temperature
transmission and to ensure the maximum surface contact with the water flow. Each pocket
socket will be screwed to receive the pocket and will be extended away from the pipe surface
so that it protrudes clear of the final surface of the insulating material. Each pocket will be
finished with its end screwed to receive a screwed hexagon dirt plug. On pipework 40mm
nominal diameter and below convenient bends or sweep tees will be used to receive the
pocket. Such fittings will not be less than 50mm nominal diameter with the part of the pipe
receiving the pocket increased to 50mm. All pockets will be fabricated in bronze hexagon nut
welded thereto.
10.5 Welding
Welding may be carried out by the electric arc or the oxyacetylene welding shall be in
accordance with "Recommended Practice for Oxy-Acetyline Welds in Mild Steel Pipe Lines"
issued by the Associated of Heating, Ventilating and Domestic Engineering Employers, or BS
2971 for Class II arc welding.
All welders shall be experienced in this particular class of work for a period of not less than 12
months immediately preceding the commencement of the welding work called for in the
specification.
The CONTRACTOR should make particular note that the special attention will be paid to the
quality of welding and frequent inspection will be made to ensure that this maintains the
highest standard.
The ADWEA/ENGINEER reserves the right to call upon the CONTRACTOR to demonstrate
the quality of the welder's work, to submit welded samples for further examination and to cut
up to 1% in number of the welds for inspection if required.
CONTRACTOR shall include for radiographic examination of up to 5% of welds in pipes of

50mm size and above if visual inspection indicates they may be below standard.
Ultrasonic testing of welds may be carried out only with written permission of the
ADWEA/ENGINEER. No sharp or gusseted bends will be given to ensure that there is no
obstruction by welding metal or pipe projection and to see that full bore is maintained in all
directions.
In all cases where branches are attached on site, the welding will be carried out at floor level
in a down hand position.
Welding fittings, tees, reducers, etc. of correct type will be used in all instances where these
are obtainable. In other cases, no branch connection will be made unless the pipes to which
it connects is two sizes larger. Flanges will have welding necks or be slip-on type welded
back and front.
Client ADWEA

10.6 Supports
The CONTRACTOR will support all necessary supports, pipe hanger rods, clips, rollers pipe
saddles and chairs as required for the efficient support of the systems pipework together with
the special supports as indicated on the drawings and specified herein. Pipe supports will be
graded in height and drop length to provide the correct grading of levels for the elimination of
the air from the systems and to allow proper drainage therefrom. Pipe fixings, supports and
hangers will be installed at intervals not greater than as specified in the schedule below.
SCHEDULE
Horizontal
Pipe Size Vertical Support
Pipework Support Spacing
mm dia. Spacing Metres
Metres
Mild Steel 15 2.1 2.2
20 2.1 2.2
25 2.1 2.2
32 2.4 3.0
40 2.7 3.3
50 3.0 3.6
65 3.3 3.9
80 3.6 4.1
100 4.2 4.8
125 4.8 5.4
150 5.2 5.8
200 5.8 6.4
250 6.3 6.6
Single mild steel rod pipe hangers will be fabricated to support the loads as specified in the
schedule below. Double mild steel rod hangers / support brackets for horizontal pipes will
have each rod size one size smaller than specified in the schedule. Double mild steel rod
hanger / supports brackets for vertical pipes have a rod size as specified in the schedule.
Vertical pipes will be stayed from the wall with not less than two pipe clips spaced equally
between the finished floor slab level and the soffit of the slab of the upper floor level. Pipe
clips for copper tube will be constructed from gunmetal.

Client ADWEA

SCHEDULE
Single Rod Hangers Maximum Loads
Rod diameter 12 mm 15 mm 19 mm 22 mm
Welded eyerod 150 kg 300 kg 550 kg 850 kg
End threaded 300 kg 600 kg 1000 kg 1500 kg
Pipe support locations will coincide where practicable with the positions of flanged joints,
sockets or union, branch pipe positions and adjacent to valves such that the adjoining
pipework will not be strained. The positioning of supports will allow access for maintenance.
Pipework fixed to wall in rooms other than plant areas will be supported by malleable iron
brackets with split type pipe holders. The brackets will be grouted into walls. Drilled
backplates will be provided when the bracket can be more neatly screwed to wooden backing
pieces or woodwork or ironwork. Pipe brackets for copper tube will be constructed from
gunmetal.
Vertical pipework fixed in service shafts and plant areas will be supported by "U" bolts bolted
to channel sections bolted to walls as indicated on the drawings.
All pipe and duct supports shall be hot dipped galvanised after fabrication.
10.7 Pipework Identification
All pipework in any area other than in habitable rooms, stores or offices shall be painted in
colours and paint types in accordance with the requirements of BS 1710. Direction arrows
indicating the direction of flow and colour bands in accordance with BS 1710 will be painted
on all pipework runs at 13m centres and close to all valves and branch connections.
In addition to painting as specified English lettering shall be painted on all services pipework
and equipment at locations approved by the ADWEA/ENGINEER. The lettering will denote
the contents of the bore of the pipe or vessel and the plant so marked. The painted signs
shall be carried out by an approved sign writer.
The manual, automatic valves and pump strainers will be identified with a valve code number
related to the valve schedule forming part of the Operating and Maintenance Manuals.
The CONTRACTOR will provide labels for each manual valve and automatic valve with the
code number as specified above engraved thereon. Each label tag will be sized to contain
15mm size lettering. The engraving will be in white on black laminated plastic material. The
labels will be secured in an easily visible position on the valve stem or handwheel secured
with a single brass ring such that the valve operation is unaffected.
All items of plant shall be labelled with traffolite labels giving the plants reference number in
50mm high letters.

Client ADWEA

11. THERMAL INSULATION ON PIPEWORK
Thermal insulation shall be applied to the following services :
a) Chilled Water
b) Condensate drains
Insulation thickness shall be as follows :
a) Chilled Water:
In conditioned spaces:
15 – 50 mm pipe dia. 25mm thick
65 mm upwards pipe dia. 32mm thick
b) Condensate drains – all sizes 13mm thick
Thermal insulation shall be applied to all chilled water flow and return pipework and to all
condensate drains.
Insulation shall also be applied on chilled water systems to all flanges, valves, pump bodies
and any other plant or equipment where heat gains or condensation are likely to occur.
The insulating material for chilled water pipework shall be non-absorbent, non-hydroscopic foil
faced phenolic foam pre-formed pipe sections having a minimum density of 35 kg/m3 and a
maximum thermal conductivity of 0.03 W/mºC. The sections shall be neatly fitted to the pipe
with a continuous application of quick-setting non-flammable adhesive. All foil laps shall be
similarly secured, and all circumferantial joints shall be sealed with 50mm wide self-adhesive
aluminium foil tape. The sections shall be cut and neatly mitred around bends, or
alternatively pre-formed bends may be used.
On chilled water services only, all flanges, valves etc. shall have purpose made removable
insulated boxes constructed from 0.8mm thick aluminium sheet constructed so that when in
position the vapour barrier over the insulation is maintained.
The insulating material for condensate drains shall be black flexible closed cell elastomeric
material with a maximum thermal conductivity of 0.03 W/mºC, and having a BS476 Class I
Surface Spread of Flame rating. The material shall be supplied as pre-formed pipe sections,
in tubular or pre-slit form, and shall be applied in accordance with the manufacturers
recommendations using a non-flammable adhesive. All exposed insulation shall be given two
coats of chlorosulphonated polyethelene paint.
11.1 Thermal Insulation – Vapour Barrier Coatings
All insulation on chilled water pipework shall be covered with two coats of a brush-applied
sealant, with a heavy duty canvas embedded into the first coat. A further two coats of a
vapour barrier finishing sealant shall then be applied.
Client ADWEA

All insulation on external chilled water pipework shall be covered with two coats of a trowel or
hand-applied weather proof vapour barrier mastic, with an open weave glass cloth embedded
into the first coat. The mastic shall be applied at a rate of 1 litre per sq.m for the first coat and
1.5 litres per sq.m for the finish coat to give a total dry film thickness of 1mm.
All sealants and vapour barriers shall have a BS476 Class I Spread to Flame rating.
All insulation in plant rooms or exposed externally shall be additionally protected by 0.8mm
thick aluminium sheet covering.
Load bearing inserts shall be incorporated into the insulation where necessary at support
points.
Full details of the proposed insulation, adhesive, coatings, sealants etc. shall be forwarded to
the ADWEA/ENGINEER for approval.
All insulation shall be applied in a neat and workmanlike manner by operatives skilled in this
trade. Any part of the insulation installation which is not the ADWEA/ ENGINEER approval is
to be stripped, removed from site and replaced by new materials to the ADWEA/ENGINEER's
approval at the CONTRACTOR's own expense.
12. VIBRATION ISOLATION
All plant and equipment shall be isolated from the building structure in such a manner that
noise and vibration is not transmitted trough the structure.
Anti-vibration equipment will be manufactured by a specialist company acceptable to the

ADWEA/ENGINEER and with standard ratings information available.
The CONTRACTOR shall submit to the ADWEA/ENGINEER for approval vibration

calculations for all equipment mounted on spring isolators and inertial bases.
The following requirements are minimum requirements and must be confirmed by the
Specialist Manufacturer's representative as being adequate for the particular equipment
proposed by the CONTRACTOR.
12.1 Pumps
Water pumps shall be mounted on inertia type bases supported on open type spring isolators
with equal stiffness in horizontal and vertical planes. They shall be supported on 10mm thick
ribbed neoprene Vibropad and will be colour coded to aid identification.
They will also have level adjustment screws and be rated for 75% more than the anticipated
design load.
The spring shall be located between the housing pad and concrete inertia base. The inertia
base for each pump shall be mounted on springs designed to give a static deflection of 25mm
at rated design load conditions, and shall be fully independent of any adjacent pad.

Client ADWEA

12.2 Air Handling Unit Floor Mounted
Floor mounted air handling units shall be mounted on open spring type hangers with 25mm
static deflection, equal stiffness in horizontal and vertical planes and a 10mm neoprene
Vibropad base. They shall have built in levelling screws and limit stops, and colour coding to
aid in identification. Units with motors over 15 H.P. shall in addition have a concrete inertia
base.
12.3 Air Handling Unit Suspended
These shall have box type spring isolation with level screws and neoprene snubbers. Spring
will be colour coded to aid identification.
Springs will be rated for 50% more than the design load and shall have a static deflection at
this design load of 25mm.
12.4 Piping
All piping connected to isolated equipment shall be supported with isolation hangers for at
least the first three points of support on all sides of the equipment.
The first point shall have a static deflection of twice the equipment deflection except that the
deflection of this point shall not exceed 50mm (with pipe work full).
The second and third supports shall have deflection of 25mm each.
For suspended piping, springs will be box type spring hangers with snubber, level
adjustments, and colour coding.
For low level piping mounted on roller system, the isolators will be open type springs with
equal stiffness in horizontal and vertical planes.
In addition, flexible connection shall be included at inlet and outlet to all items of equipment.
Flexible connections will be of full line size and will be flanged with gaskets and mating
flanges.
The connection will be a single piece leakproof seamless neoprene tube, moulded on a
copper coated steel-write spring reinforced carcass.
The connection shall be rated for services at 180ºF (82ºC).
Sizes of less than 150mm and over shall accommodate 40mm axial deflection with 25mm of
lateral deflection.
12.5 Chiller Plant Vibration Isolation
Each chiller will be mounted on Restrained spring isolators.

Client ADWEA

Each spring isolator being selected to meet the specified static point load as detailed by the
original equipment manufacturers and will provide a static deflection of 50mm.
13. ANTI-VIBRATION MOUNTING
13.1 Caged Spring Mounts
Each mounting shall consist of cast telescopic top and bottom housings containing one or
more helical steel springs of 50mm minimum diameter, as the principal isolation elements.
The mountings shall incorporate a built-in levelling device, and resilient inserts as guides for
the upper and lower housings.
The bottom plate shall be fitted with a 6mm thick neoprene pad bonded to it to reduce high
frequency flanking. When in use with equipment having a fluid weight in excess of 25% of the
total empty equipment weight suitable hold-down or restraining devices shall be incorporated.
All spring mounts shall be designed such that the lateral spring stiffness is equal to the
vertical stiffness. The static deflection shall be chosen to suit the vibration frequency.
The mountings shall also be selected for all items of plant with stiffness to cater for any
eccentric weight distribution over the unit base. An equal static deflection shall be provided
on all mounts, to avoid the possibility of flanking caused by the plant tiling and rendering one
or more of the mounts "solid".
13.2 Rubber Mattress
Where rubber mattresses are indicated they shall be of the studded rubber carpet type loaded
to 24 kg/m2 using an insitu or precast concrete overslab.
13.3 Resilient Hangers
All resilient hangers shall be of the two element design, with helical spring and neoprene-in-
shear elements mounted in a steel cage pre-drilled and taped at top and bottom to receive
threaded hanger rods.
13.4 Rubber or Neoprene Mounts
The mountings shall consist of a steel top plate and base plate completely embedded in
colour coded neoprene for easy identification of rated load capacity. The mountings shall be
moulded with non-skid ribbed construction on the top plate and base plate to eliminate the
need for bolting. All mountings, however shall be equipped with bolt holes in the base plate
and tapped holes in the top plate so that they may be bolted to the floor and equipment where
required.

Client ADWEA

13.5 Plant Bases
a) Anti - Vibration Rails
An A.V. rail shall comprise a steel beam with height saving brackets at each end. The
steel sections must be sufficiently rigid to prevent undue strain in the equipment.
b) Steel Plant Bases
Steel plant bases shall comprise an all-welded steel framework with sufficient rigidity to
provide adequate support for the equipment. The frame depth shall be approximately
1/10 of the longest dimension of the equipment with a minimum of 150mm. This form of
base may be used as a composite A.V. rail system.
c) Concrete Inertia Base
These shall consist of an all-welded steel framework with height-saving brackets, and a
frame depth of approximately 1/12 of the longest dimension of the equipment, with a
minimum depth of 150. The bottom of the frame shall be blanked off, and concrete
3
(2300 kg/m ) poured in oversteel reinforcing rods positioned 35mm above the bottom.
The total weight of the base shall be at least 1.5 times the equipment total weight.
Pouring forms for split case pumps shall be extended in width to allow for provision of
supports for suction and discharge elbows.
14. AUTOMATIC CONTROLS
14.1 General
The CONTRACTOR shall include in his tender for an Automatic Control System to be
supplied and engineered by a Specialist Controls Supplier (S.C.S.). In his choice of S.C.S. the
CONTRACTOR must ensure that all systems to be supplied are fully and exactly compatible
with the specification.
The S.C.S. shall be responsible to the CONTRACTOR for the entire control system. He shall
allow for the supply, installation and commissioning of all items and materials necessary to
achieve the control functions defined in this section and elsewhere in the specification.
Subject to the ADWEA/ENGINEER's approval, control systems may also be supplied by the
manufacturer of the equipment being controlled. Such manufacturer shall be subject to the
same terms and conditions as the S.C.S.
The S.C.S. as a specialist, will be aware of, and will include for any special services or
conditions arising from any equipment to be supplied by the CONTRACTOR, whether the
originally specified item or any proposed and approved alternate.
When the S.C.S. staff are on site they shall work in close harmony with all other trades and
shall assist all other sub-CONTRACTORs in works associated with the overall control system
installation.

Client ADWEA

The S.C.S. shall include in his costs for the preparation of all drawings, manuals, record
drawings and labels as specified. He shall allow for the regular attendance on site of a
qualified engineer to provide technical liaison during the currency of the installation and
ensure complete testing, commissioning, cleaning, making good and handling over the works
as detailed in this section.
The entire control system shall be complete with all necessary control devices, thermostats,
valves, motors, relays, switches, dampers, panels, low voltage wiring, electronic components,
etc., to provide the functions as described in this specification or required, whether specifically
mentioned or not. All controls shall be the product of one manufacturer, unless otherwise
approved in advance.
The control system shall be installed or supervised complete in all respects by competent
mechanics, regularly employed by the manufacturer of the control system.
All automatic control valves and dampers shall be manufactured by the control manufacturer
or as otherwise specified and shall be installed in pipelines and ducts by the respective trade
under the supervision of the control manufacturer. All electric wiring in connection with the
control system shall be installed as hereinafter detailed.
Complete drawings shall be submitted to the ADWEA/ENGINEER for approval before any
field installation is started. Such drawings shall give complete descriptions of all control
elements and shall show complete schematic wiring diagrams including functional description.
Drawing shall indicate specifically the type of finish of all room exposed controls, and such
finish shall be subject to the ADWEA/ENGINEER approval.
14.2 Thermostats
All thermostats except where separately indicated shall be fully proportioning and shall have
o
adjustable sensitivity range and a scale range of at least 16 C. The control point shall be
adjustable above and below its intended setting.
Thermostats shall be capable of controlling within plus or minus 0.8 degrees C but shall be
responsive to a 0.14 degree change.
In all areas served by central units, thermostats will be located in the return air stream, with
set point adjustments located in the occupied space. The set-point adjustment shall be of the
indicating type with temperature marked in degree C.
In private offices and areas set points will be accessible and adjustable. In public areas the
set-points will require a key for adjustment and thermostats shall be housed in lockable glass
covers.
Where indicated on the drawings, and as generally required, potentiometers are to be

installed. The potentiometers are to be of solid polished brass, with the wording and symbolic
representation engraved into the material and filled. The wording shall be in both Arabic and
English languages. The adjustment knob is to be of knurled brass. The style and design of the
brass mounting plate to the potentiometer is to match the type used in the electrical

Client ADWEA

installation, but in all respects the design, workmanship, finishing, etc shall be to the approval
of the ADWEA/ENGINEER.
Potentiometers shall act in conjunction with ancillary controls as required. All duct type
thermostats shall be fully proportioning and shall have adjustable sensitivity range of at least
10ºC. The control point shall be adjustable 8oC above its intended setting.
Duct thermostats shall be capable of controlling without hunting and shall respond to a
o
change of 0.14 C.
The control elements of duct thermostats shall be mounted centrally inside the return duct or
casing to measure the air temperature and this sensing shall be transmitted to the control
mechanism located on the local control panel.
In areas where decoration is to be done as a separate contract, wall mounted thermostats or

other controls may possibly be relocated by the ENGINEER. For these areas all controls shall
be concealed type, with a remote reset facility at a location to be confirmed later. It is the
responsibility of the CONTRACTOR to coordinate with the sub-CONTRACTORs to confirm
which areas are affected.
Thermostats for FCUs shall be provided with ON/OFF and multi-speed control facilities.
14.3 Indicating Thermometers
Non-remote thermometers as called for in the specification shall be flush mounted in

appropriate locations. These thermometers shall be of the dial type, minimum 88mm dia., with
remote bulb, liquid fill ore pneumatic transmission type, uniform scale, of suitable range and
employing the same type of sensing elements as the duct thermostats.
For remote thermometers, all transmitters shall be capable of measuring the duct or space
temperature and transmitting a signal directly proportional to the temperature. The range of
transmitters shall be 16ºC.
Each transmission system, (transmitter and receiver) shall have an accuracy of 1% of scale
range. All transmitters shall be located at the point of measurement.
14.4 Automatic Control Valves
All automatic control valves shall be fully proportioning with modulating plug or "V" port inner
guides, unless otherwise specified. The valves shall be quiet in operation and drive to closed
in the event of control system failure. All valves shall be capable of operating at varying rates
of speed to correspond to the exact dictates of the controllers and variable load requirements.
Full stroke time shall be between 20 seconds and 250 seconds.
Motorised valve for chilled water pumps and FCU shall be Modulating type.
The valves shall be capable of operating in sequence when required by the sequence of
operation.

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All control valves shall be sized by the control manufacturer to meet the change and cooling
loads as specified and calculated. The nominal valve size however shall be not more than
one size less than the line size into which the valve is installed, or the equipment connection
size to which it is connected.
All control valves shall be suitable for the pressure conditions and shall close against the
differential pressure involved. All control valves shall have throttling guides and renewable
seats and discs. Valve operators shall be the same manufacturer as the valve and shall be
specifically designed for the valve selected. Body pressure rating and connection type
(screwed or flanged) shall conform to the pipes schedule into which they are located.
15. TESTING AND COMMISSIONING
The CONTRACTOR will balance, regulate and set-to-work the chilled water system strictly in
accordance with ASHRAE Standards.
Pro-forma test sheets and data log sheets will be submitted to ADWEA/ENGINEER for
approval before the commencement of commissioning.
The CONTRACTOR will complete records of all commissioning data for including in the
Operating and Maintenance Manuals.
The CONTRACTOR will thoroughly clean out all pipework and items of equipment before
starting any equipment or commencing any commissioning of the system.
The CONTRACTOR will position dampers, calibrate thermostats, tension vee-belts and fit
alternative pulleys as required, to ensure the correct functioning of the air conditioning
systems in accordance with the design criteria as specified and air volumes.
The CONTRACTOR will, when the chilled water systems and equipment have been put in
working order, demonstrate that each item of plant is functioning correctly in accordance with
the Specification and will make any adjustments to ADWEA/ENGINEER approval.
The CONTRACTOR shall provide performance test certificates in triplicate for specialist
equipment together with a complete set of records indicating all plant settings air volumes for
each fan, grille, hood, etc., temperatures, water flow rates, pump and fan heads and noise
level readings together with the respective design values. The CONTRACTOR shall carry out
the performance test of the complete HVAC system in peak summer condition for minimum
five consecutive days without failure of the plant. All necessary pressures, temperatures and
humidity shall be recorded.
All hydraulic testing of pipework shall be to a pressure equivalent to twice the working
pressure. After the pressure is obtained, the test rig shall be disconnected and the pressure
shall not fall more than 2½ % of the test pressure in two hours.
The CONTRACTOR shall allow for testing the installations in whole or in part as necessary to
facilitate the progress of the Works by other trades or to enable the Works to be
commissioned in sections and no extra cost will be allowed for testing in part.

Client ADWEA

Any fault discovered during such tests shall be at once remedied by the CONTRACTOR at
his own expense and the test re-applied until the CONTRACTOR or his representative is
satisfied that the section under test is sound.
15.1 Test Instruments
The CONTRACTOR shall provide all the test instruments required for the commissioning as
specified and will demonstrate the accuracy of such instruments before the commissioning is
carried out.
The test instruments provided will include the types as specified below :
(a) Electronic Direct Reading Anemometers
(b) Inclined Gauge Manometers with Pressure Ranges to suit Fan Duties
(c) Pitot Static Tubes to suit Duct Sizes
(d) Mercury in Steel Thermometers
(e) Dry Bulb Temperature Recorders
(f) Combined Temperature and Humidity Recorders
(g) Ammeters
(h) Tachometers
15.2 Pipe Lines Testing Methods
Hydraulic pressure tests of pipelines may be carried out on individual sections of the pipelines
provided that the complete system comprising all the sections of the pipework and equipment
and fittings are subsequently tested in whole as specified.
Equipment will not be subjected to test pressure above the maximum test pressure to which
the item has been tested at the manufacturers.
Pipelines under test will be filled with fresh water.
Each section or part of the total system will be hydraulically tested as specified provided it is
isolated from the sections or parts of the total system using caps or temporary blank plates
between flanges. Flanged joints will be provided at strategic points in the systems to enable
such section pressure tests to be carried out. No test pressure will be exerted on closed
valves.
No hydraulic tests will be carried out until all the air has been vented from the system or
sections thereof. Joints or connections which leak during tests will be tightened. If leaks
prevail from tightened joint or connection the test will be stopped and recommended after the
joint has been dismantled, rejointed and made good. Welded joints will be hammer tested
under pressure.
Client ADWEA

After pressure tests have been completed to the ADWEA/ENGINEER's approval the
CONTRACTOR will drain the test water and clean out the system of tests pipework removing
all scale, dirt, sand and other foreign bodies. All traps, dirt pockets, filter screens, vent pipes
and non-return valves will be cleaned out and flushed through before any part of the system is
put into commission.
No hydraulic test water will be put into system to be tested until cleaning has been completed.
A minimum time of four hours after the completion of welding and brazing and final securing
of supports and brackets will be allowed to elapse before the part of the system to be tested is
filled with water.
The hydraulic test(s) pressure(s) will be slowly increased until it reaches a pressure of 1-1/2
times the working pressure. This test pressure will be maintained for two hours or greater time
as required to permit a full and detailed inspection of the system under test during which time
the test pressure gauge reading will not vary.
15.3 Chilled Water System Commissioning
In addition to the hydraulic tests as specified, the CONTRACTOR shall carry out all necessary
head tests, pressure tests and water flow tests to commission and establish the required
operating water flow to serve the various items of equipment.
The balancing of the water flow shall be established by regulating valves and control valves to
balanced positions computed from temperature and pressure readings taken from the various
permanent and temporary commissioning points for temperature and pressure indications
installed in the systems.
The pumps, and all regulating valves will be manufactured to know pressure flow curves
which will be provided for each pump and type and size regulating valve. This will enable the
flow rate to be established by the operating differential of each pump and double regulating
valve.
16. DESIGN, SHOP AND AS-BUILT DRAWINGS
The CONTRACTOR will furnish Design, Shop and As-built drawings in accordance with the
requirements of Specification for design ,shop and as-built drawings.
The CONTRACTOR shall prepare 'As-Built' drawings for the whole of the installations and
shall incorporate them in the Operational and Maintenance manuals.
The 'As-Builts' drawings shall show the complete installation, with full information on each
plant item, position of access, and location of electrical local isolators and shall include a
diagram of the complete system, each item of plant with its name, and each valve with its
number. The diagram shall also indicate the approximate location of each valve and plant
item.

Client ADWEA

17. OPERATION AND MAINTENANCE MANUALS
The CONTRACTOR will provide Operation and Maintenance manuals in accordance with the
requirements of Operational and Maintenance Manuals.
The CONTRACTOR will provide seven sets of operation and maintenance manuals and user
guide manuals.
In addition to the manuals as specified the CONTRACTOR will provide two sets of operating
and maintenance instructions and manufacturer's leaflets for each item of plant and
equipment prior to the site testing of that item of plant or equipment. Such information will be
used by the CONTRACTOR to assist in the site testing and commissioning of the plant and
equipment and for the training of the Employer's maintenance personnel.
18. SPARES
The CONTRACTOR will supply Spare Parts in accordance with the requirements of the Spare
Parts List.
The CONTRACTOR will fit replacement filter rolls and panels as required during
commissioning.
At the time of ordering each item of plant equipment, valves and fittings required for the
works, the CONTRACTOR will provide a manufacturer's recommended list of spares for the
items so ordered.
The spare parts will be delivered at the site together with the items of plant and equipment
appertaining thereto. The CONTRACTOR may use the spare parts as required during
commissioning procedure. Any spare parts used in such a manner will be re-ordered by the
CONTRACTOR and air-freighted to the site.
The CONTRACTOR shall guarantee a local supply of spare parts of every item during the
time of construction and for a period of two years from the date of hand-over of each building.
The parts shall be supplied and installed at no cost to the Client during the two year period.
19. WARRANTY
All Airconditioning and Ventilation Equipments shall be warranted for a period of minimum 1
year from the date of commissioning.
The compressors for Air Conditioning units shall have a special guarantee of five years from
the contractual completion date and complete compressor shall be replaced if found defective
during guarantee period.

Client ADWEA

20. QUALITY CONTROL
20.1 Quality Control
Vendor shall comply with the requirements stated in the Specification for Vendor's quality
control management.
20.2 Inspection and Testing
In general factory tests for the various Chilled water system components (Chillers, AHU,
pumps etc.) shall not be repeated but certificates and factory test data shall be made
available.
After field installation of mechanical equipment, piping, ducting and control system, the
vendor shall perform all tests as specified here in and shall demonstrate the satisfactory
operation and performance of all systems components.
The following tests shall be performed:
• Visual check of all components/equipment according to specification and final drawings.
• Electrical tests to verify the continuity and operation for all installed electrical systems.
• Chilled water system pressure testing.
• Control system test to verify satisfactory operation of any automatic or manually

operated sequence.
• Performance testing for Chiller.
• Final test for balancing by recording chilled water temperature and flow. All systems shall
be kept in operation for a period of five days during which time the final test shall be
carried out.
21. VENDOR'S DOCUMENTATION
The vendor shall submit the following documentation, in English language, along with the
supplied equipment and materials as applicable.
a) General Description of Materials, Equipment, etc.
b) Engineering Flow Schemes
c) Assembly Drawings for Erection with Overall Dimensions (Weights, Anchor, Details, etc.)
d) Electrical Power Supply and Distribution drawings.
e) Control Panel Drawings.
f) Technical Data, Characteristics Performances

Client ADWEA

g) List of Spare Parts for two year operation
h) Inspection Testing Plan
i) Calculations, Sizing
j) Test Certificate/Documentation
k) Reference for Similar Supply
l) Installation Manual/Installation instructions
m) Operating Manual/Operating Instructions
n) Maintenance Manual/Maintenance Instructions.
Delivery time during offer shall be submitted by the CONTRACTOR and distribution of
documents shall be as per Table 1 in Specification for General Technical Requirements.
22. SCHEDULE OF SUPPLIERS AND MANUFACTURERS
Refer Vendor List document.
23. CROSS REFERENCE BETWEEN SPECIFICATIONS
The CONTRACTOR is to ensure that he considers all the implications of the other Sections of
the Specification in so far as they relate to the specific works included in this Section and
particularly to the Sections relating to Electrical Installations.

Client ADWEA

Specification For Chilled Water Systems

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SPECIFICATION FOR CHILLED WATER

I:\WATER STANDARD SPECIFICATION\COPY OF ADWEA SPECS DEC 05 ED\ADWEA SS\W-H-SS\W-H-SS-003.DOC

0 02-02-2002 Approved Issue

tender: project: document: W-H-SS-003 rev: 0 sheet: 1 of: 36

2. APPLICABLE STANDARDS AND CODES .......................................... 4

3. CHILLED WATER GENERATION SYSTEM ......................................... 5

5. CHILLED WATER PUMPS.................................................................... 9

6. CHILLED WATER PRESSURISATION UNIT ..................................... 10

7. WATER TREATMENT ......................................................................... 11

8. AIR HANDLING UNITS ....................................................................... 11

9. FAN COIL UNITS ................................................................................ 15

10. PIPEWORK GENERAL ....................................................................... 16

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12. VIBRATION ISOLATION ..................................................................... 25

13. ANTI-VIBRATION MOUNTING ........................................................... 27

14. AUTOMATIC CONTROLS .................................................................. 28

15. TESTING AND COMMISSIONING ...................................................... 31

16. DESIGN, SHOP AND AS-BUILT DRAWINGS .................................... 33

17. OPERATION AND MAINTENANCE MANUALS ................................. 34

18. SPARES .............................................................................................. 34

19. WARRANTY ........................................................................................ 34

20. QUALITY CONTROL .......................................................................... 35

21. VENDOR'S DOCUMENTATION.......................................................... 35

22. SCHEDULE OF SUPPLIERS AND MANUFACTURERS.................... 36

23. CROSS REFERENCE BETWEEN SPECIFICATIONS ....................... 36

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2. APPLICABLE STANDARDS AND CODES

Air-conditioning and Refrigeration Institute (ARI)

ARI 410 Forced Circulation Air-Cooling and Air-Heating Coils

American Society for Testing and Materials (ASTM)

ASTM C 552 Standard Specification for Cellular Glass Thermal Insulation

American Society of Heating, Refrigerating, and Air Conditioning Engineer, Inc.

ASHRAE 15 Safety Code for Mechanical Refrigeration

ASHRAE Hand Books

National Electrical Manufactures Association (NEMA)

National Fire Protection Association (NFPA)

NFPA 70 National Electrical Code

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Rubber Manufactures Association (RMA)

Underwriters Laboratories, Inc (UL)

UL 181 Factory-Made Air Ducts and Connectors

UL 207 Refrigerant – Containing Components and Accessories, Nonelectrical

UL 1995 Refrigeration and Air-conditioning Condensing and Compressor Units

3. CHILLED WATER GENERATION SYSTEM

3.2 Design Criteria

Chilled water flow temperature = 6º C

Chilled water return temperature = 12º C

Minimum test pressure on pipes = 6 bar

3.3 Mode of Operation

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The chillers shall be capable of operating up to an ambient temperature of 55ºC with a

Maximum operating pressure of water and refrigerant side shall be 14 bar.

4.3 Aircooled Condensor

Slit or perforated fins will not be accepted.

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