KT&G Indonesia Project - Mechanical General Specification

L I S T
01. General common issues ······································································································· 01
02. Air conditioning duct work ································································································· 26
03. Air conditioning pipe work ································································································· 36
04. Hygienic pipe work ················································································································ 41
05. T.A.B ··········································································································································· 56

KT&G INDONESIA PROJECT MECHANICAL GENERAL SPECIFICATION
Chapter 1 General common issues
1. General issues
1.1 Applicable area

1) This specification is applied to the work for mechanical facility.
2) All work should follow the plans and specification, and if there is difference between
them, this specification precedes all.
3) Every item that is designated in either plans or specification must be executed.
4) If there is no designated issue, it must be reported to supervisor, and received the
authorization.
5) This specification is applied to whole work, and partial work should follow specific
specification.
1.2 Related regulations

All regulations that related to this work follow, and include enforcement ordinance,
regulations, and other provisions.
1) Construction act
2) Fire services act
3) Energy consumption rationalization act
4) Safety management act on high pressure gas
5) Environment conservation act
6) Waterworks act
7) Waste management act
8) Housing construction promotion act
9) Labor standard act
10) Electricity business act
11) Construction business act
12) Gunpowder act
13) Korean industrial standard
14) Industrial standardization act
15) Electricity construction business act
16) Telecommunication act
17) Regulation for electrical facility standard
18) Extension regulation
19) Safety management act for electricity equipment
20) City (provincial) ordinance
21) Other related laws
If there is any difference between the plans and related regulation, the work should
be followed the regulation. If the related regulation is amended during work period,
the work should be changed via revised regulation with prior discussion with the
company.
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1.3 Definition of terms

Terms that are used in this specifications can be defined as follows.
1) The company
It indicates the construction agent for this work [Lotte Construction Co., LTD CM
business division].
2) Supervisor
The one, who is designated by the company, commands and supervises the testing and
inspection for used material or structure.
3) Builder
This denotes the party that carries out whole or partial work through the contract with
the company.
4) Supplier
This explains the one that supplies materials and goods through the contract with the
company.
1.4 Safety management and hazard protection

1) Builder should appoint the person in charge for safety management, and the list and
safety management plan must be submitted and authorized to supervisor 15 days
before from starting construction work. Safety and hazard protection must be ensured
in every aspect of work.
2) Builder should conduct and check on the education and all sorts of issues to prevent
the occurrence of hazard and safety accident during work. If happens, it is responsible
to the builder.
3) Builder should be equipped with perfect safety facility during work. If it is determined
to 'not good' from supervisor, it must be corrected without any additional cost. If the
safety facility is not prepared in perfect, the work cannot be progressed.
1.5 Execution of work

1) All work should be carried out to ensure enough and satisfactory performance in all
sorts of facilities. The reasonably required or regulated items in work, structure, and
appearance should be executed by the responsibility of builder from the direction of
supervisor even if the issues are not listed in plans and specification. At the completion
of work, it must be reflected to cost settlement of completion drawing.
2) Contractor should re-work or modify if the work is recognized as incomplete or unfair
by supervisor.
3) By the circumstance of field, all sorts of directions by supervisor should be performed
immediately.
4) All drawings that are required for manufacturing or construction should be written and
authorized by supervisor prior to work.
5) If special consideration of supervisor is required or the one is buried or concealed, it is
pre-inspected by supervisor. Acknowledged area should be photographed in color.
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1.6 Used materials and equipments

1) All materials and equipments should be used as sequence of designated and KS
certified product(more than product) in principle. If there is no relevant items, they
should be certified product from related government and public offices or KS
corresponding product(more than product).
2) Materials and equipments for energy saving should be manufactured by the registered
company with the energy rationalization act.
3) Builder should submit authorization plan for all material and equipments requiring
acceptance within 15 days of contract. After receiving authorization, acceptance request
should be submitted and authorized at least 30 days before of starting construction.
On authorization plan, the submittal time for acceptance request and authorization
method (sample or catalog cut) should be designated.
1.7 Supplied materials

1) Delivery location for supplied material by the company should be the designated area
at on-site. Transportation within on-site including unloading is handled by the builder.
2) Builder should record delivery list for supplied material from the company, and the list
should be submitted to supervisor on request.
3) Builder has the compensation responsibility on storage, deterioration, insufficiency, and
damaged goods of supplied material.
4) Surplus material from the company should be returned immediately.
5) Details on the supplied material from the company will be provided at bidding stage.
1.8 On-site agent

1) Builder should nominate the technician with certification and vast
experience/technologies on mechanical facility area before commissioning work.
Documents that notify career (resume, copies of certificates, on-site agent list, other
documents, etc) should be submitted and authorized within 7 days of contract, and the
agent should be stationed permanently at the site.
2) Builder should station the requested on-site agent and responsible technicians by work
load at the commissioning of work. Submittal documents for technician are same as
on-site agent, and authorized by supervisor.
3) On-site agent and technicians carry out the responsibility and duty for work progression
and other issues in construction.
4) Supervisor can command the immediate replacement for on-site agent and technicians
if they are acknowledged as inappropriate. If the replacement notification is made, the
responsible person should be reelected as the above item 1).
1.9 Process management and work reporting

1) Detailed process plan of work is written in CPM, and submitted/authorized to/by
supervisor. The work should be conducted according to the plan, and updated in one
time per week.
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2) Daily and monthly report that includes the progression of work, employment of worker,
take in/out of material, various testing, and other issues should be written and
submitted for the approval of supervisor. In addition, the requested document should
be presented in prompt.
3) According to main process diagram, which is submitted prior to commission, monthly
progress plan should be submitted and authorized within 25 of previous month.
1.10 Quality management

1) Builder should present the list of responsible person for quality management and its
plan, which is approved by supervisor within 15 days after contract.
2) Execution quality management plan should denote preliminary, initial, mid-term, final
inspection, etc.
3) Builder should perform thorough quality management according to approved plan.
4) Execution quality manager should be assigned under immediate control of
representative director in builder to balance on-site agent.
1.11 On-site management

1) On-site management should be carried out by the related regulation.
(Labor standard act, Labor safety management regulation and security legislation)
2) Builder should manage the entry of worker and other personnel, and be responsible to
discipline enforcement, hygiene management, fire, theft, noise, casualty, maintenance of
hazardous item.
3) Certified safety manager should be assigned at on-site to prevent safety accident.
4) On-site should be cleaned, and information management on every material and
temporary equipment should be conducted thoroughly.
5) When receiving supplied material, it should be inspected at the presence of supervisor,
and stored under builder's responsibility. If it is stolen and damaged, builder should
compensate the relevant cost.
6) Equipment, material, facility that is prone to be contaminated or damaged should be
protected via appropriate method.
7) After the work is finished, temporary item should be removed and cleaned promptly.
8) Equipment and material that is passed inspection and testing should be stored at
designated location by supervisor. The rejected goods should be carried out from
on-site.
1.12 Blue print and working drawing

1) Builder should write and be authorized for manufacturing diagram or working drawing
at least 10 days before commencing construction.
2) Standard and notation in drawing should follow the direction of supervisor.
3) For major equipments, the working drawing, process diagram, technical specification, etc
should be submitted and approved by supervisor before commencing manufacturing.
4) Working drawing should be prepared with the cooperation of other area at on-site or
nearby area.
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1.13 Design change

1) Design change should conform the contract condition and be authorized by supervisor.
2) If the installing location and method, etc should be changed from on-site condition or
other reasons, the reason should be submitted and approved to/by the supervisor.
3) Builder should perform minute change or required work that is not listed in the plan
within contract price.
1.14 Relation to other works

1) Works that are related to construction and electrical work should be executed through
prior discussion with supervisor. Any setback and failure in other work should be
responsible to the builder.
2) For boring in floor, wall, other building structure and suspending weighted object, the
work should be evaluated on the effect of building structure with discussion of related
supervisor.
3) Builder should discuss and cooperate in utmost scale with specialty facility builder, such
as T.A.B, radiographic examination for efficient job carriage.
1.15 Authority formalities

1) Builder should write and submit every authorization, notification and its due date by
related regulation prior to commencing work.
2) Builder should conduct the required authorization procedure and notification after
completion of building and for construction work, such as licensing work. The progress
should be reported to supervisor at any time.
3) All sorts of cost for license process and notification should be charged to the builder.
1.16 Testing and inspection

1) Testing and inspection should follow this specification, Korean related regulation, etc. If
the related regulation is not registered, the builder should conduct the direction of
supervisor.
2) Required inspection and testing by government and public organization should be
passed.
3) At the designated or requested stage by supervisor, testing and inspection for
equipment and material should be performed. Acknowledged or minute issues with
certification or approval of supervisor can be omitted.
4) Issues that is difficult or impossible to conduct inspection after completion should be
performed at the presence of supervisor. In case of need, the photographic record
should be submitted. Ruler, pole, staff, etc should be placed and photographed to
determine the dimension of subject. Especially the location with impossible or difficult
to conduct inspection or designated by supervisor must be photographed.
(1) Various facility performance testing
(2) Concrete underground pipe
(3) Soil underground pipe
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5) Materials under below items should be approved by supervisor using sample or model.
Title Subject Amount Sample, model
General items Material, color, spec 1ea Sample
Insulation Density 50 ㎝, 1 ㎡ Sample and test result
Piping Material 50 ㎝ Sample and test result
Shock proofing Material 1ea Sample and test result
Equipments Material 1ea Sample and test result
Designated items Material, color, spec 1ea Sample and test result
1st sample A4 size Sample and test result
Paint 2nd sample about 1 ㎡ Model
3rd on-site sample about 1 ㎡ Sample and test result
6) Detailed plan for testing should be designated in quality management plan in 1.10
item.
1.17 Test operation

1) Builder should establish test operation plan according to performance test guideline
after completion of all work. The plan should be submitted and approved by
supervisor prior to 20 days before commencing test.
2) Testing power, water, drain, air supply and ventilation, etc should be processed without
any setback to work progress.
3) Test operation is executed by on-site condition.
Except, test operation time can be changed by circumstance.
4) Builder should remove dust or foreign body from piping and duct before commencing
test operation. After conducting test operation, replacement item should be changed
with new designated one.
5) Builder conduct overall test operation after all work is completed. Comprehensive test
operation result should be submitted and approved by supervisor.
1.18 Completion
1) Completion can be made after no disorder in comprehensive test operation result, no
objection to both parties during settlement, submission of the following documents,
and authorization of supervisor. In addition, it is acknowledged as completion for
partially used or partial completion by the need of the company through the approval
of supervisor.
(1) Completion drawing (including design change): 2 copies of diskette,
2 copies of original drawing A1,A3 (including drawing BOX), 3 copies of blue print
A1, A3, 2 copies of white paper A1, A3
① Systematic diagram
② Plan view
③ Cross-sectional diagram
④ Equipment Layout
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⑤ Detail drawing
⑥ Isometric drawing.
⑦ Line list
(2) Maintenance result report for notification by supervisor and the company (1 ea of
P/C DISKETTE)
(3) Test results or record report
(4) Copy of authorization and permission
(5) All sorts of document that is required for completion
1.19 Maintenance
1) Builder should be authorized by supervisor by submitting 3 copies of completion
documents (original: P/C diskette) including maintenance guideline, repairing tool list,
spare parts list, management personnel plan for facility management and operation.
2) OPERATION & MAINTENANCE MANUAL includes the following items.
(1) Inspection items before operation
(2) Operation guideline
(3) Maintenance and repair guideline
(4) Maintenance management
(5) Other issues for maintenance
Operation & maintenance manual is submitted as CD.
3) Surplus parts during construction site and the parts acknowledged as unnecessary by
supervisor should be carried out from on-site.
1.20 Transfer
1) After completion inspection, various related drawings and documents, test results and
inspection certificate must be transferred to management department.
2) Safety guideline and various labels should be attached in major equipment or required
place for safety and management.
3) Education on management personnel should be conducted for enough operation by
themselves, and cost is charged to builder.
2. Common issues
2.1 Steel and welding work

1) General issues
This section is applied to steel and welding work for sustaining of pipe and temporary
installation of equipment.
2) Material
(1) Steel
Steel must conform the specification of KSD 3503 (rolled steel for general
structure, more than product) and KSD 3566 (carbon steel pipe for general
structure, more than product).
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(2) Bolt
① Material for bolt, nut, washer must conform the specification of KSD 3503 (carbon
steel pipe for general structure, more than product).
② Specifications for bolt and nut are followings.
․ KSB 1002 (hexa bolt, more than product)
․ KSB 1012 (hexa nut, more than product)
③ Washer should be the certified KSB 1326 (plain washer, more than product).
④ Screw in anchor bolt is corresponded to the general one and more than 3 grade
of meter screw(more than product).
⑤ Set of high tension bolt, nut, and plain washer should be the certified KSB 1010
(set of high tension hexa bolt, hexa nut, plain washer for friction adhesion, more
than product).
(3) Welding material should be selected as the following certified product(more than
product) or with enough quality for welding by the condition.
․KSD 7004 (covered welding rod for mild steel, more than product)
․KSD 7005 (gas welding rod for mild steel, more than product)
․KSD 7006 (covered welding rod for high tension steel, more than product)
․KSD 7209 (welding rod for Tig and tungsten, more than product)
․JIS Z 3624 (BCUP-3, more than product)
3) Steel machining
(1) Line drawing
① Line drawing should be precisely executed using shop drawing, real scale drawing,
template, ruler, etc.
② Chisel, carving, punch, etc should not be used at no scratching on surface of
material.
(2) Cutting and bending
① Cutting face should be perpendicular to axis except designated one.
② For gas cutting, the cut face should be trimmed using grinder by considering
final shape, dimension, etc.
③ Thickness of steel plate for mechanical cutting should be less than 9 mm.
④ If crevice, attachment of slag is found at cut face, it must be cleaned.
⑤ Bending machining should be room temperature or heated machining. Heated
machining should be taken place at red heat, and product should not be
quenched.
(3) Correction
Deformation of material or assembled parts should be corrected at each stage not
to damaging the material.
4) Bolt connection
(1) Assembly
① Friction face should be protected with care. If any rust, oil, paint, dust that might
affect on friction are happened or attached, they must be removed before
conducting assembly.
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② Connection part should be closely adhered in friction face and then joined with
bolt.
③ If bolt head or connection face with nut is inclined more than 1/20, toothed lock
washer should be used.
④ Bolt hole is misaligned after temporary assembly, it should be adjusted with
rimmer, and any dregs should be removed cleanly.
(2) Bolt assembly: Jointing tool and testing equipment should use proper dimension of
bolt, and be thoroughly managed.
5) Welding
(1) Welder: Welder should have the certification and more than 2 years of experience in
principle. The one should pass the skill test by supervisor.
(2) Material preparation
① Adjust the poor end finish or severe groove, etc.
② Do not treat welding material disorderly. If cover is detached or damaged,
deteriorated, moisture absorbed, the material should not be used. Especially
permeation in welding rod should be controlled in great care. If any sign of this
exists, the one should not be used at any condition. (treated with welding rod
dryer)
(3) Cleaning of base material
Any moisture, oil, slag, paint, which can affect welding performance, on base material
should be removed.
(4) Execution
① Welding machine and its accessory should have proper structure and function for
given welding condition and safely conduct the welding process.
② Welded area should be free from defect and show smooth surface.
③ Welding procedure should be selected to minimize the deformation and residual
stress from welding.
④ Welding position should be adjusted to downward as possible.
⑤ In some case, the part should be pre-heated by considering material, thickness,
ambient temperature, etc.
⑥ Accident from leakage, shock, arc light, etc or fire from molten metal, arc, should be
prevented during welding work
(5) Confirmation
① Slag on top of welding parts should be confirmed by its removal.
② Any defect in welding parts should be confirmed using non-destructive test if
supervisor requests.
③ Measure dimension and shape of welding metal.
(6) Paint on welded parts
① About 200mm range at the both sides of welded parts should not be painted.
② If the severe rusting is expected at welded parts, the anti-corrosion treatment should
be applied.
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2.2 Safety guideline in welding and cutting work

1) General rules
(1) Every welding equipment and tool should be daily checked. Any damaged tool and
equipment should be replaced or repaired before welding.
(2) During welding work, more than one observer should be in ready. Proper fire
extinguisher and water bin (more than 20 liters) should be in position within 5
meters of working location.
(3) If flammable material is exposed, fire extinguishing equipment (extinguisher and
water bin with more than 20 liters of capacity) should be in near location.
(4) Flammable material and structure should be protected by relocating welding parts
or flammable one to safe place.
(5) Worker and public should be protected from welding light, flash, flame, molten
metal, etc.
(6) Cable hose and other equipment should not be in passage, ladder, and stair.
(7) Concave and convoluted parts should ventilate air or gas before cutting, heating or
welding.
(8) Gas tank should be out of range from flame, hot iron slag, etc.
(9) For cutting, welding, heating of toxic metal in closed location, ventilation facility or
protection device should be equipped.
(10) Oxygen should not be used as ventilation, cooling, dust removal or cleaning of
workplace.
(11) To weld, cut, heat the protective coating, which is not known its flammability,
should be tested the flammability before. If fragments burn up fast, it should be
treated as flammable substance.
(12) Flammable and hard protective coating should be in care for ignition. If the coating
is highly flammable, the coating of welding parts should be removed.
(13) Welding of toxic coated face in closed area should garner the removal of coating
at least 4 inch (10.16 cm) or air hosed mask to worker.
(14) Protective coating should be removed in sufficient thickness to minimize the heating
on non-removed area.
(15) If the conventional fire prevention actions in welding, cutting, heating work is not
enough, additional person should be assigned to watch any fire danger during
welding, cutting, heating.
(16) Aged hose by contact with flame should be tested double pressure than nominal
one. However, pressure should be higher than 300 psi in any circumstance.
(17) Applied flammable paint and other composite should not be heated, welded, cut.
(18) Inflammable partition should be positioned for welding or burning work at vertical
shaft or top of shaft.
2) Gas equipment
(1) For stopping the work, always close the valve and stop the supply of gas.
(2) During work, always remove torch and hose from closed area.
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(3) Oxygen, acetylene, and other fuel gas oxidizing compound should install check valve
between hose and hose.
(4) Gas hose box should be well ventilated.
3) Electrical equipment
(1) Electrical switch for welding machine should be located on top and near to
machine.
(2) Non-conducting portion of metal in welding machine should be grounded.
By evaluating earthing circuit, confirm the current conductance with enough amount
of current to initiate circuit breaker or fuse.
(3) Terminal of welding machine should not be contacted to the body.
(4) Pipe with gas or flammable liquid or conduit should not be used as earthing circuit.
(5) If the wire is not observed by person, the equipment should not be used.
(6) Welding wire with repaired or connected insulation within 3.05 meters from grip
should not be used.
(7) Welding wire should not be near to power supplying line or other high voltage
line.
(8) Welding wire should not be touched with metal scaffold.
4) Arc welding of flammable gas phase in metal
(1) If screen is not available, chlorine-based solvent should be stored at least 60.96
meters away from exposed arc. Applied area should be completely dried before
welding.
(2) Worker that is not screened for arc, should wear filter lens.
If more than two welders are exposed to arc, proper shape of filter lensed goggle
should be wore under helmet. If helmet is raised or protection gear is replaced,
handheld shield should be used to protect welder from flame and radioactivity.
(3) Welder and other employee who might be exposed to radioactivity, should be
enclosed by protective gear to alleviate any burn or damage from ultraviolet.
Welding helmet and glove should not have any hole or high reflectivity on surface.
(4) For metal arc welding for stainless steel, ventilation system and air hosed mask
should be applied to protect worker from nitric oxide.
5) Other industrial safety and health act (executive ordinance) should be followed.
2.3 Insulation work

1) General issues
This section is applied for anti-freezing, insulation of material and work for duct, pipe,
and equipments.
2) Materials
(1) Insulating materials are following.
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Maximum usage
Materials Specification and description Note
temperature
Insulating plate, cylinder, blanket,
400 ℃ for plate, pelt
Rock wool pelt, which is certified by KSF Inflammable
600 ℃ for blanket
4701-4706(more than product)
Insulating plate, cylinder, which is
Glass wool certified by KSL 9102 300 ℃ Inflammable
(glass woo, more than product l)
Other material Inflammable
(2) Exterior material should follow the below table.
Materials Specifications Note
Plain glass fabric specified in KSL 2508

Glass fabric Inflammable
(glass fabric, more than product)
Insulating plate specified in KSL 6705 (aluminum Inflammable

Aluminum thin pipe, more than product) with attachment of (M e ltin g p o in t o f
graft paper a lu m in u m : 6 5 9 ℃ )
Thickness 0.27mm with KSD 3506 (zinc plated steel

Zinc plated
sheet, more than product) and more than 244g/㎡ Inflammable
steel sheet
of standard zinc attachment
Designated color pipe with 0.35 mm of thickness
Colored pipe and 914mm of length specified in KSD 3506 (zinc Inflammable
plated steel sheet, more than product)
(3) Accessory materials should follow the below table.
Materials Specifications Note
Patterned stencil
More than 370g/㎡ of paper board
paper
Attaching more than 370g/㎡ of stencil paper to

Thin aluminum stencil
thin aluminum sheet with 0.02mm of thickness
paper
(reinforced, vapor barrier jacket)
Thickness 0.27mm with KSD 3506 (zinc plated
Zinc steel wire steel sheet, more than product) and more than Inflammable
244g/㎡ of standard zinc attachment
Following KSF 4553 (metal lath, more than

Metal lath Inflammable
product) specification
Proper length of nail with thickness of insulating

Rivet (split pin)
material and plated steel sheet
Adhesive Proper adhesive material
Corner bead More than 0.2mm of zinc plated steel sheet Inflammable
Aluminum band 0.3mm of thickness and 30mm of width Inflammable
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3) Common issues of work

(1) Inflammable material is used as fire stop at partitioned wall or space, pipe passing
area with the regulation on fire protection area and fire wall of building,
(2) For fireproof building, inflammable material of insulator, exterior, accessory material
should be used.
(3) Inspection of material should be taken before commencing work. Thickness should
be measured through pinching needle vertically after drying. In addition, by the
request of supervisor, insulator supplier should cooperate on the random density
measurement.
(4) Anti-freezing covering on the piping of interior fire hydrant, sprinkler, etc should
follow insulating method in fire fighting specification. By winding vinyl on cold
water, dew proofing should be applied before insulating work. Especially, shoe area
must be protected from dew, freezing, etc.
(5) Connection part of insulating material should not have any gap between, and
managed not to be in same line.
(6) Overlapped application of patterned stencil paper should be more than 20mm in
width, and decided by supervisor.
(7) Overlapped width of exterior tapes should be more than 15mm. For vertical pipe,
tape should be applied from bottom to top. Aluminum band is wound in 0.9m gap
for horizontal pipe, and 0.6m gap for vertical pipe. At the each end, tape should
be wound for 2 times.
(8) If steel sheet is used for finish, seam connection for straight pipe, and shrimp back
cover or factory manufacturing forming for round pipe are used. For angular tank,
shell connection is used, and round tank is for insertion connection. Light plate
area is connected through insertion of radioactivity, etc. Especially, connection at
humid interior or exterior, it should be finished with soldering or adhesive.
(9) Floor passing pipe at exterior should be finished with zinc steel sheet at 150mm of
height to protect covering material.
(10) If horizontal pipe is hold by vertical band and dew condensation is expected,
hanger should be insulated with 20mm of thickness up to 150mm of height from
top of pipe.
(11) Saddle is used for insulation of pipe holding area.
(12) Door and inspection hole that requires covering, should be treated without any
retardation of opening and insulation performance.
(13) Work for valve and accessory should follow the insulation work of pipe.
(14) Insulation stand, etc is used for the area where insulation cylinder is not available.
(15) If the thickness of insulating cylinder is not met for specification by special
circumstance, insulating plate and stand with same material should be used.
(16) Every insulating and dew proofing work should be tested by water pressure, and
confirmed by supervisor.
(17) Finishing material should use the designated method and material.
(18) Every aluminum thin sheet (paper) should be reinforced with fiberglass yarn, and
receive the approval before use.
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(19) Required adhesive for all insulating work should be inflammable.

4) Parts not requiring insulation work
(1) Duct
① Open air inlet duct
② Ventilation duct (excluding kitchen room and smoke ventilation duct)
③ Duct having internal insulation except mechanical room
If disparate cooling, heating, power system is used, open air inlet duct and
ventilation duct before passing CHP system will be excluded.
④ fiber glass duct
(2) Equipment
① Package type cooling unit and its condenser
② Package and unit air conditioner with internal insulation
③ Blower for ventilation, open air inlet, circulation, etc
④ Pumps
(3) Pipe, valve, flange
① New connection and flange of steam pipe, hot water pipe, hot water supply pipe
within building and pit
* Drainage and waste water pipe
* Rain water drain (except, horizontal line at ceiling should be insulated)
② Cooling water pipe in refrigerator
(Cooling water pipe, which passes ceiling area of air conditioning should be
insulated, and its thickness is same as water supply pipe)
(4) Hygienic equipment
① Accessory in hygienic equipment
② Pipe for water supply and drainage within concrete (except for surface dew
forming is expected from low temperature of water supply)
③ Drainage at bottom floor and exterior pipe within pit
5) Insulation thickness
(1) It refers the only thickness of insulating material, and does not include the exterior
or accessory material.
(2) If dew proof and anti-freezing is needed at the same time, insulation thickness
should apply for the larger one.
(3) If keep warming and cooling is required at the same time, the larger specification
should be applied.
6) Pipe insulation
(1) Insulating material and its thickness of water supply and fire fighting water pipe for
insulation and dew proof should follow the below table.
Pipe diameter 15 20 25 32 40 50 65 80 100 125 150 200 250 300
Insulation
thickness mm 25 25 25 25 25 25 25 25 40 40 50 50 50 50
(Water supply)
Material Rubber Foam Insulation
14
(2) Insulating material and thickness for heating, boiler, steam pipe should follow the
below table.
Pipe diameter 15 20 25 32 40 50 65 80 100 125 150 200 250 300
Insulation
25 25 25 25 25 40 40 40 40 40 50 50 50 50
thickness (mm)
(3) Insulating material and thickness for cooling water, cold and hot water should follow
the below table.
Pipe diameter 15 20 25 32 40 50 65 80 100 125 150 200 250 300
Insulation
25 25 25 25 40 40 40 40 40 40 40 40 50 50
thickness (mm)
7) Insulation of duct and equipment

(1) Insulating material and thickness for duct
Surrounding condition Insulating material Thickness (mm)
Internal temp Rubber Foam Insulation 25
12℃～40℃
External temp Rubber Foam Insulation 25
12℃～40℃
Relative humidity 70%
(2) Insulating material and thickness (mm) for refrigerator and air conditioner
Surrounding condition Air conditioner Blower Refrigerator

Glass wool 24K 50 50 50
Rock wool No. 1 50 50 50
(3) Duct lining and sound proof thickness
Glass wool 64K : more than 25mm
(4) Insulating material and thickness (mm) for boiler, wayside
Rock wool blanket No. 1: more than 75
(5) Insulation thickness (mm) of header, heat exchanger, flange, valve, etc
Glass wool insulating plate 24K Rock wool blanket No. 1
50 50
(6) Exhaust pipe in hot water supplying boiler, hot water tank, heater
Insulating material Insulation thickness (mm)
Rock wool plate No. 1, blanket
50
No. 1, glass wool plate 24K
15
8) Covering of pipe
(1) Covering for dew proofing and insulation: Covering work for steam pipe, hot water
pipe, water supplying pipe, drainage should use insulating material, which is
described in 2.3.6 of Chapter 1. Material and process sequence for insulating,
accessory, decoration is shown in the below table.
Type Usage Material and work procedure Note
Main mechanical 1) FIBER GLASS
A room 2) REINFORCED VAPOR BARRIER
Air conditioning 3) Super magic tape
room 4) Aluminum band
Buried pipe at 1) FIBER GLASS
B exterior 2) REINFORCED VAPOR BARRIER
1) FIBER GLASS
Exposed pipe at 2) REINFORCED VAPOR BARRIER Anti-smoke
C exterior 3) Super magic tape coating
4) Aluminum band
(2) Covering work for keep cooling: Covering work for cold water pipe, cold and hot
water drainage, fire fighting water pipe should use insulating material, which is
described in insulation of pipe. Material and process sequence for insulating,
accessory, decoration is shown in the below table.
1) FIBER GLASS
D Main mechanical room 2) REINFORCED VAPOR BARRIER
Air conditioning room 3) Super magic tape
4) Aluminum band
Same insulation
1) FIBER GLASS work is applied to
E Buried pipe at exterior exposed pipe at
2) REINFORCED VAPOR BARRIER interior and inside
of pit
Note) Valve, flange, strainer, etc for cold water and hot/cold water should use
detachable zinc plated steel cover (color galvanized iron).
9) Covering work of duct
(1) Insulation of rectangular duct: Insulation covering work for rectangular duct should
use insulating material, which is described in 2.3.7 of chapter 1. Material and
process sequence for accessory, reinforcing, exterior is shown in the below table.
1) Insulation pin
2) Vapor barrier (insulation plate)
A Exposed duct at interior 3) Adhesive
4) Silver foil tape
5) Aluminum band
B Buried duct at interior Same as exposed duct at interior
16
(2) Insulation work of smoke exhaust duct
Exposed rectangular
E Same as general duct
duct
Buried duct at
F Same as general duct
interior for ceiling
10) Insulation of equipment
Material and work
Type Usage Note
procedure
1) Rivet
Manufacturing technical
2) Insulation plate
specification should be followed
G Air conditioner 3) Steel frame
if inflammable board lining is
4) Zinc plated steel
applied as exterior insulation.
sheet
1) Spot welding rivet

Steeled roadway 2) Insulation plate
Aluminum plate or stainless
H Heat exchanger 3) Metal lath
steel plate might be used.
Steam header 4) Galvanized iron wire
5) Galvanized iron plate
1) Rivet or adhesive
Cold/hot water
2) Insulation plate
header Aluminum plate or stainless
I 3) Galvanized iron wire
Cold water and steel plate might be used.
4) Galvanized iron plate
circulation tank
(color)
2.4 Paint work

1) General issues
(1) This section applies to rust protection and finish paint of insulating and metallic
material for duct, pipe, equipment, pipe holder, dew proof.
(2) Paint should be formulated one that can be adjusted by illuminance of background,
temperature, permeability, etc
(3) Holding time for paint work should be chosen by material and weather condition.
(4) Paint materials should be KS certified product(more than product) if available. Only
labeled container should be warehoused.
(5) Rust proofing, anti-corrosion, finishing paint material should not affect on water
quality and non-hazardous if the material may be contacted with water supply.
(6) Finishing color should be authorized by supervisor via presenting sample or sample
book.
17
2) Material
Specification
Paint name Purpose Note
Title No.
Rust proofing paint ALD
General rust Steel, galvanized with specialized rust
proofing tape steel proofing liquid
General primary paint
KSM5311 (1)
Red lead (more than Steel General primary paint
Rust proofing product)
paint Buried pipe requiring
Asphalt paint Special parts water proofing and
corrosion
Oil KSM5312 (1)
Oil color Steel, wood,
formulation (more than Mixing color
paint building interior
paint product)
Polymer resin
KSM5312
Polymer resin paint in Steel, wood Double paint in interior
(more than
Paint white and and exterior, finishing
product)
light color
BP-S White
Epoxy resin Epoxy resin Drinking water pipe and
(more than Steel
paint paint tank
product)
Fire
KSM5312
Fire prevention prevention
(more than General paint Fire prevention
paint paint for
product)
building
General paint in interior
Aluminum Aluminum
Steel and exterior
paint paint
(heat resistant)
Metal
Etching Metal side Steel pre-treatment by
pre-treatment
primer chemical treatment primer
paint
Acrylic paint
Melamine
paint
Water based Epoxy less than 10% of
melamine Steel
paint solvent
Resin paint
Alkyd resin
paint
Oil putty Hole filling
Putty Lacquer
Steel Fast dry, finishing
enamel
Lacquer
Steel Double paint
surfacer
Oil surfacer Steel Double paint
Lacquer paint KSM2611
Industrial General paint
(more than Oil paint
gasoline mixing
product)
Oil General paint mixing Oil paint mixing
18
3) Arrangement work on paint side

(1) Steel
Type Chemical
Section Treatment
A B treatment
Waste and
1 attachment ○ ○ - Removed by scraper and wire brush, etc
removal
○ ○ Wash with gasoline, soapy water, heating with weak

2 Oil removal -
- - alkali liquid, rinse with hot water and gasoline
Chemical treatment right after acid dipping,

○ - - neutralization, hot water rinse, sand blasting
3 Rust removal
- ○ - Scraper, wire brush, grinding paper (#100-180) is
used.
After dipping into phosphate solution, dry and rinse
Chemical ○ - Phosphate
4 with hot water
treatment
○ - Chromate Dipped into chromate solution
Film
5 ○ - - Grind with paper and cloth
arrangement
Note) A = Radiator, inlet, outlet of various panel, boiler, refrigerator, heater or
similar items (baking melamine)
B = Other than above (painted side with formulated paint)
(2) Non-ferrous
Used
Section Treatment
material
Removal of
1 waste and - Removed by scraper and wire brush, etc
attachment
Removal of Wash with gasoline, soapy water, heating with weak alkali
2 -
oil liquid, rinse with hot water
Chemical
3 Primary paint (move to next process without leaving)
treatment
4) Paint types
Paint and number of paint should be as follows.
19
Paint Number of paint

Equipment and Paint types Note
State Primary Double Finishing
accessories
Holding steel goods Exposed Formulated or 2 1 1 Primary paint
(excluding galvanized aluminum paint
one) Buried Rust proofing 1 - 1
Etching primer
Insulating Galvanized
Exposed Formulated 1 1 1 treatment
exterior steel plate
before paint
Excluding galvanized
Insulating metal side - Rust proofing 1 - 1
steel
Galvanized steel pipe Exposed Formulated 1 1 1 Screw
and purpose label of
connection parts Buried Rust proofing 1 - 1
Exposed Formulated 1 - 1
Metallic conduit
Buried Rust proofing 1 - - Peeled off
more than 600℃ of
Chimney - Heat resistant 1 1 1 heat
resistance
Rust proofing for
Formulated or
Pumps - 2 1 1 primary
lacquer enamel
formulated paint
Rust proofing for
Tanks Outside Formulated 2 1 1
primary
Acrylic resin Rust proofing for
Exposed 1 1 1
paint primary
Control panels Acrylic resin Painting before
Inside 1 - -
paint installation
Backside
Paint of boiler and Lacquer or
1 1 1
heater melamine resin
Exterior steel pipe of Lacquer or
1 1 1
heater melamine resin
Rust proofing for
Formulated or
Refrigerator 2 1 1 primary
lacquer enamel
formulated paint
Acrylic lacquer
Exterior steel pipe of
or melamine 1 1 1
refrigerator
resin
Exterior steel pipe of Acrylic lacquer
air conditioner and or melamine 1 1 1
blower resin
Exterior steel pipe of Formulated or Rust proofing for
2 1 1
cooling tower lacquer enamel primary
Lacquer or
Blower hole 1 1 1
melamine resin
20
Paint Number of paint

Equipment and Paint types Note
State Primary Double Finishing
accessories
Exterior steel pipe Lacquer or
1 1 1
of heater melamine resin
Rust proofing for
Formulated or
Refrigerator 2 1 1 primary
lacquer enamel
formulated paint
Acrylic lacquer
Exterior steel pipe
or melamine 1 1 1
of refrigerator
resin
Exterior steel pipe Acrylic lacquer
of air conditioner or melamine 1 1 1
and blower resin
Exterior steel pipe Formulated or Rust proofing for
2 1 1
of cooling tower lacquer enamel primary
Lacquer or
Blower hole 1 1 1
melamine resin
Outside 1 1 1
Inside 1 1 1
Box of interior fire
hydrant or
corresponding one
Buried Rust proofing 1 - 1
Equipment and Expose Rust proofing for

1 1 1
material d primary
Duct (galvanized Expose Rust proofing for
Formulated 1 1 1
steel plate) d primary
Expose Rust proofing for

Formulated 2 1 1
d primary
Duct (steel plate)

Inside Formulated 1 - 1
Note) 1. Equipment painting in above table is for on-site painting work
21
5) Paint work
(1) Paint area: All area except following area should be painted.
① Buried
② Plating finish side except zinc
③ Buried area of galvanized steel
④ Surface finishing with specialty exterior coating
(2) Paint method
① Proper brush should be used for cleaner look by applied paint.
② Paint sprayer should be used for mechanical painting, and its diameter and type
of nozzle, air pressure should be selected by used paint for no stain.
③ Proper roller brush should be chosen for painting side to maintain uniform face.
(3) Primary rust proofing painting for pipe, equipment, steel structure holder, etc should
be executed at manufacturing facility. If the painting after assembly is not available,
double painting should be conducted through primary painting and re-coating at
insufficient area, double coating on whole area.
(4) Precautions during painting
① All surface should be uniformly painted to show no defect like stain, peeled off
area, agglomerated paint, mold, etc.
② Be cautious not to contaminate or damage on paint area, and proper protection
should be protected if needed.
③ Temperature, humidity, ventilation should be selected properly by the types of
paint and drying condition.
④ Indication band for flow direction, character, pipe indicator color, etc should be
authorized by supervisor.
(5) Test and inspection: State of paint face, material, method should be tested by work
category.
2.5 Motor
1) Resistive 3 phase induction motor
(1) Application area
This specification is applied for enclosed type (TEFC) 3 phase squirrel cage induction
motor at AC or DC less than 600V, which is installed less than 40℃ of ambient
temperature and more than 1,000m of sea level (domestically manufactured product,
more than product). If there is a difference between required specification and
manufactured one, the latter should be notified separately.
(2) Supply range
① Refer motor list.
② Motor capacity less than 110KW is low voltage induction motor from 3∮, 380V
and 1∮ 220V, 3∮ 220V of power supply. (limited to domestically manufactured
motor, more than product)
③ Except, special type and other standard specification from maker should be
submitted and authorized during bidding stage.
(3) Rating
22
① Rated voltage: 3∮, 380V 1∮, 220V 3∮, 220V

② Rated frequency: 50Hz
③ Rated output: Refer motor list.
(4) Structure
① Motor dimension: Conform KSC 4206 (dimensions of low voltage 3 phase squirrel
cage induction motor, more than product).
② Accessories: By the designation of orderer, motor should be attached with belt
pulley, basic bolt, etc.
③ Outgoing line: If not designated, it should be located at the left side of motor
from belt pulley.
④ Starter: more than 11KW and less than 11KW - Star-delta starter
less than 11KW - direct starter
⑤ Conduit box: Motor should install separate conduit box that can be rotated in
360° in step of 90°.
⑥ Ground terminal should be attached for each motor.
⑦ Enclosed or weather proof motor should have cast-iron conduit box with female
screw. This should be enough size for cable connection.
(5) Testing and property
① Property test
(a) Resistance test
(b) Idle test
(c) Restrained test
(d) Low frequency retrained test
② Characteristics
Characteristics of motor should follow annex 1-9 in KSC 4202, and determined by
KSC 4201 (characteristics evaluation for 3 phase induction motor) from 5.1.
③ Starting rotary power
Structure of rotor Starting rotary power(%)
Normal squirrel cage C more than 125
Special squirrel cage type 1, K1 more than 100
Special squirrel cage type 2, K2 more than 150
④ Instant maximum output

150 - 250 % of rated output
⑤ Temperature test
Conform temperature test in Item 7.5 of KSC 4202. (B type insulation)
⑥ Insulation withstanding test
After temperature test, confirm the significant insulation resistance of motor.
Motor should withstand 60Hz of sine curve for 1 minute. Motor in mass
production can replace this test with 1 second of load at 120% voltage.
(a) 2E + 1,000V (minimum 1,500V) between winding of stator (including starter
connected to winding of stator) and iron core
23
E: rated voltage
(b) 2E1 + 1,000V (minimum 1,500V) between winding of rotor (including starter
connected to winding of rotor) and iron core
E1: maximum induced voltage between terminals of rotor (V)
(6) Testing
① Dimensions
② Property
③ Instant maximum output
④ Starting rotary power
⑤ Temperature test
⑥ Insulation withstanding test
(7) Notation
① Title
② Structure of rotor
③ Number of poles
④ Rated output (KW)
⑤ Rated voltage (V)
⑥ Rated frequency (Hz)
⑦ Current
⑧ Number of rotation
⑨ Secondary voltage
⑩ Secondary current
⑪ Starting class
⑫ Symbol of motor
⑬ Manufacturing number or equipment number
⑭ Name of manufacturer or abbreviation
⑮ Manufacturing date
⑯ Frame number
⑰ Overload rating
⑱ Insulation class
⑲ Type of bearing and number
⑳ Wiring method
(8) Submission documents
① Contractor should submit and be authorized the following documents within
designated time frame.
(a) Appearance diagram
(b) Electrical wiring
(c) Time - current curve (temperature limit)
(d) Acceleration time - current curve
(e) Speed - torque curve at 100%, 90% and 80% of rated voltage
(f) Winding structure, stator frame, and rotor
(g) Motor characteristics document
24
② Contractor should submit 1 copy of original drawing, which can be copied, 10

copies of data and instruction manual including appearance diagram, certified test
report, installation, operation, maintenance guideline.
25
Chapter 2 Air conditioning duct work
1. General issues
Air conditioning and ventilation duct (air conditioning duct) follows the drawing for execution,
and is manufactured and installed with the following issues and SMACNA STANDARD.
If mechanical product with energy saving feature is determined to be superior from objective
test result, it can be used after the authorization of supervisor.
2. Materials and components
2.1 Materials for duct

1) Galvanized steel plate
Use 1 type of SBHG, KSD - 3506 (galvanized steel plate, more than production) and 2
types (SBHG 2).
Thickness of plate (mm) Nominal zinc plating g/㎡
more than 0.3 ~ 0.5 and below 244
more than 1.0 381
In addition, thickness of galvanized plate uses the following table as standard
(size of 1 galvanized iron sheet: 0.9 M x 1.8 M)
Notation Thickness Notation Thickness
# 16 1.6 m/m # 22 0.8 m/m
# 18 1.2 m/m # 24 0.6 m/m
# 20 1.0 m/m # 26 0.5 m/m
2) Stainless steel plate
Stainless steel plate (0.85) is used for ventilation duct for humid location (kitchen).
3) FIBERGLASS DUCT BOARD
Thickness: 25t × 60k
Usage: less than 1,500 m/m of longer face in air supplying duct
4) Reinforcing steel for flange and hanger
Use 1 type of SBHG, KSD - 3506 (galvanized steel plate, more than production)
and 2 types (SBHG 2).
Amount of zing plating follows the below table.
Thickness of plate (mm) Nominal zinc plating g/㎡
more than 1.0 381
26
5) Steel
Used material for duct manufacturing and installation should be 2 types of SB 41 or
better in KSB 3503 (rolled steel for general structure, more than production). The shape,
dimension, weight and their tolerances should conform KSD-3501 (shape, dimension,
weight and their tolerances for hot rolled coil rod steel, more than production) and
KSD-3500 (shape, dimension, weight and their tolerances for hot rolled plate, more than
production).
6) Rivet
Copper rivet is used as standard.
6) Bolt and nut
Conform KSB-1002 (hexa bolt, more than production) and KSB-1012
(hexa nut, more than production).
7) Flange packing
It should be 3mm thick asbestos plate conforming KSL-5311 or 3mm thick asbestos
tape(more than production) with KSL-5301(more than production). At the one sie,
adhesive is applied, and packing width is 20mm. Except round duct, 6mm diameter
asbestos fiber with KSL-5304 conformity can be used(more than production).
8) Compound
To minimize the leakage at duct joint, silicone sealant is used.
2.2 Components for duct

1) External air inlet and exhaust grill
External air inlet and grill should have good appearance and little noise and vibration
during operation. In addition, wind amount should be easily controlled.
Effective area of opening should be more than 50% of front area, and material is
aluminum with KSD-6701 (aluminum and aluminum alloy plate, more than production).
By the authorization of supervisor, two types of galvanized steels (SBHG 2) with
KSD-3506 or steel plate (cold rolled steel plate, more than production) can be used. It
features enough strength and structure that can prevent rain inflow. Stainless insect net
is installed and easy to detach and attach.
2) Exhaust port
(1) Exhaust port should have good appearance and little noise. Sponge rubber or pelt
packing with more than 5mm thickness should be installed.
Damper or shutter behind exhaust port should have relevant functionality and sturdy
structure. Structure with little noise and vibration should be implemented. Shutter at
backside should be 0.6mm thick steel plate.
① Effective area of porous exhaust port should be more than 40% of front area,
and front plate is made of 1.0mm thick steel plate (KSD-3512, cold rolled steel
plate, more than production) with punching.
② Attaching frame for feathered exhaust port should be made of 1.0mm thick steel
plate (KSD-3512, cold rolled steel plate, more than production). For guidance
feather, horizontal, vertical, or both can be used. Whatever it is, guidance feather
is made of steel plate (KSD-3512, more than production), aluminum plate
27
(KSD-3701, aluminum and aluminum alloy plate, more than production), or other
material in designated cross-section. In addition, wind control should be easy,
and shutter is counter wing.
③ Plate thickness for other corner in air diffuser at ceiling should be more than
0.8mm for less than 250mm of width diameter. For more than 250mm, more
than 1.0mm of steel plate (KSD-3512, more than production), aluminum plate
(KSD-6701, aluminum and aluminum alloy plate, more than production) or other
material should be used for enough induction property.
At division area from duct, damper or regulator should be installed by the need,
and connection chambers are listed in following.
less than ∮ 200 of neck diameter: 400 x 400 x 250 H
more than ∮250 ～ ∮400 and less: 500 x 500 x 300 H
more than ∮450: 600 x 600 x 400 H
(2) Resistor
It is made of formed aluminum, and should be equipped with wind control damper.
3) Inlet
It is made of aluminum plate with KSD 6701, and features good appearance, little
noise, and shutter installation by need. Shutter is made of more than 1.0mm thick
aluminum plate (KSD-6701) for clear controlling function. It features sturdy structure,
and little noise and vibration. In addition, wind control should be easy.
4) Wind control damper
Guidance feather of damper is made of more than 1.2mm thick galvanized steel plate
(KSD-3506, more than production) or more than 0.6mm thick elliptical cross-sectioned
galvanized steel plate. Clear functionality, and little noise and vibration should be
implemented. As well as resistance to air flow should be minimal. Thickness of casing
plate should be same as connection duct plate, or thicker galvanized steel or steel
plate with support should be used. Guidance feathers should be installed every 200mm
of height in duct, and overlapped area is 15mm. Non-rusting material should be
installed at casing such as zinc plated steel rod for damper and gun metal for bearing.
If damper operation is manual, install opening/closure indicator. Round duct damper is
single feather, and other issues are same as quadrangle duct.
5) Split damper
Plate thickness is more than 1.2mm steel, and length is more than 300mm. Controlling
rod is more than 9mm of steel, and controlling handle is made of bronze or pressed
steel plate. It can be opened/closed externally, and its openness can be checked.
6) SOUND ATTENUATION
(1) General issues
① Installation of sound attenuator for air conditioning duct aims for prevention of
noise transference through duct and pleasant environment.
② Duct that connected to air supply and exhaust fan should be equipped with
sound attenuator. If the minimum NC level is not passed, sound attenuator is
not needed.
③ NC (NOISE CRITERIA) LEVEL should conform the below standard.
28
④ Sound attenuator should be manufactured for proper sound/performance

characteristics by the company with noise and vibration prevention facility
certification by Code 15/47 of environment conservation act (1986.12.31 No.
3903).
⑤ Authorization drawing for SOUND ATTENUATOR must include noise calculation by
specified NC level.
⑥ SOUND ATTENUATOR is used for noise reduction, and has the benefit of
reduction at medium and low frequency range.
⑦ Noise reduction criteria for sound attenuator (for 15m/sec of wind velocity)
63 HZ : more than 2dB 1,000 HZ : more than 25 dB
⑧ Supply fan is installed at supply side, and return fan is for return side.
⑨ Sound attenuator must be installed at shortest path of fan, and conform the
noise criteria for each room.
(2) Manufacturing of SOUND ATTENUATOR
① Material
(a) Outer casing: Using #18 galvanized iron plate, T shape (40 x 5t) is used for
duct connection, and insulated for dew proofing.
(b) Internal bored pipe: Using #22 galvanized iron plate, opening should be
determined by noise reduction for frequency. Size of hole
is 5, and pitch is 7mm.
(c) Internal acoustic absorbent: Glass wool with superior acoustic absorption,
flame retardancy, dampproof (INORGANIC %
ACOUSTIC GLASS WOOL 40K) is covered with less
than 0.06mm thick P.E film to prevent the leakage
of glass fiber dust. All exterior is covered with
glass fabric (ACOUSTIC GLASS CLOTH FG 118).
(d) Internal reinforcement: Galvanized iron plate with required thickness for
deformation prevention during transport and installation
is used.
(e) AIR GUIDE: Resistance pressure by air flow should be minimized.
② Manufacturing
(a) Arrangement of splitter in duct sound attenuator follows DIL of 1) - 7).
(b) Assembly of DUCT sound attenuator should be integrated one with outer
casing and splitter to prevent internal noise.
(c) DUCT sound attenuator should be sealed to prevent air leakage.
(d) Sound attenuator connection for main body is cutting-bending.
7) Fire protection damper
(1) Fuse melting damper takes 72℃ as standard operation temperature. For kitchen
ventilation, temperature is more than 160 ℃. For smoke exhaust, it is 280℃.
(2) Closure should be manually operated using elasticity of spring or gravity.
29
(3) Casing and guidance feather should be more than 1.6mm thick steel plate
(KSD-3501, more than production).
(4) Operating support such as spring, shaft holder should be non-corrosion material.
8) Flexible duct
It features enough bending and strength, higher thermal insulation, inflammability.
9) Flexible joint
Connection part of blower and duct should use flexible joint with 150mm of flange
gap, which maintains 100mm on wrinkled state. KS certified asbestos fabric should be
used. If needed, piano wire with KSD-3556(more than production) or equivalent material
should be inserted.
10) Inspection and cleaning hole
It features easier closing/opening and little leakage of air during opening/closing.
Cover should have same thickness of duct, and is made of galvanized steel plate with
KSD-3556(more than production, more than production). Its frame uses formed steel
with KSD-3503 (cold rolled, more than production) or KSD-3501 (hot rolled, more than
production). Especially, air conditioning line should be covered with insulation. Hole
should be installed at each damper or supervisor-acknowledged location.
11) Manufacturing and installation of hood
(1) Manufacturing and installation of hood is corresponded to the one of duct, but there
is no connection in principle. If it should be connected from the condition of plate
ashlar, standing seam or overlapping connection at equal distance or center should
be made. This also applies ridge area. In addition, oil or water removing equipment
should be installed around inside cover. Cover holder features the maximum
1,500mm of gap except 4 corners. Bronze cap nut is installed at the bottom of bolt.
(2) Attachment of gauges
① Gauges should be installed at accessible location with their purposes, such as
temperature, humidity, pressure, etc. They are installed horizontally or vertically.
* No moisture, dust, hazardous gas, vibration
* No direct contact with air flow, sunlight, etc for temperature and humidity
* Nominal circulation of controlled medium
② Standard attachment height for indoor temperature/humidity gauge and controller
should be 1.5m. If more than 2 gauges are installed together, case decoration
panel is used by special mention. If indoor temperature detector or controller
should be installed at inside of duct, proper protection measure should be
implemented.
③ Temperature/humidity gauge/controller with insertion should attach by considering
thickness of insulation, etc. They should be securely attached. Temperature
decreasing part should be installed at supporting medium for attaching in wind
path.
④ Pressure detect attached to duct should be vertically installed at minimal pressure
fluctuation. Pressure difference detector should be attached by maximum level of
high pressure and low pressure.
30
3. Manufacturing of duct and installation of components
3.1 General issues

Air conditioning and ventilation duct should have minimal leakage and air resistance,
and feature low noise generation. The following conditions are should be met.
1) Structure of duct elbow pipe
Inner radius of duct elbow pipe for rectangle duct is more than the width of radius.
For round duct, it is more than diameter.
2) Structure of duct cross-sectional deformation
To deform cross-section of duct, abrupt deformation should be prevented. Smooth
shrinking and enlargement is taken, and its gradient is within 15 or 30 degree.
3) Duct structure at humid location, such as kitchen and bathroom
Horizontal exhaust at humid location should apply sealant at external connection.
4) Treatment of penetrated area in duct
Gap of duct that penetrates fire-protection and other walls should be filled with rock
wool or other insulator, inflammable material.
3.2 Manufacturing and installation of duct

For manufacturing of general duct, low speed duct is within ±50 mmAq of internal
pressure. High speed duct is faster than this value.
1) Panel thickness of duct
(1) Rectangle duct
Connection of rectangle duct for less than 250mm of longer edge in low speed
duct is button punch snap lock. If longer edge is more than 2,250mm, complex
elbow pipe or fitting pipe Pittsburgh lock is applied. All high speed duct is
Pittsburgh lock. If standard panel finish is not available for connection in flow
direction, internal folding connection is used. Panel thickness of duct follows the
below table.
Longer edge in low speed duct Longer edge in high speed duct Panel thickness
(mm) (mm) (mm)
450 and less 0.5

more than 450 ~ 750 and less 0.6
more than 750 ~ 1500 and less 450 and less 0.8
more than 1500 ~ 2250 and less more than 450 ~ 1200 and less 1.0
more than 2250 more than 1200 ~ 2250 and less 1.2
(2) Round duct
Round duct is spiral duct, and straight tube is winding of galvanized steel plate in
spiral direction using groove seam machine. Notation dimension is based on inner
diameter. Panel thickness of duct and seam pitch in straight tube follow the below
table. Width of seam folding is more than 6mm.
31
Longer edge in low speed duct Longer edge in high speed duct
Panel thickness (mm)
(mm) (mm)
450 and less 0.5
more than 450 ~ 750 and less 0.6
more than 750 ~ 1500 and less 450 and less 0.8
more than 1,000 more than 450 ~ 1200 and less 1.0
Longer edge in high speed duct (mm) Panel thickness (mm)
100 and less 100 and less
1,000 and less 150 and less
(3) Panel for chamber or sound attenuator use one step thicker plate than duct.
3.3 Duct connection

1) Connection of low speed duct
Panel thickness and connection of low speed duct follow the below table.
Longer Maximum
Corner
edge in Attachmen Reinforcin Reinforcing Connection gap in duct
piece Clip
rectangle t flange g channel round bar bolt/nut(∮) connection
(TxH)
duct (mm) (m)
300 and
1.4 x 32 - - - 1.2x25x15 9x20 1.2
less
300 ～ 750 1.4 x 32 - - - 1.2x25x15 9x20 1.2
750
1.4 x 32 - - - 1.2x25x15 9x20 1.2
～ 1,000
1,000
1.4 x 32 1.2 x 32 - - 1.2x25x15 9x20 1.2
～ 1,500
1,500
1.4 x 32 1.2 x 32 1.2x25x20 - 1.2x25x15 9x20 1.2
～ 2,250
more than
1.4 x 32 1.2 x 32 1.2x25x20 9.0 1.2x25x15 9x20 1.2
2251
※ Spot welding distance for reinforcing channel is 30mm.
(1) Duct connection is completed by inserting flame retarding neoprene packing at the
same width of cutting-bending flange (cast flange) without joint with galvanized
iron, joining with bolt, nut, and I shaped corner piece (galvanized iron 1.4T,
KSD-3506, more than production) at four corners, tightening flanges using clip
(galvanized iron 1.2T, KSD-3506, more than production) at center of duct width.
(2) Installation of attaching flange
For reinforcement of cast flange, galvanized iron 1.2T (KSD-3506, more than
production) is inserted.
32
2) Connection of high speed duct

Connection materials for high speed duct are same as the low speed duct, and
adhesive is well applied at the connection exterior. Insert both sides into duct, and join
with steel vise. Connection method is same as the direction in drawing of insertion
connection and flange connection, etc.
3.4 Duct reinforcement

1) Installation of duct reinforcing channel
At the width direction of duct, spot welding at top and bottom is conducted with
penetration. 1.2T galvanized iron with KSD-3506(more than production) is used.
(Only for longer edge is more than 1,500mm.)
2) Installation of round bar for duct reinforcement (only applied to air supply duct)
Duct is vertically penetrated at top and bottom of width center, and 9Ø of round bar
(KSD-3503, more than production) is inserted into 15mm steel pipe for general
structure. This pipe is inserted into duct, and joined with reinforcing channel and nut
(KSB 1012, more than production) at top and bottom.
3.5 Duct support

1) Support of rectangle duct
Shock proofing material can be installed at hanger to prevent vibration transfer,
if needed.
*** Hanger and supporting structure of duct ***
Hanger Supporting structure
Length of longer edge
in duct Galvanized Galvanized Maximum Galvanized Galvanized
shape steel round steel distance shape steel round steel
450 25 x 25 x 3 9A 3,000
450 ～ 750 25 x 25 x 3 9A 3,000
751 ～ 1,000 25 x 30 x 3 9A 3,000
1,001 ～ 1,500 25 x 30 x 3 9A 3,000
1,501 ～ 2,250 25 x 40 x 3 12A 3,000 40 x 40 x 3

more than 2,251 25 x 40 x 3 12A 3,000 40 x 40 x 3 12A
2) Support of round duct
Supporting structure for round duct is executed by the below table.
Maximum distance
Duct diameter (mm) Flat steel (mm) Round steel (mm)
(mm)
1,500 and less 40×40×3 12 ∅ 3.0
more than 1,500 40×40×3 12 ∅ 3.0
33
3.6 Installation of duct components

1) Installation of open air inlet and exhaust grill
Grill should take care of rain, and be installed securely. Gap between building should
be air tight by applying mortar. Connection between grill and duct should be air tight
using flange.
2) Installation of exhaust port and inlet
Proper packing is used for exhaust port and inlet to maintain air tight and appearance.
3) Installation of dampers
Damper should be installed in air tight and easy control, but inspection hole should be
featured for installing damper at ceiling or shaft. Inspection hole for shaft and ceiling
should be at easy handle operation and 450mm* as standard if no special comment. It
can be adjusted with discussion of supervisor by duct size.
4) Installation of sound attenuator
Sound attenuator installed at the inside of duct or chamber, should have secure
structure and relevant acoustic absorbance. If acoustic absorber is expected to scatter,
the material with low friction resistance and no hindrance to sound attenuating should
be installed securely.
5) Installation of inspection and cleaning hole
It features easier closing/opening and little leakage of air during opening/closing.
Connection area of duct should be securely installed using packing.
6) Manufacturing and installation of hood
Manufacturing and installation of hood is corresponded to the one of duct, but there
is no connection in principle. If it should be connected from the condition of plate
ashre, standing seam or overlapping connection at equal distance or center should be
made. This also applies ridge area. In addition, oil or water removing equipment should
be installed around inside cover. Cover holder features the maximum 1,500mm of gap
except 4 corners. Bronze cap nut is installed at the bottom of bolt.
7) Attachment of gauges
(1) Gauges should be installed at accessible location with their purposes, such as
temperature, humidity, pressure, etc. They are installed horizontally or vertically.
① No moisture, dust, hazardous gas, vibration
② No direct contact with air flow, sunlight, etc for temperature and humidity
③ Nominal circulation of controlled medium
(2) Standard attachment height for indoor temperature/humidity gauge and controller
should be 1.5m. If more than 2 gauges are installed together, thermocase
decoration panel is used by special mention.
(3) Temperature/humidity gauge/controller with insertion should attach by considering
thickness of insulation, etc. They should be securely attached. Temperature
decreasing part should be installed at supporting medium for attaching in wind
path.
(4) Pressure detect attached to duct should be vertically installed at minimal pressure
fluctuation. Pressure difference detector should be attached by maximum level of
high pressure and low pressure.
34
4. Testing and inspection
4.1 General issues

All sorts of testing for air conditioning duct should be conducted by KSF-2815 (testing
standard for smoke exhaust facility), and there is no significant failure.
4.2 Selection of testing hole

After completion of work, bushing with screw should be installed to measure wind
velocity and amount at required location for ventilation test. After testing, these holes
can be closed with plug by screw joining.
35
Chapter 3 Air conditioning pipe work
1. General issues
Air conditioning pipe work in this chapter means hot/cold water pipe.
2. Piping material
All piping material should be authorized by supervisor before use.
2.1 Steel pipe

1) Air conditioning steel pipe
- Carbon steel pipe for general pipe KSD - 3507 (white pipe, more than production)
2) If nominal diameter is exceeded, the following material is used for manufacturing.
Material Specification Note

KSD – 3503 2
Rolled steel for general less than 10 kg/cm - 7.9 t and
(more than
structure production) more
KSD – 3560 less than 10 kg/cm2- 7.9 t and
Rolled steel for boiler (more than
production) more
KSD – 3515 2
Rolled steel for welded more than 11 kg/cm - 12.7 t and
(more than
structure production) more
2.2 Connection for steel pipe

1) Same material and thickness as steel pipe in 2.1 of Chapter 5.
2) Connection for double pipe utilizes insulating union and flange.
3. Pipe components
3.1. Valve usage

1) Hot/cold water
(1) Gate valve, glove valve, butterfly valve
① 50Φ and less: gate valve KSB 2313, glove valve
(bronze valve: 10kg/㎠, more than production)
② 65Φ and less: gate valve KSB 2350,51, glove valve (cast iron valve: 10kg/㎠)
③ 65Φ and more: butter fly valve KSB 2350
(CAST STEEL BODY, LOCK LEVER HANDLE, more than production)
(steam for stainless, seat is EPDM)
(2) Usage of check valve
All check valve uses NON-SLAM (SMOLENSKY) CHECK VALVE.
① 10 kg/㎠ and less
50Φ and less = KSB 2315 (bronze or cast iron screw type)
, more than production
36
65Φ and more = KSB 2350 (cast iron 10 kg/㎠ flange) , more than production
CAST STEEL BODY & ALL SUS TRIM HAMMERLESS TYPE
② 20 kg/㎠ and less
KSB 2368 (cast steel 20 kg/cm2 flange) , more than production
CAST STEEL BODY & ALL SUS TRIM HAMMERLESS TYPE
(3) Balancing valve: It must be installed at main or subsidiary pipe for hot/cold water.
3.2 Strainer
Strainer is Y shape, and bronze screw for hot and cold water, steam is forged steel
screw in 50mm and less of nominal diameter. For 65mm and more, it is cast steel
flange. (For E/C, it is 20kg/㎠ cast steel FLANGE). Cleaning hole plug is same material,
and strainer wire mesh is made of stainless steel, which has enough effective area for
water pressure.
3.3 Automatic air change

Steam is combined use of heating lamp or float. Hot water is float type. Main body is
bronze, and bellows is phosphor bronze. Float is brass with effective functionality.
3.4 Pressure meter, elasticity meter, water level meter

Pressure meter, elasticity meter, water level meter conform KSD 5305 (Bourdon tube
pressure gauge, more than production), and its outer diameter of scale panel is
attached with 100mm cock. Maximum scale is 1.5 ~ 3 times for used pressure.
3.5 Thermometer
L type or bi-metal type is used, and diameter for round bi-metal is 100mm. The
maximum scale in thermometer is 2 times for used temperature.
3.6 Sleeve
Sleeve in pipe should be made for its usage with more than 3.2mm thick steel plate or
carbon steel black pipe. Clearance between outer diameter and sleeve should be at
least 3mm. For water proofing layer, it should not affect water proofing performance
(water stop panel), and be finished with lead coking by filling in top/bottom or
right/left.
3.7 Seal tape and silicone compound

It should be proper material for screw pipe connection, and have durability in pressure,
temperature, etc. In addition, leakage is not allowed. For screw pipe connection, seal
tape (teflon) and silicone compound is used.
3.8 Common
Specification for usage pressure and purpose should be chosen and authorized before
use.
37
4. Pipe holding and fixing

1) Hanger and support is made of silica asbestos cement, and thickness is same as
insulation.
2) Hanger should be certified KS product with suitable function and purpose.
3) Pipe support at mechanical room or with many pipelines should be rack scaffold in KSD
3503 (rolled steel for general structure). If there is much elongation and contraction by
temperature difference, steel roller is used (steam, hot water, condensation, etc).
4) Steel insert should have enough strength to support pipe.
5. Anti vibrational connection and support

1) Connecting area with rotating units, such as refrigerator, cooling tower, pump, air
conditioner, FCU, etc should use bellows flexible joint in stainless. Enough plasticity,
heat resistant, pressure resistant should be confirmed.
2) Vibration proof support for pipe should be prepared with design plan, which should be
6. Piping work
6.1 General issues

1) This items are applied to cold/hot water pipe.
2) Before pipe work, related issues on pipes and equipments in other facility should be
reviewed in detail with consideration of gradient for precise location.
3) Attachment, fixing of pipe holding steel structure and burying of sleeve should be
conducted without hesitation.
4) Pipe should be cut in right angle with tool that does not shrink the diameter. Cut area
should be finished smoothly without any ripple.
5) Before connecting pipe, check the inside of pipe and confirm no foreign body. During
pipe work, if the work is suspended or stopped for a while, pipe should be well
protected (installing cover or cap).
6) Pipe that penetrates into wall or fire prevention area should be filled with asbestos and
other inflammable material with finishing of inflammable or flame retarding caulking.
7) Underground buried pipe should be protected with cathodic protection, and authorized
by supervisor.
8) Pipe without dew-proofing and insulation should be installed with pipe split washer at
ceiling, floor, wall.
9) Pipe with newly installed connector should be installed with fixing steel at effective
location from newly installed location.
10) Burying depth of pipe for exterior pipe should be less than 1500mm. If there is no
sufficient depth for pipe, it should be protected with insulation or concrete by
authorization of supervisor.
11) Division from main pipe or insertion should be used with more than 3 elbows.
12) Gate valve should be installed as drainage at the bottom location to completely
discharge water in equipment and device.
38
13) Air contaminating locations among looped pipe, low flow rate, low temperature, low
pressure, flow direction changing are installed with automatic or manual drain valve.
For installing automatic air purging system, service valve should be installed, and
extended to the nearest drain location.
14) Top location of pipe with connection to various equipments should be installed with
automatic air change and manual service valves.
15) Attachment of pressure gauge should use siphon tube and service valve to protect
equipment from shock.
16) After completion of pipe work, designated material and color is used to classify system
at location designated by supervisor.
17) Dirt pocket should be installed when piping run of pipe through slab is long.
18) To prevent the damage from bending moment and torsion due to thermal expansion,
protection device should be installed through stress analysis.
19) Piping method should adopt reverse return method even if it is not specified.
20) Piping around equipment should have enough clearance for operation, maintenance,
inspection, and be installed with pipe branching flange in required location.
21) AIR, STEAM should be upward, and water, oils should be downward direction.
6.2 Piping for hot/cold water and cooling water

1) General issues
(1) For piping work, elongation and contraction of pipe should be considered with
equal gradient. If hindrance such as reverse gradient and air trapping is expected,
piping should not be made.
(2) Round area in main pipe should be used with round pipe.
2) Support gap
(1) Support gap in horizontal pipe should follow the below table, and round or branch
should be supported if needed.
Nominal 20 and 200 and

25 ~ 40 50 ~ 80 100 ~ 150
diameter(mm) less more
Maximum
1.8 2.0 3.0 4.0 5.0
distance (m)
(2) Vertical pipe at interior should be installed with shaking protection steel structure at
one floor.
3) Gradient
In horizontal pipe for cold/hot water, supplying pipe should be front rise, and returning
pipe is frond down. The gradient is 1/250 at minimum.
39
7. Testing and inspection
7.1 General issues

1) This section is applied to piping for hot/cold water of air conditioning facility.
2) Various pipe should be tested for internal pressure of covering work during piping work
or before burying, after completion of piping. Testing time is more than 60 minutes
without any leakage.
7.2 Hot/cold water piping

With pressure testing, more than 2 times of usage pressure is tested (at least 10kg/㎠).
7.3 Testing on welded parts

1) Welded parts should be tested with radioactive examination in KSB 0845 or JIS A3104
(radioactive examination test method and radiograph classification method for welded
parts) by the expense of the company. Class 1, 2 is good, and class 3, 4 is failure.
Modification and additional re-testing fee for failed parts are responsible to builder.
2) If failure rate is more than 20% for specified testing area, all sample test should be
conducted with the expense of builder.
40
Chapter 4 Hygienic pipe work
1. General issues
1.1 Application area

1) This specification applies to pipe work in water supply/drain for hygienic facility.
2) If used materials are applied to waterworks act, sewer act or regulations of authority,
they should conform these regulation or be authorized by supervisor.
3) This specification includes the connection to equipment, installation of T, bushing, etc
for automatic controller, and installation work for vibration proofing material of pipe.
1.2 Valve materials

1) Materials, specifications, usages for pipes in each facility are following.
(1) Water supply
50A and less phosphorous deoxidized copper pipe
(KSD-5301, more than production) L-TYPE ,
65A and more stainless steel pipe (KSD - 3595, more than production)
(2) Hot water supply and circulation
50A and less phosphorous deoxidized copper pipe
(KSD-5301, more than production) L-TYPE,
65A and more stainless steel pipe (KSD - 3595) , more than production
(3) General drain pipe, kitchen drain pipe, waterspout
PVC (VG1,DRF TYPE) , more than production
(4) Sewage water pumping pipe, ventilation, waterspout (if bypassed to store)
White steel pipe (KSD-3507) , more than production
(5) Connecting pipe between drain and hygienic equipment
Waterworks connecting pipe (KSD-6307) , more than production
2) Pipe connection should be suitable for various pipes, and feature same or better
characteristics of used pipes in shape, material, minimum pressure, etc.
3) New extension connection uses double bellows with KSD-3698 certification (cold rolled
stainless steel pipe, more than production).
4) Vibration proofing connector should be synthetic rubber, stainless steel with supporting
material for enough plasticity, heat resistance and pressure.
5) Underground buried pipe
Underground buried pipe should be cathodically protected, and authorized by
supervisor.
6) Other issues
After the completion of piping work, designated color, material, size, indication should
be used at designated location for classification of system during finishing.
1.3 Valves
2
1) less than 10kg/cm of used pressure
41
(1) Glow valve

For 50φ and less, KSB-2311 (bronze screw) , more than production
For 65φ and more, KSB-2354 (cast iron flange, steam and seat should be STS.)
(2) Gate valve
For 50φ and less, KSB-2313 (bronze screw) , more than production
For 65φ and more, KSB-2350 (cast iron flange) , more than production
(3) Butterfly valve
For 65φ and more, butterfly valve is applied (except for sewage drain [gate valve])
- CAST STEEL BODY, STS STEM, EPDM SEAT, WAFER TYPE
(4) Check valve classification
Check valve utilizes SMOLENSKY VALVE.
2
① 10kg/cm and less
50φand less = KSB 2301
2
(10kg/cm of bronze or cast iron screw) , more than production
65φand more = KSB 2350
2
(10kg/cm of flange, cast iron BOARD & ALL STS TRIM,
HAMMERLESS TYPE) , more than production
2
② 11kg/cm and more
KSB 2368
2
(cast steel 20kg/cm flange)(CAST STEEL BODY & ALL STS TRIM, HAMMERLESS TYPE)
1.4 Supporting steel structure

It can sustain the elongate, contraction of pipe, fluctuation, and load with suitable
material and diameter of pipe. If the transference of vibration is needed to be stopped,
the one with vibration proofing is used.
1) Steel insert
With galvanized steel plate, it should have enough strength to support pipe, and
feature convenient structure for connection. Deck plate should utilize separately
designated one.
2) Steel hanger
Galvanized steel with suitable diameter should be used, and have enough strength to
sustain total weight of content, pipe, and cover in supporting gap. If pipe material is
different from hanger, the insulation coating is made.
3) Pipe fixing
Steel fixing with suitable diameter should be used, and have enough strength to hold
the stress from elongation and contraction of pipe.
4) Common fixing
If multiple pipes are arranged in parallel, suitable frame steel by the number of pipes
should be used for sustaining pipe, content, and cover. By supporting gap, scaffold
with enough strength should be installed. At much elongation and contraction (steam,
hot water, hot water supply, circulation pipe), supporting structure with roller should be
42
used.
5) SLEEVE and INSERT
For underground sleeve and insert, existing one should be utilized. If needed, re-install
one. In addition, gap between sleeve and insulation face of pipe should be finished
with designated method.
6) Vibration proof
Hanger and supporting steel structure is filled with vibration proofing rubber to achieve
enough vibration proofing and strength.
1.5 Preparation of pipe

1) Location selection
Before execution, minimum distance, required gradient, relationship with other works in
parallel or crossing with other pipes should be carefully considered for precise location
selection.
2) Mold and sleeve for pipe should have enough strength before flooring or walling with
concrete, wood or sleeve in enough strength should be precisely fixed at the location.
3) insert and supporting steel fixed at ceiling and wall should be fixed at designated
location without interruption.
1.6 Cutting of pipe and steelwork around cut area

1) Pipe cutting
Pipe length should be precisely measured, and cut in right angle from axis.
Branch pipe for ventilation and drain, which have right angle to main pipe,
should be carefully cut for watching the cut angle.
Cutting tool that opens the plating or covering and reduce pipe diameter
should not be used.
2) Treatment of cutting area
Cutting area of all pipes should be smoothened by file, and finished to be flat
in right angle to axis. Back wrinkle and any residue on inside/outside of
pipe should be detached.
1.7 Inspection, cleaning of pipe inside and its protection

Every pipes should be checked for their inside to confirm no foreign material. If exists,
keep them clean.
Pipe washing should be conducted until there is no foreign body and normal water
color (by visual inspection).
After job is completed or temporarily on hold, plug and cap is used for complete
closure to prevent no inflow of foreign body.
1.8 Joining of pipe

1) Pipe connection
(1) Cast iron: mechanical joint
43
(2) Steel pipe: For 50φand less, screw joint and union joining is used. For 65φ and
more, grooved connector is used. Kitchen drain and mixed drain
(general drain) utilizes screw connection for 80φ and less. For 100φ and
more, welding connection (SLIP-ON TYPE) is used.
(3) Copper pipe : For 50φ and less, expansion pipe, and welding connection is used for
65φ and more.
(4) Stainless steel pipe: same as steel pipe.
2) Joining of copper pipe
(1) Steel pipes
① General screw connection
Joining screw conforms KSB-0222 (tapered screw for pipe, more than production)
with male thread and precise dimension.
While joining, seal tape (teflon tape) is used in male thread.
② Connector joining for screw drain pipe
Joining method conforms the previous item, and there should be a little gap
between the cross section of pipe and female screw.
③ Flange joining
3mm or less thick packing is used, and fixed into flanges by equally joining the
bolt.
For stainless steel pipe, the special stub-end and flange is used as one set. Packing
should be designated product.
④ Joining of special connector
By the purpose of piping, packing rubber ring by application with enough
functionalities of elongation/contraction of pipe, pressure resistance, air tightness.
⑤ Welding of steel pipe
It is welded to show no mixing in pipe cross-section and precise dimensions.
Anti-corrosion agent is applied to inside/outside of welded pipe or flange.
Welding connection in drain pipe (slip-on type) should be sufficiently pushed into
component, and finished only at exterior.
20 mm and less within 1.8 m

25 ～ 40 mm within 2.5 m
Stainless steel pipe 50 ～ 80 mm within 3.0 m
100 ～ 150 mm within 4.0 m
200 mm and more within 5.0 m
20 mm and less within 1.0 m

25 ～ 40 mm within 1.5 m
Copper pipe 50 ～ 80 mm within 2.0 m
100 ～ 150 mm within 2.5 m
200 mm and more within 3.5 m
If pipe deformation is expected, semi-circle

Lead pipe
supporter with more than 0.4mm thick
(exceeding 0.5m)
galvanized steel plate is installed at every 0.5m.
⑥ Welding of stainless steel pipe

Follow the technical specification of manufacturing company using TIG welding.
44
(2) Cast iron pipe

Cast iron pipe is mechanically joined. Pipe end is inserted into bottom of pipe
holder, and rubber ring is placed into pipe end without any distortion. By equally
squeezing bolts and nuts, rubber ring is made to be closely adhered to pipe end.
3) Joining of pipes in different material
Joining of pipes in different material utilizes dielectric union and its flange.
1.9 Supporting and fixing of pipe

1) Supporting gap
(1) Vertical pipe
① Cast iron straight pipe: 1 location per 1 unit
② Cast iron fitting pipe: either 1 location for 2
1 center location for 3
③ Steel pipe: more than 1 location at each floor
④ Copper pipe: within 1.2m
(2) Horizontal pipe
① Cast iron pipe (straight, fitting pipe): 1 location per 1 unit
② Steel pipe: follow supporting gap in air conditioning pipe work
③ Supporting gaps for stainless pipe, copper pipe, lead pipe are following.
(3) Within supporting gap, steel support is securely fixed not to be suspended or
vibrated.
(4) Bottom of vertical pipe should be fixed and supported with steel or concrete stand
not to be bowing or slipped into bottom by the own weight or total weight.
1.10 Penetration through wall, floor, ceiling

1) Sleeve
(1) For pipe that penetrates wall and floor, frame or sleeve is buried. Frame is made of
wood, and sleeve is general steel pipe with enough support for no movement and
deformation during concrete pouring.
① Sleeve with hump and closely adhere to waterproofing layer is installed.
② Top of sleeve is at least 50mm away from floor finish where is cleaned with
water.
③ Shape and dimension that has no hindrance to strength of penetrated wall,
beam, etc should be used.
2) Gap in penetrated area
Gap in penetrated area should be finished with designated method. If the expansion
and contraction of pipe is needed to be considered (at fire prevention and
waterproofing area), it should be carefully filled.
3) Penetration through outer wall ceiling
To prevent the inflow of underground rainwater, watertight material, such as silicone
caulking should be applied.
In addition, penetration piping through outer wall in ground floor should be plastically
connected.
45
Pipe that is not dew proofing, insulation, and penetrated through ceiling floor and wall
with exposure should be installed with washer.
1.11 Gradient of pipe

Gradient of water supply and hot water supply pipe should consider air accumulation
and drain in pipe. If gradient is not possible, reverse gradient is not allowed. Leveling
is needed at least.
Minimum gradient of pipe is following.
1) Water supply pipe: more than 1/200
2) Hot water supply pipe: more than 1/200
3) Drain pipe
(1) Pipe diameter with 75mm and less: more than 1/50
(2) Pipe diameter with 100mm and more: more than 1/100
4) Ventilation pipe should be well flowed without any waterdrop. Reverse gradient is not
allowed with connection to drain pipe.
1.12 Prevention of water hammering

If relatively high water pressure and water hammering is happened at water supply
and hot water supply pipe, water hammering protector should be installed.
1.13 Extension of pipe

Proper pipe extension should be installed where pipe and equipment might
be damaged.
1.14 Test
1) All pipes should be tested with pressure (water filling) or radiographic evaluation by
7.5 (testing on welded part) in Chapter 5 after completion of partial or whole piping.
Pipe with dew proofing and insulation, hidden, buried should be tested prior to
insulation and burying.
46
2) Standard value for pipe test is following.
Test method Pressure (water filling) test
2 times of 2 times of
Minimum 3mmAq
10kg/cm2 actual pump Water filling
pressure (0.3kg/cm2)
System pressure lifting
Minimum
60 min 60 min 60 min 30 min 30 min
holding time
Straight 0 *
Water supply,
Below water
hot water 0 **
tank
supply
Pumping 0 **
Wastewater
drain in 0
building
Ground drain 0
Drain Raindrop drain
0
in building
Discharge pipe
for drain 0
pump
Ventilation
Pressure is from the lowest part of pipe.
Note * If water work act exists, it must conform.
2
** Minimum 7.5 kg/cm .
2. Copper pipe work
2.1 General issues

Pipe material is KSD-5301”L”shape(more than production).
Copper pipe component should be same material and brass (screw joining) from
specialized manufacturer.
Welding materials are hard solder (phosphorous copper solder, silver solder) and soft
solder, which should be selected with consideration of application and pressure.
2.2 Copper pipe work

1) Cutting of pipe
(1) Pipe with less than 3/4INCH is cut by special cutter. Pipe with more than 1INCH is
cut by hacksaw, and foreign body is not allowed into pipe inside.
(2) Inside burr is completely removed with rimmer.
(3) Cutting tool that reduces diameter or peels cover should not be used.
2) Bending of pipe
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(1) Bending of hard pipe should be accomplished with special bender, and more than
90° is not allowed.
(2) Deformation or damage is not allowed.
3) Expansion
Flare pipe is expanded with flaring tool, and for welding (soldering) expansion,
expander is used with consideration of insertion length.
4) Copper pipe welding
Joining of pipe is welding and flange (more than 65ψ) joining.
If joining method is specified in drawing, it must be followed.
(1) Welding joining (insertion joining)
① Joining area of pipe and connector is well polished, and soldering cream, etc is
covered at outer face of insertion pipe.
② Joining area should be equally heated until burner flame turns green. Solder is
poured into gap.
③ After joining, attached solder should be removed to prevent corrosion of pipe.
④ For re-joining, new connector should be used.
⑤ Welding can be divided into soft solder welding and hard solder welding, which
utilizes capillary effect, as shown below table.
Section Soft solder welding Hard solder welding
Welding Soft solder: 50/50 Solder 85/5 Phosphorous copper solder, silver
material Solder 96/5 Solder solder [ Ecup, (BAG)]
Welding
200 ～ 300 ℃ 700 ～ 850 ℃
temperature
Heating Propane, LP, gas torch, electric
Oxygen acetylene, gas torch
method heater
Easy work Strong strength
Feature
Weak strength Damage to pipe if overheated
Low temperature and pressure

Purpose (less than 120 ℃) High temperature and pressure
Small pipe (50mm and less)
(2) Flange joining

Copper alloy joining in special flange is joined with hard solder welding. Packing is
inserted into flange, and securely joined by bolt and nut.
3. Installation of water supply facility and pipes around equipment
3.1 Selection of equipments and materials

1) General issues
(1) Equipment and material for water supply facility should not be not-contaminating
structure and material.
(2) Used material should follow KS standard. If there is no standard, it should be
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2) Valves for water supply

(1) Air vent valve
KSB-2340 (air valve for waterwork, more than production) certified product with
automatic air venting function should have precise operation, and endure maximum
pressure.
(2) Depressurizing valve
Cast iron valve should be made of bronze or synthetic rubber, and endure
maximum usage pressure. Secondary pressure should not be affected by primary
pressure, and not generate vibration, noise, and water hammering.
(3) Bowl tab
For less than 50mm of diameter, screw bronze is used. For more than 65mm of
diameter is flange. Valve body is cast iron, and valve and seat is bronze with no
obstacle such as water hammer and vibration during closing. These materials can
sustain usage pressure. Bowl should be made of copper and stainless steel.
(4) Water level control valve (combined use with ball top and electronic) - installed at
every water tank and high water tank
For less than 50mm of diameter, screw bronze is used. For more than 65mm of
diameter is flange. Valve body is cast iron, and valve and seat is bronze with no
obstacle such as water hammer and vibration during closing. These materials can
sustain usage pressure. Bowl should be made of copper and stainless steel.
(5) Safety valve
As pop spring, main body is made of cast iron (less than 50mm of diameter can be
screw bronze). Major parts are bronze or stainless steel with precise function. Spring
conforms KSD-3701 (spring steel, more than production).
(6) Electronic valve
Power voltage of 85 ~ 100% and frequency of 95 ~ 105% in control circuit is
changed by either, and equipped with precise electronic valve. Main body is cast
iron (less than 50mm of diameter can be screw bronze). Major parts are bronze or
stainless steel with precise function.
3) Strainer
For less than 50mm of diameter, it is made of Y shape cast steel or bronze. For more
than 65mm of diameter, it is Y shape or U shape flange in cast steel. Cleaning plug is
made of brass, and strainer is stainless steel or copper with enough effective area.
4) Vibration proof connection and new extension
By need, reinforcing material with spheric or cylindrical synthetic rubber, stainless
steel or steel bellows should have enough pressure and heat resistance. For vibration
application, it has enough flexibility.
5) Pressure gauge
Pressure gauge should conform KSB-5305 (Bourdon tube pressure gauge, more than
production), and be attached with cock.
Maximum scale in pressure side should have more than 1.5 times and less than 3
times of maximum pressure.
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6) Water meter
It should be certified product by measurement act.
3.2 Execution
1) General pipes
(1) Horizontal pipe should have upward gradient by propagation direction for upward
water supply pipe. For downward water supply pipe, it should be downward
gradient by propagation direction. It should be equally graded for eliminating air
trapping and water drain.
(2) Flange connection is joined for easy maintenance and repair of pipe at proper
location.
Union can be used at pipe with less than 50mm of diameter.
(3) Valves can be union for maintenance need.
(4) Air chamber and other equipment can be attached by need for preventing water
hammering.
(5) Cross-connection pipe cannot be allowed in waterworks system.
(6) Countermeasure for reflow protection should follow the technical standard for
general pipe (industry development administration).
2) Pipes around pump
(1) Pumping pipe should have proper upward gradient to high water tank.
(2) Induction horizontal pipe should be minimal (at least 3D) to pump with proper
upward gradient.
(3) Pipe should be sufficiently fixed with vibration proofing connection to eliminate
distortion of pipe.
(4) Drain around pump should be installed with more than 32mm thick indirect drain.
3) Pipes around tank
(1) Pipe connected to tank securely fixes to eliminate the load to flange.
(2) Each connecting pipe excluding drain and ventilation should be attached with
flexible joint connector.
(3) Drain and overflow of tank is indirect discharge.
4) Water meter and other equipments
(1) Installation location of water meter should be easy to inspection and replacement.
With consideration of shock resistance, it is fixed or supported.
(2) Depressurizing valve should be installed with bypass (including strainer) with
consideration of space for maintenance and replacement. Pressure gauge is installed
at primary and secondary, and depressurizing valve is adjusted by secondary
pressure.
(3) Air vent valve is installed at top part that collects air.
(4) Ball tab is installed at the highest location in water supply tank where features easy
maintenance and no overflowing.
(5) Discharging port in water level valve should be installed at higher location than the
highest level. Secondary valve is installed at distance from discharging port and
cover of manhole.
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4. Installation of hot water supply facility and pipes
4.1 Selection of equipments and materials

1) General issues
Equipments and materials for hot water supply facility conform KS with non
contaminating structure and material. If there is no suitable standard, it should be
2) New extension
It should be bellows with cover, and conform KS. In addition, usage temperature should
be endured, and authorization of the company is needed.
3) Valves, strainer, vibration proofing connection, axial connection pressure gauge for hot
water supply should follow the same standard for water supply with endurance of
temperature.
4) Thermometer
This is L shape thermometer with insulation and KSB-5302 (glass insulator, more than
production) certification in material and performance. Scale is larger than 120℃.
4.2 Execution
1) General pipes
(1) Y connector is used that reverse circulation in gravitational system is
expected.
(2) Extension connector is installed.
Pipe with extension connector is equipped with fixing structure at effective location.
(3) Heat resistant material is used for protecting pipe.
(4) It should be equally graded for eliminating air trapping and reverse gradient.
(5) For upward pipe, temperature supply pipe should have upward gradient. For
circulating pipe, downward gradient is needed. For downward pipe, hot water
supply and circulation pipe should be downward gradient by propagation direction.
Gradient is 1/150 for gravitational and 1/200 for forced circulation.
(6) Other issues conform water supply pipe.
2) Pipes around equipment
(1) Flange and valve is attached for easy detach/attachment of equipment.
(2) Pipe should be fixed and supported not to be loaded directly.
(3) Reflow protector should be installed at connection to hot water tank.
(4) Drain for hot water tank and safety valve is indirect discharge.
(5) Lined circulation pump should be supported with scaffold with vertical or horizontal
connection to flange. By considering natural convection, bypass is installed at
circulation pipe.
(6) Water pump for hot water conforms the one for water supply.
(7) During the installation of water pump, connection to water pump cannot be lead
pipe and hard PVC pipe. Other issues conform the installation of water supply
pump.
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(8) Attachment of automatic temperature control valve is securely installed with bypass
(including strainer) at easy maintenance and handling.
5. Drain and ventilation facility
5.1 Selection of materials and equipments

1) General issues
Follow sewage act and related regulations.
2) Cleaning port
(1) Cleaning port on top of floor should be certified shape and dimension or passed
related standard for cleaning port (connecting media).
(2) Cleaning port on bottom of floor should be certified shape and dimension or
passed related standard for plug (connecting media).
3) Trap
(1) Depth is 50~100mm. For air conditioning, 1.5 times of fan static pressure is needed.
(2) Trap formation by assembly or partition is not allowed.
(3) If cover exists, trap should be installed to prevent the inflow of gas from
downstream.
(4) Foothold in bottom drain trap should have enough strength and
temperature stability.
(5) U trap should be certified with KSB-1532 (screw drain connector, more than
production) or KSD-4307 (cast iron pipe, more than production).
(6) Grease trap features dividing structure, and is installed at cover for maintenance.
4) Ventilation
Larger effective area than cross-sectional area of ventilation with enough corrosion
resistance is needed.
5) Vibration proof connection
It follows vibration proofing and new extension of water supply facility with little
change in cross-section.
5.2 Execution
1) General issues
Equipments and pipes should feature required safety and protection from sewage act,
construction act, environment saving act, waste cleaning act, and other related
regulations. Other issues conform the general characteristics of pipe.
2) Installation of cleaning port
(1) Cleaning port is installed at following location.
Starting point of drain pipe and main pipe
Within 30m of long horizontal pipe or direction changing at more than 45° of
angle Bottom or nearby location in vertical drain pipe
Nearest location from connection of horizontal main pipe and ground drain
Location other than the above with requirement
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(2) Cleaning port is installed at easy cleaning location. If wall, floor, pillar affect on
cleaning, more than 300mm for less than 65mm diameter pipe and more than
450mm of space for more than 75mm diameter pipe is maintained.
(3) For buried pipe, it should be installed to be extended to finishing face of floor or
wall. If burying is unavoidable, inspection hole is installed at cleaning port.
(4) Every cleaning port is installed to be opened at right angle or opposite to drain.
(5) Cover will stop the leakage, and protect from foreign body.
(6) If cleaning port is installed at waterproofing layer, layer holder is securely fixed with
receiving frame. After application of cinder concrete, top face of cleaning port is
parallel to floor finish.
3) Installation of bottom drain trap
(1) Floor drain should be installed at easy maintenance, management, and authorized
by the company.
(2) Depth is 50～100mm.
(3) Supplying water cannot be directly connected.
(4) If floor is waterproofing layer
① Waterproofing layer receiving frame of trap is installed with parallel to concrete
finish, and securely filled with mortar at the gap between main body and
concrete.
② After waterproofing work, clogging of water drain hole is checked and fixed.
③ After cinder concrete application, trap top and floor finish should be parallel.
④ If floor is not waterproofing layer
Trap face is installed with parallel to concrete finish, and securely filled with
mortar at the gap between main body and concrete.
4) Installation of ventilation
(1) If ventilation port is near to entrance, window of nearby building, it should be
installed at more than 600mm vertically from top of opening.
(2) Ventilation for penetrating outer wall should be installed downward.
5) General drain pipe
(1) If joining of horizontal branch pipe is made, it should be acute angle at less than
45 degree, and joined at near horizontal gradient.
(2) If lead pipe is bending, cross-section should be maintained to be round, and branch
is not connected on bent area.
(3) Double trap is not installed at drain pipe.
(4) T connector and cross connector is not allowed for horizontal main/branch pipe.
(5) Union and flange is not allowed at middle of drain pipe.
(6) PVC pipe for raindrop cannot be connected to drain pipe.
(7) Pipe should not be exposed or buried without proper protection where freezing is
expected.
(8) Drain pipe cannot be bored for screw or welded.
(9) Gradient for horizontal pipe should be proper without unevenness.
Gradients for indoor horizontal drain pipe are following.
* For 30mm ~ 50mm of diameter, less than 1/50
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* Fore more than 250mm of diameter, flow rate should be at least 0.6m/sec.
6) Pipe for indirect drain
(1) Drain for following device and equipment should be indirect drain.
Refrigerator, dishwasher, washing machine, or equivalent
High water tank, water tank, water supply pump or equivalent
Steam and hot water system
(2) Indirect pipe should be installed for easy cleaning and washing.
(3) Indirect drain is not allowed for flushing, washbowl, sink, kitchen sink, etc.
7) Raindrop drain pipe
(1) Vertical pipe for raindrops should not be used as vertical drain pipe and ventilation.
(2) If acknowledged by temperature change, structure, connection or sleeve is installed.
(3) Trap is not allowed for vertical pipe connected to horizontal pipe for raindrops.
8) Ventilation pipe
(1) Top of ventilation vertical pipe should be connected to vertical pipe by raising one
level for each ventilation port.
(2) Bottom of ventilation vertical pipe should be connected to vertical or horizontal pipe
with 45℃ Y shape connector.
(3) Vertical ventilation pipe cannot be used as raindrop vertical pipe.
(4) End of ventilation pipe should be 150mm higher than ceiling.
(5) All ventilation pipes should be connected to drain for eliminating reverse gradient.
(6) Ventilation pipe is installed at the nearest location at 45° or vertical venting.
ventilation with more than 150mm from overflow at the highest hygienic
equipment should be connected.
(7) Ventilation pipe cannot be bored for screw, and welded.
(8) Ventilation of indirect drain should be single pipe.
6. Installation of hygienic equipment
6.1 General issues

1) Selection of hygienic equipment
If the same equipment is installed to be seen at the same time, distortion, smudge of
hygienic equipment should be installed not to be seen through one time selection.
2) Discharging space
Discharging space should have more than standard value for hygienic performance.
3) If partial of equipment is buried into concrete, connection between equipment and
concrete/mortar should be covered with 3mm thick asphalt or anti-corrosion covering.
For stall urinal, filler (sand or equivalent) is filled at contacting face.
4) Installation of wall attaching ceramic ware conforms the following.
(1) If it is installed at tiled wall, installation wood with application of antiseptic is
securely fixed at tiled wall.
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(2) For framed wall or plywood wall, hardwood with enough strength to support
equipment should be installed.
(3) For lath mortar or fire resistant board wall, wood with enough size and strength as
pillar should be installed.
(4) For installation at concrete wall, expansion bolt is used.
(5) For installation at metallic panel or light weight steel frame board, steel plate or
angle or sturdy wood is installed as supporter.
(6) If stand is used, it should be leveled at height, and securely fixed to floor.
5) Installation of washer
Washer is installed at penetration of wall and floor for water supply, hot water supply,
washing and drain pipe that are exposed at interior.
Washer should be fixed without gradient and shaking.
6) Ceramic ware and metallic attachment should be properly protected after installation
and before use.
6.2 Details
1) It should be installed by the recommended method from manufacturer.
2) Other detailed issues follow air conditioning, standard specification from Korea
Refrigerating Association.
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Chapter 5 T.A.B
1. General issues

This specification applies to T.A.B(Testing, Adjusting & Balancing) for mechanical unit.
1.2 Safety management and hazard prevention

1) Contractor should appoint the person in charge for safety management, and the list
and safety management plan must be submitted and authorized to supervisor 15 days
before from starting construction work. Safety and hazard protection must be ensured
in every aspect of work, and safety guideline at on-site by Lotte must be followed.
2) Contractor should be responsible to hazard and safety accident during work.
1.3 Qualification of builder

T.A.B contractor should have the below conditions.
1) Main business area should be T.A.B on environment system (air conditioning).
2) Full time employee who has many experience on system adjustment should be held.
3) The company should be registered technical service company in MOST to prove the
preciseness of submitted data.
1.4 Plan for work execution

Contractor should submit work execution plan and be authorized within 60 days.
Service execution plan should include the following.
1) Service execution procedure and method
2) Organization and HR input plan
3) Detailed process
4) Equipment list
5) Execution procedure and method for related work
6) Reporting forms and submission time
7) Other requirements
1.5 On-site agent

1) Builder should nominate the technician with certification and vast
experience/technologies on T.A.B area before commissioning work. Documents that
notify career (resume, copies of certificates, on-site agent list, other documents, etc)
should be submitted and authorized\, and the agent should be stationed permanently
at the site.
2) Builder should station the requested on-site agent and responsible technicians by work
load at the commissioning of work. Submittal documents for technician are same as
on-site agent, and authorized by supervisor.
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3) On-site agent and technicians carry out the responsibility and duty for work progression
and other issues in construction.
4) The one should not have any disqualification from Code 7 (on-site agent) in
Construction Contract Condition and Code 12 (assignment of construction engineer) in
Construction Business Act.
1.6 Execution of work

1) All work should be carried out to ensure enough and satisfactory performance in all
sorts of facilities. The reasonably required or regulated items in work, structure, and
appearance should be executed by the responsibility of builder from the direction of
supervisor even if the issues are not listed in plans and specification. At the completion
of work, it must be reflected to cost settlement of completion drawing.
2) Contractor should re-work or modify if the work is recognized as incomplete or unfair
by supervisor.
3) If temporary structure such as on-site office and storage should be installed, all sorts of
issues should be followed the direction of supervisor.
4) If special consideration of supervisor is required or the one is buried or concealed, it is
pre-inspected by supervisor. Acknowledged area should be photographed in color.
1.7 Process management and reporting

1) Detailed process plan of work is written in CPM, and submitted/authorized to/by
supervisor 15 day before commissioning. The work should be conducted according to
the plan, and updated in one time per month.
2) Daily and monthly report that includes the progression of work, employment of worker,
take in/out of material, various testing, and other issues should be written and
submitted for the approval of supervisor. In addition, the requested document should
be presented in prompt.
3) According to main process diagram, which is submitted prior to commission, monthly
progress plan should be submitted and authorized within 20 of previous month.
1.8 On-site management

1) On-site management should be carried out by the related regulation.
(Labor standard act, Labor safety management regulation and security legislation)
2) Builder should manage the entry of worker and other personnel, and be responsible to
discipline enforcement, hygiene management, fire, theft, noise, casualty, maintenance of
hazardous item.
3) On-site should be cleaned, and information management on every material and
temporary equipment should be conducted thoroughly.
4) Equipment, material, facility that is prone to be contaminated or damaged should be
protected via appropriate method.
5) After the work is finished, temporary item should be removed and cleaned promptly.
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6) Equipment and material that is passed inspection and testing should be stored at
designated location by supervisor. The rejected goods should be carried out from
on-site.
1.9 Choice and design change

1) Choice
(1) Supervisor can request the partial re-evaluation to contractor if it is considered to be
very important.
(2) Supervisor can request the T.A.B program change with consideration of circumstance.
2) Design change
(1) Fee for additional installation of equipment and tool after contract should be
discussed with supervisor. Trifle and little change for function should be conducted
by the expense of builder.
(2) Builder should cooperate with supervisor for good execution of work. If dispute
occurs, the one should follow the direction of supervisor.
1.10 Relation to other work

Works that are related to construction and electrical work should be executed through
prior discussion with supervisor. Any setback and failure in other work should be
responsible to the builder.
1.11 Testing for equipments and materials

1) Testing and inspection under KS standard should follow the corresponding standard and
other related regulations.
2) Quality and specification for all materials and equipments in work should be matched
with design document, and be authorized before use.
3) Fee for required testing and inspection is handled by the builder.
1.12 Completion
Completion can be made after no disorder in comprehensive test operation result,
submission of the following documents, and authorization of supervisor.
1) Processing result for pointed issues by supervisor
2) All sorts of documents to authority
3) T.A.B result report
T.A.B result report should be composed with the below system summary.
(1) Cover that indicates major system equipment, on-site location, contract number,
signature of supervisor, report submission date
(2) System overview and description (diagram)
(3) Materials and equipments that are used in test
(4) Opinion for T.A.B report, which is beneficial to authorization
(5) Opinion of T.A.B builder, which is beneficial to operation and management
(6) Name and signature of author in system summary
(7) Record for performance and top point in induced during T.A.B execution
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(8) System operation status and completion of building
1.13 Submitting documents

Builder should submit the following documents, and be authorized by supervisor.
1) Commission of work (4 copies each)
(1) Work commission
(2) On-site agent list (resume, copy of qualification and organization)
(3) Overall process flow
(4) Work execution plan
2) During work
Process report
(1) Daily process report
(2) Weekly process report
(3) Monthly process report
(4) Monthly detailed process table
3) Completion
Completion documents: 7 copies
1.14 Transfer
1) After completion inspection, completion documents should be handed over
management.
2) Enough education should be conducted on managing personnel with the expense of
builder.
1.15 Warranty
1) Failure warranty term is two years from completion.
2) Builder should immediately correct any failure during warranty without additional cost.
2. Special issues

1) Testing, adjusting, balancing on mechanical facility is conducted, and work scope is
following.
(1) System Review
(2) Water Balancing (Hydronic)
(3) Air Balancing
(4) Sound Testing
(5) Vibration Testing
(6) Pressure Test for Duct System
(7) Adjustment of automatic control
(8) Writing report
(9) Etc
2) TEST should include the below system at minimum.
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(1) Air flow measurement

① Duct system
② Fan
③ Motor
④ Air conditioner
⑤ Fan coil unit
⑥ Various coils (AHU, chiller, heat exchanger)
⑦ Heating unit
⑧ Diffuser, grill, register
⑨ V.A.V terminal
⑩ Other designated issues
(2) Fluid measurement
① Pipe system
② Pump
③ Freezer
④ Compressor (excluding air compressor)
⑤ Cooling tower
⑥ Condenser
⑦ Heat exchange
⑧ Boiler (including winter time)
⑨ Other designated issues
(3) Sound Test
(4) Automatic control SYSTEM
(5) TEST VALVE TREATMENT
(6) CONTROL VALVE CALIBRATION
2.2 T.A.B condition

T.A.B execution procedure and material should conform the standard of below
associations.
1) SYSTEM MANUAL 40 from ASHRAE
2) TAB for environment system from SMACNA
3) International environmental measurement standard from AABC
4) Procedure standard for system TAB from NEBB
5) Air circulation from American Hygienic Society if applicable
------ REMARKS -----
* ASHRAE : AMERICAN SOCIETY OF HEATING, REFRIGERATION AND AIR
CONDITIONING ENGINEERS, INC.
* SMACNA : SHEET METAL AND AIR CONDITIONING CONTRACTORS NATIONAL
ASSOCIATION, INC
* AABC : ASSOCIATED AIR BALANCE COUNCIL
* NEBB : NATIONAL ENVIRONMENTAL BALANCING BUREAU
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2.3 Measurement tool

1) Requirements
(1) Builder should supply all equipments and materials for T.A.B .
(2) Builder should submit the document that proves used material and equipment is the
most appropriate for T.A.B.
2) Tool testing ( precision )
Builder should submit any proving document if there is any question for life cycle,
operation status, etc from supervisor.
3) Other issues
Builder should record measurement tools for each part as portion of system summary.
2.4 Adjusting and balancing

1) Overview
Balancing and adjustment of water or air in building is most important aspect in
system performance of cooling, heating, air condition. Therefore, T.A.B must be
executed for precise test and adjustment, balancing air and hydro system.
2) Performance warranty
After completion of T.A.B, if guarantee or re-evaluation on recorded system and
equipment is required, the builder should submit equipment performance warranty and
be authorized by supervisor.
3) Report forms
(1) Builder should use authorized reporting form.
(2) Report should include every air and hydro system.
(3) Report must record design and actual status with inclusion of below data at
minimum.
① Air distribution system
(a) System number and location
(b) Fan RPM
(c) Pressure loss in filter (mmAq)
(d) Fan inlet and discharge pressure
(e) Fan motor current and operating heater
(f) Air circulation (CMM)
(g) Open air (CMM)
(h) Open air temperature (DB, WB)
(i) Recycled air temperature (DB, WB)
(j) ENTERING coil condition (DB: heating, DB & B: cooling)
(k) Fan discharge status (DB, WB)
(l) Air supply in main duct (CMM)
(m) Adjustment ratio between design and actual
(n) Circulation by ZONE
(o) Opening of air valve in each system
② Exhaust and recirculation system
(a) Date
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(b) System number and location

(c) Room or supplied area
(d) Fan RPM
(e) Fan motor current and operating heater
(f) Total circulation (CMM)
(g) Fan induction pressure
(h) Fan discharge pressure
(i) Adjustment ratio in design and actual value
③ Room data
(a) Room number
(b) Number of supply and exhaust system
(c) Air supply of diffuser (CMM)
(d) Air exhaust of register and grill (CMM)
(e) Area and size ratio of air supply and exhaust port
(f) Adjustment ratio in design and actual value
④ Hydro system
(a) External status during test
(b) Title and number of pump
(c) Pump RPM
(d) Pump current (individual and interactive operation)
(e) Rated current for all motor: operating heater
(f) Induction and discharge pressure of pump: individual and interactive
(g) Flow rate of pump (LPM): individual and interactive
(h) Supply and circulation temperature of pump media
(i) Supply and circulation flow rate of heat exchanger (LPM)
(j) Supply and circulation flow rate of all coils (LPM)
(k) Pressure drop of all coils
(l) Circulating air temperature in AHU
(m) Circulating air pressure in AHU
(n) Combustion status of boiler
(o) Inlet and exit temperature in boiler
(p) Current of refrigerator and cooler
(q) Inlet and exit temperature in refrigerator and cooler
(r) Saturation temperature of condenser
(s) Refrigerant temperature in condenser
(t) Adjustment ratio in design and actual value
4) Adjusting and balancing procedures
(1) Overview
Builder should perform test, adjustment, balancing through below procedure, and
test result must be recorded in report form.
(2) 1st step
① Fan testing and adjustment for design value
② Test and recording of motor for various filters
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③ Air flow is measured at design value by penetrating Pitot tube into main duct.
④ Open air flow is tested and adjusted to design value.
⑤ Recirculating air flow is tested and adjusted to design value.
⑥ Inlet and exit temperature for cooling and heating air is tested and recorded. (
DB : heating, DB, WB : cooling )
⑦ When valve is completely opened, air flow temperature at re-heating coil is
tested and recorded.
⑧ Air flow in every location is adjusted as design.
⑨ Diffuser, grill, register is tested, and adjusted within 10% of design.
If more than 4 equipments are operated in one space, each is tested and
adjusted within 15% of design requirements.
⑩ Diffuser, grill, register must indicate the location and area.
- Diffuser, grill, register, and all tested equipments should record specification,
type, number and manufacturer.
- Testing on diffuser, grill, register should include speed, composed speed,
composed wind capacity.
- With collaboration of engineer in controller manufacturer, automatic damper
should be adjusted to operate as design requirements. Builder must check the
preciseness of controller, and make the list.
- Diffuser, grill, register is adjusted to show minimum wind capacity.
Filter pressure gauge and set tap at maximum pressure should be tested.
(3) Hydro system
① All valve excluding the closed one for normal state should be opened.
② Every filter must be cleaned before test.
③ Water quality in system must be tested.
④ Individual and interactive operation status of pump must be confirmed.
⑤ To check the air containment or water level in system, expansion tank should be
checked.
⑥ Air discharging at maximum point of system should be checked along with the
operation of related equipments. Manual air vent in hydro system is checked for
no air.
⑦ Temperature controller should be fixed to cool all coils.
⑧ The following procedure is taken for complete heating of hot water coil.
⑨ With cooperation of engineer from controller manufacturer, temperature of
hot/cold water should meet the design value.
⑩ Perfect air balance must be performed prior to adjust the balance in hydro
system.
(4) 2nd step
After completion of 1st step, the following 2nd step is conducted.
① Flow rate of cold/hot water pump is adjusted to design requirements.
② Adjust flow rate of cooling water.
③ Adjust flow rate through coils in heat exchanger, radiator, re-heating.
63
④ Check the circulation and leaving temperature in heat exchanger and adjust
design requirement temperature.
⑤ Check temperature of mixed water in radiator.
⑥ Confirm temperature of inflow water in cooling and heating coil.
⑦ Conduct balancing adjustment for cooling and heating coil.
⑧ If 3 - WAY valve is installed, flow rate should be adjusted to be same as
circulation in coil or heat exchanger.
⑨ After the completion of flow rate measurement and adjustment for coil, mark
and record data.
(5) 3rd step
After completion of 1st and 2nd step, the following 3rd step is conducted.
① After adjustment completion of pump and heat exchanger coil, recheck and
adjust if required.
② Pressure gauge is installed at coil, and pressure drop in coil is measured with
fixing flow rate for heating and cooling.
③ Valve adjustment follow the adjustment of cooling water.
④ The followings are recorded and checked for basic elements in cooling/heating.
(a) Inlet temperature
(b) Outlet temperature
(c) Pressure drop in coil
(d) Pressure drop through valve
(e) Discharge and induction pressure during pump operation
(f) Mechanical specification for pump
(g) Rated current in motor during pump operation
(h) Maintenance of flow meter
(i) Check pressure drop through steam valve when all equipments are opened
(j) With collaboration of engineer at temperature controller manufacturer,
humidity and moisture in air supply system is checked and adjusted.
2.5 Reporting and recording

1) Report and test plan
(1) Builder should submit 3 copies of T.A.B reports before final test.
(2) Builder should submit T.A.B final results, and be authorized by supervisor.
2) Record
(1) Report must record precisely the measured flow rate during T.A.B.
(2) T.A.B final test plan should record the corresponding air inlet number and flow
station number in balancing log.
2.6 Final test and adjustment

1) During final test, all system must be operated within 5 days. Balancing valve and
damper must be precisely notified for maintenance of building.
2) During final test, the following test should be conducted in parallel.
(1) Sound test
64
(2) Vibration test

(3) Air pollution measurement
(4) Temperature and humidity measurement for indoor cooling/heating
(5) Etc
3) During final test, the failure from imputation should be reworked or repaired without
any additional cost for retest.
65

KT&G Indonesia Project - Mechanical General Specification

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KT&G Indonesia Project - Mechanical General Specification

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L I S T

01. General common issues ······································································································· 01

02. Air conditioning duct work ································································································· 26

03. Air conditioning pipe work ································································································· 36

04. Hygienic pipe work ················································································································ 41

05. T.A.B ··········································································································································· 56

Chapter 1 General common issues

1.1 Applicable area

1.2 Related regulations

1.3 Definition of terms

1.4 Safety management and hazard protection

1.5 Execution of work

1.6 Used materials and equipments

1.7 Supplied materials

1.8 On-site agent

1.9 Process management and work reporting

1.10 Quality management

1.11 On-site management

1.12 Blue print and working drawing

1.13 Design change

1.14 Relation to other works

1.15 Authority formalities

1.16 Testing and inspection

1.17 Test operation

2.1 Steel and welding work

2.2 Safety guideline in welding and cutting work

2.3 Insulation work

Other material Inflammable

(2) Exterior material should follow the below table.

Materials Specifications Note

Plain glass fabric specified in KSL 2508

Insulating plate specified in KSL 6705 (aluminum Inflammable

Thickness 0.27mm with KSD 3506 (zinc plated steel

Attaching more than 370g/㎡ of stencil paper to

Following KSF 4553 (metal lath, more than

Proper length of nail with thickness of insulating

3) Common issues of work

(19) Required adhesive for all insulating work should be inflammable.

Pipe diameter 15 20 25 32 40 50 65 80 100 125 150 200 250 300

Material Rubber Foam Insulation

Pipe diameter 15 20 25 32 40 50 65 80 100 125 150 200 250 300

Material Rubber Foam Insulation

Pipe diameter 15 20 25 32 40 50 65 80 100 125 150 200 250 300

Material Rubber Foam Insulation

7) Insulation of duct and equipment

Surrounding condition Air conditioner Blower Refrigerator

Type Usage Material and work procedure Note

B Buried duct at interior Same as exposed duct at interior

(2) Insulation work of smoke exhaust duct

Type Usage Material and work procedure Note

1) Spot welding rivet

2.4 Paint work

3) Arrangement work on paint side

○ ○ Wash with gasoline, soapy water, heating with weak

Chemical treatment right after acid dipping,

Paint Number of paint

Paint Number of paint

Buried Rust proofing 1 - 1

Equipment and Expose Rust proofing for

Expose Rust proofing for

Duct (steel plate)

Note) 1. Equipment painting in above table is for on-site painting work

① Rated voltage: 3∮, 380V 1∮, 220V 3∮, 220V