KENCANA SQUARE

PIPING AND ACCESSORIES

SECTION AC-060
Page 1

1.0

GENERAL

1.1

DESCRIPTION
.1

1.2

1.3

1.4

Work of this Section shall conform to the requirements of the Contractor

Documents.

WORK INCLUDED
.1

Pipe.

.2

Fittings.

.3

Unions and Couplings.

.4

Escutcheons.

.5

Sleeves.

.6

Welding Procedures.

.7

Pre-insulated Pipe

SUBMITTALS
.1

Submit shop drawings indicating detailed piping layouts, anchoring

details, anchor points, guide details, etc.

.2

Submit manufacturer's data for hangers, fittings, and pipe.

.3

Submit dimensioned drawings to the E.R. for approval showing pipe

penetrations through core walls, slabs and other structural elements,
anchor and guide locations, etc.

.4

Submit pipe expansion and flexibility calculations.

QUALITY ASSURANCE
.1

All piping work to conform to the latest edition of the appropriate ANSI or
ASME Code for Pressure Piping.

.2

Employ only skilled welders registered with the Department of

Occupational Safety and Health (DOSH), each holding a currently active
certificate, dated within 12 months, from a recognized testing laboratory,
indicating satisfactory welding test results in accordance with
recommended practices. Retest is required if welder has not performed
welding for a period of 90 days. Maintain copies of certificates at the job
site. Non certified welders shall not be employed.

.3

All welding consumables shall be stored and handled in accordance with

manufactures recommendation.

KENCANA SQUARE
PIPING AND ACCESSORIES
SECTION AC-060
Page 2

.4

Employ an independent testing agency to perform random ultrasonic tests

on 10% of the welded joints to verify full penetration of welds in
accordance with accepted British Standards. If more than 5% of the
welds fail to meet B.S. requirements, then Contractor shall test 100% of
the welds. All failed welds to be cut out and new pipe welded.

.5

Test steel pipe in accordance with the latest edition of acceptable, ASME
Standards for Welded Steel Pipe, B 31.3.

2.0

PRODUCT

2.1

GENERAL
.1

This section details the requirements in respect of materials and

workmanship in general for the installation of pipework, fittings and
accessories for the pipework system required for this project.

.2

The installation of the pipework system shall comply with the relevant
British Standard specification, Local Authority Regulations and By-Laws.
All installations shall be tested and approved by the relevant Local
Authority where necessary.

.3

All necessary fees, for approval of the installation shall be paid by this
sub-Contractor.

.4

All pipework shall be supplied, installed, connected up and tested in the

positions generally as shown on the accompanying drawings. The exact
location of the pipe runs shall be ascertained by this sub-contractor on
site to suit the prevailing conditions. The work shall be executed in an
approved manner avoiding as far as possible any interference with the
work of other trades.

.5

All pipework shall be installed following the latest technique and practice.
Allowance shall be made for thermal expansion of the pipework as shown
on the drawings where required.

.6

Galvanising: Hot process inside and outside of pipe with zinc coating,
minimum 0.1 gm per cm2.

.7

All pipes shall c/w mill certificate from factory of manufacture.

KENCANA SQUARE
PIPING AND ACCESSORIES
SECTION AC-060
Page 3

2.2

TYPE OF PIPES
.1

PIPING SCHEDULE
SERVICE

NOMINAL
SIZE

PIPE

25mm to
50mm

Black Mild Steel

BS 1387 Class C

65mm
to150mm

Black Mild Steel

BS 1387 Class C

200mm to
400mm

Carbon Steel
Pipe to
API 5L Gr. B

Chilled
Water

400mm &
above
Condensate
Drains
(Cooling
Coils) &
Indirect
Wastes
Vent &
Relief

.2

Electric Welded
Carbon Steel
Pipe to API 5L
Gr. B

15mm to
50mm

Galvanised mild
steel BS 1387
Class C

15mm to
50mm

Galvanised Mild
Steel to BS 1387
Class C

FITTINGS
Screwed
Malleable iron
to BS 143 &
1256
Butt Welding
Malleable Iron
Fitting to BS
143 & 1256
Butt Welding
Fitting to
A 234 Gr.
WPB
Butt Welding
Fitting to A
234 Gr. WPB
Galvanised
Screwed
Malleable iron
to BS 143 &
1256
Galvanised
Screwed
Malleable iron
to BS 143 &
1256

JOINTING
METHOD
Screwed

Butt
Welding or
mechanical
coupling
Butt
Welding
or
mechanical
coupling
Butt
Welding or
mechanical
coupling

Screwed

Screwed

Allowable working stress value for seamless pipe is 25% of pipe specified
minimum tensile stress value. Minimum allowable stress value for
seamed pipe shall be 85% of the values calculated for seamless pipe.

KENCANA SQUARE
PIPING AND ACCESSORIES
SECTION AC-060
Page 4

2.3

PIPE WALL THICKNESS FOR SCHEDULED PIPE TO API 5L Gr.B

.1

2.4

2.5

NOMINAL PIPE
SIZE

PRESSURE

REQUIRED WALL THICKNESS

(mm)

200mm

1600 kpa

5.56

250mm

1600 kpa

6.35

300mm

1600 kpa

6.35

350mm

1600 kpa

6.40

400mm

1600 kpa

7.10

450mm

1600 kpa

7.10

STEEL PIPE JOINTING

.1

On black steel pipework all joints up to and including 65 mm dia. shall be

made by means of screwed or welded connections. Pipes 80 mm dia. and
above shall be joined by means of welded or flanged connections or
mechanical coupling depending on the location of the pipework.

.2

On galvanised steel pipework joints up to and including 65 mm dia. shall

be made by means of screwed connections. Pipes 80 mm and above
shall be joined by means of flanged or mechanical couplings screwed
connections.

.3

In all cases where pipes are joined to flanged equipment, the appropriate
mating flanges shall be used.

FLANGES FOR STEEL PIPE

.1

2.6

CHILLED WATER PIPE

Flanges shall be of mild steel to B.S. 10 Table E or F as necessary. All

flanged joints shall be flush and aligned, and shall be made with
corrugated jointing rings, coated on both side with the recommended
jointing compound. All bolts shall be hexagonal-headed steel in
accordance with the provisions of B.S. 28 with washers and nuts.

STEEL PIPE FITTINGS

.1

In all cases galvanised pipe fittings shall be used on galvanised pipework

and black pipe fittings on black steel pipework unless written confirmation
is supplied by the Engineer.

.2

In general all fittings shall be of the malleable iron type, but in all cases
entirely suited to the working and test pressures of the circuit concerned.

.3

Where welding is employed for jointing black steel pipes, fittings shall be
of butt welding type with chamfered edges.

KENCANA SQUARE
PIPING AND ACCESSORIES
SECTION AC-060
Page 5

2.7

2.8

.4

On all changes of direction, long radius bends and sweep or pitcher tees
shall be used. Bends and offsets on black steel pipe may be formed by
pulling and/or fire setting, in these case the pipes shall be thoroughly
descaled and cleaned before fittings.

.5

Reductions in the diameter for through-flow pipes shall be made by

means of reducing sockets. Eccentric reducing sockets shall be used on
horizontal pipes and concentric reducing sockets for vertical pipes only.

COPPER PIPE JOINTING

.1

All copper pipework up to and including 1 1/2 dia. shall be joined by

means of capillary or compression fittings or may be brazed. Generally
copper pipe work on view shall be brazed or capillary connectors or
adaptors shall be used to present a pleasing appearance, compression
connectors or adaptors may be used where the pipes are concealed,
where periodic dismantling is expected and at terminal joints to
equipment. Copper pipework 2dia. and above shall be joined by means
of brazed or flanged connection. At terminal joints to equipment flanged
joint shall be used to facilitate maintenance, dismantling and repair.

.2

All brazed joints shall be made using a hard solder such as silver Solder
or Silfos. Under no circumstances will be use of an acid based flux or
fluid be permitted. After brazed joints are made, they shall be thoroughly
cleaned and washed to remove all traces of flux before installation.

FLANGES FOR COPPER PIPE

.1

2.9

All copper pipework shall be assembled by means of sufficient pairs of

gunmetal or composite steel/gunmetal flanges to facilitate dismantling.
Gunmetal or composite flanges shall be manufactured in accordance with
B.S. 10 Table F or E as necessary. Flanged joints shall be flush and
aligned and shall utilise corrugated jointing rings, coated on both sides
with the recommended jointing compound.

COPPER PIPE FITTINGS

.1

All copper fittings up to and including 32 mm dia. shall be of the capillary

or compression type, sizes 50 mm dia. and above shall be of the flanged
type.

.2

In all cases the type of fittings used shall be entirely suited for their
application, special regard being paid to refrigerant properties and the
pressures involved.

.3

Where capillary fittings are used they shall have built in solder rings,
thereby requiring only flux and heat to make a truly clean joint.

.4

Bends may be pulled as necessary, but in all cases a proper bending

machine with formers for the varying pipe diameters shall be used to
produce bends entirely free from buckling.

KENCANA SQUARE
PIPING AND ACCESSORIES
SECTION AC-060
Page 6

2.10

.5

Reduction tees may be brazed into the larger pipes. In these cases great
care must be taken to ensure the hole cut in the larger pipe has the
required matching compound curve. Oversize holes, filled in with brazing
after the joint has been made will not be permitted.

.6

If called upon to do so, the sub-contractor shall submit to the Engineer

samples of copper fittings and speciments of brazed joints for approval
before any work is carried out.

EXPANSION JOINTS
.1

Wherever possible, advantage shall be taken of changes in direction of

pipes to take up expansion and contraction due to temperature changes
of the pipe and its contents.

.2

In addition expansion joints shall be provided as indicated on the

drawings. An approved type of roller guides shall be installed on either
side of the expansion joint to prevent blocking during expansion or
contraction of the pipework.

.3

The number and position of the expansion joints and pipe anchors shall
be such that the expansion or contraction takes place without undue
stress on the pipework to meet the following worst conditions.
Chilled water
Hot water
Steam & Condensate
Condensing water

40F to 95F
79F to 220F
70F to 350F
70F to 120F

.4

The expansion joints shall be of the quided belows type or telescopic type
of approved manufacture suitable for the temperatures and pressures
encountered for the particular service.

.5

For the expansion joints on pipes 2 dia. and below standard expansion
bends or loops of approved manufacture could be used. If the bend is
made of welded pipe, the butt weld in the pipe shall be located in the
neutral axis of the bend.

.6

The total of expansion bends or loop provided shall be sufficient to permit

free movement. Expansion bends when detailed shall be carefully made
to the dimensions shown and installed as per the drawings.

.7

All piping laid in ducts or inaccessible positions, which are difficult to lag,
shall be lagged before being put into place. Care shall be taken to ensure
that the insulation is not damaged during installation of the pipes.

KENCANA SQUARE
PIPING AND ACCESSORIES
SECTION AC-060
Page 7

2.11

2.12

UNIONS AND COUPLINGS

.1

Provide unions where required for the removal of equipment. For piping
80mm and smaller, use ground joint type of malleable iron with brass
seats for iron pipe, and made of brass for brass pipe and copper tubing.
For piping 100mm and larger use forged steel slip-on flanges for ferrous
piping and bronze flanges for copper piping. Unions and couplings to be
at 150% of working pressure.

.2

Provide insulating dielectric coupling to BS 2871 Table X at each joint

between steel or zinc (galvanised) and copper; up to 50mm size. Larger
sizes to be flange type with insulator spacers and washers. Couplings to
be rated at 150% of minimum working pressure.

.3

Provide grooved mechanical coupling of ductile iron conformity to ASTM

A-536, Grade 65-45-12 for all pipe joints of galvanised pipeworks.

ESCUTCHEONS
.1

2.13

Galvanised Iron cover sleeve hubs or fitting projections. Provide

escutcheons for exposed piping through floors, ceilings, walls and
partitions in finished areas, and piping through all fire rated separations.
Attach escutcheon to building material, not to pipe.

PIPING SLEEVES
.1

Pipes passing through walls, floors or any other partitions shall be fitted
with pipe sleeves. Sleeves for galvanised or black iron pipe shall be of
galvanised pipe off-cuts; and sleeves for copper pipe shall be similar but
of brass or copper.

.2

Pipe sleeves fitted in walls or partitions shall end flush with the finished
plaster or other surface finish.

.3

Pipes sleeves fitted in floor shall generally end above the finished floor
level except in Plant Rooms and other areas where wet floors are
expected in these cases the sleeves shall end 2 above the finished floor
level, and tightly caulked with suitable diameter firestop material

.4

Where pipes pass through floor trench covers, special flanged sleeves
shall be fitted to form a water tight seal.

.5

Sleeves fitted on insulated pipes shall be oversize to allow the insulation

to be continued through them.

.6

Where pipes pass through fire break walls or other partitions clearance
between pipe or insulation and sleeve shall be tightly packed with suitable
diameter firestop to form a sound and fire barrier. Insulation shall be
continuous through sleeve.

KENCANA SQUARE
PIPING AND ACCESSORIES
SECTION AC-060
Page 8

2.14

.7

Insulating material shall be suitable approved type with a minimum fire

resistance value to comply with the requirements of the Local Fire
Department.

.8

Where necessary for poured concrete fabrications, the Sub-Contractor

shall supply the pipe sleeves to the Building Contractor together with the
necessary information for these sleeves to be correctly positioned in the
shuttering before the concrete is poured.

.9

Generally pipe sleeves shall be one (10 nominal diameter larger than the
service pipe concerned except for sizes 4 bore and above where they
may be specially constructed from not less than 1/8" galvanised sheet
steel.

PREINSULATED PIPING SYSTEM

.1

ABOVEGROUND PIPEWORK
.1

All thermally insulated aboveground chilled water pipework shall

be preinsulated black steel pipe conforming to the following
specifications:

.2

Insulation shall be pipe in pipe without air gap, with physical

properties indicated below. This material must be installed strictly
in accordance with the manufacturers recommendations.

(a)

Service Pipe:
Up to and including 6 dia. shall be heavy gauge black
steel pipes to BS 1387 or equivalent (ASTM A106
SCH.40), Pipes 8 and over shall be API 5L Grade B
standard weight or equivalent.
In either case the pipe shall be suitable for the pressure
service specified elsewhere.
All pipes shall have ends suitably prepared for welding and
shall be capped for transport and storage.

(b)

Outer Casing:
Shall be:
Spiral formed outside locked seam galvanised iron type of
the following gauges
Up to 8 dia.

26 gauge

9 and above

24 gauge

KENCANA SQUARE
PIPING AND ACCESSORIES
SECTION AC-060
Page 9

(c)

Insulation
Insulation shall be CFC free rigid polyurethane foam
machine injected into the annulus between service pipe
and casing by a one shot factory process and shall have
the following physical properties:
Density: 50kg/m3 min.
Thermal conductivity; k value 0.023 w/mK (0.15 Btu/ft2
hrF in) at 20C (68F) mean.
Compressive strength: 275 Kpa (40psi) minimum
Closed cell content: 90% by volume minimum
Preinsulated Piping Systems

(d)

Completed System:
Water vapour permeability 1.8 x 10-5 metric perms (2.6 x
10-2 perm inch)
Fire rating: 2 hr at 1800F and shall be certified to the
approval of the Department of Fire Services, Malaysia.
The complete piping shall be painted to colours approved
by the ERs.

(e)

Thickness of Insulation

(i) Shall be of such thickness as to prevent condensation

forming on the outer casing under following conditions:
Ambient Temp

RH%

Fluid Temp

35C (95F)
30C (86F)

90
95

6C (43F)
6C (43F)

(ii) Shall be 1 thick for pipes up to 4 NB and for 5 and

over 2 nominal thickness.
Calculation of thickness to substantiate
condensing of surface is required.

(f)

non-

Installation
Joints between preinsulated units and valves are to be site
insulated in situ and correctly vapour sealed.

KENCANA SQUARE
PIPING AND ACCESSORIES
SECTION AC-060
Page 10

Particular attention is drawn to the following topics covered

in the manufacturers recommendations and must be
strictly adhered to:
Handling and Storage
Supports, Hangers and Anchors
Provision for Contraction and Expansion.
.2

UNDERGROUD PIPEWORK
All thermally insulated underground pipework shall be pipe in pipe without
air gap of the physical properties indicated below. Installation must be
strictly in accordance with the manufacturers recommendations.
(a)

Service Pipe
Up to and including 6 dia. pipe shall be black steel pipe to BS
1387 or equivalent. 8dia. and over shall be API 5L Grade B
standard weight or equivalent.
In either case the pipe shall be suitable for the pressure service
specified elsewhere.
All pipes shall have ends suitably prepared for field welding and
shall be capped for transport and storage.

(b)

Outer Casing:
High density polyethylene Pipe Grade 5010 Type II carbon black
stabilised, extruded in one piece.

(c)

Insulation:
Insulation shall be CFC-free based rigid polyurethane foam
machine injected into the annulus between the service pipe and
outer casing by a one shot factory process and shall have the
following poperties:Density: Nominal in situ 75kg/m3 (4.81b / ft3)
Thermal conductivity: k value 0.023 w/mK (0.15 Btu/ft2 hr F in) at
20C (68F) mean.
Compressive strength; 300 KPa 944psi) at room temp
Closed cell content; 90% by volume minimum
Insulation thickness:
thicknesses shall be

Unless

otherwise

specified

insulation

KENCANA SQUARE
PIPING AND ACCESSORIES
SECTION AC-060
Page 11

(d)

Pipe up to 32mm NB (1 )

25mm (1) nom thickness

Pipes between 40mm and

125mm NB (1 1/2^-5)

32mm (1 )nom thickness

Pipes between 150mm and

200mm NB (6 & 8)

40mm (1 ) nom thickness

Pipes 250mm and over (10)

50mm (2) minimum thickness

Fittings
All fittings shall be factory fabricated and insulated so that the only
site insulation shall be straight joints between the preinsulated
units.
The service pipe fabrication shall be in accordance with the
welding specification specified elsewhere herein.
All casings for fittings shall be prefabricated from high density
polyethylene. Casing fabrication shall be effected by either hot
plate, hot gas or extrusion welding processes.
All casing fabrication welds shall be tested by the high voltage
spark method to prove pressure tightness and weld integrity.

(e)

Bulkheads
Bulkheads where required shall be the heat shrinkable modified
cross linked polyethylene type, suitable for the service
temperature specified elsewhere.
Where preinsulated units are supplied exclusive of bulkheads, the
exposed foam faces shall be coated with sealant, factory applied.

(f)

Joints
Only the straight joints between the preinsulated units shall be site
insulated. Straight joints shall be site insulated using rigid
polyurethane foam.
The casing joint shall be completed with a polyethylene wraparound heat shrink sleeve.

(g)

Arrangement and Layout Piping

The drawings indicate the designed and approximate positions
and arrangement of all piping.

KENCANA SQUARE
PIPING AND ACCESSORIES
SECTION AC-060
Page 12

Contraction and Expansion shall be accommodated by sufficient

bends so that the system is sufficiently flexible to absorb the whole
of its contraction or expansion, without developing excessive
stresses in either the piping itself or the connection equipment.
In the Contractors installation drawing which shall be submitted to
the Engineer for his approval prior to installation, all pipework shall
be positioned with due regard to these requirements and shall be
in accordance with the manufacturers recommendations.
The Contractor is expected to be fully conversant with the
manufacturers installation and handling recommendations.
(h)

Drain Lines
Drain pipes discharging chilled water condensation from drain
pan, etc. shall be insulated with close-cell insulation material to
approval.

3.0

EXECUTION
.1

The pipe lengths shall be cut with standard pipe cutters, threads cut with
standard thread dies and ends reamed before assembly. Improperly cut
threads shall not be filled with paint or plumbers rope.

.2

The pipes shall be installed in continuous as far as practicable and joints

shall be made to form a permanent fixture except where a fitting or outlet
is to be connected.

.3

All pipes, fittings, valves and accessories shall be thoroughly cleaned

internally and externally, prior to installation and again where required
before closing up. On completion of the installation, all pipework, fittings
valves and accessories shall be thoroughly cleaned internally to ensure
that the interior of the pipe is free from any grit, dirt or foreign bodies.

.4

As far as practicable only easy sweep bends shall be used.

.5

The piping and fittings shall be free of any internal projections or

restrictions which may impede smooth flow of the fluid.

.6

This Sub-Contractor shall ensure that all joints are tight and drip-proof
and all hidden joints in pipework shall be welded.

.7

All screwed connection shall be coated with graphite and oil at time of
making such joints.

.8

Flange connections shall have their meeting faces machined to a true

surface square with the axis of the pipe.

KENCANA SQUARE
PIPING AND ACCESSORIES
SECTION AC-060
Page 13

.9

All exposed pipework shall be installed so that clearance of approximately

2 is left between the outside of the pipe or insulation and the nearest
wall, ceiling or equipment surface. Pipes shall be run at a minimum
distance apart to enable them to be individually insulated and painted.
Combined insulation of two or more pipes will not be approved. Pipe joints
or fittings will not be permitted within the thickness of walls, floors or any
other partitions.

.10

All straight vertical run of pipe more than 100 in length shall have dirt
pockets formed from equal tees and plugs at the low point of the risers.

.11

Before horizontal runouts are taken off such vertical riser air bottles shall
be fitted using equal or reducing tees at the high point of the risers.

.12

In all plant rooms the pipework shall be installed with flanges and/or
unions dependent on the pipe size at intervals not exceeding 12 feet to
facilitate repair or dismantling.

.13

All fixing of pipe hangers or brackets to the building structure shall be by

means of approved nylon or metal expansion plugs. Suitable receiving
holes shall be cut by approved rotary-percussion electric drills to give true
and accurate drillings.

.14

Any open ended pipe or pipe connection left overight or for any
considerable period shall be protected from the entry of dust, sand etc.,
by the fixing of plastic or softwood plugs.

END OF SECTION AC-060