University of Brighton Standard Specification for ... · Standard Specification for Mechanical...

DEPARTMENT OF ESTATE AND FACILITIES MANAGEMENT

University of Brighton

Standard Specification for

Mechanical Services

February 2015


Standard Specification for Mechanical Services

Contents

1 Contract Documents .............................................................................................................. 1

1.1 General ............................................................................................................................. 1

1.2 Related Documents .......................................................................................................... 1

1.3 Builders‟ Work................................................................................................................... 2

1.4 Particulars of Work ........................................................................................................... 2

1.5 Plant and Equipment......................................................................................................... 2

1.6 Control .............................................................................................................................. 2

2 General Specification ............................................................................................................ 3

2.1 Boilers .............................................................................................................................. 3

2.2 Gas Fired Boilers .............................................................................................................. 4

2.3 Pumping Equipment ......................................................................................................... 6

2.4 Calorifiers and Cylinders ................................................................................................... 7

2.5 Water Heating ................................................................................................................... 7

2.6 University Standard Arrangement for New/Refurbished Toilets ......................................... 8

2.7 Cold Water Cisterns/Storage/Expansion Tanks .............................................................. 14

2.8 Pressurisation Sets ......................................................................................................... 15

2.9 Space Heaters ................................................................................................................ 15

2.10 Ductwork ......................................................................................................................... 18

2.11 Electrical Equipment and Wiring ..................................................................................... 21

2.12 Pipework/Tubing ............................................................................................................. 24

2.13 Valves and Cocks ........................................................................................................... 29

2.14 Additional Instrumentation .............................................................................................. 31

2.15 Thermal Insulation .......................................................................................................... 32

2.16 Painting........................................................................................................................... 35

2.17 Spacing of Services ........................................................................................................ 39

2.18 Identification of Services and Plant ................................................................................. 40

2.19 Testing and Commissioning ............................................................................................ 42

2.20 Operating and Maintenance Manual ............................................................................... 44


1

Standard Specification for Mechanical Services

1 Contract Documents

1.1 General

The standard specification is a reference document for use by all electrical and mechanical

contractors undertaking general maintenance, repairs and new installation within the

University‟s buildings.

The document must be read in conjunction with the individual specification for each project

and schedule of work.

Where details have not been specified, use the document to form a basis for required

materials etc. to complete the work.

The document details the following:

Work standards;

Materials for particular projects;

Procedures;

Test requirements;

Documentation;

Safety standards.

1.2 Related Documents

The standard specification must be read in conjunction with, and take full account of:

Special conditions of contract;

Detailed Schedules of Work against particular projects;

Health and Safety at Works Act 1974 and regulations and statutory instruments

passed by Parliament, and codes of practice issued by the Health and Safety

Executive;

Workplace (Health, Safety, and Welfare) Regulations 1992;

The Management of Health and Safety at work regulations 1999;

The Provision and use of work equipment 1998;

Personal Protective equipment at work regulations 2002;

Manual handling Regulations 1992;

Control of Asbestos at work Regulations 2006.


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The Factories Act 1961;

Water Supply (Water Fittings) Regulation 1999;

The Gas Safety (Installation and Use) Regulations 1998;

Institute of Gas Engineers Utilization Procedures (IGE/UP/1, IGE/UP/1A and

IGE/UP/2);

Hazardous Waste (England & Wales) Regulations 2005;

Environmental Act 1996; Environmental Protection Act 1990, and E.P.A. (Duty Of

Care) Regulations 1991;

BS 7671, 2004, the I.E.E. regulations for electrical installations, seventeenth

edition;

The Electricity Supply Regulations 1992;

Construction (Health, Safety and Welfare) Regulations 1996;

The University of Brighton Standard Specification for Electrical Services.

1.3 Builders’ Work

Unless specified, the electrical and mechanical contractors will be responsible for all builders‟

work associated with any mechanical or electrical work undertaken and must be completed

to the acceptable standard of the Employer.

1.4 Particulars of Work

The tenderer is responsible for all measurement and compilation of quantities required

together with visiting the site as necessary. No extras will be allowed on account of

insufficient knowledge or inaccurate measurements or error.

The contractor will be responsible for isolating, draining down and filling / venting systems to

which work is carried out. The contractor MUST label and lock off any valve or system he

isolates to indicate the service is being worked on. The label must state the contractors

name and contact telephone number.

1.5 Plant and Equipment

The Contractor shall provide all the necessary plant and equipment for the proper execution

of all specified and instructed works including scaffolding, lifting tackle, machinery and

appropriate tools. The contractor shall be responsible for the carrying the above to the place

where they are required, for the necessary erection and subsequent removal.

Please note: electrical work tools of above 110 Volts will not be allowed.

It will be necessary to provide written “Risk Assessment” and method statements against all

elements of work as required conforming to the Health and Safety at work regulations.

1.6 Control

All works will be controlled via the University‟s Estate and Facilities Management Department

under the direct control of the Building Services Engineer or Contract Administrator‟s

Representative (CAR).


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2 General Specification

2.1 Boilers

Boilers shall be of the type detailed in the schedule of works, being purpose-designed for

firing by one of the following methods and be compatible for connection to a TREND BMS. In

general apart from domestic installations, a minimum of two boilers shall be installed sized to

match the load.

Gas with forced air burner;

Gas with atmospheric burner;

Gas/ oil dual fuel forced air burner;

Gas Pre-mix burners

Boilers shall be erected and pipework connections made thereto strictly in accordance with

Manufacturer's instructions.

Each boiler shall be provided with the following mountings:

Safety valve

Altitude or pressure gauge

Thermometer

Emptying cock(s) or drain valve(s)

A distinct and easily visible number where two or more boilers are provided

numbered from left when facing front of boilers.

Where automatic control is specified all necessary fittings and equipment shall be provided

with the boiler.

All flues shall be constructed of Stainless Steel and be of Twin Wall design and shall satisfy

the requirements of the boiler manufacturer and including draught stabilisers where required,

liners, and terminals as necessary.

All boiler flue pipes shall be adequately supported and provided with cleaning doors and

15mm plugged tapping for flue gas sampling. Where a flue pipe enters a brick chimney the

Contractor shall supply a metal sleeve (25mm larger than flue pipe diameter) for building in.

The space between the sleeve and the flue pipe shall be caulked to a minimum depth of

50mm with non-combustible silk-glass rope. The flue pipe and sleeve shall finish flush with

the inside face of the flue.

Flues on Atmospheric boilers shall have provision to remove the draught Stabiliser for

service purpose without dismantling the flue system.

Where indicated a combined explosion-relief flue-access door and draught-stabiliser with an

adjustable counter-weighted metal vane shall be provided. All components shall be of

corrosion-resisting alloys.


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On an open vented system an open vent pipe shall be taken from each boiler but on

installation of two or more boilers the open vent pipe from each boiler shall be connected into

a common vent pipe through a three-way valve.

Boiler doors shall be fitted with stops to prevent damage to thermal insulation. Where

possible all controls shall be arranged so that they are accessible from the boiler front.

Where an oil/gas burner is hinged mounted a micro-switch shall be fitted to ensure that the

burner can only fire when the mounting is fully closed.

Immediately each boiler is erected and before connecting to any pipework, it shall be

hydraulically tested.

Before insulation is applied all joints in the combustion chamber and flue pass system shall

be satisfactorily sealed against leakage to suit the design pressure conditions of the

combustion chamber.

The boiler/burner manufacturers will be required to commission all new plant and a full set of

operating instructions and commissioning figures being forwarded to the CAR

2.2 Gas Fired Boilers

Unless otherwise specified all forced draught gas burners shall be manufactured by Riello or

Weishaupt.

All atmospheric gas appliances shall be automatic electric ignition (Not Permanent Pilot) and

be compatible with a TREND BMS system.

The University‟s preferred boiler type is fully condensing, with Broag or Atag being the

preferred manufacturer for commercial boilers, and Atag or Glow-worm for domestic boilers.

Gas Burners

Gas-fired boilers shall be capable of the duty indicated when burning gas of the calorific

value or gas group of the appointed “Shipper”. Gas burners shall be atmospheric, pre-mix, or

forced-air type complete with:

Flame failure device;

Adjustable water-way thermostat;

Overriding limit device (manual re-set type);

Gas pressure governor;

Electric ignition;

Suitable brass pockets to be provided for all thermostats.


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Maintenance

Only manufacturer‟s replacement parts must be fitted to all burners unless otherwise agreed.

Modifications will not be allowed without prior written consent from the Building Services

Engineer or CAR

Pipework

The gas supply shall be run to the boiler(s) from the meter position as indicated, complete

with a master gas valve (lever operated ball pattern) positioned after the main enters the

boiler room and adjacent to the boiler room access door.

Adjacent to, and downstream of the master gas valve, an electrically operated gas

hydromotor type shut off valve shall be installed and wired to operate from the boiler room

fire /safety circuit.

Pipework should be sized to ensure that under full flow conditions the required pressure is

available at the burner inlet. There should be no undue pressure fluctuations due to varying

flow rates caused by operation of other plant and equipment on the same line. It must be

ensured that when all gas appliances are in operation there is sufficient pressure available

for the burner and also that the operation of one appliance will not affect the other.

All pipework should be in steel to BS 1387 with appropriate ungalvanised fittings and

adequate provision made for draining and cleaning.

Above each gas burner a fusible link type fire detector will be fitted complete with all

necessary wiring to:

Hold the valve open the electric gas safety valve under normal conditions;

Close the electric gas safety valve in the event of abnormal heat, and switch off

the boiler plant.

An Emergency stop switch shall be supplied and installed adjacent to the boiler room

entrance/exit and be connected to operate the fire/safety circuit. The installation will allow

ready access to all plant and components to facilitate operation of maintenance.

Full compliance with current standards and legislation must be implemented to ensure a safe

installation.


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2.3 Pumping Equipment

General

All pumps shall be installed in accordance with the Manufacturer's instructions with pipework

and electrical wiring arranged for easy removal and maintenance. On floor mounted

horizontal direct drive pumps, the motor shall normally be accessible from the front, to

facilitate maintenance.

Heating and Hot water primary circuits shall be fitted with two pumps (Duty and Stand-by).

Each pump shall be fitted with inlet and outlet isolating valves, and a non-return valve.

The University‟s preferred pump manufacturer is Grundfos.

BMS Controls associated with circulating pumps.

Pump failure will be monitored by the BMS system and will form part of the controls work.

Where inverter driven pumps are used each head must be provided with a permanent power

supply with the control and fault status activated/monitored by the TREND BMS system.

All pumps will be fitted with local electrical isolators.

All pumps will be fitted with inlet and outlet isolation valves and unions/flanges for ease of

removal.

Circulating Pumps

Heating and hot water service pumps will be as specified in the schedule of works. H.W.S.

secondary circulation pumps in direct contact with water will be constructed having bronze

bodies and stainless steel moving parts.

On Hot Water System Secondary Circulation circuits, only one pump shall be installed to

reduce the risk of Legionella forming in a standby set.

A spare pump head must be provided.

Sump Pumps

Sump pumps shall be of the automatic operating type as specified (Generally Grundfos).

Automatic pumps shall be complete with „failure alarm monitoring back to a prominent

position, a float switch mechanism, foot valve, and strainer. A union or flange shall be

provides to couple the pumps flexible pipework to the rigid above ground pipework, to ease

disconnection for maintenance. All open sump pits shall be covered by purpose made

chequered plate or grates, finished flush with the finished floor.

All motors and control equipment will comply with safety standards as detailed in the BS

7671, the 17th edition of the I.E.E. Regulations and University of Brighton Standard Electrical

Specification.


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2.4 Calorifiers and Cylinders

Calorifiers and cylinders shall be of the size, capacity and recovery rate as specified and

contain the following:

An altitude gauge;

A thermometer;

An open vent pipe on systems open to atmosphere, or manufacturer‟s unvented

kit;

A thermostatic control (as indicated);

A safety thermostat control (manual re-set);

A water sample test point at the bottom of the unit;

A drain cock;

An over pressure Relief valve;

Temperature and pressure Relief valve on mains unvented systems.

All storage calorifiers, unless otherwise specified, shall be stainless steel, high efficiency,

and fast recovery, suitable as singular or multi-modular installation.

On installations of two or more high output calorifiers, each unit must have its own separately

run safety vent NOT discharging over the cold water storage tank.

All storage calorifiers/cylinders above 300 litres capacity shall be fitted with detachable

bolted ends and hand holes, and a water sample point from the lowest level. Hand holes

shall be not less than 150mm diameter and shall be provided with cover secured by studs

and nuts. Joints shall be made with approved jointing material.

2.5 Water Heating

Direct Fired Gas Water heaters shall be internally protected by Permmaglas Ultra coating,

and incorporate a control system which enables a Legionella prevention program. The unit

shall be room sealed, condensing and un-vented where possible.

The University‟s preferred manufacturer is A.O.Smith, with their BFC unit meeting the above

requirements, but any product from their range may be accepted.

In general all Electric point of use water heaters will be manufactured by Zip Water Heaters,

and be of the un-vented type (Zip Varipoint III, or the Zip Aquapoint III) with 2.2kW heater

elements.

The units shall be fitted with manual reset over temperature thermostats, control thermostats

with a range between 20-75º C, and an expansion relief valve set to 6 bar.

Over sink instantaneous electric water heaters shall be manufactured by Heatrae Sadia and

Express model.


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2.6 University Standard Arrangement for New/Refurbished Toilets

These standards are for new toilets either in existing buildings or in new builds, and for

refurbished toilets. The main aims are to conserve water, prevent scalding to occupants and

standardise on material quality.

Flexible hose connections are not permitted for hot and cold water tap outlets.

The preferred option is for waterless urinals and blended hot water through a single

self-closing tap for hand washing with the hot supply being served from the builds central hot

water plant. If central plant is not available or if long dead-legs would be created, then local

electric water heating will be required. If on refurbishment work it is found that the drainage

system is not suitable for waterless urinals then a cistern and flush controls system should

be used.

Note: All work must comply with „The Water Supply (Water Fittings) Regulations 1999‟ and

any later amendments.

Under the above regulations dual flush WCs can now be used as long as the part flush does

not exceed 1/3 of full flush, which is now 6 litres on new works. It is only necessary to install

dual flush WC cisterns in ladies toilets.

Only competent persons to install any water systems.

Standard Arrangement for Urinals connected to cold water down service (preferred

option) or mains supply (A):

Standard urinal bowls are to be used with standard waste fittings (i.e. NOT specialist

waterless urinal fittings). Urinals will subsequently be served with biological chemical cubes.

Connect the flush pipe/s to a cold water down service (preferred option) or a water main via

a time flow control valve (Mira TF503) for use by the cleaner. If connected to a mains water

supply then install a type DC pipe interrupter Valve (Nabic Type 2565) below the flow control

valve (single urinal installation only), all installed below the main isolation valve (Crane D191

or D171).

On multi urinal installations a break/cistern must be installed and connected to a time flow

valve (Mira TF503) for use by the cleaner.

Flush pipe work shall be in 15mm stainless steel with purpose made fittings and the pipe set

where necessary.

Standard arrangement for Urinals when using a cistern type (D)

Standard urinal bowls are to be used with standard waste fittings (i.e. NOT specialist

waterless urinal fittings). Urinals will subsequently be served with biological chemical cubes.


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The flush pipes shall be served from a local cistern with a time flow control valve fitted, for

use by cleaners.

Standard Arrangement for Basins with existing hot and cold water supplies (B)

From new local isolating valves (Crane D171 or D191) extend to a point as close a possible

to underneath the basins and install an Oventrop Brawa-Mix blending valve complete with

strainers and NRV‟s. From the outlet of this blending valve connect to DOUGLAS DELABIE

Time flow taps fitted to the basins. ( A 15mm Oventrop Brawa-mix valve will serve 2 / 3

basins. If 4 basins, a 22mm blending valve can be used, but if more than 4 basins it is best to

have a 15mm blending valve serving a pair of basins.) Each blending valve set must have it‟s

own hot and cold service valves, and each basin tap must have a service valve.

The outlet temperature from the blending valve shall be set at 42º C.

Where this arrangement is used, then single hole tap basins are best.

OR (E)

As above for the blending valve, but with an infra-red sensor operated tap normally with the

sensor built in to the spout as in the Armitage Shanks Sensor Flow systems. This type of

system is best used when there is space to mount the control boxes, wiring and solenoid

valves inside a Vanity unit, or where a new „system type‟ toilet refurbishment is being

installed.

Standard Arrangement for Basins when Cold water main supply only is available (C)

Install over the centre of each basin a Heatrae Sadia Concept or Handy 3 type

instantaneous electric water heater. The mains water supply to each heater shall have a

service valve installed underneath the basin. Each heater shall have an electrical isolator

located at high level (out of wet hand reach) and a flex outlet adjacent to the heater.

Standard arrangement for basins when cold mains supply only and elbow taps

required for medical use

Use the same pipework arrangement as system „B‟ but the hot supply will be provided by a

Zip unvented electric water heater, normally located under the sink, sized for the number of

basins (normally a Zip AP 50, 5 litres capacity, or a Zip AP 100, 10 litres capacity). The water

heater should be set at 60º C and the blender valve used to serve the single elbow lever tap.

Disabled Toilet basins

If a Twyford‟s DOC-M Super pack has been specified, then it will come with an approved

TMV-3 thermostatic mixer tap (single hole tap). If this tap is not supplied, then use a Mira

Rada Termotap-3. This also for use in a single hole basin and must be connected to

balanced pressure hot and cold water services. Both of these options must have service

valves on the hot and cold supplies.


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Useful Contacts:

Self-Closing Taps:

Model Tempostop basin tap 15 sec code 745250

Douglas Delabie

7 Henderson House

Hithercroft Road

Wallingford

Oxfordshire

OX10 9DG

Tel: 01491 824449

Oventrop Brawa-mix blending valves and Nabic type 2565 DC pipe interrupter:

Pipeline Centre or BSS

Sensor Flow Taps:

Armitage Shanks PIR Basin Mounted Proximity Taps (Ref 95.050.149) plus control unit (Ref

7963002) for up to 10 taps.

Available from BSS group

Instantaneous Water Heaters:

Heatrae Sadia Express over-sink instantaneous water heater.

Available from PTS – 01273 466801

Mains Unvented Electric Water Heaters:

Zip AP50 or AP100


Urinal Flush Control:

Smartflush SF103B

Available from:

Springwell Microelectronics Ltd.

197 Raikes Lane

Birstall

Batley

West Yorkshire WF17 9QF

Tel: 01924 420029


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Elbow Operated Tap:

Pegler type 2158 QT050H


Mira Rada Thermotap-3



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2.7 Cold Water Cisterns/Storage/Expansion Tanks

All storage vessels shall be of the capacities and sizes specified and constructed of glass

resin reinforced plastic.

One piece or split moulded tanks shall be manufactured from unsaturated polyester resin

reinforced by glass fibre chopped strand materials built to BS 4994 and unaffected by the

extremes of temperature. The inner surface of the tank must be smooth with generous radii

to facilitate official and thorough cleaning.

All one-piece tanks must be evenly supported over the whole base area on a flat level

surface.

Moulded sectional tanks will be erected on site in full accordance with the manufacturer‟s

requirement for base mounting. All panels are to be UV stabilised and self-coloured to

eliminate on site painting and jointed with purpose sealant and stainless steel bolts.

All new tanks must conform to the current Water regulations and include a close-fitted lid;

screened warning pipes/overflows and vents.

All tanks will be pre-insulated as specified or with either wrap round insulating jackets or

purpose built sections including pre-made insulation. On larger section tanks a bolted

inspection/access hatch will be provided as specified.

Each tank/cistern will be fitted with an equilibrium type ball valve of the specific size and

suited to the available mains pressure.

Overflow pipes shall be at least twice the diameter of the normal size of the ball valve fitted

or 32mm diameter, whichever is the greater and comply with the latest water regulations.

Multi-pool tanks will be connected to a common overflow system with the main discharge

pipe being of a 50mm minimum diameter run to a predominant position on the outside of the

building so ensuring an overflow is easily identifiable.

All pipe connections above 50mm diameter to be secured by full face metal flanges with

pipework being fully supported.

In general, the mechanical contractor will ensure that when replacement tanks are required,

the supports/platform is suitable and in good sound order. Should any doubt occur or repairs

be required further advice must be obtained from the CAR

During inspection or maintenance visits please report to the CAR if the area is unsafe to

work in or poorly illuminated so the necessary safety improvements can be implemented.


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2.8 Pressurisation Sets

Will be as specified and installed/commissioned by the manufacturer to suit the system and

will include:-

High and low pressure switches;

System pressure gauge;

Unit pressure gauge;

Facility to connect to the TREND BMS system

The high/low pressure switches shall be interlocked to shut down the boilers and pumps on

high or low system pressure situations. If used in conjunction with BMS system suitable

alarms should be included in the control circuit.

The University‟s preferred manufacturer is Mikrofill EFD unit. Where these are installed a

filtered electrical supply will be required for these units.

Expansion vessels shall be correctly sized to match the system and be of the correct type.

2.9 Space Heaters

Radiators

Radiators shall be of the high output and low water content and sized as specified and

manufactured to BS EN 442 1997.

The positions of radiators and heights above floors and below window sills shall be

confirmed with the CAR before ordering. The minimum clearance between the floors and the

underside of a radiator shall be 150mm and it is essential that radiators and valves do not

project above the underside of the window sill.

Each radiator shall be provided with a chrome plated union wheel valve, or thermostatic

radiator valve on the flow and lockshield valve on the return.

The use of domestic model valves is not acceptable.

Each radiator shall be provided with an air vent plug or chrome plated air cock.

Each radiator shall be provided with purpose designed supports to suit the type of radiator

and wall construction.

The University‟s preferred manufacturer is Stelrad Elite or Rettig Purmo compact range, and

Stelrad LST2 type radiators.


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Natural Convector Heaters

Convector heaters shall be of the types and patterns specified, being complete with back

plates and dampers. Where recessed, concealed or built-in convectors are specified details

of the openings and of any fixings or framing required shall be supplied.

Two supports shall be provided for each wall-mounted convector not exceeding 1.2m long

and three supports for each convector longer than 1.2m.

Natural convector heaters shall be provided with air cocks accessible from the front or side

without dismantling the casings.

Unless otherwise indicated, all flow connections shall be provided with union valves with

wheel handles and return connections with union valves with lockshields.

Fan Convectors

Fan convectors shall be suitable for 230 volts supply and complete with fan speed set at low,

a low temperature cut out thermostat, washable filter, lockable access panel, 100mm plinth

(floor standing only), connections for remote room thermostat, air discharge from lower grill,

and powder coated casing.

Additional requirements for thermostatic controls, time switches, etc. shall be specified, with

the mechanical contractor being responsible for all external wiring and connection including

bonding from an adjacent electrical supply.

The University‟s preferred manufacturers are Thermal Heating Systems, and S+P Coils ltd.

The Thermal units for floor standing shall be their „Q‟ units, and wall / ceiling units shall be „K‟

units TT type and powder coated white.

Continuous Perimeter Heating

Perimeter heaters shall be of the radiant or combined radiant/convection types, or steel-

encased finned tube convection type as specified.

They shall be complete with all ancillary items including back plates, internal and external

cover strips, dummy sections, valve boxes and control dampers etc. so that each heater

presents a continuous unbroken appearance.

A seal shall be provided at the back of each heater to prevent streaking of the walls.

Copper connecting pipework between the elements of continuous perimeter convectors shall

have capillary or compression joints to suit the finned elements in accordance with the

Manufacturer's requirements. The tube shall be of the same grade and diameter as the

element tube. Expansion bellows with integral guides as supplied by the Manufacturer shall

be fitted into the connecting pipework.


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Perimeter heaters shall be provided with readily accessible air cocks and unless otherwise

indicated, union valves having non-metallic wheel handles on the flow connections and union

valves with lockshields on the return connections.

Erection of perimeter heaters shall be strictly in accordance with Manufacturer's

recommendations.

The University‟s preferred manufacturer is Thermal Heating Systems.

Radiant panels

Radiant panels etc. shall be of the ratings and dimensions specified.

All surface plates shall be smooth and free from buckles and waves. Where connections

pass through the sides of the panel they shall be sealed effectively. The space between the

edges of the panel and the wall or ceiling surface to which the panel is to be attached shall

be completely sealed.

Unit Heaters

The rated capacity, operating conditions, patterns and controls of unit heaters shall be as

specified.

Heaters shall be provided with two or more points of suspension and shall be so suspended

that their direction of discharge can be adjusted as necessary.

Flow connections shall be provided with union valves with wheel-handles and the return

connections with union valves with lockshields.

Electrical connection will be required to an adjacent supply with the provision of overload

protection on fan circuits above 1kw.


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2.10 Ductwork

Ducting

All ductwork must conform to the following specifications and be installed by a specialist

agent/manufacturer, in accordance with CIBSE current guides of practice

Ducting will be constructed from cold rolled, annealed, flattened galvanised mild steel sheet,

true in section, not twisted with knocked-up longitudinal seams on ducting of 0.6mm and

0.8mm thickness.

Ductwork over 0.8mm thick, must have riveted longitudinal seams with rivets at

approximately 35mm centres with edges dressed down flush to produce an airtight joint.

Ductwork connections to equipment in plant rooms to be manufactured from 1.6mm thick

galvanised steel sheet as detailed above.

All ducting external to Plant Rooms shall have swaged slip joints, the lap in each case being

not less than 40mm. Slip joints shall have solid or welded corners and shall be arranged in

the direction of air flow. The joints shall be secured with rivets or self-tapping screws at

50mm centres in ducts having sides smaller than 1000mm and by 12mm x 6mm diameter

mushroom headed screws, spring washers and captive nuts at 70mm centres in ducts

having sides greater than 1000mm.

Flanged joints must be provided and secured on all ductwork connections to equipment and

be of the same section as recommended for intermediate stiffness with bolts at 100mm

centres. Where angle frames are fitted the corners of the duct shall not be split and the ends

of the ducts shall be lapped over the angle 15mm. The corners of all angle joints shall be

neatly rounded off unless they are mated to a unit with square cornered angles.

Bends must be constructed with a radius to the centre of the duct not less than the depth of

the duct. Those with a radius less than 300mm shall have internal guide vanes which are

evenly spaced approximately 100mm apart.

The leading edges of all such vanes shall be covered with solid rubber strip to minimise

excess noise.

Expansions and contractions in all ductwork shall have an included angle of not more than

30º.

Where ductwork passes through the building fabric i.e. walls, floors, 13mm felt gaskets or

sleeves shall be provided and covered by 32mm angle flanges fixed to ductwork.

All joints shall be sealed finally with 50mm grey, self-adhesive duct tape, or a suitable mastic

compound.

Suitable access panels shall be provided in the ductwork to enable cleaning and inspection.


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Test points for sampling air velocities and temperature must be provided consisting of a

25mm diameter aperture covered by a screwed plate, the number and location will be

specified by the CAR

All measurements for ducting shall be taken on site as the work proceeds and working

drawings of all proposed ductwork shall be submitted to the (CAR) for general approval prior

to fabrication. Details of air volumes and velocities in ducts and grilles will be calculated to

enable the Contractor to balance the systems and on completion, to submit a written

schedule giving details of mean air velocities and volumes at each grille diffuser and louvre.

Supports

All ductwork shall be supported rigidly and at centres to prevent sagging and vibration on

purpose-made hangers. No supports shall be constructed from material lighter than that

specified for the angle joint flanges and each length of duct must be supported separately

and at centres not greater than 2 metres apart. Hair felt or other sound absorbent material

shall be placed between duct supports and ducts.

Dampers

Include for the supply and fittings of dampers where indicated on the Drawings. The multi-

leaf opposed blade type shall be of regulation pattern with a suitable number of double leaf

blades not wider than 230mm and set in a frame with angle iron flange connections. In the

Plant Room the dampers shall be fitted with a metal scale with raised letters indicating

"Open" and "Shut" and intermediate positions. Elsewhere "Open" and "Shut" positions shall

be clearly indicated.

Butterfly dampers shall be of the single plate pattern constructed from 14 gauge galvanised

mild steel sheet bolted to a 12mm diameter mild steel rod supported in bosses welded to the

ductwork and fitted with an adjusting lever. "Open" and "Shut" positions shall be clearly

indicated on the ductwork.

Fire Dampers

Fire dampers shall be either (i) single plate dead-weight pattern or (ii) interlocked multi-

shutter pattern. (iii) connection to the fire alarm system.

Single Plate Fire Dampers

These shall be constructed of galvanised mild steel sheet, at least 1.7mm thick, suitably

braced to prevent distortion. When closed, the damper shall fit closely against a galvanised

mild steel angle frame, with a minimum overlap of 20mm. The clearance between the

damper and the sides of the duct shall be 0.01mm per 1mm length of damper side.


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Multi-Shutter Dampers

These dampers shall comprise a series of continuous interlocked galvanised steel shutters,

each shutter of not less than 1.7mm thickness, mounted in a rolled galvanised mild steel

frame. The damper when used in the vertical position to be clearly marked to indicate the

top. Where the damper is to be mounted in the horizontal position the closing action of the

dampers to be spring actuated.

Connection to the Fire Alarm

On particular installations as specified, fire dampers will be connected to the local 12/24 volt

smoke head circuit to operate on action of the fire alarm. The damper to be automatic

opening on re-setting of the fire alarm system.

Generally

All dampers shall comply with the British Standard Code of Practice. Fire dampers are to be

held in the open position by means of an approved pattern fusible link or other suitable

device set to operate at 68oC. The link to be fixed in an exposed position in the centre of the

leading blade, each half of the link to be attached to an angle bracket by means of a

galvanised mild steel chain.

Fire dampers shall have a minimum fire resistance of 2 hours. Where longer periods of fire

resistance are called for, two dampers, each of 2-hour standard shall be used.

Fire dampers shall be installed completely in accordance with the Manufacturer's instructions

and when ductwork mounted, shall have an inspection door in a convenient position adjacent

to the damper, large enough to facilitate testing and maintenance of both the damper and its

actuating device.

Access Doors

Provide and install access doors, with rubber linings or gaskets on all ducts at intervals, at

ductwork connections to all fans, dampers, filters etc., for inspection, cleaning and

maintenance purposes.

The openings in the ductwork shall be properly stiffened at the edges with wrought iron

frames riveted or welded to the duct, the door being similarly stiffened at the edges and

cross braced, with rubber sealing joint mounted on each door. Each door shall be secured in

the closed position by means of wing nuts or other quick release fasteners. Doors shall

follow the sizes shown on the Drawings, but where such dimensions are not given, the

access area provided by each door shall equal two-thirds of the cross-sectional area of the

ductwork covered.

Cleaning access doors unless otherwise specified will be positioned on all horizontal take

offs from vertical risers and at each change of direction, excluding short lengths of stub ducts

where terminals can be removed for cleaning.


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2.11 Electrical Equipment and Wiring

Motors and Control Gear

All motors shall be continuously rated, fractional hp motors being totally enclosed but motors

larger than 1 hp shall be screen protected and drip proof.

Motors on fan convectors and automatic control equipment shall be suitable for single phase

supply but all other motors shall be suitable for 3-phase supply unless otherwise specified.

Each motor shall be controlled by a suitable starter with adjustable overloads manual reset

and single phase prevention as necessary but without no volt release unless otherwise

specified. Starters shall otherwise be rated for intermittent duty and be suitable for direct on

line starting for motors up to 5hp rating and for star-delta starting for larger motors.

Motors under automatic control shall have starters arranged for automatic restart when

voltage is restored following interruption of mains supply.

Contactor operating coils shall be supplied at not more than 230 volts, and be fitted with DC

rectification, where operation is remotely controlled a protective fuse shall be provided.

Each starter shall be controlled by an isolator except in the case of duplicate pumps where a

changeover switch shall be provided.

Where starters are mounted remote from motors, an isolator shall be fitted adjacent to each

motor and clearly marked.

The mechanical Contractor must allow to undertake all internal wiring, connections and

bonding on all powered mechanical plants from an adjacent isolator installed by others.

Control Panel

The switchgear and equipment shall be 500v pattern with distribution boards being supplied

with 2 spare ways per phase in addition to those required for any future equipment specified.

Supplies from fuse spur units will not be acceptable.

Where multiple items of equipment, i.e. distribution boards, circuit breakers, starters,

isolators etc. are located together as in the boiler room or elsewhere as specified, they shall

be housed in a purpose made cubical type control panel. The panel shall be fabricated of

2.0mm thick mild steel with all external corners and corner angles neatly rounded, hinged

front access door incorporating a key operated isolating switch, the whole to have a

hammered stove enamelled finish.

All equipment shall be housed within the panel but with control rotary switches, reset buttons,

selectors and instruments mounted in the face of the panel. “Run” and “Tripped” indicator

lamps shall also be provided in the face of the panel for all starters. Overload reset facilities

shall be provided on the face of the panel, with all items clearly marked with engraved labels.


22

All internal panel wiring shall be in P.V.C. insulated cable arranged in purpose made looms

and complete with numbered terminals and terminal tabs, all to British Standards

requirements for control panel wiring.

The final location of the panel and layout of the equipment thereon shall be agreed with the

CAR on site.

Space shall be provided on the panel to accommodate the isolator.

On small installations the use of multi-service units contained in a rust protected steel

container complete with DIN rail mounting will be acceptable as detailed in the Schedule of

Works.

Three sets of panel wiring diagrams will be required with all new works and where any

significant wiring alterations to a panel system have been undertaken. These must be

submitted for approval before the installation can be accepted as complete.

See „University‟s Standard BMS Controls‟

Temperature Controls

In general all new control panels will incorporate a TREND Control system, which will

monitor the plant, and allow control from the central office, but allow hand control from the

site.

Controls for the heating and/or hot water services systems shall be as detailed in the

Schedule of Works and shall be commissioned and tested to comply with the current BS

7671, 16th edition of the I.E.E. regulations.

Where BMS is not used, all time clocks shall be of the quartz range containing synchronous

motors with a spring reserve or battery backup of not less than 24 hours.

Wiring

The system of wiring shall, in general, be P.V.C. cables to BS 450/750volt grade, with heat

resistant cable being used in positions adjacent to boilers and on all connections to water

thermostats and valves. The cable to be encased in H.G. galvanised conduit run on the

surface of walls and ceilings and secured at intervals of not more than 1.2m by means of

purpose made distance saddles fixed to the walls/ceilings with brass c/s wood screws. No

conduit runs will be allowed within the floor screed or secured surface to the floor.

Galvanised trunking shall be installed where multiple runs of conduits are necessary, i.e.

more than four conduits. A clearance of 5mm shall exist between wall surfaces and

electrical conduits and 150mm between gas, water and steam pipes and electrical conduits.

Where practicable, conduits shall not be installed directly above hot water pipes.

The conduit system shall be carefully planned and erected to avoid all unnecessary bends,

sets or change of direction. Not more than two right angle bends and not more than four


23

sets shall exist between consecutive draw-in or inspection boxes; purpose made elbows and

tees shall not be used. Termination of conduits at equipment shall be by means of socket

and brass male bush.

Final connections to equipment and motors shall be carried out using copex flexible conduit,

bonding wires (earth) between fixed conduit system and equipment or motors being wired

externally.

Electrical connections to all burners shall be by means of a multi-pin socket and plug, with

screw top and scraper earth.

Circuit Identification and Labelling

All switchgear and distribution boards shall be identified by attached white engraved labels

secured by screws and with black lettering adequately describing the function of unit or

circuit controlled.

Standard colour phase buttons shall also be fitted to the outside of all switchgear and

distribution boards to indicate to which phase they are connected. Prior to completion of the

work, circuit schedules shall be provided for the distribution board clearly describing the

nature of the load connected to each circuit, wattage and rating of protection. The individual

circuit cables and protective devices within the distribution boards will be clearly labelled and

identified on a separate schedule contained in a purpose made frame, either secured

adjacent to the board or internal door of the respective control panel.

The wording of all circuit lists and labels shall be approved by the CAR before they are

made. The typed circuit lists, and wiring diagrams shall be framed and secured inside the

panel.

In order to ensure the correct operation of all controls, relevant circuit details shall be

obtained from the Manufacturers.

Testing

On completion of the work a full test will be required as detailed in accordance with BS 7671

and the results to be entered on an official NICEIC/ECA Test and Completion Certificate and

submitted within 14 days to the CAR


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2.12 Pipework/Tubing

Tubing shall be of the following type and quality as specified in the description/Schedule of

Works:

NOTE: Flexible connections are not acceptable on hot and cold water services and tap

outlets.

Heating Installation

Mild steel Heavy quality to BS1387;

Light gauge copper to BS EN 1057-R250, Table X.

Hot Water Service

Including all discharge pipes from safety valves and AAVs, both heating and HWS.

Light gauge copper to BS EN 1057-R250, Table X;

NOTE: Where there are extensions or alterations to existing galvanised hot and cold water

systems then use the Uponor Unipipe multilayer composite system.

Cold Water Service

Underground - Blue MDPE (Medium Density Polyethylene) pipe to BS 6572 Internal - Light gauge copper to BS EN 1057-R250, Table X Gas and Oil Fuel Lines

Above Ground - Mild steel medium quality, black. Wrapped with Denso waterproof tape where external. Internal gas services to be finished with yellow ochre paint and gas marker tape

Underground - Gas Services: plastic covered mild steel medium quality tube

with screwed joints. Joints to be double wrapped with Denso waterproof tape to a minimum of 150mm either side of screwed joint. Or Yellow Medium Density Polyethylene gas distribution pipe to British Gas Engineers standard PS/PL2 Part 1 with electro fusion fittings. Oil Lines: mild steel medium quality black to BS 1387 with welded joints, protectively wrapped with Denso waterproof tape.


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Gas Pipework

All workshops, Kitchens and laboratories shall have a “Master Gas Valve” installed adjacent

to the normally used exit. This “Master Gas Valve” shall isolate all gas to the room served.

All gas isolating valves shall have a pressure test point fitted downstream for tightness

testing purpose and be labelled „Master Gas Valve‟.

Foam Inlets, Overflows and Heating Vents

Mild steel, medium quality shall be used.

NOTE: Some overflows as specified will be allowed in plastic tubing.

Joints and Fittings

Unless otherwise indicated, joints and fittings shall be as follows:-

Steel Pipework

For pipework up to and including 50mm diameter, malleable screw joints shall be used

complying with BS EN 10242. These shall have taper threads to BS21 and shall be made

with suitable jointing material.

For pipework above 50mm diameter, joints may be either screwed or welded.

To facilitate future dismantling where pipework is connected to an appliance, valve or

elsewhere, ground-in spherical seated unions shall be used for pipework up to and including

65mm diameter and flanges for pipework above 65mm diameter. Mating flanges for items of

plant and equipment, excluding valves, shall be fabricated of the same material and table as

the plant and equipment. All other flanges shall be Carbon steel to BS 4504 (metric) or BS

10 (imperial), and the joints made with non-asbestos joint rings (BS7531) and compound.

Screwed fittings other than sockets shall be malleable cast iron, banded or beaded pattern,

screwed BSP thread (BS EN 10242). Purpose-made welded fittings shall be used on welded

pipework.

Copper Pipework

Generally all copper fittings will be from the Yorkshire „Xpress‟ or „Geberit‟ system, but where

it becomes impractical do use this system, or on Gas services then use Yorkshire solder

ring Capillary type fittings with lead free solder shall be used. Compression fitting in general

will not be allowed unless agreed with the CAR

NOTE: A Hot Work Permit will need to be obtained from the CAR prior to any soldering or

hot work commencing.


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All flux and solders used must conform to the requirements of the Water Regulations.

Jointing compounds will only be of the following:

Gas - Boss Gastite, or equivalent to BS 5292. Water services - Boss green potable water pipe jointing compound (U.K. National

Water Council Approved), Boss PTFE or GTPTFE (larger sizes) to BS 6956 part 5.

PVC or Polyethylene Pipework

On UPVC and ABS tubes solvent welded fittings shall be used, or Electro fusion fittings.

On water polyethylene tubes compression fittings with internal ferrules shall be used.

On Gas Polyethylene tube electro fusion fittings shall be used.

General (Fittings and Connections on all Jointing)

Pitcher tees, bends, twin elbows etc., shall be of the same size as the pipework connected to

them. Bushing shall NOT be used, with the exception of restricted space, and then only by

permission of the CAR.

Square tees shall be used where short sweep fittings could cause air to be trapped in the

system, especially on dead-leg branches of domestic hot water supply systems and on all

cold water installations.

Eccentric reducing sockets shall be used to facilitate air-venting and draining and where

changes of diameter are made in runs of nominally horizontal pipework.

Bends shall be used, in preference to elbows, except in boiler and plant rooms.

The execution of welding and competence of the welder shall be in accordance with the

current edition of "Welding of Mild Steel Pipelines Work" issued by the Heating and

Ventilating Contractors Association in conjunction with the NJC for the Plumbing Industry.

The CAR shall have the right to call upon the Installer:

• To demonstrate the quality of the welder‟s work;

• To submit welded samples for further examination;

• To produce the applicable certificate of competence, e.g. Coded welder on

pipework of above 4” (100mm) or on medium temperature or pressure pipework;

When welding, soldering or cutting with a torch, every precaution shall be taken to prevent

fire and the CAR must be informed and a “Hot Working Permit” issued prior to work

commencing.


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Pipework must be reamered after cutting and shall be free from burrs, rust, scale and other

defects and shall be thoroughly cleaned before erection.

All open ends of pipework left during the erection progress of work shall be blanked off with

purpose-made metal or wood plugs or blank counter flanges, until final connection is made.

All pipework routes shall follow lines of walls, floors and ceilings etc., as directed by the CAR

External surfaces of pipes or insulation thereon shall have a clearance of 25mm between

pipes, a minimum clearance of 100mm from floors, 75mm from ceilings and 25mm from the

finished face of walls or other surfaces.

Joints shall not be made in the thickness of any floor, wall or ceiling and pipework shall not

be embedded in the structure of floor unless otherwise indicated or instructed by the CAR

All pipes passing through walls, floors or ceilings shall be provided with sleeves cut to allow a

projection of 3mm beyond the finished wall except in lavatory blocks or kitchens where

projection shall be 50mm above finished floor level. The sleeves shall be of the same

material as the tube.

All visible hot and cold water supply pipework, fittings and brackets etc. within shower

compartments or run through showers etc. shall be of heavy duty chrome plated or stainless

steel. All pipework shall be prefixed on site and approved by the CAR prior to chrome

plating.

Pipe Supports, Expansion and Anchor Points

Spacing brackets shall be sufficient to ensure adequate support of pipe-work but in all cases

shall not exceed the distances detailed below.

Nominal Bore Intervals for Horizontal Runs Intervals for Vertical Runs

15mm 1.8m 2.5m

20 to 32mm 2.5m 3.0m

40 to 50mm 3.0m 3.6m

65mm and over 3.6m 4.5m


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Supports for Copper and PVC Pipework

Nominal Bore Intervals for Horizontal Runs Intervals for Vertical Runs

15mm 1.5m 1.8m

22 and 28mm 1.8m 2.4m

35 and 42mm 2.4m 3.0m

54mm 2.4m 3.0m

67mm and over 3.0m 3.6m

Where in contact with copper pipework, all brackets and clips shall be constructed from

copper or brass. Chrome pipework in showers shall have chrome on brass clips fitted with

chrome or stainless steel screws.

All low level pipework in rooms shall be supported at intervals not exceeding 1.5m.

In addition to above, all vertical pipes shall be supported at the base and at least one other

point. Branches from risers shall not be used to support the riser.

Pipework in trenches and ducts shall be positioned as high in the trench/duct as possible and

supported by means of suitable steel supports built into slots left in top of the trench with

carrying rods and split pipe rings up to 65mm, above 65mm purpose-made supports shall be

used. Each pipe shall be supported individually.

Pipework in ceiling spaces shall be supported upon angle iron or suitable steel brackets.

Retaining 'U' bolts shall be provided on alternative angle irons to prevent lateral movement.

Pipework shall be supported to allow free movement for expansion and contraction,

particularly at the ends of long runs where a change of direction occurs.

Provide and fix anchor points in positions as detailed on the Drawings.

Venting

All pipework shall be installed to enable systems to be adequately vented, and wherever

necessary air cocks fitted. Air bottles or automatic air vents shall be fitted where shown on

the drawings, and when contained within a void or false ceiling the location will be indicated

by a plastic disc of colour and style to that approved by the CAR.

Air bottles shall be made from 50mm tube approximately 225mm long fitted with a cap and

6mm air cock. They shall be fitted to equal tees or have 50mm connections where the main

is 50mm bore or over. Where an air bottle is fixed out of reach a 6mm extension tube shall

be run from the cap to within 150mm of the floor, terminating with a 6mm needle-seated key-

operated air cock.

All Automatic Air Vents shall have a service valve and a drip lines taken to within 150mm of

the floor level which shall be run in 15mm copper tube.


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Draining

All systems shall be installed so that the whole of the pipe runs and vessels can be

completely drained.

Draw-off cocks shall be provided on boilers, cylinders and vessels, at all low points and

where indicated on the Drawings.

Final Connections

All pipework shall be connected direct to all ball valves, taps on all sanitary fittings, flushing

cisterns, kitchen, laundry and sluice equipment etc. in full compliance with current Water

Regulations, and shall include service valves.

2.13 Valves and Cocks

Generally, valves and cocks shall be of the patterns specified, with matt finish to bodies and

shields: where exposed to view in rooms, valves and cocks shall be polished chrome plated

finish, with connections matched to pipework.

All valves shall be fitted in accessible positions for operation and maintenance. Lockshield

valves shall be fitted with closed shields.

Unless otherwise specified stopcocks shall have crutch handles and be fitted with fixed

jumpers for hot water and cold water tank supply and loose jumpers for cold water mains

supply.

Each gas appliance shall be fitted with a suitable pressure governor (which shall be supplied

with the appliance), an isolating valve, and a non-return valve when specified.

Safety and relief valves shall be suitable for the operating conditions of the systems and as

indicated or required by the British Standard (or BS-EN equivalent) for the boilers, calorifiers

or pressure vessels to which they are connected. They shall be of the totally enclosed

spring-loaded type with padlock and shall have a full bore discharge connection fitted with a

copper waste pipe to within 150mm of the floor, suitably supported and set to discharge

away from the vessel.

Ball float valves shall be equilibrium pattern of the sizes indicated and shall suit the cisterns

specified. Ball float valves for use with feed and expansion cisterns shall be arranged to shut

off when the cistern contains 150mm of water. The floats of ball valves shall be of heavy

copper with brazed or bronze welded seams and boss, or but may be of plastic for cold water

cisterns.

Where modifications or extensions to existing services are to be carried out, all valves and

cocks which are to be removed and re-fixed shall be thoroughly cleaned, overhauled and

glands repacked before re-use, to the satisfaction of the CAR.


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Each mixing valve for domestic hot water service shall be of the thermostatic type to the

pattern specified, and be complete with lockshield service valves, strainers and non-return

valves on the inlets and, where indicated, a lockshield valve on the outlet, the whole in

chrome plated finish.

Multi-point mixing valves shall be provided with locked temperature control (i.e. key-

operated) set to the temperature specified.

All mixing valves and associated equipment shall be installed strictly in accordance with the

Manufacturer's recommendations and/or instructions, with particular reference to the

positioning of the strainers. Compliance to Water Regulations.

The following valves are approved for use:

3 way vent valves - Up to and including 50mm Boss 9645 Over 50mm Model 1688 by Brownall.

Auto air eliminators - Spirax AE 30CV and to be fitted with service valve.

Relief Valves - Pre-set spring loaded type with lockable bonnet.To Relevant British Standard (pressure rating must be stamped on the body)

Drain off cocks - Crane Model D171 H/U in plant rooms and voids etc.

- Crane D340 or Boss 371 ls in public areas.

Isolation Valves - Up to and including 50mm Crane Model D171 lever operated ball valves or Boss 9665. 65mm and above, Bonded liner threaded lugged pattern butterfly valve Boss or Crane F614, or Cast Iron Gate valve type Crane FM 124, Boss 7XS.

Flow Measurement Regulating Valve

- Crane Model D930/ DM930 double regulating Valves (DRV)

Master Gas Valve - Crane D191

Radiator Valves - Wheelhead and Lockshield, Oventrop Combi 4 lockshield or Pegler Bellmont II Polished chrome plated valves to BS 2767-10. (on copper pipework compression connections will be accepted)

Thermostatic radiator valves - Oventrop series A, or AV6 with Uni DG white head

Bronze Check Valves - Boss or Crane Swing pattern

Strainers - Boss or Crane “Y” pattern to suit the application.

Service Valves (water) - For service valves on copper water pipework to Basins, WC / Urinal cisterns chrome plated Allen key operated ball valves with compression connections will be accepted


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Electric Gas Shut-off valve

- Johnson Hydromotor type 240 volt

Oil Fire Valves - Alcon electric DC Rectified

Gas Non-Return valves - Amal Otan.

Heating and Hot Water control valves

- Satchwell lift and lay pattern control valves or Belimo equivalent

Type BA back-flow preventer - Nabic fig 255, Danfoss BA 2760, Honeywell BA

Type CA back-flow preventer - Danfoss CA 296

Type EB check valve - Honeywell RV284, Mira CV 1015

Type DC pipe interrupter - Nabic Type 2565

HWS Blending Valves - Oventrop Brawa-mix complete with strainers and NRV‟s

Time Flow control valves - Mira TF503

Laboratory bench gas taps - Brownall lift/turn type compliant to BS 1552

2.14 Additional Instrumentation

Thermometers

In addition to boilers, cylinders and calorifiers, thermometers shall be fitted in the following

positions:

On each heating return in Boiler Room;

On each water outlet of each 3-way mixing valve as specified;

Thermometers shall be fixed so that the tails are truly subjected to the temperature

of the water to be measured and shall be fitted in a separate brass pocket (filled

with oil or grease);

Right angle or obtuse angle thermometers shall be provided for fitting to vertical

pipes or vertical faces of cylinders etc.;

Thermometers for pipework and vessels shall be of the dial type having steel back

with chrome plated bezel and graduated 0oC to 100oC or to suit the application;


32

Altitude Gauges

Altitude gauges, where specified, shall be steel backed with chrome plated bezel. They shall

be calibrated to not less than 1⅓ (one and one third) times and not more than twice the

operating pressure.

In addition to the indicating black pointer, gauges shall be provided with an adjustable red

pointer set to indicate the normal working pressure or head of the system. The gauges shall

be so assembled that the glass has to be removed to adjust the pointer. Gauges shall be

fitted with lever handle plug cocks.

In addition to the indicating black pointer, gauges shall be provided with an adjustable red

pointer set to indicate the normal working pressure or head of the system. The gauges shall

be so assembled that the glass has to be removed to adjust the pointer. Gauges shall be

fitted with lever handle plug cocks.

2.15 Thermal Insulation

Thermal insulation shall be to current British Standards, BS 5422:2001, BS 5970:2001 and

applied to the following:

All boilers, steel flues and vessels in the Boiler/Plant Rooms.

All pipework (excluding open vents, drains, blowdown/discharge pipes, air and gas

services) in Boiler/Plant Rooms.

All pipework (excluding drains, air and gas services) in ceiling, roof spaces, pipe

casings, voids and tank rooms.

All water pipework, external above ground, and pipework in external and internal

ducts.

Ventilation ductwork where indicated.

Other locations as indicated.

The insulation thickness tables included in this specification are in accordance with

BS 5422:2001 which is specified by DETR as the basis of qualification for

Enhanced Capital Allowances for thermal insulation and as a means of complying

with Building Regulations, Part L (Conservation of fuel and power)

All materials shall be applied in accordance with the manufacturer‟s

recommendations.

Thermal insulation shall be as follows:


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Boilers

Boilers (where not provided with manufacturers insulating jackets as standard) shall be

insulated with mineral wool insulating sections, and be finished with polished aluminium

sheet of 0.50mm thick, secured with pop rivets or sherardised self-tapping screws.

Vessels

Vessels (where not provided with manufacturers insulating jackets as standard) shall be

insulated with mineral wool or foil faced phenolic foam insulating sections, and be finished

with polished aluminium sheet of 0.50mm thick, secured with pop rivets, sherardised

self-tapping screws or aluminium banding. On chilled and cold water vessels the foil facing

shall be fully sealed to provide a continuous vapour barrier at all joints, terminations and

protrusions through the insulation. Care shall be taken to avoid damaging the vapour barrier

when installing the cladding. Phenolic foam shall not be used on vessels operating above

100ºC.

Pipework

All pipework, unless otherwise specified, shall be insulated with mineral wool or phenolic

foam foil faced sections which shall be secured with purpose made tape. On chilled and cold

water pipework the foil facing shall be fully sealed to provide a continuous vapour barrier at

all joints, terminations and protrusions through the insulation. Phenolic foam shall not be

used on pipework operating above 100ºC.

Pipe Supports

Proprietary high density load bearing phenolic foam insets shall be installed at all supports

for chilled and cold water pipework.

Different types of finish may be specified, but in general the following types will be used:-

In Boiler Rooms the finish shall be polished aluminium sheet of 0.50mm thick, secured with

pop rivets or sheridised self-tapping screws or banding. Seams shall be aligned and where

possible be obscured from view. Bends and tees shall be formed from purpose made

aluminium fittings, with ends of sections finished with purpose made aluminium end caps.

Care shall be taken to avoid damaging the vapour barrier when installing the cladding.

Surface mounted external of plant room shall be finished with semi rigid rolled plastic

sheet of 0.35mm thick (Isogenopak), secured with purpose made nylon/plastic rivets. Seams

shall be aligned and where possible be obscured from view. Bends and tees shall be formed

from purpose made fittings, with ends of sections finished with purpose made aluminium end

caps.

In Ceilings, Voids, Pipe casing, and Tank rooms it shall be finished with factory applied

Bright Class „O‟ reinforced aluminium foil, with all joints sealed with purpose made foil tape.


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On external pipework it shall be finished with silver „Ventureclad‟ system.

On external Ductwork it shall be finished with silver metal cladding.

Valves

All valves and un-insulated flange joints in the plant room shall be insulated with purpose

made wrap around valve/pipe jackets. These jackets shall be attached with the use of Velcro

and drawstrings.

General

Insulation shall always be finished off separately around each pipe. Flanges and valves shall

be insulated unless otherwise specified. Pipe insulation shall be terminated prior to the

flange with enough room to remove the flange bolts without damaging the insulation

Flanges and valves shall be insulated with proprietary removable insulated covers. Prior to

insulation being fitted, all steel pipework shall be treated with two coats of red oxide paint. All

exposed sections of pipework following insulation shall be finished with black gloss paint.

Copper pipework shall be cleaned thoroughly to remove all moisture, surplus flux, building

material debris and dust.

No insulation to be fitted until all pipework has been hydraulic tested and approved by the

CAR.

Cold Water Storage and Feed and Expansion Tanks

All cold water storage tanks, including the feed and expansion tank, shall be completely

lagged with Resin bonded mineral wool or phenolic foam foil faced slabs having properly

formed joints. Slabs should be adequately fixed to tanks with metal bands or general

purpose adhesive and proprietary insulation pins; corners of tanks to have metal angle

complete height of tank to prevent metal bands cutting into the insulation.

The top slab where necessary be in sections to facilitate removal.

Boiler Flue Insulation

Insulation shall be placed over a 25mm air space formed by means of expanded metal

lathers supported on metal spacing stools to ensure a rigid assembly.

Rigid mineral wool sections 40mm thick shall be applied, being securely wired and reinforced

with 25mm mesh X 1.0mm galvanised wire netting, the whole to be finished with polished

aluminium.


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Ductwork Insulation

Rigid phenolic foam foil faced duct slab insulation shall be used. The insulation to be cut to fit

so that top and bottom pieces overlap the sides and fixed and finished as silver metal

cladding.

Duct Supports

Proprietary high density load bearing phenolic foam inserts shall be installed at all ductwork

supports.

Finishes

Where exposed in plant rooms the finish shall be polished aluminium sheet. All joints to be

secured with pop rivets or sherardised self-tapping screws or banding. Care shall be taken to

avoid damaging the vapour barrier on cold air ducting. On inspection/cleaning doors (which

will not be insulated) the aluminium finish shall be formed around the opening to enable the

access door to be removed without disturbance to the insulation.

In voids and roof spaces the finish shall be aluminium foil with all joints sealed with purpose

made foil tape. Where external or a weatherproof finish is required, a black neoprene

membrane (Polyisobutylene or Oponal) shall be used with all joints having a 50mm overlap,

sealed with solvent welding agent.

2.16 Painting

All materials and brackets to be used in the installation with the exception of those formed

from copper, gunmetal or bronze or finished galvanised, shall be given two coats of Red

Oxide paint. All steel or cast-iron goods which show signs of rust shall be carefully wire

brushed down, all rust removed prior to painting.

After fitting and testing of all pipework, all black pipework shall be thoroughly cleaned and

painted with two coats of Red Oxide. Screwed joints only on galvanised pipework shall be

thoroughly cleaned, and painted.

Upon completion of the thermal insulation all unlagged pipework, cast iron valves, hangers

and brackets within Boiler Rooms, Plant Rooms and Tank Rooms shall be painted two coats

of Red Oxide primer and finished with heat resistant gloss Black paint.

Where special additional paintwork or finishes are required to be provided on particular

pieces of equipment, such finishes are specified separately. Gas pipework in Boiler and

Plant Rooms shall be finished to I.G.E. Regulations, Yellow Ochre to BS 08 C 35.


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APPENDIX 1 – THICKNESS TABLES – in accordance with BS 5422:2001

Table 1: Environmental thickness of insulation for non-domestic heating installations to

control heat loss (Reference BS 5422: REV 2001 – Table 12)

Steel pipe size (mm)

Hot face temperature of installation (oC)

+75 +100 +150

Thickness of Insulation (mm)

NB

OD

Phenolic foam

Mineral wool

Phenolic foam

Mineral wool

Mineral wool only

15 21 15 30 15 40 50

20 27 15 40 20 40 60

25 34 20 40 20 40 60

32 42 20 40 20 50 65

40 48 20 40 25 50 65

50 60 20 40 25 50 65

65 75 25 40 25 50 75

80 89 25 50 30 60 75

100 114 25 50 30 60 75

150 168 25 50 35 60 75

200 219 30 50 35 60 80

250 273 30 50 35 60 80

300 324 30 50 35 60 80

Vessels and flat surfaces

35 50 40 65 90


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Table 2: Thicknesses of insulation for chilled and cold water supplies to prevent

condensation on a low emissivity outer surface with ambient air conditions of 25ºC and 80%

rh (Reference BS 5422:REV2001 – Table 8)

Steel pipe size (mm)

Temperature of water (oC)

+10 +5 +0

Thickness of Insulation (mm)

NB

OD Phenolic foam

Mineral wool

Phenolic foam

Mineral wool

Phenolic foam

Mineral wool

15 21 15 20 15 25 20 30

20 27 15 25 15 30 20 40

25 34 15 25 20 30 25 40

32 42 15 25 20 30 25 50

40 48 15 30 20 30 25 50

50 60 15 30 20 40 25 50

65 76 20 30 25 40 30 50

80 89 20 30 25 40 30 50

100 114 20 30 25 40 30 50

150 168 20 40 30 50 35 60

200 219 20 40 30 50 40 60

250 273 25 40 30 50 40 65

300 324 25 40 35 60 40 65

Vessels and flat surfaces

30 50 40 65 50 80

Table 3: Environmental thickness of insulation for domestic central heating installations

(+75ºC) and hot water supply systems (60ºC) to control heat loss in potentially unheated

indoor areas with ambient air temperature of 1ºC (Reference BS 5422:REV2001 – Table 14).

Outside diameter of copper pipe (mm)

Water temperature of 60ºC/75ºC

Thickness of insulation (mm)

Phenolic foam Mineral Wool

10 15 25

12 15 25

15 15 30

22 20 40

28 20 40

35 25 40

42 25 40

54 25 50

Cylinders 35 50


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Table 4: Environmental thickness for ductwork carrying warm air (Reference

BS 5422:2001 – Table 1)

Temperature difference between air inside ductwork and ambient air (ºC)

10 25 50

Environmental thickness of insulation

Phenolic foam

Mineral Wool Phenolic foam

Mineral wool Phenolic foam

Mineral wool

20 40 25 50 35 65

Table 5: Thickness of insulation for condensation control on ductwork carrying chilled air in

ambient conditions 25oC, 80%rh for insulation having a low emissivity finish 0.05

(Reference BS 5422:REV2001 – Table 10)

Minimum air temperature inside the ductwork (ºC)

15 10 5 0

Thickness of insulation (mm)

Phenolic foam

Mineral wool

Phenolic foam

Mineral wool

Phenolic foam

Mineral wool

Phenolic foam

Mineral wool

20 30 25 50 40 75 50 100

APPENDIX 2 – APPROVED INSULATING MATERIALS

A PHENOLIC FOAM (Temperature up to 100ºC)

A1 Phenolic Foam Pipe Insulation

Rigid cfc-free “Class O” phenolic foam, pre-formed bore-coated pipe sections

having nominal density of 35kg/m³ and thermal conductivity of 0.018 W/m.K at 10ºC

mean temperature. Supplied complete with factory applied “Bright Class O

reinforced aluminium foil facing. Kooltherm pipe insulation as manufactured by

Kingspan Insulation Ltd or equal and approved.

A2 Phenolic Foam Laminated Slabs

Rigid cfc-free “Class O” phenolic foam laminated slabs having a nominal density of

40 kg/m3 and thermal conductivity of 0.018 W/m.K at 10oC mean temperature.

Supplied complete with factory applied “Bright Class O” reinforced aluminium foil

facing Kooltherm Ductslabs as manufactured by Kingspan Insulation Ltd or equal

and approved.

A3 Phenolic Foam Laminated Slotted Slabs

Rigid Slabs as described under A2 are back-slotted to provide sufficient flexibility for

application to cylindrical surfaces of 350mm diameter and above.

A4 Load Bearing Phenolic Foam Inserts for Pipe and Duct Supports

Rigid cfc-free “Class O” high density phenolic foam purpose designed pre formed

pipe support inserts and duct support strips supplied with factory applied “Bright


39

Class O” reinforced aluminium foil facing. Kooltherm K-Blocks and Duct Support

Strips as manufactured by Kingspan Insulation Ltd or equal and approved.

B MINERAL WOOL (Temperatures up to 230ºC

B1 Mineral Wool Pipe Insulation

Rigid bonded “Class O” mineral wool, pre-formed sections having a normal density

of 80 kg/m3 and thermal conductivity of 0.037 W/m.K at 50oC mean temperature.

Supplied complete with a factory applied “Bright Class O” reinforced aluminium foil

facing. Crown SA Pipe Insulation is manufactured by Owens Corning Alcopor Ltd or

equal and approved.

B2 Mineral Wool Rigid Slabs

Rigid bonded “Class O” mineral wool slabs having a nominal density of 48kg/m3 and

thermal conductivity of 0.034 W/m.K at 10oC mean temperature. Supplied complete

with a factory applied “Bright Class O” reinforced aluminium foil facing. Crown Rigid

Duct Insulation as manufactured by Owens Corning Alcopor Ltd or equal and

approved.

B3 Mineral Wool Flexible Blanket

Flexible bonded “Class O” mineral wool blanket having a nominal density of 28

kg/m3 and thermal conductivity of 0.034 W/m.K at mean temperature. Supplied

complete with a factory applied “Bright Class O” reinforced aluminium foil facing.

Crown Universal Ductwrap as manufactured by Owens Corning Alcopor Ltd or equal

and approved.

B4 Mineral Wool Lamella Mat

Bonded “Class O” mineral wool mat having a nominal density of 24 kg/m3 and

thermal conductivity of 0.040 W/m.K at 10oC mean temperature. Supplied complete

with factory applied “Bright Class O” reinforced aluminium foil facing. Crown Lamella

Mat as manufactured by Owens Corning Alcopor Ltd or equal and approved.

2.17 Spacing of Services

Before the installation of mechanical services commences, it is essential that arrangements

are made with other trades to ensure a minimum clearance of 150mm from other services.

Where underground services (gas, water, electrical, GPO and television cables etc.) are to

be accommodated in a common trench, the spacing, separation and depth of all services

shall not be less than the minimum requirements of the Public Utility providing the service,

and the accepted standard of practice.


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2.18 Identification of Services and Plant

On completion of a new boiler/plant room installation or revamp, a system identification

installation chart and pipework schematic will be required positioned in the boiler/plant room.

All pipework and ductwork in boiler and plant room, insulated or not, will be identified

detailing individual services and direction of flow. The identification will follow the form of

bands provided on the entry and exit from the boiler or plant room as well as connections to

items of plant or equipment all to BS 1710, 1984.

Valves and damper charts will be positioned with the system installation and pipework

schematic as agreed with the CAR indicating number, size, location and duty of each valve

or damper. The charts will be typed on A4 size and encapsulated before fixing to the

wallboard with brass screws. Two further copies of these charts on A4 paper will be required

by the CAR before completion of the project.

All valves, cocks and dampers in boiler or plant rooms, roof spaces, ceiling voids, trenches,

ducts and tank rooms will be individually numbered, having white plastic laminated discs

clearly figured in black fixed to the appropriate item by means of a brass „S‟, ring clip, or

chain.

Each circulated pump and fan shall also be identified as above with circuit/area served on

the control panel and on the pump and fan unit.

System Identification Installation Charts

System Schematics

Supply and fix a referenced schematic diagram (or diagrams) of all systems as installed,

including equipment and ancillary schedules. Show scheduled information on diagram.

Identify all items by appropriate reference characters as agreed with the CAR.

On all projects where additional plant is added to the existing installation, an „installed

drawing‟ will be required detailing the date of work plant, type and size, pipework runs,

connection points etc. to be submitted with the final invoice.

Control Schematics

Supply and fix a referenced schematic diagram (or diagrams) of all control systems as

installed, including equipment and ancillary schedules. Show scheduled information on

diagram.

All drawings will be encased with a perspex glazed sheet contained in a suitable frame with

mounting attachments.


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Pipework Identification

Standards

Colour code and label to BS 1710: 1984

Primary

Apply colour bands, 300mm wide, to each Identification pipe at least: once in every room or

enclosed area at intervals not exceeding fifteen metres at every junction, at every valve, at

every inspection and access position into service shafts, false ceilings, bulk heads etc.

Secondary

Apply colour bands, 50mm wide, and Identification superimpose a legend identifying circuit,

direction of fluid or gas flow, nominal pipe bore and, where appropriate, fluid or gas pressure.

Legends and Flow Direction Arrows

Apply to colour bands by transfers of an approved type.

Valve and Cock Identification

Standards

Identify each valve, cock, stop valve, air vent, drain cock etc. with disk engraved with

numerical reference, except where exposed in occupied areas (unless otherwise indicated).

Colours

Use primary and secondary identification colours of associated system for painted or self-

colour disks.

Discs

Securely attach metal or laminated plastic discs, minimum diameter 35mm to each item.

Legends

Engrave disks with permanent characters, minimum height 6mm.

Danger and Warning Notices

Hazardous Systems

Colour code and label hazardous systems and equipment to requirements of Health and

Safety Executive Guidance Notes, and the instructions of the CAR.


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2.19 Testing and Commissioning

All Mechanical Services other than Gas

The whole of the heating installation, hot and cold water, oil services, and ventilation plant

shall be subjected to pressure and performance tests.

Before any tests are carried out, 48 hours‟ notice of such tests shall be given in writing to the

CAR in order that he may be able to witness tests if required.

Should any section of the works be tested without any notice having been given to the CAR,

such test shall be again carried out in his presence and if the work has been covered up it

shall be uncovered without expense to the University.

Pressure tests shall be carried out as required and before any non-conducting composition

or paint is applied.

Pressure tests shall be of 30 minutes duration with the pressure equal to one and a half

times the head of water on the apparatus or 350 kPa (3.5 bar) whichever is the greater,

except for pipework in floor or external ducts which shall be tested to 700 kPa.

Immediately each boiler is erected and before connecting to pipework it shall be hydraulically

tested to above pressure.

Oil and air pipework or plant shall be pneumatically pressure tested, with water pipework and

plant being hydraulically pressure tested.

Due allowance must be made to provide the necessary water or air pressure pumps and all

necessary plugs, blank flanges and temporary filling connection etc. for sealing off open

ends in order that the installation may be tested in sections if required by the progress of the

building operations.

Any faulty materials revealed during such tests shall be removed and replaced without

expense to the University.

All heating and water systems shall be flushed out with clean water until all scale, rust and

dirt are removed, and then disinfected in accordance with the new water by-law. During the

flushing out, provision shall be made to exclude filters, pumps, mixing valves and other items

of plant which could be damaged by the cleaning operations.

On completion of potable water supplies and following a successful pressure test, the system

shall be sterilised to comply with HS (G) 70.

Before the above flushing out is carried out, 48 hours‟ notice shall be given in writing to the

(CAR) in order that he or his representative may be present.


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The following specific performance test will be required to demonstrate the satisfactory

operation of each system installed.

Boiler Plant

Pressure and output tests (giving flow and return temperatures and time taken from cold to

achieve design temperatures when fully operational).

Efficiency tests giving CO2, O2, NOx and CO content, smoke number, flue gas temperatures

at boiler flue outlet and burner oil or gas pressure and Burner input rate. The commissioning

and testing of boiler/burner plant shall be carried out by the boiler/burner manufacturer.

Heating System

Circulation and operating tests giving flow and return temperatures of each circuit, room

temperatures, settings of all thermostatic equipment and settings of automatic control

equipment.

Demonstration shall be given to the CAR of the operation of each piece of control equipment

with simulated conditions as necessary. Where automatic control equipment, with or without

mixing/diverter valves is installed, the control equipment Manufacturer shall carry out the

commissioning and testing.

Water Supply Systems

Flow checks at all draw-off points and ball valves shall be made.

Circulation tests on H.W.S. systems as for heating system with all draw-offs closed.

Ventilation Plant

Air flows and temperatures at all inlet and outlet positions and efficiency tests and pressures

of filters as necessary.

Should any of the systems fail to operate due to faulty materials or workmanship, any

removals and reinstatements shall be without expense to the University.

Certified copies of all test results (in duplicate) shall be submitted to the CAR.

Due allowance must be made to train operating staff in the proper firing, regulation and

maintenance of the entire installation, including pumps and all control gear and oil burners.

Provide and fit in an approved position in the Boiler Room, Instructions for Operation of the

Installations. The layout and wording shall be agreed with the CAR, after which they shall be

photo-printed on to a white laminate board. Provide two further copies of these instructions

on A4 sheets.


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Gas Installations

The whole of the gas services shall be subjected to pressure and performance tests. Before

any tests are carried out 48 hours‟ notice of such tests shall be given in writing to the CAR in

order that he or his representative may be present.

Should any section of the works be tested without notice having been given such test may be

required to be carried out again in the presence of the CAR, and if the work has been

covered up it shall be uncovered without expense to the University.

On completion of the pipework - or section(s) of same if required by the progress of the

building operations - prior to connections to appliances and gas meter the whole shall be

tested to IGE/UP/1 or IGE/UP/1A Procedures at a pressure of 1.5 times the maximum

operating pressure.

On completion of all connections to gas appliances and meter the valve on the inlet side of

the meter shall be closed and the whole installation tested to IGE/UP/1 or IGE/UP/1A

Procedures.

Purging - Prior to the gas installation being put into service all gas pipework shall be purged

as detailed in the IGE/UP/1 or IGE/UP/1A procedures.

The installation shall have pipework and all appliances lit to ensure gas is available to

support combustion. All governors to be adjusted as necessary.

Carry out performance test by checking that flow at outlets, pressure settings of governors

and input consumption of all equipment to conform to Manufacturer's specifications.

A line diagram of all gas pipework, above and including 25mm diameter, shall be fitted

adjacent to the meter position as called for in Gas Safety Regulations. This to be photo-

printed on to a white laminate board. A copy of this line diagram and the gas soundness

certificate shall be submitted to the CAR.

The Completion Certificate will not be issued until this Clause has been complied with

completely.

2.20 Operating and Maintenance Manual

(Two hard copies and one electronic copy on a CD)

On completion of any major works an operating and maintenance manual will be required to

be produced containing schedules of plant, test results, records and drawings etc. The

document must be to the accepted standards of the CAR and be in a bound typewritten form.

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