GENERAL

MATERIALS AND WORKMANSHIP

SPECIFICATION

VOLUME 3

ELECTRICAL AND MECHANICAL WORKS

ISSUE NO. 5

JANUARY 2011
[this page not used]
 GENERAL MATERIALS AND WORKMANSHIP SPECIFICATION

TABLE OF CONTENTS

VOLUME 1 CIVIL AND STRUCTURAL WORKS

Section 1 General – Civil and Structural Works
2 Temporary Works
3 Site Clearance
4 Landscaping Works
5 Fencing
6 Drainage Works
7 Earthworks
8 Geotechnical Works
9 Carriageways: Sub-base Material and Bituminous Materials
10 Concrete Carriageways
11 Miscellaneous Roadworks
12 Traffic Signs, Road Markings and Road Studs
13 Work for Electrical and Mechanical Installations
14 Water Supply Pipeworks
15 Not Used
16 Not Used
17 Piling Works
18 Formwork and Finishes to Concrete
19 Steel Reinforcement
20 Concrete and Joints in Concrete
21 Prestressing
22 Steelwork
23 Bridgeworks
24 Water Retaining Structures

VOLUME 2 ARCHITECTURAL WORKS

Section 25 General – Architectural Works
26 Masonry and Blockwork
27 Waterproofing and Tanking
28 Roofing and Wall Cladding
29 Curtain Walling
30 Internal Cladding Systems
31 Carpentry and Joinery

General Materials & Workmanship Specification (i) January 2011

Issue No. 5
VOLUME 2 ARCHITECTURAL WORKS (CONTINUED)
Section 32 Internal Cladding Systems
33 Linings, Sheathings, Drywall Partitions and Toilet Cubicles
34 Suspender Ceilings
35 Architectural Metalwork (Including Metal Doors and Shutters)
36 Ironmongery
37 Hard Floor Finishes
38 Flexible Floor Finishes
39 Wall Finishes
40 Painting and Decoration
41 Fire Protection and Fire Stopping Systems
42 Signage
43 Not Used

VOLUME 3 ELECTRICAL AND MECHANICAL WORKS

Section 44 Abbreviations, Standards and General – Electrical and Mechanical
45 Electrical Power Supply
46 Low Voltage Switchboards
47 Sub-Mains Electrical Distribution Equipment
48 Wiring and Cables
49 Cable Management Systems
50 Wiring Accessories and Miscellaneous Electrical Equipment
51 General Lighting Systems
52 Uninterruptible Power Supply System (UPS)
53 Motors
54 High Voltage Electrical Services
55 Not Used
56 Not Used
57 Earthing and Bonding System
58 Lightning Protection System
59 Electromagnetic Compatibility
60 Inspection, Testing and Commissioning - Electrical Services
61 Air Handling Units
62 Fan Coil Units
63 Fans
64 Split Type Air Conditioning Unit
65 Window Type Air Conditioning Unit

General Materials & Workmanship Specification (ii) January 2011

Issue No. 5
VOLUME 3 ELECTRICAL AND MECHANICAL WORKS (CONTINUED)
Section 66 Air Cooling Coils
67 Dampers and Air Volume Control Devices
68 Registers, Diffusers and Grilles
69 Air Filters
70 Ductwork and Fittings
71 Water Handling Equipment
72 Pipeworks, Fittings and Valves
73 Thermal Insulation
74 Sound Attenuator
75 Noise and Vibration Control
76 Electrical Equipment and Installation
77 Automatic Controls
78 Instruments
79 Testing, Inspection and Commissioning – Mechanical Services
80 Automatic Sprinkler System
81 Hydrant and Hose Reel System
82 Gaseous Fire Extinguishing System (FM200)
83 Fire Alarm and Detection System
84 Portable Hand Equipment
85 Visual Fire Alarm
86 Exist Sign and Directional Sign
87 Pipework, Valves and Fittings
88 Pumps and Tanks
89 Electrical Equipment and Installation
90 Inspection, Testing and Commissioning – Fire Services
91 Foul Water Disposal
92 Storm Water Disposal
93 Water Supply
94 Hot Water Supply System
95 Pipework, Fittings and Valves
96 Town Gas Reticulation
97 Pumps and Tank Level Controls
98 Electrical Equipment and Installation
99 Inspection, Testing and Commissioning – Hydraulic Services
100 General Building Management System
101 Mechanical Building Management System

General Materials & Workmanship Specification (iii) January 2011

Issue No. 5
VOLUME 3 ELECTRICAL AND MECHANICAL WORKS (CONTINUED)
Section 102 Voice and Data Cabling
103 Public Address System
104 Access Control System
105 Trunked Mobile Radio System
106 Closed Circuit Television System
107 Master Antenna Television (MATV)
108 Inspection, Testing and Commissioning Systems
109 Not Used
110 Not Used
111 Not Used
112 Not Used
113 Not Used
114 Not Used
115 Not Used
116 Not Used
117 Not Used
118 Not Used
119 Not Used

VOLUME 4 AIRFIELD WORKS

Section 120 General - Airfield Works
121 Airfield Ground Lighting System
122 Airport Lightning Warning System
123 Fixed Ground Power System
124 High Mast Lighting system
125 Pre-conditioned Air Supply Units
126 Aircraft Parking Aid System
127 Airfield Supervisory Control and Data Acquisition System
128 Aircraft Loading Bridges
129 Perimeter Fence Lighting System
130 Jet Blast Screens

General Materials & Workmanship Specification (iv) January 2011

Issue No. 5
108.10 Testing and Commissioning Equipment and Instruments
108.11 Notifications
108.12 Inspection and Testing
108.13 Specific Inspection, Testing and Commissioning Requirements
108.14 Testing and Commissioning Requirements for Fibre Optic and UTP
Cables

SECTION 109 NOT USED

SECTION 110 NOT USED

SECTION 111 NOT USED

SECTION 112 NOT USED

SECTION 113 NOT USED

SECTION 114 NOT USED

SECTION 115 NOT USED

SECTION 116 NOT USED

SECTION 117 NOT USED

SECTION 118 NOT USED

SECTION 119 NOT USED

General Materials & Workmanship Specification

Issue No. 5, Volume 4 – Electrical & Mechanical Works
Table of Contents 13/13 January 2011
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GENERAL MATERIALS AND WORKMANSHIP SPECIFICATION

VOLUME 3 – ELECTRICAL AND MECHANICAL WORKS

SECTION 44 ABBREVIATIONS, STANDARDS AND GENERAL –ELECTRICAL

AND MECHANICAL

44.1 Definition and Abbreviations

44.2 Relevant Codes and Standards
44.3 Not Used
44.4 Workmanship
44.5 Materials
44.6 Installation of Equipment
44.7 Energy Efficiency and Conservation
44.8 Welding
44.9 Drawings Provided by the Contractor
44.10 Painting and Finishes
44.11 Facility Identification

SECTION 45 ELECTRIC POWER SUPPLU

45.1 Power Supply Conditions

45.2 General Power Supply

SECTION 46 LOW VOLTAGE SWITCHBOARDS

46.1 General
46.2 Relevant Codes and Standards
46.3 Materials
46.4 Submissions
46.5 Workmanship

SECTION 47 SUB-MAINS ELECTRICAL DISTRIBUTION EQUIPMENT

47.1 General
47.2 Relevant Codes and Standards
47.3 Materials
47.4 Submissions
47.5 Workmanship

SECTION 48 WIRING AND CABLES

48.1 General
48.2 Relevant Codes and Standards
48.3 Materials
48.4 Submissions
48.5 Workmanship

General Materials & Workmanship Specification

Issue No. 5, Volume 4 – Electrical & Mechanical Works
Table of Contents 1/13 January 2011
SECTION 49 CABLE MANAGEMENT SYSTEMS

49.1 General
49.2 Relevant Codes and Standards
49.3 Materials
49.4 Submissions
49.5 Workmanship

SECTION 50 WIRING ACCESSORIES AND MISCELLANEOUS ELECTRICAL

EQUIPMENT

50.1 General
50.2 Relevant Codes and Standards
50.3 Materials
50.4 Submissions
50.5 Workmanship

SECTION 51 GENERAL LIGHTING SYSTEMS

51.1 General
51.2 Relevant Codes and Standards
51.3 Materials
51.4 Submissions
51.5 Workmanship

SECTION 52 UNINTERRUPTIBLE POWER SUPPLY SYSTEM (UPS)

52.1 General
52.2 Relevant Codes and Standards
52.3 Materials
52.4 Installation

SECTION 53 MOTORS

53.1 General
53.2 Relevant Codes and Standards
53.3 Materials
53.4 Submissions

SECTION 54 HIGH VOLTAGE ELECTRICAL SERVICES

54.1 General
54.2 Relevant Codes and Standards
54.3 HV Switchgear
54.4 Distribution Transformer
54.5 High Voltage Cable
54.6 Pilot Cables
54.7 Submissions

General Materials & Workmanship Specification

Issue No. 5, Volume 4 – Electrical & Mechanical Works
Table of Contents 2/13 January 2011
SECTION 55 NOT USED

SECTION 56 NOT USED

SECTION 57 EARTHING AND BONDING SYSTEM

57.1 General
57.2 Relevant Codes and Standards
57.3 Materials
57.4 Earthing Resistance
57.5 Earth Fault Loop Impedance
57.6 Submissions
57.7 Workmanship

SECTION 58 LIGHTNING PROTECTION SYSTEM

58.1 General
58.2 Relevant Codes and Standards
58.3 Materials

SECTION 59 ELECTROMAGNETIC COMPATIBILITY

59.1 General
59.2 Relevant Codes and Standards
59.3 Electromagnetic Compatibility (EMC)

SECTION 60 INSPECTION, TESTING AND COMISSIONING – ELECTRICAL

SERVICES

60.1 General
60.2 Terminology
60.3 Testing and Commissioning Phases
60.4 Quality Plans
60.5 Phase Notices
60.6 Test Results Forms
60.7 Phase Reports
60.8 Relevant Codes, Standards and Regulations
60.9 Contractor’s Testing and Commissioning Staff
60.10 Testing and Commissioning Equipment and Instruments
60.11 Notifications
60.12 Inspections and Testing
60.13 Specific Inspection, Testing and Commissioning Requirements
60.14 HV Distribution Cables
60.15 HV Distribution Transformer
60.16 Confidence Trials Phase
60.17 Emergency Generators
60.18 Daily and Underground Fuel Tanks
60.19 Pilot Cables

General Materials & Workmanship Specification

Issue No. 5, Volume 4 – Electrical & Mechanical Works
Table of Contents 3/13 January 2011
SECTION 61 AIR HANDLING UNITS

61.1 General
61.2 Relevant Codes and Standards
61.3 Selection
61.4 Materials
61.5 Submissions
61.6 Workmanship

SECTION 62 FAN COIL UNITS

62.1 General
62.2 Relevant Codes and Standards
62.3 Materials
62.4 Submissions
62.5 Workmanship

SECTION 63 FANS

63.1 General
63.2 Relevant Codes and Standards
63.3 Materials
63.4 Submissions
63.5 Workmanship

SECTION 64 SPLIT TYPE AIR CONDITIONING UNIT

64.1 General
64.2 Relevant Codes and Standards
64.3 Materials
64.4 Submissions
64.5 Workmanship

SECTION 65 WINDOW TYPE AIR CONDITIONING UNIT

65.1 General
65.2 Relevant Codes and Standards
65.3 Materials
65.4 Submissions
65.5 Workmanship

SECTION 66 AIR COOLING COILS

66.1 General
66.2 Relevant Codes and Standards
66.3 Materials
66.4 Submissions
66.5 Workmanship

General Materials & Workmanship Specification

Issue No. 5, Volume 4 – Electrical & Mechanical Works
Table of Contents 4/13 January 2011
SECTION 67 DAMPERS AND AIR VOLUME CONTROL DEVICES

67.1 General
67.2 Relevant Codes and Standards
67.3 Materials
67.4 Submissions
67.5 Workmanship

SECTION 68 REGISTERS, DIFFUSERS AND GRILLES

68.1 General
68.2 Relevant Codes and Standards
68.3 Design and Performance Criteria
68.4 Materials
68.5 Submissions
68.6 Workmanship

SECTION 69 AIR FILTERS

69.1 General
69.2 Relevant Codes and Standards
69.3 Design and Performance Criteria
69.4 Materials
69.5 Submissions
69.6 Workmanship
69.7 Inspection, Testing and Commissioning

SECTION 70 DUCTWORK AND FITTINGS

70.1 General
70.2 Relevant Codes and Standards
70.3 Design and Performance Criteria
70.4 Materials
70.5 Submissions
70.6 Workmanship

SECTION 71 WATER HANDLING EQUIPMENT

71.1 General
71.2 Relevant Codes and Standards
71.3 Selection
71.4 Materials
71.5 Submissions
71.6 Workmanship

SECTION 72 PIPEWORK, FITTINGS AND VALVES

72.1 General
72.2 Relevant Codes and Standards
72.3 Materials
72.4 Submissions
72.5 Workmanship
General Materials & Workmanship Specification
Issue No. 5, Volume 4 – Electrical & Mechanical Works
Table of Contents 5/13 January 2011
SECTION 73 THERMAL INSULATION

73.1 General
73.2 Materials
73.3 Submissions
73.4 Workmanship

SECTION 74 SOUND ATTENUATORS

74.1 General
74.2 Relevant Codes and Standards
74.3 Materials
74.4 Submissions
74.5 Workmanship

SECTION 75 NOISE AND VIBRATION CONTROL

75.1 General
75.2 Materials
75.3 Submissions
75.4 Workmanship
75.5 Design and Testing Requirements

SECTION 76 ELECTRICAL EQUIPMENT AND INSTALLATION

76.1 General
76.2 Relevant Codes and Standards
76.3 Materials
76.4 Submissions
76.5 Workmanship

SECTION 77 AUTOMATIC CONTROL

77.1 General
77.2 Relevant Codes and Standards
77.3 Design and Performance Criteria
77.4 Materials
77.5 Submissions
77.6 Workmanship

SECTION 78 INSTRUMENTS

78.1 General
78.2 Relevant Codes and Standards
78.3 Design and Performance Criteria
78.4 Materials
78.5 Submissions
78.6 Workmanship

General Materials & Workmanship Specification

Issue No. 5, Volume 4 – Electrical & Mechanical Works
Table of Contents 6/13 January 2011
SECTION 79 TESTING, INSPECTION AND COMMISSIONING – MECHANICAL
SERVICES

79.1 General
79.2 Terminology
79.3 Testing and Commissioning Phases
79.4 Quality Plans
79.5 Phase Notices
79.6 Test Results Forms
79.7 Phase Reports
79.8 Standards and Regulations
79.9 Contractor’s Testing and Commissioning Staff
79.10 Testing and Commissioning Equipment and Instruments
79.11 Notifications
79.12 Inspections and Testing
79.13 Factory Testing
79.14 Type Test Certificates
79.15 Site Testing and Commissioning
79.16 Rebalancing and Recommissioning to Suit Completion

SECTION 80 AUTOMATIC SPRINKLER SYSTEM

80.1 General
80.2 Relevant Codes and Standards
80.3 Materials
80.4 Submissions
80.5 Workmanship
80.6 Pre-action Sprinkler System

SECTION 81 HYDRANT AND HOSE REEL SYSTEM

81.1 General
81.2 Relevant Codes and Standards
81.3 Materials
81.4 Submissions
81.5 Workmanship
81.6 Street Hydrant System

SECTION 82 GASEOUS FIRE EXTINGUISHING SYSTEM (FM200)

82.1 General
82.2 Relevant Codes and Standards
82.3 Materials
82.4 Submissions
82.5 Workmanship

SECTION 83 FIRE ALARM AND DETECTION SYSTEM

83.1 General
83.2 Relevant Codes and Standards
83.3 Materials
83.4 Submissions

General Materials & Workmanship Specification

Issue No. 5, Volume 4 – Electrical & Mechanical Works
Table of Contents 7/13 January 2011
SECTION 84 PORTABLE HAND HELD EQUIPMENT

84.1 General
84.2 Relevant Codes and Standards
84.3 Materials
84.4 Submissions
84.5 Workmanship

SECTION 85 VISUAL FIRE ALARM

85.1 General
85.2 Relevant Codes and Standards
85.3 Materials
85.4 Submissions
85.5 Workmanship

SECTION 86 EXIT SIGN AND DIRECTIONAL SIGN

86.1 General
86.2 Relevant Codes and Standards
86.3 Materials
86.4 Submissions
86.5 Workmanship

SECTION 87 PIPEWORK, VALVES AND FITTINGS

87.1 General
87.2 Relevant Codes and Standards
87.3 Pipework and Fittings Materials
87.4 Valves and Fittings Materials
87.5 Submissions
87.6 Workmanship

SECTION 88 PUMPS AND TANKS

88.1 General
88.2 Relevant Codes and Standards
88.3 Materials
88.4 Submissions
88.5 Workmanship

SECTION 89 ELECTRICAL EQUIPMENT AND INSTALLATION

89.1 General
89.2 Relevant Codes and Standards
89.3 Materials
89.4 Workmanship

General Materials & Workmanship Specification

Issue No. 5, Volume 4 – Electrical & Mechanical Works
Table of Contents 8/13 January 2011
SECTION 90 INSPECTION, TESTING AND COMMISSIONING – FIRE SERVICES

90.1 General
90.2 Terminology
90.3 Testing and Commissioning Phases
90.4 Quantity Plans
90.5 Phase Notices
90.6 Test Results Forms
90.7 Phase Reports
90.8 Standards and Regulations
90.9 Contractor’s Testing and Commissioning Staff
90.10 Testing and Commissioning Equipment and Instruments
90.11 Notifications
90.12 Inspections and Testing
90.13 Type Test Certificates
90.14 Factory Tests
90.15 Model Tests
90.16 Site Testing and Commissioning
90.17 FSD Inspection and Witness of Tests
90.18 Plant Integration Phase
90.19 Testing and Commissioning Report and Certificate of Completion

SECTION 91 FOUL WATER DISPOSAL

91.1 General
91.2 Relevant Codes and Standards
91.3 Materials
91.4 Submissions
91.5 Workmanship

SECTION 92 STORM WATER DISPOSAL

92.1 General
92.2 Relevant Codes and Standards
92.3 Materials
92.4 Submissions
92.5 Workmanship
92.6 Installation
92.7 Testing

SECTION 93 WATER SUPPLY

93.1 General
93.2 Relevant Codes and Standards
93.3 Water Supply Requirements
93.4 Materials
93.5 Submissions
93.6 Workmanship

General Materials & Workmanship Specification

Issue No. 5, Volume 4 – Electrical & Mechanical Works
Table of Contents 9/13 January 2011
SECTION 94 HOT WATER SUPPLY SYSTEM

94.1 General
94.2 Relevant Codes and Standards
94.3 Materials
94.4 Submissions
94.5 Workmanship

SECTION 95 PIPEWORK, FITTINGS & VALVES

95.1 General
95.2 Relevant Codes and Standards
95.3 Materials
95.4 Submissions
95.5 Workmanship

SECTION 96 TOWN GAS RETICULATION

96.1 General
96.2 Relevant Codes and Standards
96.3 Materials
96.4 Gas Detection System
96.5 Submissions
96.6 Workmanship and Installation

SECTION 97 PUMPS AND TANK LEVEL CONTROLS

97.1 General
97.2 Relevant Codes and Standards
97.3 Materials
97.4 Submissions
97.5 Workmanship for Pump Installation

SECTION 98 ELECTRICAL EQUIPMENT AND INSTALLATION

98.1 General
98.2 Relevant Codes and Standards
98.3 Materials
98.4 Workmanship
98.5 Submissions

General Materials & Workmanship Specification

Issue No. 5, Volume 4 – Electrical & Mechanical Works
Table of Contents 10/13 January 2011
SECTION 99 INSPECTION, TESTING AND COMMISSIONING – HYDRAULIC
SERVICES

99.1 General
99.2 Terminology
99.3 Testing and Commissioning Phases
99.4 Quality Plans
99.5 Phase Notices
99.6 Test Results Forms
99.7 Phase Reports
99.8 Standards and Regulations
99.9 Contractor’s Testing and Commissioning Staff
99.10 Testing and Commissioning Equipment and Instruments
99.11 Notifications
99.12 Inspections and Testing
99.13 Type Test Certificates
99.14 Factory Tests
99.15 Site Testing and Commissioning

SECTION 100 GENERAL BUILDING MANAGEMENT SYSTEM

100.1 General
100.2 Relevant Codes and Standards
100.3 System Description
100.4 Monitoring and Control I/O Points

SECTION 101 MECHANICAL BUILDING MANAGEMENT SYSTEM

101.1 General
101.2 Relevant Codes and Standards
101.3 System Description
101.4 Hardware
101.5 Monitoring and Control I/O Points
101.6 System Interfaces

SECTION 102 VOICE AND DATA CABLING

102.1 General
102.2 Relevant Codes and Standards
102.3 System Description
102.4 Fibre Optic Cables
102.5 Twisted Pair Cables
102.6 Distribution Frames
102.7 Voice and Data Outlets (VDO)
102.8 Cable Management and Identification
102.9 Cable Installation
102.10 Cable Testing

General Materials & Workmanship Specification

Issue No. 5, Volume 4 – Electrical & Mechanical Works
Table of Contents 11/13 January 2011
SECTION 103 PUBLIC ADDRESSING SYSTEM

103.1 General
103.2 Relevant Codes and Standards
103.3 System Description
103.4 Performance Criteria of Equipment
103.5 Electromagnetic Interference

SECTION 104 ACCESS CONTROL SYSTEM

104.1 General
104.2 Relevant Codes and Standards
104.3 System Description
104.4 Field Security Devices
104.5 System Testing and Commissioning

SECTION 105 TRUNKED MOBILE RADIO SYSTEM

105.1 General
105.2 Relevant Codes and Standards
105.3 System Description

SECTION 106 CLOSED CIRCUIT TELEVISION SYSTEM

106.1 General
106.2 Relevant Codes and Standards
106.3 System Description
106.4 CCTV Cameras and Accessories
106.5 CCTV Cabling Network
106.6 Video Recording System
106.7 Testing and Commissioning

SECTION 107 MASTER ANTENNA TELEVISION (MATV)

107.1 General
107.2 Relevant Codes and Standards
107.3 General Performance Requirements
107.4 Cable

SECTION 108 INSPECTION, TESTING AND COMMISSIONING SYSTEMS

108.1 General
108.2 Terminology
108.3 Testing and Commissioning Phases
108.4 Quality Plans
108.5 Phase Notices
108.6 Test Results Forms
108.7 Phase Reports
108.8 Standards and Regulations
108.9 Contractor’s Testing and Commissioning Staff

General Materials & Workmanship Specification

Issue No. 5, Volume 4 – Electrical & Mechanical Works
Table of Contents 12/13 January 2011
108.10 Testing and Commissioning Equipment and Instruments
108.11 Notifications
108.12 Inspection and Testing
108.13 Specific Inspection, Testing and Commissioning Requirements
108.14 Testing and Commissioning Requirements for Fibre Optic and UTP
Cables

SECTION 109 NOT USED

SECTION 110 NOT USED

SECTION 111 NOT USED

SECTION 112 NOT USED

SECTION 113 NOT USED

SECTION 114 NOT USED

SECTION 115 NOT USED

SECTION 116 NOT USED

SECTION 117 NOT USED

SECTION 118 NOT USED

SECTION 119 NOT USED

General Materials & Workmanship Specification

Issue No. 5, Volume 4 – Electrical & Mechanical Works
Table of Contents 13/13 January 2011
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SECTION 44 ABBREVIATIONS, STANDARDS AND GENERAL – ELECTRICAL AND
MECHANICAL

44.1 DEFINITIONS AND ABBREVIATIONS

Abbreviations used in this Volume of the General Materials and Workmanship

Specification shall have the following meanings:

AC : Alternating Current
ACB : Air Circuit Breaker
ACRA : Air-conditioning & Refrigeration Association of Hong Kong
ACS : Access Control System
ADC : Air Diffusion Council
AFFL : Above Finished Floor Level
AHU : Air Handling Unit
Al : Aluminium
AISI : American Iron and Steel Institute
ANSI : American National Standards Institute
AOCC : Airport Operations Control Centre
AODB : Airport Operational Data Base
APM : Automated People Mover
ARI : American Air-conditioning and Refrigeration
ASCII : American Standard Code for Information Interchange
ASHRAE : American Society for Heating, Refrigerating and Air-
conditioning Engineers
ASME : American Society of Mechanical Engineers
AS/NZS : Australian/New Zealand Standard
ASTA : Association of Short-Circuit Test Authorities
ASTM : American Society for Testing and Materials
BD : Building Department
BMS : Building Management System
BNC : Bayonet Neill-Concelman
BS : British Standards
BS EN : European Standard adopted as British Standards
BSI : Building Systems Integration
BSIHP : Building Systems Integration Headend Processor
CADD : Computer Aided Drafting Design
Cap : Chapter
CASE : Computer Aided Software Engineering
CCD : Charged Coupled Device

General Materials & Workmanship Specification 1/34 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 44–Abbreviations, Standards & General–E&M
 CCIR : International Consultative Committee on Radio-communication
CCITT : The International Telegraph and Telephone Consultative
Committee
CCTV : Closed Circuit Television
CFC : Chlorofluorocarbon
CHW : Chilled Water
CLP : China Light & Power Co. Ltd.
CONDW : Condenser Water
COP : Coefficient of Performance
CPC : Circuit Protective Conductor
CSA : Contract service availability
CT : Current Transformer
Cu : Copper
DB : Dry Bulb
DC : Direct Current
DI : Ductile iron
dia : Diameter
DIDW : Double Inlet Double Wheel
DOL : Direct on Line
DOS : Disk Operating System
DP : Double Pole
dpi : Dots per Inch
E&M : Electrical and Mechanical
EA : Exhaust Air
EEC : European Economic Community
EEX : EEX is the combination of E and EX, of which E denotes
European Standard and EX denotes Explosion Protection
Symbol (When an “E” precedes the “EX”, the product is in
conformity with European Standard)
E/F : Earth Fault
EMC : Electromagnetic compatibility
EMI : Electromagnetic interference
EMSD : Electrical and Mechanical Services Department
EN : Euro-Norm
EPDM : Ethylene Propylene Diene Monomer
EPROM : Erasable Programmable Read Only Memory
ERP : Effective Radiated Power
ESI : Electricity Supply Industry
FCU : Fan Coil Unit

General Materials & Workmanship Specification 2/34 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 44–Abbreviations, Standards & General–E&M
 FCS : Fixed Communications System network
FEWG : Fire Evacuation Warning Generators
FFL : Finished Floor Level
FIL : Facility Identification Label
FIN : Facility Identification Number
FRP : Fire Resistance Period
FSD : Fire Services Department
FSDCOP : Codes of Practice for Minimum Fire Service Installations and
Equipment and Inspection, Testing and Maintenance of
Installations and Equipment published by FSD of HKSAR
FTNS : Fixed Telecommunications Network Suppliers
FTU : Formazin Turbidity Units
GBMS : General Building Management System
GI : Galvanized Mild Steel
GM&WS : General Materials and Workmanship Specification
GUI : Graphical User Interfaces
HCFC : Hydrochlorofluorocarbon
HDF : House Distribution Frame
HEC : Hongkong Electric Company Limited
HFC : Hydrofluorocarbon
HKIE : The Hong Kong Institution of Engineers
HKSAR : The Government of the Hong Kong Special Administrative
Region of the People’s Republic of China
HRC : High Rupture Capacity
HV : High Voltage
HVAC : Heating, Ventilation and Air Conditioning
HVCA : Heating Ventilating Contractors’ Association
IAQ : Indoor Air Quality
IDF : Intermediate Distribution Frame
IEC : International Electrotechnical Commission
IEE : Institution of Electrical Engineers (United Kingdom)
IGBTS : Insulated Gate Bipolar Transistors
I/O : Input / Output
IP : Index of Protection
ISO : International Standards Organization
LAN : Local Area Network
LCD : Liquid Crystal Display
LED : Light Emitting Diode
LEL : Lower Explosive Limit
General Materials & Workmanship Specification 3/34 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 44–Abbreviations, Standards & General–E&M
 LPHW : Low Pressure Hot Water
LSF : Low Smoke and Fume
LSOH : Low Smoke Zero Halogen
LV : Low Voltage
MATV : Master Antenna Television
MB : Megabyte
MBMS : Mechanical Building Management System
MCB : Miniature Circuit Breaker
MCC : Motor Control Centre
MCCB : Molded Case Circuit Breaker
MCT : Measuring type Current Transformer
MDF : Main Distribution Frames
MDPE : Medium Density Polyethylene
MSB : Main Switch Board
MFTNC : Mason-Flex Twin Sphere Neoprene
MICC : Mineral Insulated Copper Conductor
MTBF : Mean Time Between Failures
MTTR : Mean Time to Restore
MVAC : Mechanical Ventilation and Air Conditioning
NC : Noise Criterion
Ni : Nickel
NFPA : National Fire Protection Agency
NTSC : National Television Systems Committee
OA : Outdoor Air
O/C : Over Load
O&M : Operating and Maintenance
OFTA : Office of the Telecommunications Authority
OS : Operating System
OSI : Open Systems Interconnection
PA : Public Address
PABX : Private Automatic Branch Exchange
PAF : Public Address Distribution Frame
PAL : Phased Alternate Lines
PAU : Primary Air-handling Unit
PC : Personal Computer
PCT : Protective type Current Transformer
PE : Polyethylene
PF : Power Factor
General Materials & Workmanship Specification 4/34 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 44–Abbreviations, Standards & General–E&M
 PCB : Polychlorinated Biphenyls
PCP : Pump Control Panel
PDS : Power Distribution System
PID : Proportional Integral Derivative
PIN : Personal Identification Number
PLC : Programmable Logic Controller
PN10 : Pressure rating at maximum working pressure up to 1,000 kPa
PN16 : Pressure rating at maximum working pressure up to 1,600 kPa
PN25 : Pressure rating at maximum working pressure up to 2,500 kPa
PN40 : Pressure rating at maximum working pressure up to 4,000 kPa
PPM : Part Per Million
PRV : Pressure Reducing Valve
PSM : Plug Setting Multiplier
PTTA : Partially Type Tested Assemblies
PVC : Poly-vinyl Chloride
PWL : Sound Power Level
PWM : Pulse Width Modulation
RA : Returned or Re-circulated Air
RAM : Random Access Memory or Read Write Memory
RCB : Residual Circuit Breaker
RCCB : Residual Current Circuit Breaker
RCD : Residual Circuit Device
REF : Restricted Earth Fault
RF : Radio Frequency
RFI : Radio Frequency Interference
RH : Relative Humidity
RISC : Reduced Instruction Set Computing
RMS : Root Mean Square
RMU : Ring Main Unit
RTI : Response Time Index
SA : Supply Air
S/C : Server/ Concentrator
SCADA : Supervisory Control and Data Acquisition
SCHW : Secondary Chilled Water
SCR : Silicon Controlled Rectifiers
SMACNA : Sheet Metal and Air Conditioning Contractors’ National
Association
SNMP : Simple Network Management Protocol

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 SP : Single Pole
STP : Shielded Twisted Pair (Cable)
SWA : Steel Wire Armor
TCP/IP : Transmission Control Protocol/Internet Protocol
TDF : Tenant Distribution Frame
TDS : Total Dissolved Solid
TEFC : Totally Enclosed Fan Cooled
TODC : Time-Of-Day Clock
TTA : Type Tested Assembly
TMR : Trunked Mobile Radio
TMS : Time Multiplier Setting
TP : Triple Pole
UK : United Kingdom
UHF : Ultra High Frequency
UL : Underwriters Laboratory
UPS : Uninterruptible Power Supply
UTP : Unshielded Twisted Pair (Cable)
UV : Ultraviolet
VAC : Ventilation/Air Conditioning
VAV : Variable Air Volume
VDO : Voice/ Data Outlet
VSD : Variable Frequency Drive
WB : Wet Bulb
WSD : Water Supplies Department
XLL SF : Cross Linked Low Smoke and Fume
XLPE : Cross Linked Polyethylene

Abbreviations of units of measurement used in this Volume of the GMWS shall be

referred to the International System of Units (SI).

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44.2 RELEVANT CODES AND STANDARDS

(a) The edition of the codes and standards listed in this volume of the General
Materials and Workmanship Specification (GMWS) are for information only.
The Contractor shall comply with the latest edition of these codes and
standards, including all amendments issued by the relevant institutions, as at
the date of the Letter of Acceptance.

(b) The Works shall comply with the standards and codes of practice of the
following institutions:

BSI - British Standard Institution

IEC International Electrotechnical Commission
IETF Internet Engineering Task Force
CIBSE Chartered institution of Building Services Engineers, U.K.
LPC Loss Prevention Council
FOC Fire Officers’ Committee
IEE Institution of Electrical Engineers, U.K.
ISO International Standard Organization
ASHRAE American Society of Heating, Refrigerating and Air-
Conditioning Engineers, Inc.
ASME American Society of Mechanical Engineers
ASTM American Society of Testing and Materials
NBS National Bureau of Standards
NEMA National Electrical Manufacturer’s Association
NFPA National Fire Protection Association
UL Underwriters’ Laboratories, Inc.
DIN Deutsches Institut für Normung eV

(c) The following regulations, codes and standards shall apply to the relevant
parts of the Works:

(i) Electricity Ordinance 1999 (Chapter 406) and its subsidiary regulations

(ii) Code of Practice for Electricity Wiring Regulation by Electrical and

Mechanical Services Department HKSAR, 2009 Edition, hereinafter
referred to as part of “The Code of Practice” or “COP”.

(iii) IEC 60364 - Electrical Installation in Buildings

(iv) BS 7671 - Requirements for Electrical Installation

(v) Air Pollution Control Ordinance 2001 (Chapter 311) and its subsidiary
regulations.

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 (vi) Noise Control Ordinance 2004 (Chapter 400) and its subsidiary
regulations.

(vii) General Specification for Air-conditioning, Refrigeration, Ventilation

and Central Monitoring and Control System Installation in Government
Building, Hong Kong – 2007 Edition by Building Service Branch,
Architectural Services Department. (Hereinafter referred as the AC
G/S).

(viii) Code of Practice for Minimum Fire Services Installations and

Equipment and Inspection and Testing of installation and Equipment –
July 2005 Edition by FSD.

(ix) HKFSD Circular Letters

(x) Code of Practice for Fire Resisting Construction – 1996 Edition by BD

(xi) General Specification for Fire Service Installation in Government

Buildings, Hong Kong – 2007 Edition by Building Service Branch,
Architectural Services Department. (Hereinafter referred as the FS
G/S)

(xii) Building Ordinance 1990 (Chapter 123) and its Subsidiary Regulations

(xiii) General Specification for Building – 1993 Edition, Volumes 1 and 2 by

Architectural Services Department

(xiv) Building Services Branch Testing and Commissioning Procedures for

various installations issued by Architectural Services Department.

(xv) Code of Practice of Energy Efficiency of Lighting Installation by EMSD

(xvi) Guideline on Energy Efficiency for Lighting Installations by EMSD

(xvii) Code of Practice of Energy Efficiency of Electrical Installation by

EMSD

(xviii) Guideline on Energy Efficiency for Electrical Installations by EMSD.

(xix) Code of Practice of Energy Efficiency of Air Conditioning Installation by

EMSD.

(xx) Guideline on Energy Efficiency for Air Conditioning Installations by

EMSD

(xxi) Design Manual: Barrier Free Access 1997 by BD

(xxii) CLP and/ or HEC Power Supply Rules

(xxiii) General Technical Specification for Communal Aerial Broadcast

Distribution and Aerial Distribution Systems issued by EMSD.

(xxiv) General Technical Specification for Public Address System by EMSD

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 (xxv) ANSI/ASHRAE 15 Safety Code for Mechanical Refrigeration (latest
edition)

(xxvi) ISO 1662 Refrigerating Plant

(xxvii) ARI 550/590 Performance Standard or Eurovent Standard

(xxviii) IEE Electrical and Wiring Regulations for Earthing

44.3 NOT USED

44.4 WORKMANSHIP

Workmanship shall be to the highest standard. Only personnel skilled in the

appropriate trade shall carry out work. Attention shall be given to the neatness and
alignment of equipment, cable, conduit and/or pipe runs as is appropriate.

44.4.1 Supervision of Equipment Installation Work

(a) “Registered Electrical Workers” of the appropriate grade for the amperage
shall be employed to carry out electrical work in pursuant of Regulation 19 (1)
of the Hong Kong Electricity (Wiring) Regulations made under Section 59 of
the Electricity Ordinance Chapter 406. When the electrical work has been
completed, “Work Completion Certificates” shall be completed and duly signed
by the Registered Electrical Worker(s) and the Contractor.

(b) The Contractor shall provide a competent Site foreman engaged on a full-time
basis on Site for each electrical and mechanical trade.

(c) All supervisory staff from foreman level upwards shall be expected to be
competent in the use of both spoken and written Chinese and English due to
the international nature as demanded for the Hong Kong Airport.

44.5 MATERIALS

Materials shall comply with the Specification and the requirements of the Contract.
Where recognized Standards have not been specified, materials shall be to the
highest standard currently available and be subjected to review without objection by
the Project Manager.

44.5.1 Material Finishes

(a) Material finishes shall comply with Section 22

(b) Structural steel and iron

(i) heavy protective or galvanized finish.

(c) Unpainted steel parts

(i) passivated cadmium plate galvanized or zinc plated as appropriate.

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 (d) Screws, nuts, bolts and springs

(i) steel components shall be bright steel zinc, chromium plated or

sherardized finish. All non-ferrous screws to be electro-tinned, or to
have nickel or chromium plate finish. Springs where possible to be of
phosphor bronze or nickel silver.

44.5.2 Corrosion Resistant Steel

(a) Unless otherwise specified, stainless steel tubes and plates used in the Works
shall be in accordance with the following standards:

(i) Austenitic stainless steel tubes complying with BS 6323 : Part 1 – 8;

and

(ii) Stainless and heat resisting plate, sheet and strip complying with BS
1449 : Part 2.

44.5.3 Cast Iron

(a) Cast iron shall not be used for systems containing high-pressure air, oil or
water or for any components subject to tension or impact stresses.

(b) Where cast iron is used, grades shall not be inferior to Class 14 of BS 1452.

44.5.4 Aluminium and Aluminium Alloys

(a) Wrought aluminium and aluminium alloys for electrical purposes shall comply
with BS 2898.

(b) Unless otherwise specified, aluminium or aluminium alloy when used for
components shall either be painted or be anodized to give a deposit of not
less than 50g/m2. Aluminium and aluminium alloys shall not be in direct
contact with dissimilar metals.

44.5.5 Bronze

(a) Bronze castings for bearings, packing boxes, and similar applications shall be
of the phosphoric bronze type to BS 1400.

44.5.6 Brass

(a) Brass tubing shall be of the heavy gauge seamless type and shall comprise
70% copper, 29% zinc and 1% tin.

44.5.7 Copper

(a) Copper tubing shall be of the seamless type to BS 2871.

(b) Copper for electrical purposes shall conform to the requirements of BS 1432 :
Part 4 and BS 1977 as appropriate for the duty.

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44.5.8 Fabrics, Cork, Paper, etc.

Fabrics, cork, paper and all similar materials where not subsequently protected by
impregnation, shall be adequately treated with a fungicide reviewed without
objection by the Project Manager. Sleeving and fabrics treated with linseed oil or
linseed oil varnishes shall not be used.

44.5.9 Wood

Any woodwork that forms part of the Permanent Works shall be appropriately
treated in a manner reviewed without objection by the Project Manager to protect it
against the ingress of moisture, growth of fungus or other forms of deterioration, and
it shall be fire resistant.

44.5.10 Adhesives

Adhesives shall be specially selected to ensure use of types that are impervious to
moisture, resistant to mould growth and other forms of attack or deterioration.

44.5.11 Insulating Materials

Non-impregnated paper, fabric, wood or press-palm shall not be used for insulating
purposes. Where synthetic resin bonded insulating boards are used, all cut edges
shall be sealed with a varnish reviewed without objection by the Project Manager.

44.5.12 Bolts, Studs, Nuts and Washers

(a) All bolts, studs and nuts shall be to a relevant standard reviewed without
objection by the Project Manager and to metric dimensions and shall generally
be of bright steel. Those items included in moving machinery subject to
vibration, high temperature or pressure shall be of high tensile material
reviewed without objection by the Project Manager. The use of black grade
bolts may only be permitted in locations reviewed without objection by the
Project Manager.

(b) Bolts, studs, nuts and washers shall be made of free machining quality
stainless steel when:

(i) subject to frequent adjustment or removal, such as the adjusting bolts for
gland rings or stuffing boxes, removable screws on gratings, manhole
bolts and adjustable bearings.

(ii) used for any application subject to an outdoor corrosive atmosphere.

(c) Bolts, studs and nuts shall be suitably machined. Rolled threads may be
permitted if they conform to a standard reviewed without objection by the
Project Manager. Washers shall be provided under all nuts and also bolt
heads where appropriate. Bolts and studs shall protrude by at least one
thread pitch beyond the outside face of nuts. Where beveled washers are
used they can be compressed only once.

(d) Jacking screws shall be of high tensile steel with fine threads of a form
reviewed without objection by the Project Manager.

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 (e) Nuts, bolts, tap-bolts, set pins and any other items included in moving
machinery subjected to vibration shall be secured with locking devices
reviewed without objection by the Project Manager.

(f) Where bolts pass through structural members taper washers shall be fitted
where necessary to ensure that no bending stress is caused in the bolt.

44.5.13 Bedplates, Alignment, Leveling and Fixing

(a) All bedplates of fabricated construction shall, prior to final machining, be fully
stress-relieved.

(b) The Contractor shall design the holding-down, alignment and leveling bolts
completed with anchorages, nuts, washers, packing and anti-vibration
arrangements required to attach the Plant to the structure, without exceeding
the design stresses of the structure.

(c) To facilitate the alignment and leveling of larger components, all bedplates
shall incorporate jacking screws suitably arranged to provide for movement of
driving motors in both axial and transverse directions. Motor seating pads
shall be so arranged that single piece machined packers can be inserted in
place of shims of requisite thickness under each foot, or pair of feet, on
completion of alignment.

(d) After final alignment checks have been completed, and the unit runs at
nominal output for not less than six hours alignment shall be rechecked and
the unit securely dowelled to the bedplates.

44.5.14 Dissimilar Metals

As far as practicable the use of dissimilar metals in contact shall be avoided, but,
where unavoidable, these metals shall be so selected that the electro-chemical
potential difference between them does not exceed 250 millivolts. If this is not
possible, the contact surfaces of one or both of the metals shall be electroplated or
otherwise finished in such a manner that the potential difference is reduced to within
the required limits or the two metals shall be insulated from each other by suitable
means reviewed without objection by the Project Manager.

44.5.15 Ducting, Pipework, Cable Tray and Trunking Supports

Unless otherwise specified, the supports and hangers shall be constructed of mild
steel which shall be hot dipped galvanized coated or with a minimum thickness of
250 micron of "Kelvar Sintercoat LLOPE" halogen free thermo plastic coating
meeting Class 1, BS 476 : Part 1, or equivalent.

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44.6 INSTALLATION OF EQUIPMENT

44.6.1 Installation of Equipment

The equipment shall be carefully unpacked, assembled and installed in accordance

with the Contractor’s Drawings reviewed without objection by the Project Manager
and any instructions of the equipment manufacturer. All equipment, apparatus,
materials, and parts delivered to Site shall be kept in the packing cases or under
protective coverings until required for use. Where so packed or covered the
enclosures shall be clearly marked to identify the contents as to their types, grades,
materials and manufacturer.

44.6.2 Lifting and Handling

All lifting and handling shall conform to manufacturer's instructions or the

instructions printed on the shipping container. All handling and positioning
techniques employed, including lifting, skidding, and jacking, shall be performed in a
manner that will avoid subjecting the equipment to undue flexure and stress. Hooks
and slings shall not be attached in any manner that can possibly result in bending,
damaging, or breaking any part of the equipment. Pallets, cradles, and skids shall
be used wherever necessary to safely handle equipment. Lifting eyes and lugs
provided shall be used on equipment in making lifts. Saddles, spreader beams or
other special lifting equipment required shall be supplied.

44.6.3 Anchoring and Grouting

Carefully plumb and align all units and associated equipment, fully bolt and securely
anchor to foundations, floor or other supports. Where grouting is required the
equipment shall be carefully aligned on shims and grouted in accordance with the
following procedures as the minimum requirement:

(a) Leveling and Aligning

(i) location:
leveling and aligning shimming shall be accomplished with a minimum
number of blocks and shims. The number of blocks and shim packs,
their size and location shall be in strict conformance with the
manufacturer's requirements. Leveling blocks and shims, if required,
shall be placed on each side of anchor bolts and at locations where the
base could sag;

(ii) materials:
leveling blocks and shim stock shall be mild carbon steel saw cut or
sheared with all burrs and rough surfaces removed by filing. Shims of
other type of materials shall be subject to the prior review without
objection by the Project Manager. Wedges for shimming shall not be
permitted;

(iii) equipment with leveling screws:

a steel leveling plate shall be placed under each leveling screw on
equipment furnished with leveling screws. Plates shall not protrude
beyond the edge of the equipment base. When leveling screws are
used, shim or block equipment shall be used to relieve the load on the
screws prior to grouting. The equipment shall then be lowered making
adjustments with leveling screws;

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 (iv) equipment without leveling screws:
rectangular steel leveling blocks shall be placed on the foundation bolt
on equipment without leveling screws. Additional steel leveling blocks
shall be placed directly under all parts of the base that carry direct
heavy loads. Leveling blocks shall be spaced to give uniform support,
and shall not project beyond the edge of the base. With the unit
resting on leveling blocks, the unit shall be adjusted to establish
alignment and elevation. Levels shall be checked in both directions.
Shims shall be installed as required to maintain even weight
distribution on all leveling blocks. If wedges are used in adjusting
elevations, the base shall be supported in the final level position
entirely by the leveling blocks and not partially by wedges. Grout pads
may be substituted for steel leveling blocks. Wedges shall not be used
as shims. All temporary wedges used for raising equipment shall be
removed before equipment is tightened down or grouted. Leveling
blocks and shims shall be positioned to not interfere with the placing of
grout;

(b) Grouting

Grouting to structural steelwork, machine bases, crane rails, electrical and

mechanical equipment and other electrical and mechanical installations shall
comply with the requirements as follows:

(i) the Project Manager shall be notified before items of equipment are
grouted;

(ii) concrete surfaces shall be scrabbled to remove laitance and loose

material and to expose the aggregate before the item or equipment is
installed in position;

(iii) the voids to be grouted shall be cleaned and thoroughly wetted

immediately before grouting. Excess water shall be removed by using
compressed air jet;

(iv) grout shall be mixed and placed by methods reviewed without objection
by the Project Manager;

(v) if grouting is to be carried out in two operations, holding down bolts

shall be grouted into preformed pockets. Sufficient time as specified by
the Project Manager shall be allowed for the grout to cure and for the
bolts to be tensioned before the remaining voids are grouted; and

(vi) exposed grout surfaces shall have a uniform, dense and smooth
surface free from trowel marks that is produced by steel toweling of the
exposed surfaces under firm pressure. The exposed surfaces shall be
cured by either:

- using a liquid curing compound applied to the surface by a low

pressure spray until a continuous visible covering is achieved, or

- covering the surface with Hessian or sacking; the Hessian or

sacking shall be lapped and securely held in position and shall be
kept damp for at least 4 days.

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44.6.4 Final Alignment

(a) After grout has set for a minimum of five days, the level and alignment of the
equipment shall be checked and adjusted to the correct level and alignment.
Where practicable, shims shall be installed as required for adjustments
between component parts of the equipment without disturbing the bond
between the grout and the underside of the equipment base. Where the
necessary level and alignment adjustments require breaking of the bond
between the equipment base and the grout, original grout shall be removed
and the base shall be re-grouted after completion of leveling and alignment.

(b) Shaft coupling alignment

(i) the shafts of all machinery utilizing shaft couplings between drivers
and speed reducers and equipment shall be aligned carefully and
accurately, and where practicable, test direction of rotation of the driver
before the final shaft coupling connection is made;

(ii) type of shaft misalignment:

all necessary corrections shall be made to eliminate both types of shaft
misalignment defined below:

- Angular misalignment : Shafts having axis concentric but not

parallel; and

- Parallel misalignment : Shafts having axis parallel but not

concentric.

(iii) the foundation bolt nuts shall be securely tightened after confirmation or
correction of equipment level and alignment on the seasoned grout.
Back-off leveling screws at this time so that equipment shall be
supported on the grout; and

(iv) after the equipment has been lubricated, the equipment shall be slowly
turned over, carefully checked for clearances and improper adjustments
of alignment, and such corrections made as required. After final
alignment is obtained, the equipment shall be operated for a period of
time in accordance with the manufacturer's installation and operating
instructions and the alignment re-checked and adjusted if necessary.

44.6.5 Lubrication

(a) All machinery and equipment shall be lubricated unless factory lubricated prior
to running the machinery and equipment. The Contractor shall lubricate
machinery and equipment in strict accordance with the recommendations of
the manufacturer using the products specified by the manufacturer. An
itemized list of required lubricants and hydraulic fluids shall be prepared
including quantities, required for all machinery and equipment. The itemized
list shall be submitted to the Project Manager for review without objection.

(b) Bearings shall be protected at all times against the possible entrance of
foreign matter. In the event that matter other than lubricant enters the bearing
casing, the Contractor shall inform the Project Manager and submit proposals
to remedy the situation.

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44.6.6 Calculations for Equipment Installation

The Contractor shall submit calculations to the Project Manager for review as
requested that substantiate the method for the installation of equipment, including
any necessary footings, plinth, etc.

44.7 ENERGY EFFICIENCY AND CONSERVATION

44.7.1 General

All Plant, equipment, systems and services provided by the Contractor shall conform
to the energy efficiency and energy conservation requirement as stipulated in the
Codes of Practice for Energy Efficiency of Air Conditioning Installations, Lighting
Installations, Lift and Escalator Systems and Electrical Installations issued by
Electrical and Mechanical Services Department of the Hong Kong SAR
Government.

44.7.2 Energy Efficiency Labelling

The Contractor shall submit to the Project Manager for review technical data such
as equipment brand, model, working capacity, energy efficiency grades and
categories as stipulated under the EMSD Energy Efficiency Labeling Scheme for
room coolers, electric storage-type water heaters, compact fluorescent lamps and
other equipment, where appropriate, as specified under the EMSD Labeling
Scheme.

44.8 WELDING

44.8.1 Procedures

(a) Full details of proposed procedures for off-Site and on-Site welding shall be
submitted to the Project Manager for review without objection. Welding shall
not commence until the procedures have been reviewed without objection by
the Project Manager.

(b) Unless otherwise specified, all welds shall be subjected to random testing.
Pipeline weld samples shall be cut for review as directed from specimens that
are identical to installed Works and subject to X-ray or destructive weld tests
as directed by the Project Manager.

44.8.2 Welded Joints

(a) The design of welded joints and connections, and the fabrication of welded
steel parts shall conform to the requirements of a relevant code for structural
steelwork reviewed without objection by the Project Manager, and shall also
be stress-relieved to a code reviewed without objection by the Project
Manager.

(b) Members to be joined by welding shall be accurately cut to size and, where
required, shall be rolled or pressed to the proper curvature in accordance with
the Contractor’s Drawings, reviewed without objection by the Project Manager.
Weld Sites shall be machined to produce the correct profile for the required
type of welding.

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 (c) Surfaces prepared for welding shall exhibit sound metal without laminations
and other injurious defects. Surfaces of plates to be welded shall be free from
rust, grease, mill scale and other foreign matter over a distance of at least 25
mm back from weld edges.

44.8.3 Qualification of Welders

(a) All welding operators proposed by the Contractor for the manufacture,
assembly or erection on Site of pressure-tight or highly-stressed components
shall be qualified in accordance with a relevant code and shall be reviewed
without objection by the Project Manager in this respect prior to
commencement of work.

(b) If at any time, in the opinion of the Project Manager, the work of any welder
appears questionable, the welder shall be required to undergo, in the
presence of the Project Manager, tests to determine the welder's ability to
undertake satisfactorily the type of work upon which he is engaged. An
independent examiner reviewed without objection by the Project Manager
shall then undertake appropriate tests upon the welded specimens.

44.8.4 Welding Process

(a) All welding shall be performed by a process which will exclude the atmosphere
from the molten metal and, wherever possible, under procedure control using
automatic machines. Electric arc welding is preferred.

(b) Welding electrodes for manual electric arc welding shall be of the heavily
coated type, suitable for all positions of welding.

44.8.5 Butt-Welding

Care shall be exercised in aligning and separating edges of members to be joined

by butt-welding in order to assure complete penetration and fusion at the bottom of
the joint. Where fillet welds are employed, members shall fit closely and be held
together during welding.

44.8.6 Cleaning of Welds

After deposition, welds shall be cleaned of slag and shall show uniform sections,
smoothness of weld metal, featheredges without overlay and freedom from porosity,
inclusions and undercut. Visual inspection at the edges and ends of welds shall
indicate sound fusion with the parent metal. In the case of pressure-tight
components, all slag shall be removed by shot blasting.

44.8.7 Testing and Inspection of Welds

Unless otherwise specified, particulars of proposed methods for carrying out testing
on welds, such as non-destructive testing and 100% radiographic testing, and
inspection shall be submitted to the Project Manager for review without objection.

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44.9 DRAWINGS PROVIDED BY THE CONTRACTOR

The Employer’s Drawings indicate the general arrangement and design intent of
E&M systems and E&M works. The Contractor shall, unless otherwise directed by
the Project Manager, shall comply with the following:

44.9.1 Contractor’s Drawings

(a) The Contractor shall submit detailed Contractor’s Drawings to the Project
Manager in compliance with the Contract, and shall at least include:

(i) symbols and notations compatible with the Employer’s Drawings;

(ii) architectural layouts with room names and room reference numbers,
inclusive of detailed runs of conduits, trunking cable, piping, ductwork,
equipment layout, including sufficient space for maintenance and
control panel access;

(iii) complete layout or assemblies of switchgears, distribution board,

cable, wiring and equipment, pipe assemblies, details of pipe fittings,
valve cabinets, pump assemblies, water tanks, AHU, chilled water and
condensate drain pipes, including all essential minor components and
accessories;

(iv) weight and dimension of all plant and equipment including positions of
all fixings, hangers and supports;

(v) working clearances for all items including clearance for maintenance
access;

(vi) schematic diagrams for all piping, ductwork and electrical systems;
and

(vii) proposed setting levels of all adjustable tripping devices, level control
for water tanks, MVAC control devices and system monitoring
instrument, including testing and commissioning procedures.

44.9.2 Contractor’s Drawings of Manufactured Plant

(a) The Contractor shall submit to the Project Manager for review without
objection Contractor’s Drawings which include detailed drawings of the
equipment and Plant, including control systems and wiring diagrams, supplied
by specialist manufacturers.

(b) These Contractor’s Drawings shall include detailed construction, principal

dimensions and weights, clearances for maintenance, control wiring diagrams,
and environmental issues, etc. No work should proceed on or off the Site prior
to the notice of no objection from the Project Manager.

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44.9.3 Contractor’s Drawings – Schematic Piping, Ductwork and Wiring Diagrams

(a) The Contractor shall submit schematic diagrams showing the layout of each
item of equipment clearly identified with all interlocking and related facilities
and interfacing requirements with other services.

(b) These drawings should include logic sequence piping, ducting and wiring
diagrams showing full details including terminal and wire numbers, liquid and
air flow rates, colour code etc. for all items of electrical/electronic equipment.
Inter-locking, reset or similar facilities shall be clearly shown.

(c) Line diagrams should also be prepared and submitted for all physical wiring
detailing positions, enclosures, fixings, support, protection, sizes and number
of cables, piping, ducting and equipment for all runs. Contractor’s Drawings
also include those for switchgear, starter, control/ instrumentation/ motor
control panels/ air-conditioners and fans control/ ventilation facilities

(d) The schematic layout drawings shall show positions in relation to the building
structure and other plant, equipment and/or installations.

(e) Contractor’s Drawings shall include the physical construction and the internal
and external layout of all panels, cabinets, and cubicles including the physical
arrangement of all major and vital components, bus-bars, phase separation
barriers, interconnecting wiring, labels etc.

(f) Contractor’ Drawings shall include controls and wiring diagrams and
schematics for all internal and external wiring including all interlocks and
connections from the panels to external equipment and interfacing work with
other services.

(g) Contractor’s Drawings shall also include the proposed full wording of all labels
to be installed in Chinese and English characters.

44.9.4 As-Constructed Drawings

(a) The “As-Constructed” drawings submitted by the Contractor for E&M works
shall include the following:

(i) schematic diagrams of all systems;

(ii) individual floor plans and sections to a scale of not less than 1:50
showing all installations accurately located;

(iii) plant room layouts, with sections, to a scale of not less than 1:20;

(iv) wiring, piping, ducting and schematic diagrams with setting and
adjustments noted for all electric/electronic control systems, control
panels, motor starters, interlocks, air-conditioners, fans, ventilation
facilities, etc;

(v) sizes and positions of all plant, equipment, switch room, etc. clearly
identified by its service and dimensioned location;

(vi) equipment numbers previously reviewed without objection by Project

Manager.

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 (b) The Contractor shall provide and install in the main L.V. switch room and
generator room schematic diagrams in the form of non-fade reduced prints
framed underglass to the satisfaction of the Project Manager.

44.10 PAINTING AND FINISHES

44.10.1 General - Materials

(a) All parts of the work related to Sections 44 to 108 shall be painted with first
quality enamel paints, reviewed without objection by the Project Manager
except as otherwise specified or exempted from painting in the Specification.

(b) The requirement for painting of all pipe work and ductwork is in addition to the
colour coding or banding specified in the Specification.

(c) Paint shall be selected to withstand the temperature on the surface that it is
applied, and shall be suitable in all respects for the environmental conditions
in which it shall be located.

(d) All paint used shall be from one manufacturer reviewed without objection by
the Project Manager. Finishes shall be full gloss unless otherwise specified.

(e) Before ordering any primer, undercoat and finishing paint, the Contractor shall
submit the colour scheme to the Project Manager for review without objection.

44.10.2 Plant, Machinery and Equipment

All items of plant, machinery and equipment supplied painted ex-factory shall be
given one finishing coat of full gloss enamel, except where the manufacturer's
standard finish has received a notice of no objection from the Project Manager.

44.10.3 Exposed Metal Work

(a) Exposed metalwork shall be wire-brushed and cleaned from rust, scale, dirt
and grease, and shall then be given one priming coat, one undercoat and one
finishing coat of full gloss enamel reviewed without objection by the Project
Manager.

(b) The priming coat for exposed galvanized iron shall be galvanized iron primer
reviewed without objection by the Project Manager.

(c) The priming coat for exposed non-ferrous metalwork shall be suitable for the
metal to which it will be applied and reviewed without objection by the Project
Manager.

44.10.4 Concealed Metal Work

(a) All galvanized iron surfaces concealed in roof spaces, false ceilings, building
ducts etc. shall not be painted.

(b) All black iron and steel surface shall be wire brushed and given one coat of
zinc chromate.

(c) Colour banding for identification shall be provided.

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44.10.5 Ductwork, Pipework and Metal Sheathing

(a) Uninsulated ductwork, internally insulated ductwork, uninsulated pipework and

metal sheathing shall be painted as for exposed or concealed metalwork as
applicable.

(b) Turned parts of valves, controls etc, shall be cleaned and polished to the
satisfaction of the Project Manager.

(c) Hammered aluminium cladding shall not be painted.

44.10.6 Plastered Finish Insulation

Plastered finish insulation surfaces shall be given one coat of size, one undercoat
consisting of two parts of ordinary undercoat to one part of sealer, and one finishing
coat of full gloss enamel.

44.10.7 Colour Schemes

(a) The whole of the installation shall be painted in accordance with the following
schedule:

(i) pipeworks:

Identification - BS 1710: Identification of pipelines and services

Colour - BS 4800: Colour codes for schedules of particular
coding materials and substances carried*

* Detailed colour code schedules for materials and substances

carried such as cold water, hot water, steam, combustible liquids,
gas, acids, air, are described in Section 44.10.10.

(b) Equipment shall be painted and colour coded to BS 381C for identification,
coding and special purposes of particular equipment as follows:

Colour No.
Control Panels : Grey ---
Electrical Motors : As directed As directed
Electrical Conduits : As directed As directed
All other equipment : As directed As directed

Painting colour for exposed insulated ductwork in shopping area shall be

further advised as directed.

(c) Where any pipes, ducts, cable containments and the like are visible from any
public area, all such pipes, ducts, cable containments and the like, including
but not limited to associated supports, shall be painted grey (RAL7036) or as
otherwise instructed by the Project Manager.

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 (d) Where any pipes, ducts, cable containments, equipment and the like are
visible from the Head of Stand road, all such pipes, ducts, cable containments
and the like, including but not limited to associated supports, shall be painted
to grey (RAL7036) or as otherwise instructed by the Project Manager.

(e) All pipes, ducts, cable containments, equipment and the like, including but not
limited to associated supports, which are located in any open air-cooled chiller
space on the plant deck, shall be painted to grey (RAL7036) or as otherwise
instructed by the Project Manager.

(f) All cable containments, equipment and the like, including but not limited to
associated hanging supports, which are located inside glazed lifts, shall be
painted to dark grey (RAL7036) or as otherwise instructed by the Project
Manager.

(g) All ceiling mounted fixtures including but not limited to, diffusers, grilles,
sprinkler heads, detectors, remote indicators, modules and visual fire alarm,
lighting fittings, speakers, etc and their associated supports, which are
exposed to view from any public area, shall be painted to grey colour
(RAL7036) or as otherwise instructed by the Project Manager.

(h) All ceiling mounted fixtures including but not limited to, diffusers, grilles,
sprinkler heads, detectors, remote indicators, modules and visual fire alarm,
lighting fittings, speakers, etc and their associated supports, which are
exposed to view inside the toilets, nursing areas, prayer room, bulk head of
retail cabins and F&B cabins, shall be painted to white colour (RAL9016)
coated or as otherwise instructed by the Project Manager.

(i) All sprinkler heads under the escalators shall be silver colour coated by the
manufacturer. Colour sample shall be submitted to the Project Manager for
review without objection.

(j) All temporary protective coatings on bright metal finishes shall be removed.

44.10.8 Finishes

(a) Cleaning and Painting

The following exposed metal surfaces, including the internal and external
surfaces of piping, shall be thoroughly cleaned of all dust, oil, grease, dirt,
scale and rust by grit or shot-blasting and then ground smooth where
necessary. Immediately thereafter, surfaces shall receive treatment detailed
as follows:

(i) surfaces of castings, steel work, piping and plant which shall be in
direct and permanent contact with concrete shall be painted and
covered, prior to shipment to Site, with one single coating of Portland
cement wash or other proprietary coating plus a lapping of black
bitumastic paint or equivalent reviewed without objection by the Project
Manager;

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 (ii) internal surfaces of all oil service ferrous pipes and fittings shall be
carefully inspected to ensure that all scale and other particles or
contaminants have been removed and shall then be protected in a
manner reviewed without objection by the Project Manager to prevent
deterioration during transport and subsequent erection;

(iii) external surface of accessible ferrous pipes and fittings shall be

treated with two coats of primer paint reviewed without objection by the
Project Manager prior to dispatch from the place of manufacture; and

(iv) external surfaces of all plant items in damp environments shall, unless
made of non-ferrous metal, be coated with a bituminous compound
reviewed without objection by the Project Manager. All access ladders
and platforms and associated supporting steelwork shall be
galvanized.

(b) All other exposed surfaces, except where otherwise specified shall be
thoroughly cleaned of all dust, oil, grease, dirt, scale, rust or other
contaminants by power brushing, or preferably by shot or grit blasting, and
shall then be coated with one coat of primer paint immediately. Following
witnessed factory tests, any rough surfaces shall be filled in and carefully
dressed smooth, on completion of which further treatment shall be detailed as
follows:

(i) interior surface of oil-filled chambers and tanks, and the external
surfaces of piping or fittings included therein, shall receive one
undercoat followed by two final coats of oil-resistant enamel paint of
colour and type reviewed without objection by the Project Manager;

(ii) internal surfaces of cubicles, kiosks, boxes, etc., containing wiring or

other apparatus, and the internal compartments of plant components
forwarded to Site in assembled or partially assembled condition, shall
be paint-finished with primer and two coats of white enamel, the last of
which shall be an anti-condensation finish;

(iii) external surfaces of panel suites, cubicles, kiosks, marshalling and

junction boxes, etc., shall be well finished in stove enamel, or powder
coating process reviewed without objection by the Project Manager,
and with colour in accordance with BS 381C;

(iv) all surfaces forming an interior accessible compartment shall receive

one undercoat to be followed by two final coats of white oil-resistant
enamel paint, or a powder coating process reviewed without objection
by the Project Manager; and

(v) external surfaces of all other plant components shall be finally painted
in colours reviewed without objection by the Project Manager.

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 (c) Galvanizing

(i) hot dip galvanized coatings on iron and steel articles:

- unless otherwise specified, the galvanized coatings shall be

applied by the hot dip process and shall consist of a smooth, clean
zinc coating free from defects and of uniform thickness to
manufacturer’s recommendation complying with BS 729;

- all drilling, punching, tapping and bending of parts shall be

completed and all burrs removed before galvanizing is done; and

- preparation for galvanizing and the galvanizing itself shall not

adversely affect the mechanical properties of the wire or coated
material;

(ii) unless otherwise specified, semi-finished products such as hot dip

galvanized steel sheet suitable for subsequent fabrication shall have
the following coating weights:

- where no paint finish is required the coating weight shall be not

less than 300g/m2 of surface, that is, 150g/m2 on both sides;

- where paint finish is required the coating weight shall be not less
than 120 g/m2 of surface, that is, 60 g/m2 on both sides; or

- steel wire, coating thickness shall comply with the tests of BS 443.

(d) Paint Finish Schedule

Unless otherwise specified, the Contractor shall apply paint finish to all
exposed metalwork including supporting rods and brackets, cable trays,
trunking, lighting fittings, pipework, ductwork, surface conduits and
accessories and other equipment.

(i) method of application:

- paint finish shall be regarded as an additional finish applied over

hot dip galvanized steel sheet or extruded aluminium surface, or
other coatings, already defined elsewhere in Specification. Details
shall be submitted to the Project Manager for review without
objection; and

- paint finish shall be applied at manufacturer's works prior to

delivery to Site for installation.

44.10.9 Painting on Site

(a) General

The process shall be applicable to supportive rods and brackets, pipework,

ductwork and other equipment that are fabricated on Site and shall include the
following. No site painting shall be applied to all items of electrical equipment
supplied painted. Only touch-up as directed shall be required.

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 (b) Preparation

(i) galvanized surfaces shall be washed with white spirit to remove dirt
and grease. If the metal coating is defective, instructions shall be
obtained from the Project Manager before proceeding; and

(ii) mild steel or ductile iron surfaces shall be scraped or wire-brushed to

remove rust and loose scale and welding slag or splatter. Crevices
shall be cleaned out. Oil, grease and dirt shall be removed by power
brushing or using white spirit.

(c) Colour Control

(i) colour shall be as specified or as directed by the Project Manager. For

each finish colour, the colour of undercoat recommended by the paint
manufacturer shall be used; and

(ii) control samples: each paint type on the corresponding surface shall be
submitted for review without objection by the Project Manager. No
painting on Site shall commerce until the submitted samples have
received a notice of no objection from the Project Manager.

(d) Cleaniness

(i) all brushes, tools and equipment shall be kept in a clean condition;

(ii) all surfaces shall be kept clean and free from dust during painting and
drying; and

(iii) a suitable receptacle for liquids, slops, washing shall be provided.

Disposal shall be in accordance with the EPD Procedures.

(e) Preparation of Materials

Paints shall be prepared as recommended by the manufacturer. Any paints

showing impurities, lumps, skin or uneven consistency shall be strained
through fine gauge prior to application. Different paints shall not be mixed.
Paints shall be stirred to attain an even consistency before use.

(f) Protection

Freshly applied paints shall be adequately protected from damage. “Wet

Paint” signs shall be exhibited and protective barriers shall be provided on Site
where necessary. Surfaces adjacent to those being painted shall be
adequately protected.

(g) Application

Paints shall be applied in accordance with the manufacturer's

recommendations to clean and dry surfaces in dry atmospheric conditions and
after any previous coats have properly hardened.

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 (h) Priming

(i) Priming coats shall be applied by brush unless other methods are
specifically recommended by the manufacturer;

(ii) Priming coats shall be of adequate thickness as recommended by the

manufacturer;

(iii) Any primed surfaces that have deteriorated on Site or in transit shall
be touched-up or re-primed to the satisfaction of the Project Manager;

(iv) Metal surfaces shall be primed on the same day they have been
cleaned;

(v) Unless otherwise specified, undercoats shall be applied by brush in a

wet, even film all over surfaces, avoiding uneven thickness at edges
and angles;

(vi) All priming and undercoats shall be rubbed down to a smooth surface
with abrasive paper and all dust shall be removed before applying the
next coat;

(vii) Unless otherwise specified, finish coats shall be applied by brush in a

wet, even film all over surfaces, avoiding brush marks, sags, runs and
other defects. Second coat shall be applied within 48 hours of first
coat; and

(viii) Surface shall be cut in neatly and clearly. Adjacent surfaces shall not
be splashed or marked

(i) Material for Painting

All coating materials shall be submitted for review without objection by the
Project Manager;

Coating materials shall be delivered in manufacturer’s sealed containers,

clearly labeled with the following information:

(i) Type of material;

(ii) Brand name, if any;

(iii) Intended use; and

(iv) Manufacturer's batch numbers.

(j) Paints

(i) for hot-dip galvanized finish

- etch primer shall be zinc chromate primer ICI Dulux FD500-388 or

equivalent;

- undercoat shall be ICI Dulux speed undercoat A545-101 or

equivalent;

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 - finish coat shall be ICI Dulux gloss finish A365-line or equivalent;
and

- 1 primer, 1 undercoat and 2 finish coats shall be applied.

(ii) for extruded aluminium surface

- each primer shall be IMP Unite 220 or equivalent;

- finish coat shall be polyurethane, IMP Imperite 330 or equivalent;

and

- 2 primers and 2 finish coats shall be applied.

(iii) for other finish/ surface

- undercoat shall be ICI Dulux speed undercoat A543-101 or

equivalent;

- finish coat shall be ICI Dulux gloss finish A365-line or equivalent;

and

- 1 primer, 1 undercoat and 2 finish coats shall be applied.

(iv) paint samples, manufacturer's literature and certificates shall be

reviewed without objection by the Project Manager.

44.10.10 Pipes and Ducts

(a) Pipes and Ducts

(i) the final external treatment for insulated pipes and ducts shall be as
indicated on the Employer’s Drawings or in the Specification;

(ii) bare ducts, pipes and ducts concealed in false ceiling or ducts not
normally accessible and/or seen need not be painted but appropriate
colour code indications shall be applied;

(iii) insulated pipes and ducts run in normally visual positions shall be
plastered or as otherwise specified and shall be painted to the
appropriate identifying colour plus identifying colour code bands;

(iv) all piping and ductwork run in normally visual areas shall be painted in
the appropriate colour throughout and identified with appropriate colour
code bands;

(v) ferrous pipework not normally accessible and/or seen shall be painted
with two coats of primer paint reviewed without objection by the Project
Manager and identified with appropriate colour code bands; and

(vi) All services identification labelling and indication shall be located in

such a manner as to be concealed by ceiling panels and the like.

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 (b) Plant and Pipework

All Plant, unless otherwise specified, shall be finished in a colour specified or

as directed by the Project Manager.

(c) Identification of Pipelines

(i) colour code numbers stated in the table below are those of BS 4800
colour code reference.

(1) Basic Identification Colour BS 4800

Green 12D45
Silver 10A03
Brown 06C39
Yellow Ochre 08C35
Violet 22C37
Light Blue 20E51
Black 00E51
Orange 06E51
(2) Safety Colour
Red 04E53
Yellow 08E51
Auxiliary 18E53
(3) Code Indication Colour
Crimson 04D45
Emerald Green 14E53
Yellow 10E53

(ii) all pipework in the plant rooms shall be finished generally in

accordance with BS 1710. All pipework, where exposed on surfaces
outside the plant room, shall either be painted as in the plant room or
to match the surrounding surface with distinguishing colour code
bands plus flow arrows in the specified colour scheme as reviewed
without objection by the Project Manager.

(iii) pipes and pipelines should be painted in colours either in accordance

with BS 1710 or as reviewed without objection by the Project Manager
completed with the identification colour code indicators. The basic
identification colour or the decoration colour shall be applied over the
whole length of the pipe with colour code indicators placed at all
junctions, at both sides of valves, service appliances, bulkheads, wall
penetrations and at any other places identification is necessary as
directed by the Project Manager.

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 (iv) valves may be painted in the same colour as the associated pipework,
except where the pipeline is part of the fire services installation and
has been coded only with the safety colour, the valves involved shall
be fully painted 'safety-red'.

(v) the direction of flow of fluid shall be indicated by an arrow over the
basic identification colour and painted white or black in order to
contrast clearly with the basic identification colour.

(d) Schedule of Colour

Colour numbers as stated in the following table are those of BS 4800

Schedule of paint colours for ready paints.

Description Basic Colour Code Indication 10mm approx. Basic

Colour Colour
Pipework:
Drinking Green Blue Green
Cooling Green White Green
(Primary)
Boiler Feed Green Crimson White Crimson Green
Condensate Green Crimson White Crimson Green
Water Chilled Green White Emerald White Green
Green
Mains Green White Blue White Green
Supply, Cold
Mains Green White Blue White Green
Supply, Hot
Sea, River Green
Untreated
Fire Fighting Green Safety Red Green
Gases In either Yellow Ochre
gaseous or
liquefied
condition
(exception)
Compressed Air Light Blue
Steam Silver Grey
Oil Lubricating Brown Emerald Green Brown
Gas Town Yellow Ochre Emerald Green Yellow
Ochre
Drainage Black
Acids & Alkalines Violet

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 (e) Number of paint coats required

All painted surfaces, as a minimum shall receive at least one primer coat and
two coats of the finishing colour. Ferrous surfaces shall receive one primer
coat of red zinc or zinc chromate, one under-coat and two finishing coats.

(f) Copper pipe and Fitting

Copper pipes and fittings for refrigerant that are not insulated shall be polished
bright and coated with heat resisting clear synthetic varnish of type reviewed
without objection by the Project Manager.

(g) Protective Measures Against Corrosion

Where normal painting is not practicable, all possible measures to eliminate

corrosion shall be applied to the Plant including correct materials, special
protective coating coverings and special anti-corrosive paints, which shall
generally be specified on Employer’s Drawings or stated in the Specification.
If they are not specified, a painting proposal shall be submitted by the
Contractor to the Project Manager, for review without objection.

44.11 FACILITY IDENTIFICATION

44.11.1 Facility Identification Numbers

(a) A facility is any item managed by the facility management system. A facility
can be a product, system, equipment, finish etc. Each facility to be installed
under the Contract shall be allocated a unique “Facility Identification Number”
(FIN) by the Project Manager. The FIN shall be used during the Works and in
facility data sheets, to uniquely identify each item.

(b) The FIN shall be up to an 11-character number arranged in three fields, as

shown below:

0123- XXX -4567

(c) The first field will contain up to a four-character reference that will be the
Contract number.

(d) The second field will contain up to a three-letter code that will identify the type
of facility. The codes will be listed in the AAHK's Facility Management and
CADD Standard Manual.

(e) The third field will contain up to a four-digit number that will identify the
individual item. Where there are five or more identical units of one item, for
example, light fittings, the same number may be used for each item subject to
review without objection by the Project Manager.

44.11.2 Facility Identification Labels

(a) The Contractor shall provide a “Facility Identification Label” (FIL) for every
facility. They shall be of multi-layer formica or other similar material, subject to
review by the Project Manager, capable of withstanding the environment in
which the facility is located and retaining legibility for a minimum of ten years.

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 (b) Each FIL shall be engraved with the appropriate FIN and shall be of sufficient
size, generally not less than 100mm long by 20mm high, to permit adequate
spacing between characters and fixings to ensure legibility. Each FIL shall be
attached to the facility at mounting positions, reviewed without objection by the
Project Manager, by brass roundhead bolts and nuts or brass woodscrews, or
similar fixings reviewed without objection by the Project Manager. Adhesives
or self-tapping screws shall not be permitted.

(c) The Contractor shall submit one sample of each proposed FIL to the Project
Manager for review.

(d) All lettering used on FIL shall be "Helvetica Bold" capitals, 10mm high, with
black letters on a white background unless otherwise specified.

(e) In the event the Works include replacing a facility, the Contractor shall fix to
the replacement item a FIL bearing the same FIN as the defective item, unless
instructed otherwise by the Project Manager.

44.11.3 Facility Data Sheets

(a) The Contractor shall submit a “Facility Data Sheet” (FDS) for each facility with
a FIN to the Project Manager for review without objection. The FDS shall be
provided in a database format and shall contain full details of the facility, with
information not less than that shown in Table 44.3.

Table 44.3: Minimum Information Required on Facility Data Sheet

General Description of Facility

Attribute Description
Facility FIN Facility Identification Number
Facility Name Full name of facility
Facility Description General description of facility
Facility Location Detailed description of where facility is located
Facility Value Estimated value in HK$ of facility based on
tender sum
Installation Date Date facility was installed
Date facility first used The date the facility was first used
Date of Acceptance Date facility was accepted by the Employer
Manufacturer Party who manufactured the facility
Supplier/Vendor Party from where facility is purchased (local
agent)
Contractor Party who installed the facility
Manufacturer’s Model/Serial Internal coding used by manufacturer
Number
Performance Size and rating of facility
Drawings Relevant drawings associated with the facility

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 Physical Data
Attribute Unit Shipment Operating
Height M
Depth M
Width M
Diameter* Mm
Weight Kg
Quantity Number off
*Spare Parts List
Attribute Description
Part Number Internal part no. used by manufacturer
Part Name Name of the part
Part Description General description of part
Quantity Number of parts used in the Plant
Supplier/Vendor Supplier of part
Manufacturer Manufacturer of part
Unit Price Unit price of part
Currency Foreign currency used for payment
Alternative Part No. Internal part no. of the alternative part
Alternative Part Name Name of the alternative part
Alternative Part Desc. General description of the alternative part
Manufacturer of Alternative Part Manufacturer of the alternative part
Supplier of Alternative Part Supplier of the alternative part
(Note: If alternative parts are to be supplied, the E&M Contractor shall
propose, for the AAHK’s review, appropriate FINs)
*Environmental Requirement
Attribute Unit
Minimum Operating Temp. °C
Maximum Operating Temp. °C
Optimal Operating Temp. °C
Minimum Operating Humidity %
Maximum Operating Humidity %
Optimal Operating Humidity %
Acoustic Level dB (A)
Heat Dissipation KW

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 *Electrical Requirement
Attribute Unit
Voltage V
Frequency Hz
*Power Consumption
Attribute Unit
Current A
Power W
Power Factor
*Equipment Reliability
Attribute Unit
Average Down Time hour
Mean Time Between Failure hour
*Preventive Maintenance Requirement
Attribute Unit
Warranty Period month
Preventive Maintenance month
Frequency
*Where applicable

44.11.4 Practice of Labeling

(a) Manufacturers' nameplates shall generally be provided for all plant and
equipment and shall show serial and model numbers and date of manufacture.

(b) Examples of items requiring facility identification labelling shall include valves,
motor starters, fans, distribution boards, gauges, contactors, cable terminals in
switchboards, circuit breakers, computer workstations, cabinets, junction
boxes, etc.

(c) Labels shall be attached to valves (or pipe adjacent thereto) with a light gauge
metal band or alternatively to be screwed to the insulated valve box where
provided. These labels shall state the valve number.

(d) Distribution boards, starters etc. shall be labelled indicating the circuit number,
phase and item controlled.

(e) Label shall be screwed or riveted to sheet metal. Adhesive fixing shall not be
permitted. Self-tapping screws are not acceptable.

(f) Details of exact lettering shall be agreed with the Project Manager prior to
manufacture.

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44.11.5 Schedule of Assets

The Contractor shall submit the Schedule of Assets to the Project Manager for
review without objection not later than 1 month prior to the submission of the first
draft of the Operations and Maintenance Manual. The Schedule of Assets shall be
prepared in accordance with the Authority’s Specification for the Preparation of
Operations & Maintenance Manuals.

44.12 SERVICE PENETRATIONS

(a) Where ductwork penetrates through walls, floors or ceilings/roofs, the

penetration through the building element shall be detailed as follows:

- An oversize, 18 gauge mild steel sleeve shall be built into the

construction leaving 15-25 mm clearance all round the duct and any
insulation. The gap shall be filled with 24-32 kg/m3 fibreglass, giving slight
compression during packing. The packing is then covered with two 12
mm plasterboards to both sides and caulked using a non-setting sealant.

(b) Where pipe work penetrates the building fabric, the penetration shall be
detailed as follows :

- An oversize sleeve shall be built into the construction leaving a consistent

clearance of 15-25 mm all round the pipe when installed. This gap shall
be packed carefully with 24-32 kg/m3 fibreglass and the ends of this
packing are to be caulked using a non-settling sealant.

- Where the piped service is to be thermally insulated, the insulation shall

terminate at both ends of the sleeve and a seal between the surface of
the thermal insulation and the end of the shall be provided by the use of a
single bellows arrangement using a flexible material having a minimum
surface weight of 5kg/m2.

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SECTION 45 ELECTRIC POWER SUPPLY

45.1 POWER SYSTEM CONDITIONS

(a) The Hong Kong International Airport receives power supply from CLP via a
11kV network or 380V. The system voltage at the HV side is 11kV +10%, -
2.5% 3-phase. A number of transformers have been installed to step down
the voltage for the AAHK equipment and internal electrical distribution system
within the periphery of the airport. The nominal power supply for the internal
electrical distribution network is from 380V ±6%, 3-phase 4-wire, unless
otherwise specified.

(b) The HV system shall be solidly earthed.

(c) Earthing shall be a TNS system throughout.

(d) Transformers have been specified to step down the voltage to 380/220V.

(e) Selection and installation of all equipment shall be subjected to the approval of
the relevant authorities and reviewed by the Project Manager.

(f) The system frequency is 50 Hz, ±2%

(g) The control supply shall be 24V, 1-phase, 2-wire, 50Hz. Control voltages less
than 24V shall be permitted wherever such voltages are design features of
factory-wired equipment that form part of the supplied equipment.

(h) Interlocking between motor control center shall be carried out at 24V, 1-phase,
2-wire, 50Hz through interposing relays. Voltage transformers shall be
provided as applicable.

45.2 GENERAL POWER SUPPLY

(a) Power supply from CLP Power Hong Kong Co. Ltd. will be at 11kV or 380V,
50 Hz, 3-phase.

(b) All electrical equipment shall be rated according to the following operating
conditions, unless otherwise specified:

CLP system fault level - 350 MVA;

(c) During humid seasons, heavy surface condensations of moistures on

insulations inside switch enclosures can occur. This may coincide with severe
contamination on insulator surfaces due to dust, fibre or other solid particles.
Together they may cause disruption to power supply.

(d) Full allowance shall be provided so that the occurrence of short circuits or
overloads on any circuits shall not affect or trip the protective devices or
switchgears in the upstream circuitry and in the switchboards. The circuitry
shall effectively isolate the faulty circuit, leaving the unaffected circuits
operating normally.

General Materials & Workmanship Specification 1/2 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 45 – Electric Power Supply
 (e) Wherever earth fault detection system is required, allowance shall be provided
for overloads. Proper adjustment to the system shall be provided such that
discrimination is still maintained.

(f) Wherever circuit protection devices are installed without any earth leakage
detection capability, the devices shall be so arranged to trip on earth leakage
with the over-current protection by ensuring low earth loop impedance in
accordance with the Code of Practice for the Electricity (Wiring) Regulations of
EMSD.

(g) The set levels of all adjustable tripping devices shall be clearly marked on
equipment. Records of set levels shall be submitted to the Project Manager for
record.

(h) The method for earthed equipotential bonding and auto-disconnection of

power supply shall be adopted for the protection against any indirect contacts,
in accordance with the IEE Wiring Regulations.

General Materials & Workmanship Specification 2/2 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 45 – Electric Power Supply
SECTION 46 LOW VOLTAGE SWITCHBOARDS

46.1 GENERAL

(a) The LV switchboards shall be self-contained floor standing extensible multi-

cubicle type assembled from compartments housing the circuit breakers,
fused switchgear, relays, busbars, controls etc. suitable for services condition
as specified hereinafter and complying with British and International Standards
and Codes of Practice.

(b) LV switchboard shall comply with the general power supply conditions referred
to in Section 45.2 of this General Materials and Workmanship Specification,
unless otherwise specified.

(c) Switchboards shall be type-tested assemblies (TTA) as defined in BS EN

60439-1, manufactured, factory assembled and tested by a specialist
switchboard manufacturer. The complete assembly shall be capable of
withstanding the maximum mechanical stresses to which it may be subjected
under fault conditions.

(d) The electricity supply to the LV switchboards shall have the following
characteristics unless otherwise specified:

Rated Operational Voltage : 220/380V ±6%, 3-phase

4-wire, 50 Hz ±2%, AC
Rated short time withstanding current : 50 kA for 1 second
Power factor : Incoming 0.25 lagging

(e) As far as practicable, the use of electrically dissimilar metals in contact shall
be avoided. If this is not possible, the contact surfaces of one or both of the
metals shall be electroplated or the two metals shall be insulated from each
other.

(f) All materials and components used in the LV switchboards shall be of the
same make and brand as the type tested ones.

(g) Adhesives shall not be used in the LV switchboards unless otherwise

specified.

(h) All bolts, studs, nuts and washers shall be high tensile stainless steel or
cadmium plated the same as those used in type testing. When tolerance
limitations preclude plating, corrosion-resistant steel shall be used.

(i) Washers shall be of lock type and provided under all nuts and bolt heads
unless otherwise specified. Bolts and studs shall protrude by at least one
thread pitch but not more than five thread pitches beyond the outside face of
nuts.

(j) Where circuit protection devices are not provided with earth leakage detection,
the circuits shall trip on earth leakage by means of the over-current protection
by ensuring low earth loop impedance in accordance with the EMSD Code of
Practice for the Electricity (Wiring) Regulations.

General Materials & Workmanship Specification 1/28 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
 (k) The Contractor shall arrange all components, including but not limited to, the
ACBs, MCCBs, fused switches, switches and busbars, in a simple manner to
facilitate subsequent operation and maintenance of the LV switchboard.
Cable access and connection shall be provided for both top / bottom entry of
main incoming cables and top exit for outgoing cables unless otherwise shown
on the Employer’s Drawings. The LV switchboard shall be assembled and
factory tested in Hong Kong prior to delivery to the site.

46.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document stated below, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 88 Cartridge fuses for voltages up to and including

1,000 V AC and 1,500 V DC
BS 88 : Part 2 Cartridge fuses for voltages up to and including
1,000V AC and 1,500V DC Specification for fuses
for use by authorized persons (mainly for industrial
application). Additional requirements for fuses with
fuse-links for bolted connections
BS EN 60051-1/IEC 60051-1 Direct acting indicating analogue electrical
measuring instruments and their accessories.
Specification for definitions and general
requirements common to all Parts
BS 159 Specification for high-voltage busbars and busbar
connections
BS 1432 Specification for copper for electrical purposes:
high conductivity copper rectangular conductors
with drawn or rolled edges
BS 1433 Specification for copper for electrical purposes.
Rod and bar
BS 2757/IEC 60085 Method for determining the thermal classification
of electrical insulation
BS 5685 Electricity meters
BS 6004 Electric cables. PVC insulated, non-armoured
cables for voltages up to and including 450/750 V,
for electric power, lighting and internal wiring
BS 6231 Specification for PVC-insulated cables for
switchgear and controlgear wiring
BS 7264 Shunt capacitors for AC power systems having a
rated voltage above 1,000 V
BS 7430 Code of practice for earthing
BS 7671 Requirements for electrical installations. IEE
Wiring Regulations
BS 9564 Specification for push-button switches of assessed
quality: generic data and methods of test; general
rules for the preparation of detail specifications
General Materials & Workmanship Specification 2/28 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
 BS EN 55014 Electromagnetic compatibility. Requirements for
household appliances, electric tools and similar
apparatus
BS EN 60044 Instrument transformers
BS EN 60269/IEC 60269 Low-voltage fuses

BS EN 60439/IEC 60439 Specification for low-voltage switchgear and

controlgear assemblies
BS EN 60439-1/IEC 60439-1 Specification for low-voltage switchgear and
controlgear assemblies. Type-tested and partially
type-tested assemblies
BS EN 60529/ IEC 60529 Specification for degrees of protection provided by
enclosures (IP code)
BS EN 60622 Sealed nickel-cadmium prismatic rechargeable
single cells
BS EN 60831 Shunt power capacitors of the self-healing type for
AC systems having a rated voltage up to and
including 1,000 V
BS EN 60871 Shunt capacitors for AC power systems having a
rated voltage above 1 kV
BS EN 60898/IEC 60898 Specification for circuit-breakers for over-current
protection for household and similar installations
BS EN 60947/IEC 60947 Specification for low-voltage switchgear and
controlgear
BS EN 60947-2/IEC 60947-2 Specification for low-voltage switchgear and
controlgear. Circuit-breakers
BS EN 60947-6-1 Specification for low-voltage switchgear and
controlgear. Multiple function equipment.
Automatic transfer switching equipment
IEC 60189 Low-frequency cables and wires with PVC
insulation and PVC sheath
IEC 60227 Polyvinyl chloride insulated cables of rated
voltages up to and including 450/750 V
IEC 60255 Electrical relays
IEC 60364 Electrical installations of buildings
IEC 60521 Class 0.5, 1 and 2 alternating-current watthour
meters

General Materials & Workmanship Specification 3/28 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
46.3 MATERIALS

46.3.1 Switchboards

(a) The LV switchboards shall be constructed from self supporting, modular top,
side and back panels and doors of not less than 2 mm thick electro-galvanized
sheet steel built on a substantial framing to provide a rigid construction and
clear accessibility to all internal components within the LV switchboard.

(b) The degree of protection of enclosures shall be to IP 31 for indoor use and IP
54 for outdoor use as specified in BS EN 60529. The bottom and top of the
switchboard shall be closed and made to be vermin-proof by means of non-
magnetic, fire-proof barrier metal plates with suitable cut-outs for cables
and/or busway terminations as specified.

(c) The complete LV switchboard shall comply with Form 3b for the non-essential
Section and Form 4 for the essential Section according to BS EN 60439-1.

(d) For Form 4 segregation, the busbars, risers and droppers, and cable
terminations including cable lugs, bolts and nuts shall be fully insulated. This
shall be achieved by applying heat shrinkable materials to the busbars and
shrouds at the busbar joints and cable terminations.

(e) Detachable panels at the back of the LV switchboard completed with gaskets
for dustproof and a pair of handles for every panel for easy fixing/removal of
the panels shall be provided.

(f) LV switchboards shall be of uniform height not exceeding 2,100mm, and

uniform depth front-to-back not exceeding 1,100mm throughout its length and
shall present a neat and tidy appearance. All control and indication
components mounted on or within the LV switchboard shall be arranged and
located between 500 mm and 1,800 mm above the finished floor level.

(g) All doors shall have concealed hinges and shall be interlocked with the switch
mechanism. Dust-excluding gasket of neoprene or materials with the same
function and performance shall be provided for all doors. Doors shall not be
operable without switching off of the corresponding switchgear, including
ACBs, MCCBs, fuse switches and switch fuses, etc.

(h) Proper arrangement for air circulation shall be made within each compartment
of the LV switchboard and equipment shall be adequately sized to ensure that
the internal temperature of the LV switchboard shall be within the operating
ranges of all electrical and electronic components including switchgear,
controlgear, busbars, relays, and timers inside the LV switchboard. Ventilating
louvers with internal screen shall be provided at the side or back of the
switchboard but not in the front. No forced ventilation to any components of
the switchboard is allowed.

(i) All insulators, including busbar support, shall be non-hygroscopic and non-
deteriorating.

(j) A base frame made up of steel channel with a minimum height of 100mm of
substantial strength at the bottom of the LV switchboard shall be provided.

General Materials & Workmanship Specification 4/28 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
 (k) Each switchboard shall be provided with one or more metal plates, marked in
a durable manner and located in a place such that they are visible and legible
when the switchboard is installed. The following information shall be given on
the nameplates:

(i) the manufacturer’s name or trade mark;

(ii) type designation or identification number or other means of

identification making it possible to obtain relevant information from the
manufacturer;

(iii) BS EN 60439-1;

(iv) type of current;

(v) rated operating voltage (and frequency in case of AC);

(vi) rated insulation voltage;

(vii) short-circuit strength;

(viii) degree of protection; and

(ix) rating of main busbars;

(l) Other information as required under Clause 5.1 of BS EN 60439-1 shall be

provided in the relevant documents, the circuit diagrams or in the
manufacturers list or catalogue.

(m) All steelwork shall be thoroughly cleaned of all dust, oil, grease, dirt, scale,
rust and other contaminants by an approved method, such as chemical
pickling, and shall be epoxy powder coated immediately at the manufacturer’s
works. The epoxy powder coating shall be not less than 50 microns thick.

(n) The final colours for the equipment shall be the manufacturer’s standard
colours, unless otherwise specified.

(o) Where the Employer’s Drawings show incoming or outgoing cables to be

XLPE insulated armoured steel wire, the Contractor shall supply and install
cable glands complying with BS 6121. The LV switchboard manufacturer shall
incorporate removable gland plates suitable for these glands. The gland
plates shall be constructed of a non-ferrous metal or non-conducting material.

(p) The gland plates and supporting steelwork shall have sufficient strength to
limit deflection of the gland plates to not greater than 20mm after cable
installation.

(q) Where the main power circuits incorporate plug and socket connectors,
interlocks shall be provided to ensure that plugs are fully engaged before the
circuit can be switched on. The circuit shall be switched off before the plug
can be withdrawn.

(r) Cable terminations and space for future terminations shall be appropriate for
the sizes of cable shown on the Employers Drawings and shall not be limited
to compliance with BS EN 60439.
General Materials & Workmanship Specification 5/28 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
 (s) Identification of terminals for each connecting conductor shall comply with BS
EN 60439 Part 1. All terminals shall be marked in accordance with BS5472.

(t) The LV switchboard shall be assembled in such a manner as to form a flush

fronted continuous board of uniform height, depth and width. The LV
switchboard shall be suitable for floor mounting without the requirement of a
separate mounting structure.

(u) The LV switchboard shall be provided with removable lifting eyes to facilitate
the safe lifting and positioning of the LV Switchboard. The lifting eyes shall be
removed after the switchboard is in place and replaced by screw-in brass
plugs.

(v) All sectionalised elements of the LV Switchboard, to facilitate assembly on

site, shall be provided with a means of aligning the adjacent sections to
ensure final accurate alignment.

(w) Switchboard compartments shall be fitted with hinged doors complete with
neoprene or foam rubber gaskets. Doors shall be provided with lever type
locking handles having integral cylinder locks. All locks shall be openable with
a common key. Two numbers of keys per lock shall be provided up to a
maximum of 10 per switchboard.

46.3.2 Busbar

(a) Busbars shall be made of hard drawn, electro-tinned, high conductivity, bare
rectangular solid copper bars to BS 1433. Full size phase and neutral bars
shall be provided. Busbars shall be provided to extend each outgoing terminal
of the functional units to the cabling compartment.

(b) Busbars, busbar connections and bare conductors forming part of the
equipment of the LV switchboard shall comply as regards current-carrying
capacity at 40°C without exceeding the temperature rise as stated in BS EN
60439-1.

(c) The insulation voltage of the busbar system shall be 1,000V AC.

(d) Conductors between busbars and outgoing protective devices not short-circuit
type-tested to a fault current of 50 kA for 1 second at 0.25 lagging power
factor shall be insulated by approved means to ensure that “an internal short-
circuit between phases and/or between phases and earth is only a remote
possibility” as stated in BS EN 60439-1.

(e) The main busbars, busbar droppers and risers shall be type-tested to BS EN
60439. The configuration of the busbar assembly contained in the LV
switchboard shall be the same as that shown on the type test drawings. Any
change in the configuration shall require separate type test certificates.

General Materials & Workmanship Specification 6/28 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
46.3.3 Air Circuit Breakers (ACBs)

(a) All ACBs shall comply with and be fully type-tested to BS EN 60947-2.

(b) Performance and electrical characteristic shall meet the following

requirements:

Number of poles : 4 (for incomers and bus-sections)

3, with bolted-type neutral link (for outgoing
breakers)
Rated insulation voltage : 415V AC minimum
Rated frequency : 50 Hz

Rated uninterrupted current : As shown on the Employer’s Drawings

(derated to suit Site
conditions)
Rated short-circuit making : Not less than 105 kA
capacity
Rated ultimate short-circuit : Not less than 50 kA
breaking capacity (Icu)
Utilization category : B
Rated short-time withstand : Not less than 50 kA
current (Icw)
Rated service short-circuit : 100% of Icu
breaking capacity (Ics)
Tripping mechanism : Shunt trip using DC power source as
specified hereafter

(c) ACBs shall be provided with hand charged and motorised spring charger
closing mechanism using AC system voltage power source and push button.

(d) A mechanically operated visual ON/OFF/ISOLATED indicating device shall be

provided to indicate breaker positions. A local “Trip” push button shall be
provided for manual tripping.

(e) ACBs shall be of the horizontal withdrawable pattern with three positions for
CONNECTED/TEST/ISOLATED. ACBs can only be closed fully when in the
CONNECTED position. In the TEST position, it shall be possible to operate
the ACB (for ACB with motorised charging spring only) to close and test the
secondary and auxiliary contacts, but not the main isolating contacts.

In addition, ACBs shall also meet the following requirements:

(i) electrical connection between the ACB and the busbar system of the
LV switchboard shall be of plug and socket type with automatic
screening shutters to shield the fixed terminals in the LV switchboard
when the ACB is withdrawn. The shutters shall be properly labelled to
indicate whether they are for incoming or outgoing terminals and
provided with padlock facilities;

General Materials & Workmanship Specification 7/28 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
 (ii) the ACB cannot be inserted or withdrawn when in the closed position.
Attempted withdrawal shall not trip a closed ACB;

(iii) live parts of the ACB shall not be accessible from the front of the LV
switchboard unless the ACB is drawn out; and

(iv) means shall be provided to padlock the ACB in each of its

CONNECTED, TEST and ISOLATED positions.

(f) Suitable interlocking facilities shall be provided such that:

(i) the ACB cannot be plugged in or withdrawn when it has been closed;

(ii) the ACB cannot be closed until it is fully engaged in either the
CONNECTED or the TEST position;

(iii) the ACB cannot be slowly closed except in the TEST or ISOLATED
position;

(iv) it shall not be possible to initiate the closing action of the energy stored
spring mechanism until the spring has been fully charged; and

(v) where key interlocking (e.g. Castell or similar) is employed, tripping of

a closed ACB shall not occur if an attempt is made to remove the
trapped key from the mechanism.

(g) A 30V DC shunt trip coil shall be provided for tripping of the ACBs. A trip
circuit healthy lamp shall be provided for each circuit breaker. 30V DC closing
coil shall be provided for automatic closing.

(h) The shunt trip coil shall be capable of tripping ACBs under all conditions.
Power supply to the shunt trip and closing coils shall be fed from battery
equipment.

(i) The following circuit protection device shall be provided for ACBs:

(i) one 3 element induction type relay for overcurrent protection where
indicated on the Employer’s Drawings;

(ii) one single element induction type relay for earth fault protection where
indicated on the Employer’s Drawings; and

(iii) shunt trip release operated by DC supply of 30V obtained from the
battery c/w charger.

(j) Whenever the ACB is required to be interfaced with GBMS system, the
ON/OFF/Fault/Trip status of the ACB should be provided and interfaced with
GBMS for monitoring.

46.3.4 Fused Switchgear

Fused switchgear shall be suitable for use in LV switchboard assembly. Refer

Section 47 of this General Materials and Workmanship Specification.

General Materials & Workmanship Specification 8/28 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
46.3.5 Fuses, Carriers and Bases

Refer to Section 47 of this General Materials and Workmanship Specification.

46.3.6 Moulded Case Circuit Breakers (MCCBs)

Refer to Section 47 of this General Materials and Workmanship Specification.

46.3.7 Automatic Transfer Switches

(a) Automatic transfer switches shall comply generally with BS EN 60947-6-1.

(b) Automatic transfer switches shall incorporate 4-pole ACBs or MCCBs suitably
rated for heavy-duty applications in a range of ambient temperatures from 0°C
to 45°C, each automatic transfer switch shall be equipped with, but not be
limited to, the following:

(i) ACB or MCCB as specified to connect and disconnect the load to and
from the source of power;

(ii) sensing/supervisory circuits to constantly monitor the condition of

power sources and thus provide the signal necessary for ACB, MCCB
and related circuit operation;

(iii) electrical and mechanical interlocking to facilitate automatic/manual

changeover from the normal source to the standby source;

(iv) automatic/manual changeover selector switch;

(v) interlocking facility to ensure that the normal breaker being tripped on
fault will not cause the standby breaker to close or vice versa, unless
the breakers are reset manually. Provide padlock facilities for both
breakers to prevent accidental re-closure during maintenance;

(vi) the changeover system between the normal and standby sources shall
be as follows:

- a 3-phase undervoltage relay with time delay facility shall be

provided in the LV switchboard to monitor the voltage condition of
the normal source. Upon failure of one or more phases of mains
supply or a reduction of voltage to a value of 90% to 70%
(adjustable) of the nominal value, the normal breaker shall be
tripped by the undervoltage relays;

- another set of undervoltage relays as specified above shall also be

provided to monitor the voltage condition of the standby source.
Once the voltage from the essential supply reaches 90% of the
nominal value, the standby breaker shall close automatically; and

- upon restoration of the normal power supply, which has been

determined stable after a time delay, the standby breaker shall
open and the normal breaker shall close, transferring the loads to
the normal supply. It shall also be able to switch the load back to
the normal supply under manual control;

General Materials & Workmanship Specification 9/28 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
 (vii) automatic/off/manual changeover selector switch, test switch and
auxiliary accessories shall be provided for operation mode selection
and testing of the automatic transfer switch; and

(viii) indication light, showing which source the switch is connected, shall be
provided.

46.3.8 Current Transformers (CTs)

(a) All CTs shall be conformed and tested to BS EN 60044 and be rated for Class
B temperature rise and a primary voltage of 660V.

(b) CTs shall be of epoxy resin encapsulated type and shall be capable of
providing the necessary output to operate the connected protective device or
instruments.

(c) The secondary circuit of each CT shall be earthed at one point only. Means
shall be provided for disconnection of these earth connections at readily
accessible positions for testing.

(d) Protection CTs shall be of Class 5P 20 or better. The product of rated

accuracy limit factor and rated output of the protection CT shall not be less
than 10 times the rated burden of the trip circuit including the relays,
connection leads and overcurrent release where applicable.

(e) Measurement CTs shall have rated secondary current of 5A and rated output
suitably matched with the burden of the measuring instrument. The accuracy
shall be Class “1” or better.

(f) Current transformer provided in plastic castings and of the split core type will
not be accepted. Protective current transformer shall have a short-time rating
of 50 kA for 3 seconds.

(g) Type test certificate for magnetizing current and rated accuracy factor shall be
supplied for each type and ratio of current transformer.

46.3.9 Protective Relays

(a) The microprocessor-based digital protection relay shall provide time delayed
three-phase overcurrent protection and earth fault protection and shall allow a
variety of following selectable characteristic curves according to IEC 60255:

(i) Normal Inverse (NINV) IDMT curve;

(ii) Very Inverse (VINV) IDMT curve; and

(iii) Extremely Inverse (EINV) IDMT curve.

(b) The digital relay shall have self supervision function through a fail-safe relay. It
shall be capable of recording fault data once there is fault detection or
tripping. Trip test, parameter settings and output relay assignments shall be
protected by password. Trip test shall be done on the front panel while
parameter settings and output relay assignments shall be done either on the
front panel or by PC software. The digital relay shall have the ability to display
measuring values as primary quantities.
General Materials & Workmanship Specification 10/28 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
 (c) The digital relay shall have remote monitoring and parameters setting features
and shall be able to link up with PC-based Building Management System via a
communication port RS485.

(d) The digital relay shall be type-tested by an Independent Accredited

Laboratory.

(e) The relay shall comply with the following standards:

Design Standards: Generic standard: EN50082-2, EN

50081-1
Product stand: EN60255-6, BS142
Specified ambient service Temperature limits:
In operation -25°C to +70°C
In storage -25°C to +70°C
Moisture-carrying capacity class F as per DIN Relative humidity <95% at 40°C for
40040 and per DIN IEC 68, part 2-3: 56 days
Insulation test voltage, inputs and outputs 2.5 kV (eff.) / 50Hz; 1 min
between themselves and to the relay frame as
per EN60255-6, IEC255-5
Impulse test voltage, inputs and outputs 5 kV; 1.2 / 50μs, 0.5J
between themselves and to the relay frame as
per EN60255-6, IEC255-5
High frequency interference test voltage, 2.5 kV / 1MHz
inputs and outputs between themselves and
to the relay frame as per EN60255-6, IEC255-
22-1
Electrical discharge (ESD) 8 kV air discharge, 6 kV contact
test as per EN 61000-4-2, IEC 255-22-2: discharge
Electrical fast transient (Burst) test as per EN 4 kV / 2.5 kHz, 15 ms
61000-4-4, IEC 255-22-4:
Power frequency magnetic field immunity test: 100 A / m continuously
EN 61000-4-8 1000 A / m for 3 s
Radiated electromagnetic field disturbance electric field strength: 10 V / m
test as per ENV 50140, IEC 255-22-3:
Guided radiated electromagnetic field electric field strength: 10 V / m
disturbance test as per ENV 50141:
Surge immunity test as per EN 61000-4-5: 4 kV
Radio interference suppression test as per EN limit value class B
55011:
Radio interference radiation test as per EN limit value class B
55011:
Mechanical test: Shock: Class 1 as per DIN IEC 255
T 21-2
5 g/11 ms, n = 3 at energised
conditions and
10 g/16 ms, n= 1000 at
deenergised conditions
Vibration: Class 1 as per DIN IEC
255 T 21-1
0.5 g/10 - 150 Hz, n = 1 with 1
octave each minute and
1 g/10 - 150 Hz, n = 20 with 1
octave each minute
Degree of protection: IP54 by
enclosure of the relay case and
front plate
Over-voltage class: III
Relay case material: self-
extinguishing
General Materials & Workmanship Specification 11/28 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
 (f) The digital protection relay shall comply with the following requirements:

(i) The relay shall comply with the following technical requirements:

Current Input 1A or 5A via standard protection

Overcurrent Setting
Earth Fault Setting
Time Multiple Setting
Power Consumption
AC Burden (Maximum)
under transformer
0.2 – 4 x In in step of 0.01; 0.02;
0.05; 0.1 x In
0.01 – 2.0 x In in step of 0.001;
0.002; 0.005; 0.01; 0.02; 0.05 x In
0.05 – 10 in step of 0.01; 0.02; 0.05;
0.1; 0.2
- Standby 3W
- Operating 5W
- 0.2VA at In = 1A
- 0.1VA at In = 5A

(ii) The relay shall comply with the following technical requirements:

(iii) At least 5 fault records shall be stored in a non-volatile memory and be

retained against failure of operational supply. Each fault record shall
include at least the type of fault/alarms, current values, date & time of
tripping;

(iv) The digital relay shall be capable of storing disturbance records which
can be obtained by PC software. The disturbance record shall record
the waveform of pre-trigger and after trigger of the fault event. The
time interval shall be capable of being set by the operator;

(v) The digital relay shall be accommodated in a dust-proof case to IP54

and shall be of the flush-mounted draw-out type on the font panel of
the switchboard cubicle. When the relay is in the withdrawn position,
the associated current transformers shall be automatically short
circuited;

(vi) The digital relay shall be suitable for operating on D.C. power supply at
16V - 360V;

(vii) The digital relay shall provide at least 4 programmable auxiliary

contacts for tripping and alarming. 1 No. auxiliary contact dedicated for
watchdog. Blocking logic shall be included;

(viii) The digital relay shall be capable of resetting the fault either on the
relay front panel, by external voltage supply or by PC software; and

(ix) The digital relay shall have circuit breaker failure protection supervision
of phase currents during tripping. Trip indicators shall be provided for
identification of the type of fault condition.

General Materials & Workmanship Specification 12/28 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
46.3.10 Control and Auxiliary Relays

(a) Relays shall be plug-in type, rack mounted, provided with cable connection
sockets and anchored by quick fastening vibration-proof devices.

(b) All contacts shall be double breaking type. Relay coils shall be suitable for AC
or DC operation as required.

(c) Contact elements and operating coils shall be replaceable and be enclosed in
transparent dust-proof plastic case for easy inspection.

(d) Each relay shall have a minimum of two pairs of normally open and two pairs
of normally closed spare contacts.

(e) All auxiliary circuit wiring shall be PVC-insulated with designated conductor
temperature of 90°C to BS 6231 of not less than 2.5mm2 conductor.

46.3.11 Volt-free Contacts (Dry Contacts)

Volt-free contacts shall be provided as shown on the Employer’s Drawings. They

shall comprise a pair of contacts operated directly by the equipment but electrically
separated such that no electrical potential derived from the equipment appears at
the contacts. Use volt-free contacts to complete external control, alarm or indication
circuits. The volt-free contacts shall be rated at 1A, 250V or better.

46.3.12 Ammeters

(a) Ammeter shall be accuracy Class 2.5 to BS EN 60051-1.

(b) Ammeters shall be capable of carrying their full load current without undue
heating and shall not be damaged passage of fault current at the maximum
fault levels of the switchgear.

(c) All ammeters shall have a continuous overload capability of 120% of the upper
limit of the scale for two hours. They shall be 10 mm diameter and have 90°
scale dial, with external zero adjustment.

(d) Ammeters shall have maximum demand pointers, manually resetable to zero.

46.3.13 Voltmeter

(a) Voltmeters shall be of accuracy Class 2.5 to BS EN 60051-1.

(b) The range shall be suitable for line voltage and phase voltage measurements.
They shall be 100 mm in diameter and have 90° scale dial, with external zero
adjustment.

(c) Voltmeters shall be connected to the incoming side of the power supply
through 6 ampere HRC fuses and links.

General Materials & Workmanship Specification 13/28 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
46.3.14 Ammeter Selector Switch

(a) The ammeter selector switch shall be mounted on the front of the panel and
shall be of the rotary type with make-before-break contacts for selection to
read Brown-Black-Grey-neutral currents with L1-L2-L3-N marked clearly on
the switch.

(b) The selector switch shall have ‘OFF’ position.

(c) Contacts shall be rated for a thermal current of 6 amperes 220V 50 Hz.

46.3.15 Voltmeter Selector Switch

(a) The voltmeter selector switch shall be mounted on the front of the panel and
shall be of the rotary type with break-before-make contacts for selection to
measure Brown-Black, Black-Grey, Grey-Brown and Brown, Black and Grey
phase voltages with L1-L2, L2-L3, L3-L1, L1-L2-L3 marked clearly on the
switch.

(b) The selector switch shall have ‘OFF’ position.

46.3.16 Digital Multifunction Power Meter

(a) All digital multifunction power meters shall provide true RMS values.
Information provided by each digital multifunction power meter shall include
frequency, current, demand current, voltage, real power, reactive power,
apparent power, demand power, power factor, accumulated energy,
accumulated reactive energy, and total harmonic distortion (THD) of each
current and voltage, all updated at the same rate. Digital multifunction power
meters shall be microprocessor-based. The meter shall be able to
communicate with the GBMS / SCADA System by means of plugging in a
communication module and without further modification of the basic unit.

(b) It shall be housed in a single front access industrial grade enclosure designed
and built as an integral part of the meter by the original manufacturer. The
meter shall then be panel mounted in the LV switchboard cubicles.
Alternatively, the meter can be configured for DIN rail mounting. The display
shall either be LED. or LCD. back light, with auto blinking function for
prolonging the life of the display. The front face shall be protected to not less
than IP54.

(c) Replacement of meter shall not require the switching off of the respective
switchgear. All wiring shall be routed to allow easy removal of the cable
connectors for maintenance. Current transformers shorting block shall be
provided such that current inputs can be disconnected without open circuiting
the current transformers. The shorting block shall be wired so as not to affect
the operation of protective relays.

(d) The maximum and minimum values of the each parameter measured by the
unit shall be stored in memory. The values in memory shall be recalled and
displayed upon pressing a switch on the meter. Lithium battery, with a battery
life not less than 7 years, shall power the memory.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
 (e) Digital multifunction power meters shall comply with the following technical
requirements:

Maximum direct voltage input : 600V A.C. between phase;

Other voltage inputs : Through potential transformers;
Current input (In) : On current transformers, In / 5A
(secondary);
Measurement : True RMS value of line current for each
phase and neutral current;
True RMS value of phase-neutral voltage
for each phase;
True RMS value of line voltage for each
phase;
Active power, kW;
Reactive power, kVAr;
Apparent power, kVA;
Frequency, Hz;
Power factor;
Energy, kWhr;
Accuracy : Voltage : ± 0.5%;
Current : ± 0.5%;
Power : ± 1%;
Power factor : ± 2%;
Frequency : ± 1%;
Energy : ± 1%;
Service condition : Temperature from 0°C to 50°C;
R.H. up to 80%; and
Communication : Series link RS-232 or RS-485 for numeric;
4 – 20mA output for analogue.

(f) The current and voltage signals shall be digitally sampled at a rate high
enough to provide valid data for waveform analysis and true-RMS metering
accurate beyond the 30th harmonic (fundamental of 50Hz).

(g) The digital multifunction power meter shall be rated for an operating
temperature 0°C to 50°C and have an over current withstand rating of 500A
for 1 second.

(h) All setup parameters required by the digital multifunction power meters shall
be stored in non-volatile memory and retained in the event of a auxiliary
power supply interruption. Any battery or other device used to provide non-
volatile memory shall be serviceable from the front of the digital
multifunction power meter and servicing shall not require removing the
circuit monitor from the equipment in which it is mounted.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
 (i) The auxiliary power supply shall be provided from the AC power within the
LV switchboard.

(j) The digital multifunction power meter shall accept inputs from industry
standard instrument transformers (5A secondary CTs).

(k) The digital multifunction power meter shall meet the following requirements:

(i) Accuracies shall be maintained for 0-100% load.

(ii) No annual recalibration by users shall be required to maintain these

accuracies.

(l) Voltage and current for all phases shall be sampled simultaneously to
assure high accuracy in conditions of low power factor or large waveform
distortions (harmonics).

(m) The digital multifunction power meter shall be applied in three-phase, four
wired systems. A fourth CT input shall be available to measure neutral or
ground current. In four-wire connection, the digital multifunction power meter
shall utilise the circuit neutral common reference and not earth ground to
provide metering accuracy.

(n) The digital multifunction power meter shall be capable of being applied
without modification at nominal frequency of 50Hz.

(o) The digital multifunction power meter shall have an integral, continuous
duty, long-life display to provide local access to the following metered
quantities which shall be updated every second. Also the minimum and
maximum value of each instantaneous quantity since last reset of
minimum/maximum shall be accessible:

(i) Current, per phase RMS, three-phase average and neutral

(ii) Voltage, phase-to-phase, phase to neutral, and three-phase average

(phase-to-phase and phase-to-neutral)

(iii) Real power, per phase and three-phase total

(iv) Reactive power, per phase and three-phase total

(v) Apparent power, per phase and three-phase total

(vi) Power factor, per phase and three-phase total

(vii) Frequency

(viii) Demand current, per phase and three-phase average

(ix) Demand real power, three-phase

(x) Demand apparent power, three-phase

(xi) Accumulated Energy (kWh and kVARh)

(xii) THD, current and voltage, per phase

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Section 46 – Low Voltage Switchboards
 (p) Reset of the following electrical parameters shall also be allowed from the
from the front of the digital multifunction power meter:

(i) Peak demand current

(ii) Peak demand power (kW) and peak demand apparent power (kVA)

(iii) Energy (kWh) and reactive energy (kVARh)

(q) The digital multifunction power meter shall be equipped with all the
necessary equipment and devices to enable all of the above monitoring and
control signals to be transmitted to and from the GBMS / SCADA system.

(r) The digital multifunction power meter shall have a 25 year life. The
microprocessor-base shall be designed to have allowable replacement with
the latest model without a complete change of the power meter.

46.3.17 Push Button Switches

(a) The push-button switches shall comply with and be tested and certified to BS
9564. The electrical ratings shall be 500V AC or 250V DC as appropriate.
Push buttons for alarm duty shall be minimum of 2A rated and that for control
duty 10A rated.

(b) Push buttons shall be individually flush mounted units with metallic chromium
plated and polished solid brass body and ring, circular tri shape and
approximately 20 mm in diameter. All push buttons used shall be identical in
shape and size, unless otherwise specified.

46.3.18 Terminal Blocks

Terminal blocks for control wiring shall be rated at not less than 20A and shall clamp
the wire securely between two plates secured by a captive screw. Terminal blocks
shall have easily removable copper links to short circuit adjacent terminals or shall
be fitted with suitable fuse/fuse holder where required. Pinch screw type terminal
blocks shall not be accepted.

46.3.19 Indicating Lamps

(a) Indicating lamps shall be individual flush mounted units. Lamps shall have
chromium plated and polished solid brass body and ring, with metallic
threaded section, and shall be circular in shape of approximately 20 mm in
diameter. All indicating lamps used shall be identical in size and shape unless
otherwise specified.

(b) All indicating lamps, luminous push buttons, selector and control switches
shall be of the heavy duty switchboard type, suitably insulated and rated for
the voltage level and current rating intended.

(c) The indicating lamps shall be designed to permit removal of lamp lenses and
bulb from the front of the units without the need of any special tool and
opening of the panel doors.

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Section 46 – Low Voltage Switchboards
 (d) Lamps shall be well ventilated.

(e) Indicating lamps shall be of long life type, operate on 6V for incandescent
lamp through built-in transformer or 24V for LED lamp with transformer, with
push-to-test facility.

46.3.20 Sequence Timers

Delay timers shall be of the motorized type, suitable for 220V ±10% single phase
application. When the timer motor is de-energized, the time unit shall reset by itself.
Unless otherwise stated or required for individual applications, all timers shall have
adjustable timing between 0 - 10 seconds.

46.3.21 Delay Opening Systems

(a) Where specified, delay trip devices shall be provided to work in conjunction
with no-volt devices only and shall not affect the tripping characteristics
associated with excess current, overload or earth leakage protection.

(b) Delay trip devices shall only operate in the event of the mains failing to supply
a voltage of sufficient magnitude to keep the contactor closed and/or to
prevent the no volt trip from operating The delay shall be to 5 seconds
(adjustable) and shall be charged capacitor latch devices.

(c) Switches for circuit breaker control shall be of the pistol grip type, with spring
return to the neutral position, and with an interlock to prevent repetitive closing
without moving first to the trip position.

46.3.22 Automatic Power Factor Correction Equipment

(a) The power factor correction capacitors in each set of automatic power factor
correction equipment shall comply with the following:

Rated voltage : 380V, 3 phase;

Rated Frequency : 50 Hz;
Rated output : As specified on Employer’s Drawings;
Step output : 50 kVAr; and
Standard : BS 7264, BS EN 60831, BS EN 60871, BS
EN 60931.

(b) The control relay shall have the following characteristics:

Measuring, control - Suitable for supply systems of 380/220V

operating voltage with neutral conductor;
Control current - Connected to CT 2500/5A burden 5 VA
minimum Class I, without additional adaptor;
Contacts for contactor - Control relay capable of withstanding 2500V
switching AC, 5A, 1200 VA;
Test voltage - Supply connecting cable and contactor
connecting cable 1500V, 50 Hz, CT
contactor: 500V 50 Hz;

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Section 46 – Low Voltage Switchboards
 Harmonics - A filter is incorporated to avoid falsified
measuring results. Not to be confused with
the filter circuits for the PF correction
equipment;
C/K value - Adjustable from 0.05 to 1A;
PF reversal point - Adjustable from 0.85 lagging to 1;

No-voltage release - Operates automatically due to drop-out of

control relays if voltage fails;
Indicator for operating and - LED / LCD;
steps
Switching time from one - From 10 seconds to 3 minutes according to
step to another reactive load;
Manual switching - Two push-buttons for manual operation,
suitable to check functioning to relay;
Connection - With 3 cable whips, i.e. 3-wire supply cable,
2-wire CT Connecting cable; & 6 or 12
control cable;
Mounting - With angle brackets and threaded bolts;
Temperature range - From -10°C to 60°C; and
Power consumption - Approximately 35 mA.

(c) The capacitor supplied shall be of cabinet type integrated in a separate

cubicle, and shall be in three identical three phase units connected in delta by
rigid copper bars with suitable current rating, with the specified rated output
when operated on the specified system voltage.

(d) The capacitors shall be of low loss dry-type, metallized polypropylene (MPP)
film type with self-healing properties and fitted in a sheet steel plate enclosure
filled with non-inflammable medium. The capacitor units shall be hermetically
sealed and manufactured from continuous metal foil and low loss high quality
dielectric material.

(e) The capacitors shall be provided with directly connected discharge resistors
which shall reduce the residual voltage from the rated peak alternating voltage
to 75V or less measured at the capacitor bank terminals within 3 minutes after
disconnection from the source of supply. The discharge resistors shall be
protected by an insulating cover.

(f) The capacitors shall comply with the requirement of IEC 60831 and IEC
60070. Each unit shall be fitted with an internal discharge device which shall
reduce the residual voltage to 50V or less after the capacitor is disconnected
form the supply within 1 min. The total capacitor losses shall not exceed 0.5
Watt per kVAr.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
 (g) The power factor regulating relays with a minimum of 6 pre-determined steps
shall be supplied for the automatic regulation of the overall power factor at the
LV switchboards. It shall be possible to preset the corrected power factor
through the power factor control relay in the range of 0.85 to 0.95 lagging.
The capacitors in each bank shall be controlled by an automatic multi-step
capacitor control relay capable of switching the appropriate amount of
capacitors ‘IN’ or ‘OUT’ to achieve the best average power factor. A no-volt
resetting feature shall be incorporated to ensure that, in the event of power
interruption, all capacitors involved are disconnected from the LV installation
and re-connected in accordance with the aforementioned arrangement upon
supply resumption.

46.3.23 Panel Heaters

(a) Each Section of the LV switchboard shall have a panel heater capable of
providing 60W per cubic metre of the LV switchboard. All heaters shall be
shrouded and mounted at the bottom of the LV switchboard.

(b) Panel heaters shall include a fuse and rotary ON/OFF selector switch,
thermostatic controls and a lamp to indicate the energization of the heaters at
the front.

(c) Panel heaters shall operate from the mains supply derived from the LV
switchboard.

46.3.24 Battery/Charger System

(a) One set of storage battery bank/charger shall be provided inside the LV
switchboard to provide independent source for the control of the LV
switchgear and controlgear.

(b) The battery charger shall be dual rectifier charger of constant potential type,
complete with the following as a minimum. All alarms and protection modules
shall be in printed circuit card with solid state chassis, easily dismounted and
replaced.

(i) DC voltmeter and ammeter;

(ii) surge suppressor;

(iii) float, auto and manual boost charging selection and function;

(iv) battery discharging indication;

(v) protection against over-charging and indication;

(vi) charger failure alarm;

(vii) battery low voltage indication and alarm; and

(viii) protective devices on the input and output circuits.

When under the boost charge selection, the battery shall be fully charged from
the fully discharged condition within 8 hours.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
 (c) The storage battery bank shall be of heavy-duty industrial type design for the
purpose intended. Battery cells shall be maintenance free, rechargeable, high
performance nickel cadmium type having a proven service life of at least 7
years.

(d) Under fully charged condition, the battery shall be capable of tripping the
associated ACBs and controlgear consecutively at least 20 times without
being discharged to a level where damage may be caused to the battery. The
battery shall be sized to operate under the specified range of ambient
temperatures.

(e) The output voltage of the battery bank shall be monitored by a control circuit
which shall raise a local and remote alarm when the battery/charger fails.

(f) The battery circuit shall be adequately suppressed against radio interference
to limits laid down in BS EN 55014.

46.3.25 Lifting Truck

A purpose made, wheeled, hydraulically operated lifting truck shall be supplied in

each switch room and generator room. Each lifting truck shall be completed with a
raise and lower mechanism to enable all circuit breakers to be lifted clear of their
housings.

46.3.26 RUBBER FLOOR MAT

A rubber floor mat of approved type to BS921 of 9mm thick shall be provided both
in front and at the rear of each LV switchboard inside the switch room and
generator room.

46.4 SUBMISSIONS

46.4.1 Particulars of Low Voltage Switchboards System

(a) The following particulars of the proposed low voltage switchboards shall be
submitted to the Project Manager for review:

(i) details of equipment and components and manufacturer's data, including

time-current curves for each type and rating of circuit breaker and fuse
proposed, magnetising curves of CTs proposed etc.;

(ii) Contractor’s Drawings including detailed LV switchboard construction

drawings showing busbar arrangements, panel layout with all
dimensions and layout plan demonstrating sufficient space has been
allowed for switchboard maintenance.

(iii) Contractor’s Drawings including electrical control wiring diagrams

showing details of all wirings internal and external to the LV switchboard,
together with terminal numbers for cable terminations;

(iv) setting levels of all adjustable tripping devices;

(v) calculation on battery sizing;

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Section 46 – Low Voltage Switchboards
 (vi) equipment weight;

(vii) maximum heat dissipation from the LV switchboard;

(viii) schedule of labels, inscriptions and colours;

(ix) surface treatment of the LV switchboard; and

(x) proposal for testing procedures and report format for testing of the LV
switchboard at the manufacturer's works and on Site.

(b) Contractors Drawings, showing circuits and wiring diagrams shall be

submitted to the Project Manager for review without objection. The
Contractor’s Drawings and diagrams shall clearly indicate:

(i) All equipment incorporated in the switchboard.

(ii) Fuse, circuit-breaker and disconnector (switch) ratings.

(iii) Current transformer ratios, class, terminal markings and outputs.

(iv) Instruments, including scale details and accuracy class.

(v) Relay types and characteristics.

(vi) Colours of indicating lamps.

(vii) Position of switches and details of function.

(viii) Internal connections of all apparatus with all terminal markings.

(ix) All equipment on circuit diagrams in the open or de-energized position.

(x) Arrangement of busbars with details of sizes, supports and insulation.

(xi) Primary and/or secondary plug contacts.

(xii) Wire ferrule numbers and arrangement of terminal blocks.

(xiii) Size, type and colours of secondary wiring.

(xiv) The main physical dimensions, drawing attention to any necessary

clearances required for removing covers, opening doors, operating
handles, withdrawing equipment, busbars or trunking, and gaining
admission for maintenance.

(xv) Position of all equipment on panel faces in

(xvi) dicating whether flush or projecting and, if projecting, the greatest

projection.

(xvii) Identification of all equipment with type numbers and the appropriate
label engraving describing function and coding.

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Section 46 – Low Voltage Switchboards
 (xviii) Foundation details including total weights, recommended points of
support and additional strength of foundations to withstand any
dynamic forces due to switchgear operation under service and fault
conditions.

(xix) Cable entry details, including gland and gland plate provisions.

(c) The following samples of the proposed low voltage switchboards system
shall be submitted to the Project Manager, for review without objection:

(i) indicating lamps;

(ii) control relays;

(iii) ammeter selector switch;

(iv) voltmeter selector switch;

(v) push button switches; and

(vi) label engraving describing function and coding.

46.5 WORKMANSHIP

46.5.1 Busbar

(a) Busbar and busbar connections shall be constructed in accordance with the
requirements of BS EN 60439-1.

(b) Whenever a vertical Section of the LV switchboard contains more than one
outgoing circuit, the switchboard shall be provided with busbar risers or
droppers to which the outgoing circuits are connected. Busbar risers and
droppers shall be as short and as straight as possible and shall be so
arranged that all conductors of the outgoing circuits can be brought onto the
bars without undue bending.

(c) Jointing of sections of busbars shall be made by stainless steel bolts and nuts
or clamps, silver plated or tin-plated at joints whenever applicable. Washers
and locknuts to all bolts shall be provided. The length of overlap at joints shall
not be less than the width of busbars to be jointed.

46.5.2 Cable Arrangement

(a) All the necessary cable lugs etc. shall be provided and fixed in positions on
mounting plates and straps, to suit the types and directions of entry of the
cables.

(b) Cable conductors shall be arranged for all circuits within the LV switchboard in
a tidy manner and all conductors shall be secured mechanically at regular
intervals to restrain any movement of the conductors, either under operation
conditions (e.g. thermal expansion, vibration, etc.) or due to short circuit in any
one of the circuits, that may cause any damage or short circuit to any healthy
bare live parts in the LV switchboard.

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Section 46 – Low Voltage Switchboards
 (c) All outgoing circuits shall have separate compartments and/or shall be
screened so that equipment for any one circuit can be maintained without risk
of contact with live connections of any other circuit.

46.5.3 Cable Terminations

(a) Insulated conductors shall not rest against bare live parts or sharp edges.

(b) All LV terminals shall be shrouded and any other terminals which may remain
live with the mains isolated by heat shrinkable insulation. Adequate
cautionary signs shall be provided.

(c) When the external cables are designated as being either XLPE or PVC
insulated multi-core cables, armoured or un-armoured, the appropriate units of
the switchboard shall be supplied with suitable brass compression glands of
the correct sizes.

(d) Compression glands for XLPE or PVC insulated and sheathed twin and
multi-core cables shall comply with BS 6121. All component parts of a cable
gland shall be from the same manufacturer.

(e) Where cables are single core, the gland plates shall be of a non-ferrous metal.

(f) When plug and socket connections are used in the main circuits, interlocks
shall be incorporated to ensure that plugs are fully engaged before the
associated circuit can be put into service.

(g) Cable connections and small wiring shall comply with BS 5472 and BS 6231.

(h) Each connection shall have separate incoming and outgoing terminals and no
more than two wires shall be connected to any terminal.

46.5.4 Control and Internal Wiring

(a) All wiring shall be bunched neatly by nylon type cable ties and installed in PVC
trunkings or flexible PVC tubing. Colour coded cable shall be used for
identification.

(b) Wiring across door hinges shall be enclosed by a flexible PVC tubing and loop
wiring to permit the opening of doors and removal of components for
inspection without disconnecting and over-flexing of the cables.

(c) Supplies for control circuits shall be taken from within the compartment of the
related item of switchgear and protected by a HRC cartridge fuse unit. The
control fuse and the wiring shall be completed with labels and wire numbers
for circuit tracing and trouble shooting purposes.

(d) Small wiring shall be neatly bunched and cleated in harness form, using
purpose-made plastic cable ties, or shall be enclosed in purpose made plastic
small wiring trunking. Metal 'buckle clips' shall not be used. Wiring cleated to
metal surfaces shall be spaced off or insulated from the metal. Wiring to
swing doors or other moveable items shall be flexible cables neatly bunched
and constrained by a flexible harness or loom.

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Section 46 – Low Voltage Switchboards
 (e) All small wiring shall be of stranded copper with a cross sectional area of not
less than 1.5 sq. mm with PVC insulation in accordance with BS 6231, Type B
or fire rated cables for the low voltage switchboard / motor control centre
serving the fire sevices equipment.

(f) Small wiring associated with external circuits shall be connected to terminal
strips which shall be conveniently arranged to facilitate the termination of
incoming multi-core cables. These terminals shall be of the 'Klippon' type, or
equivalent reviewed without objection by the Project Manager.

46.5.5 Wiring Terminations

(a) Cables having the same number shall be terminated at adjacent terminals and
interconnected by means of cable jumpers at the terminal block.

(b) Terminals which may remain live when the equipment is isolated from the
mains supply shall be shielded and labeled adequately from accidental
contact.

(c) White ferrules shall be provided on each terminal for circuit identification,
numbered according to the wiring diagrams previously reviewed without
objection by the Project Manager.

46.5.6 Fuses and Links

(a) Fuses and links shall be provided to enable any circuit to be isolated as
necessary for maintenance and test purposes without isolating the whole of
the control circuit.

(b) Fuses and links shall be mounted in a readily accessible position within the LV
switchboard. Fuses and links, functionally associated with the same circuit
shall be grouped.

(c) At least 10% of the total number of fuses and links and not less than 2 spare
fuses and links shall be provided for each rating of fuses and links to be
provided for the LV switchboard. Spare fuses and links shall be fitted in clips
within a dedicated compartment of the LV switchboard.

46.5.7 Terminal Blocks

(a) Terminal blocks for interfacing with other systems shall be located in
dedicated and segregated compartments at either or both ends of the LV
switchboard.

(b) Terminal blocks shall be grouped according to the function and voltage of the
control circuit., Each group shall be segregated from every other groups.

(c) No more than two wires shall be connected to one terminal.

(d) At least 10% of the total number of terminal blocks and not less than 2 spare
terminals for each terminal block, shall be provided.

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Section 46 – Low Voltage Switchboards
 (e) The incoming cable cores shall be terminated at the lower or outer side of the
block, the outgoing cable cores at the upper or inner side of the terminal block,
and cable links on any free side.

(f) Terminal blocks at different voltages shall be segregated into groups,

distinctively labelled and provided with permanent rigid barriers. Terminals in
groups shall have separate flame retarding transparent plastic covers.

(g) All spare contacts shall be wired to terminal blocks suitably positioned for
external wiring.

46.5.8 Earthing

(a) Equipotential bonding shall be provided for all doors, cover plates, etc., to
ensure earth continuity. The circuit protective conductor shall be sized
according to the maximum cross-Section of supply lead to the equipment
attached to the doors, cover plates, etc., and in any case not less than 2.5
mm2.

(b) A tinned copper earth bar of dimensions not less than 50 × 6 mm shall be
provided along the whole length of the switchboard bonding the framework of
all modular sections, complete with terminals for connections to the armouring
or metal sheath of all incoming and outgoing circuits, the integral earth
busbars of busducts, and to the electrical earth.

(c) An external earth terminal shall be provided on the outside of both ends of the
LV switchboard for earthing connection to the electrical earth.

(d) For each switch room, and generator room, a purpose made earthing device
shall be supplied by the Contractor to replace the air circuit breaker for
earthing the outgoing busbars when the latter is removed from the housing.
The device shall be provided with padlocks to secure it in the connected
position. Portable earthing leads shall not be accepted as an alternative to
the purpose made earthing device. A wooden box shall be provided for
storage of the earthing equipment.

46.5.9 Label

(a) Permanent laminated self-coloured traffolyte or similar plastic labels of ample

sizes shall be provided for each of the units both at the front and in the cabling
compartment on the LV switchboard, engraved in English and Chinese
characters. The labels shall be fixed firmly by means of chromeplated screws.
Generally, labels shall not be less than 75 mm high and the lettering shall be
of not less than 50 mm high

(b) The wording of the labels shall describe the type of unit, the designation, the
current rating and the circuit identification in a clear and concise manner. A
schedule of labels shall be submitted for review without objection by the
Project Manager before engraving is carried out.

(c) Warning labels shall be provided on the rear panels with white lettering on a
red background in both English and Chinese characters denoting ‘DANGER –
380V’. Similar warning labels shall be provided for all live parts, including test
terminal blocks.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
 (d) Warning labels at the front and in the cabling compartment shall be provided
for each automatic/remote closing or changeover switch denoting ‘BEWARE -
AUTOMATIC CLOSING’.

(e) Warning labels shall be provided for the terminals of the DC supply control
circuit which may remain live when the main equipment is isolated from the
mains supply to reduce the risk of accidental contact.

46.5.10 Finishes

The finished coating of the LV switchboard shall be made good any damage and
painted by hand to its original finish color on completion of the installation as
specified in Section 46.3.1 (m) and (n).

46.5.11 Wiring Diagrams

A LV switchboard wiring diagram showing the compartment layout with busbar and
circuit arrangement shall be provided as if viewed from the point of access to the
enclosure. The wiring diagram shall be suitably treated to prevent deterioration from
dirt and age, and shall be securely fastened to the inside of the access door of that
compartment.

46.5.12 Internal and Control Wiring

(a) All cables shall be adequately rated single core multi-strand conductors of not
less than 1.5 mm2, run on PVC cleats or trunkings.

(b) Sleeve type cable markers shall be fitted to both ends of each length of cable
to denote its function. The function letter shall be followed by a number
identifying the individual wire. Each branch of any connection shall bear the
same identification mark. Where it is necessary to identify branches which are
common, different identification marks for the branches shall be employed
only if there are common through links or are connected to separate terminals
which are then common by removable connections. Numbering shall read
from the terminal outwards on all wire. Circuit function letters and wire
numbers shall be in accordance with the following table:

Circuit Function Letters Wire Number

C Current transformers for over current 10-29 : brown phase
protection (including combined earth-
30-49 : black phase
fault protection) and instruments
50-69 : grey phase
D Current transformers for metering 90 : circuit protective conductors
and voltage control directly connected to the earthing
bar
J D.C. supply 1-69
H A.C. supply 1-69
K Closing and tripping control circuit Any integer from 1 upwards
L Alarms and indications initiated by Any integer from 1 upwards
auxiliary switches and relay contacts

(c) Different insulation colours shall be provided to distinguish the various circuits.
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Section 46 – Low Voltage Switchboards
46.5.13 Air Circuit Breakers (ACBs)

All Air Circuit Breakers (ACBs) without external overcurrent IDMT protection relays
shall be completed with built-in overload protection. Only extremely inverse
overcurrent relay shall be used, all protection relay shall be of the type approved by
the Power Supply Company.

46.5.14 Low Voltage Switchboards

(a) The Contractor shall provide one complete set of spare fuses for each rating
of fuse switch installed for each LV switchboard. The Contractor shall install
on the wall inside the Switch Rooms, a wooden board with brass hooks for
hanging the spare fuses. The board shall be smooth on both front and edges,
and shall be painted subject to the review without objection the Project
Manager. All fuses shall be supplied by the Contractor. The Contractor shall
frame and post the as-fitted control circuit diagrams and schematic wiring
diagrams (at least A2 size) inside each switch room.

(b) The Contractor shall confirm that the overall size of each LV switchboard can
be installed in the respective switch room in compliance with the Specification,
Power Supply Company’s and EMSD’s requirements.

(c) The Contractor shall allow adequate spacing and make provision inside the
switchboard for the installation and connection of the Power Supply
Company’s meters and other equipment including the metering panels,
marshalling boxes, current transformers and link boxes etc. in accordance
with the Power Supply Company’s requirements.

(d) The Contractor shall provide the generator fault remote alarm and the remote
lamp indication of ‘Generator Fault’, ‘Generator Running’, and ‘Essential
Power On’ from the generator to the corresponding LV switchboards.

46.6 TESTING AND COMMISSIONING

Section 60 of this General Materials and Workmanship Specification shall be

referred to for testing and commissioning of LV switchboard.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 46 – Low Voltage Switchboards
SECTION 47 SUB-MAINS ELECTRICAL DISTRIBUTION EQUIPMENT

47.1 GENERAL

(a) The switchgear and associated equipment, operating at low voltages, may be
assembled on Site from individual items of components. The switchgear and
associated equipment shall be manufactured to the relevant current
International Electrotechnical Commission (IEC) Standards referred to in
Section 47.2.

(b) Sub-mains electrical distribution equipment shall comply with the general
power supply conditions referred to in Section 45.2 of this General Materials
and Workmanship Specification.

(c) Enclosures for switchgear and associated equipment shall be of totally

enclosed type. For indoor applications, the enclosure shall have an ingress
protection (IP) of a least IP 41 for the top surface and IP 31 for the other
surfaces of the enclosure. For outdoor applications, the enclosure shall be of
at least IP 54.

(d) Systems and equipment shall be of proven performance having a proven track
record of reliable service over a minimum of 10 years in similar environments
and usage patterns as the proposed installation.

(e) Unless otherwise specified, switchgear and associated equipment except

MCCBs and MCBs shall be metal-clad. All ferrous metal parts shall be
galvanized or chrome plated unless the final finish has been painted or
enameled in the manufacturer’s factory.

(f) All switch panel boards and distribution panel boards shall be factory
assembled.

(g) All switchgears, control panels and distribution boards located where
accessible by the public shall be provided with hinged lockable doors to
prevent unauthorized access.

(h) All extraneous conductive parts shall be electrically continuous.

(i) Section 60 of this General Materials and Workmanship Specification shall be

referred for the testing and commissioning.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 47 – Sub-Mains Electrical Distribution Equipment
47.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as at the date of the Letter of Acceptance.

BS 88 Cartridge fuses for voltages up to and including

1,000V AC and 1,500V DC
BS 88 : Part 2 Cartridge fuses for voltages up to and including
1,000V AC and 1,500V DC Specification for fuses
for use by authorized persons (mainly for industrial
application). Additional requirements for fuses with
fuse-links for bolted connections
BS 91 Electric cable soldering sockets.
BS 1432 Specification for copper for electrical purposes:
high conductivity copper rectangular conductors
with drawn or rolled edges
BS 1433 Specification for copper for electrical purposes.
Rod and bar
BS 4293 Specification for residual current-operated circuit-
breakers
BS 5486 : Part 11 Low-voltage switchgear and controlgear
assemblies. Specification for particular
requirements of fuseboards
BS 5486 : Part 12 Low-voltage switchgear and controlgear
assemblies. Specification for particular
requirements of type-tested miniature circuit-
breaker boards
BS 7671 Requirements for electrical installations
BS EN 60269/IEC 60269 Low-voltage fuses
BS EN 60439/IEC 60439 Specification for low-voltage switchgear and
controlgear assemblies
BS EN 60439-1 Specification for low-voltage switchgear and
controlgear assemblies. Type-tested and partially
type-tested assemblies
BS EN 60529/IEC 60529 Specification for degrees of protection provided by
enclosures (IP code)
BS EN 60898/IEC 60898 Specification for circuit-breakers for overcurrent
protection for household and similar installations
BS EN 60947-2/IEC 60947-2 Specification for low-voltage switchgear and
controlgear. Circuit-breakers
BS EN 60947-3/ IEC 60947-3 Specification for low-voltage switchgear and
controlgear. Switches, disconnectors, switch-
disconnectors and fuse-combination units

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Section 47 – Sub-Mains Electrical Distribution Equipment
 IEC 60755 General requirements for residual current
operated protective devices
BS EN 61008 Specification for residual current operated circuit
breakers (RCCB)
BS EN 61009 Specification for residual current operated circuit
breakers with integral overcurrent protection for
household and similar use (RCBO)

47.3 MATERIALS

47.3.1 Fused Switchgear and Isolating Switches

(a) All fused switchgear and isolating switches shall comply with and be type
tested to BS EN 60947-3 for uninterrupted duty and all live parts shall be fully
screened from the front.

(b) All fused switchgear and isolating switches shall have the following electrical
characteristics:

rated operation voltage : 380/220V;

rated frequency
rated insulation voltage
rated thermal current and rated
operational current/power for
uninterrupted duty
rated short-circuit current
rated short-time withstand current
utilization category
: 50Hz;
: 415V;
: as shown on the Employer’s
Drawings;
: 40 kA;
: at least twenty times the maximum
rated operational current for a
duration of 1 second.; and
: AC-22A for general application and
AC-23A for electrical motor circuits,
unless otherwise specified.

(c) Fused switchgear and switches shall be triple pole with neutral link, triple pole
with switched neutral, double pole or single pole with neutral link, as specified.
The neutral link shall be accessible and detachable from the front of the fused
switchgear panel.

(d) Fused switchgear and switches shall be totally enclosed type and suitable for
surface mounting or installation in a switchboard cubicle as specified. The
cases and doors shall be manufactured from at least 1.6 mm thick galvanized
sheet steel finished and rust proofed. The doors shall be gasketed and fitted
with ball catch lock or equal reviewed without objection by the Project
Manager.

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Section 47 – Sub-Mains Electrical Distribution Equipment
 (e) Fused switchgear and switches shall have mechanical interlocks between the
door and the switch operating mechanism and shall be so arranged that the
door cannot be opened with the switch in the ON position. Similarly, it shall
not be possible to close the switch with the cubicle door open, except that
provision shall be made within the cubicle to defeat the mechanical inter-lock
and close the switch with the door in the open position for test purposes.

(f) Fused switchgear and switches shall be fitted with mechanical ON/OFF
indicators with operating handles of the semi-flush or telescopic pattern.
Means shall be provided for padlocking in the ON or OFF position.

(g) Fused switchgear shall be provided with adequate accelerating springs and
toggle action to ensure positive quick-make and quick-break action,
independent of the speed of operation of the handle, and shall be capable of
closing onto and remaining closed on a fault, and able to operate even if the
mechanism spring is broken. All contacts shall be silver plated for service
reliability.

(h) An earth terminal shall be provided for every fused switchgear and isolator.

47.3.2 Molded Case Circuit Breakers (MCCBs)

(a) MCCBs shall comply with and be type tested to BS EN 60947-2 or IEC 60947-
2.

(b) MCCBs shall have the following performance characteristics:

rated operation voltage : 380/220V;

rated frequency : 50Hz;
rated insulation voltage : 415V;
rated uninterrupted current : as shown on the Employer’s Drawings;
rated short-circuit breaking capacity : 40 kA at power factor less than 0.25
lagging unless otherwise specified; and
short circuit performance category : P1
short circuit performance : IEC 60947-2

(c) MCCBs with built-in protection shall have thermal-magnetic, hydraulic

magnetic or solid state over-current tripping mechanism to give a fixed, stable
inverse time-current characteristics for time delay in overload circuit protection
and instantaneous short-circuit interruption. The operating characteristics at
40°C shall be such that:

(i) the time delay on overload tripping is inversely proportional to the

overcurrent up to a threshold value of approximately seven times the
rated current; and

(ii) there shall be no intentional time-delay on overcurrent tripping due to

short-circuit or heavy overcurrent exceeding the threshold value (i.e.
approximately 7 times the rated current).

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Section 47 – Sub-Mains Electrical Distribution Equipment
 (d) MCCBs shall be totally enclosed in a moulded casing formed from an
insulated material and to a protection of not less than IP 30. The MCCB
enclosure shall allow sufficient space for installing cable lugs that suit the
largest incoming cables to the MCCB. . The palm width of cable lugs shall
comply with BS 91 Table 2. There shall also be sufficient space for proper
cable termination with cable bending radii in accordance with BS 7671,
otherwise proper extension cable terminals and/or cable box shall be
provided.

(e) The operating mechanism shall be independent manual and trip-free.

Indication of “OFF” position shall occur only when the specified isolation
distance on each pole has been attained. Reliable visual indication of “ON”,
“TRIP” and “OFF” position. Facilities shall be provided for padlocking the
MCCB in the “OFF” position.

(f) Where shunt release is specified, this shall operate correctly at all values of
supply voltage between 70% and 120% of the nominal supply voltage under
all conditions of the MCCB up to the short-circuit breaking capacity of this
circuit breaker. MCCBs incorporating shunt release shall be provided with
block terminals and shunt release lead cables.

(g) MCCBs shall be of proprietary manufacture with ASTA certificate.

(h) MCCBs inside LV switchboard shall be plug-in type.

(i) All MCCBs rated at 200A and above shall be completed with built-in earth fault
protection.

(j) Utilization category of MCCBs shall be AC-22 for general purpose or AC-23
for electric motor circuits.

(k) Whenever the MCCB is required to be interfaced with GBMS system, the
ON/OFF/Fault/Trip status of the MCCB should be provided and interfaced with
GBMS for monitoring.

47.3.3 Miniature Circuit Breakers (MCBs)

(a) MCBs shall comply with and be type tested to BS EN 60898 or IEC 60898.

(b) MCBs shall have a minimum rated short circuit capacity of 6 kA.

(c) Cable terminals of the MCBs shall be at top and bottom of the units with
access from front, and suitable for terminating the size of solid or stranded
conductor in accordance with BS EN 60898.

(d) Unless otherwise specified, lighting and power circuits fed from MCB boards
shall be protected by Type B MCBs. Motor circuits shall be protected by Type
C MCBs. Transformers, charging equipment and X-ray machines shall be
protected by type D MCBs. The type, thermal and magnetic characteristic
shall be of an equivalent technical performance to those detailed in BS EN
60898 and BS 7671. Energy limit class of MCB shall be class 3 according to
BS EN 60898.

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Section 47 – Sub-Mains Electrical Distribution Equipment
 (e) The breaker operating mechanism shall be of the thermal-magnetic to give a
fixed, stable, inverse time-current characteristics in according with BS EN
60898. The load handling contacts shall not be able to hold closed against a
fault.

(f) The MCBs shall be totally enclosed in a moulded insulating case.

(g) MCBs shall be provided with facility for locking the operating toggle on either
“ON” or “OFF” positions.

(h) In addition, the MCBs shall be capable of being connected in cascade with
fuses to BS 88 up to a rating of 160A in situations where the appropriate
prospective short circuit current at the supply side is up to 22 kA.

47.3.4 Residual Current-operated Circuit Breakers (RCCBs)

(a) RCCBs shall be double pole or four-pole current-operated, housed in a totally

enclosed moulded case, manufactured and type tested in compliance with BS
EN 61008. The casing of the RCCB shall be constructed of totally enclosed
moulded-case insulating materials to withstand the fault level as certified to BS
EN 61008.

(b) RCCBs shall be designed to the rail mounting method inside the distribution
board.

(c) RCCBs shall have minimum short circuit making and breaking capacity of 3 kA
with rated residual making and breaking capacity to be ten (10) times the rated
current of RCCBs or 500A, whichever is the greater.

(d) RCCBs shall be instantaneous tripping type without time delay function.
Tripping operation of RCCBs shall not involve amplification of operating
residual current and shall be independent of the line voltage.

(e) Operating characteristics of RCCBs shall be of type a.c. as specified in BS EN

61008 for which tripping is ensured for residual sinusoidal alternating current,
whether suddenly applied or slowly rising. Type A RCCBs shall be provided as
specified in case of residual currents with d.c. components.

(f) Multi-pole RCCBs shall be interlocked internally such that an earth leakage
current through any one phase shall trip all the poles of the RCCBs
simultaneously.

(g) Unless otherwise specified, the rated residual operated current shall be 30mA.

(h) Provision shall be made for testing the automatic earth-leakage tripping by an
integral test device. A device shall be fitted for prevention against automatic
re-closing after the RCCBs has tripped on earth leakage.

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Section 47 – Sub-Mains Electrical Distribution Equipment
47.3.5 Residual Current-operated Circuit Breakers with Integral Overcurrent
Protection (RCBOs)

(a) RCBOs shall be single-pole, double-pole or four-pole current operated circuit

breaker as specified and housed in a totally enclosed moulded-case type
tested to BS EN 61009.

(b) RCBOs shall be designed to the rail mounting method inside the distribution
board.

(c) In addition to the electrical and operating characteristics stated in Section

47.3.4 in this General Materials and Workmanship Specification, RCBOs shall
have minimum short circuit making and breaking capacity of 6000A with rated
residual making and breaking capacity to be ten (10) times the rated current of
RCBOs or 500A, whichever is the greater.

(d) Energy limiting class shall be of class 3 in accordance with BS EN 61009.

(e) Unless otherwise specified, RCBOs shall have instantaneous tripping

characteristic of type B, except for application of motor circuit or high inrush
current situation where type C shall be provided. Multi-pole RCBOs shall be
interlocked internally such that an earth leakage current through any one
phase shall trip all the poles of the RCBOs simultaneously.

(f) Provision shall be made for testing the automatic earth-leakage tripping by an
integral test device. A device shall be fitted for prevention against automatic
re-closing after the RCBOs has tripped on earth leakage.

47.3.6 Fuses, Carriers and Bases

(a) Fuses shall comply with BS 88 : Part 2, Class Q1 fusing factor, designed to
handle the anticipated short circuit current, and of the cartridge type.

(b) The contacts of the fixed portion of the fuse or link carrier shall be shrouded so
that accidental contact with live parts cannot be made when the cartridge is
removed. It shall be possible to change fuses with the circuit alive without
danger of contact with live parts.

(c) The voltage rating shall be 415V AC 50 Hz or 500V DC as relevant. The rated
breaking capacity of fuses shall be 80 kA at 415V AC 50 Hz or 40 kA at 500V
DC.

(d) For power factor correction capacitors, fuse links shall have fusing factor not
less than 1.5.

(e) Fuse and link bases and carriers shall be of plastic moulded insulating
material of a make reviewed without objection by the Project Manager.
Ceramic materials will not be accepted. Fuse bases and carriers shall have a
construction different from those for links for the neutral as to prevent wrong
fitting of fuses and links.

(f) Fuse bases and carriers shall be colour coded, white for isolating link, light
green for control and black for all other fuses, with phase indication.

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Section 47 – Sub-Mains Electrical Distribution Equipment
 (g) Fuses and links in the same circuit shall be mounted in adjacent positions in
the same row Fuses for controls and voltmeters shall be mounted on the front
of the panel by back-connected fuse holders.

(h) Cartridge fuses shall have a rated breaking capacity of 50 kA at rated voltage
and the utilization category shall be gG unless otherwise specified.

(i) The dimensions of fuse links shall be standardized in accordance with Table 2
of BS 88 : Part 2.

47.3.7 Distribution Fuseboard

(a) Distribution fuseboards shall comply with BS EN 60439-3 and shall be factory-
built assemblies, type tested and certified to have a fused short circuit of not
less than 16.5kA at a power factor of not exceeding 0.3 lagging.

(b) Distribution fuseboards shall be totally enclosed, constructed from sheet steel
having a thickness of not less than 1.5 mm and shall be rust proofed. The
front cover shall be hinged or screwed-on, and access to the fuses for
replacement shall only be possible after the front cover is opened or removed.

(c) Distribution fuseboards shall utilize cartridge fuses to BS 88 : Part 2, Class Q1

fusing factor. Use of semi-enclosed fuse shall not be permitted.

(d) Phase and neutral busbars shall be tinned copper and shall be adequately
supported and secured with the necessary strength to withstand through faults
of a rating equal to that of the fuse fault rating and of continuous current
carrying capacity equal to the incoming switchgear or fuses. The current
rating of the neutral busbar shall be not less than that of the phase busbars.

(e) Fuses shall be mounted in moulded fuse carriers which shall be designed to
provide for busbar connection at one end and cable termination at the other.
There shall be no risk of touching live parts when inserting the fuses. The
fuse carrier shall be unaffected by the heat generated by a blown fuse.

(f) Distribution fuseboards shall be provided with live, neutral and earthing
terminals for the incoming cables. There shall be one neutral and one earthing
terminal for each outgoing fuseboard circuit.

47.3.8 Molded Case Circuit Breaker (MCCB) Distribution Boards

(a) The design, construction, and testing specification of MCCB distribution

boards shall comply with BS EN 60439-1.

(b) The configuration of the busbars, busbar supports and the busbar mounting
arrangement shall be type tested and certified to a short-time withstanding
current of not less than 22 kA in the case of boards with busbar rating less
than 400A or 40 kA in the case of boards with busbar rating 400A or above, or
the prospective short circuit current which can occur at the point of installation
whichever is the largest for 0.2 second at a voltage of not less than 380V.

(c) The enclosure of MCCB distribution boards shall be constructed from sheet
steel of a thickness not less than 1.5 mm and shall be rust proofed.

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Section 47 – Sub-Mains Electrical Distribution Equipment
 (d) MCCB distribution boards shall be provided with a moulded-case isolating
switch having a current rating not less than that of the supply side protective
device unless otherwise specified.

(e) MCCB distribution boards shall be provided with triple-pole and neutral copper
busbars of rating not less than that of the supply side protective device. All
busbars shall be of hard drawn copper and shall be electro-tinned. Neutral
busbars shall be of the same cross section area as the phase busbars, and
shall have adequate number of terminals for all outgoing circuits including
spare ways.

(f) Outgoing MCCBs shall be mounted on both sides of the busbars. The
connection between the MCCBs and the phase busbars shall be by means of
copper tapes and bolted joints.

(g) MCCB distribution boards shall be provided with live, neutral and earthing
terminals for the incoming cables. There shall be one neutral and one
earthing terminal for each outgoing MCCB way.

47.3.9 Miniature Circuit Breaker (MCB) Distribution Boards

(a) MCB distribution boards shall be factory-built assemblies for indoor use and
fully comply with and type tested to BS EN 60439-1. All MCB boards shall be
capable of withstanding through faults of not less than the MCB rated fault
breaking capacity as specified without sustaining permanent damage.

(b) MCB distribution boards shall be totally enclosed type and suitable for surface
mounting. The enclosures shall be manufactured from galvanized sheet steel
of not less than 1.2 mm and rust proof. The doors shall be gasketed and fitted
with ball catch lock or equal reviewed without objection by the Project
Manager.

(c) The moulded back plate assembly shall be of sheet steel of substantial
thickness and attached to the back of the enclosure for mounting of MCB,
RCCB, RCBO and double pole or triple pole all insulated switches as
specified.

(d) MCB distribution boards shall be provided with a moulded-case, all-insulated,

double-pole or three-pole incoming switch-disconnector (isolating switch)
having a current rating of not less than that of the supply side protective
device whenever specified. This incoming switch-disconnector shall have a
Utilization Category of AC-22A. However, switch-disconnector of Category
AC23A shall be provided in the event of any one of the outgoing circuits being
fed for motor circuits.

(e) The metal front plate assembly shall be of sheet steel and shall be finished to
the same colour as the distribution board enclosure. The front plate shall be
screwed on the enclosure, making the assembly suitable for both surface and
flush mounting. The front plate shall be affixed with labels for circuit and
phase identification.

(f) MCB distribution boards shall be suitable for flush or surface mounting as
specified. Flush mounting shall be so arranged that the assembly is flush with
the surface of the wall and shall not cause any adverse effect to the heat
dissipation of internal devices.

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Section 47 – Sub-Mains Electrical Distribution Equipment
 (g) All current carrying parts of the MCB distribution boards such as busbars,
neutral and earthing terminals, incoming cable terminals etc. shall be of
electro-tinned copper. The phase and neutral bars shall be of the same size.

(h) MCB distribution boards shall be provided with live, neutral and earthing
terminals for the incoming cables. There shall be one neutral and one earthing
terminal for each outgoing MCB way.

(i) MCB distribution boards shall be suitable for operating at 380/220V 50Hz AC
supply.

(j) MCB distribution boards shall be supplied with all necessary components and
accessories to form a complete assembly. All MCB distribution boards shall be
of robust construction, dust proof to at least IP42, surface mounted and fitted
with identification labels. Conduit knockouts shall be provided on top, bottom,
and both sides.

(k) All MCB distribution boards shall be provided with an integral incoming switch-
disconnector (isolating switch) where called for in the Schedules. They shall
be of the same manufacturer as the MCB boards.

47.3.10 Busbar Chambers

(a) Busbar chambers shall be manufactured and tested in compliance with BS EN

60439 or IEC 60439. It shall be type tested to withstand a rated fused short
circuit current at least equal to that of incoming switchgear and type tested to
the rated operation current.

(b) Busbars shall be made of hard drawn, electro-tinned high conductivity, bare
rectangular solid copper bars to BS 1432 or BS 1433. Full size neutral bars
shall be provided.

(c) Busbars shall be adequately supported by non-hygroscopic insulators and

rigidly braced to withstand the maximum mechanical stresses to which it may
be subjected under fault conditions.

(d) Busbar chambers shall be totally enclosed type and suitable for surface
mounting. The cases and doors shall be manufactured from galvanized sheet
steel finished and rust proofed. The thickness of the sheet steel shall not be
less than 1.5 mm for current ratings not exceeding 500 A, and not less than 2
mm for current ratings of 500 A or above.

(e) The front cover and end plate shall be removable and normally held in position
by non-ferrous metal screws.

(f) The cross-sectional area of the interconnecting cables between busbar

chambers and switchgears shall not be less than that of the incoming or
outgoing cables connecting to the other side of the switch.

(g) Manufacturer's standard busbar cable clamps, sockets and fittings shall be
used for clamping the cables onto the busbars.

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Section 47 – Sub-Mains Electrical Distribution Equipment
47.3.11 Watt Hour Meters and Meter Chambers

(a) Meter chambers shall be made from galvanized steel of not less than 1.6 mm
thick and shall be of ample size to accommodate the required number of
meters. Provision shall be made to enable the meters to be fixed inside the
chamber without removing the chamber from the wall.

(b) Meter chambers shall be fitted with a hinged metal front cover with a glass
window provided for each meter. The size of the window shall allow the meter
dials and the serial numbers of the meters to be easily read.

(c) Watt-hour meter shall comply with EN 60521. The register shall be of drum
type and the principal unit in which the register records shall be in kilowatt-
hours (kWh). The casing shall be of black phenolic moulding with an
inspection glass window at the front.

(d) Watt-hour meter shall have Class 2 accuracy calibrated at the normal working
voltage and frequency.

47.4 SUBMISSIONS

47.4.1 Sub-Mains Electrical Distribution Equipment

(a) The following particulars of the proposed sub-mains electrical distribution

equipment shall be submitted to the Project Manager for review without
objection:

(i) detailed schedules of equipment and components and associated

manufacturer's data including, time-current curves for each type and
rating of circuit breaker and fuse provided, manufacturer's type-test
certificates and testing documents;

(ii) the maximum let through energy and the peak cut-off current of the
protective device such as fuseswitch, MCCB, MCB and RCBO etc.
against the prospective short circuit current;

(iii) co-ordinated Contractor’s Drawings showing the equipment layout in

plant rooms, including elevations showing the arrangement of the
electrical distribution equipment; and

(iv) details on labelling and circuit record card.

(b) The following samples of the proposed sub-mains electrical distribution

equipment shall be submitted to the Project Manager for review without
objection:

(i) MCBs;

(ii) RCCBs; and

(iii) RCBOs.

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Section 47 – Sub-Mains Electrical Distribution Equipment
47.4.2 MCB Distribution Boards

The Contractor shall submit catalogues, drawings, installation details and samples
with detail of finish and colour to the Project Manager for review without objection
prior to manufacture.

47.4.3 Busducts

The Contractor shall submit catalogues, drawings, sectional and installation details
of the busducts to the Project Manager for review without objection prior to
manufacture and installation. The busduct layout and installation details drawings
shall be prepared by the busducts specialist supplier / manufacturer.

47.5 WORKMANSHIP

47.5.1 Fused Switchgear and Isolating switches

(a) All fused switchgear and isolators shall be mounted securely on walls or in
switchboards by non-ferrous metal screws.

(b) All fused switchgear and isolators shall be clearly labelled and marked with
phase and neutral identification with Brown, Black, Grey and Blue colour
respectively.

47.5.2 Molded Case Circuit Breakers

(a) MCCBs shall be fitted to the MCCB distribution board or switchboard securely
by non-ferrous metal screws and bolts fixed securely. They shall be mounted
on the standard rails at the back of the MCCB distribution board.

47.5.3 MCB, RCCB and RCBO

(a) MCBs, RCCBs and RCBOs shall be fitted to the MCB board securely by non-
ferrous metal screws fixed securely. They shall be mounted on the standard
rails at the back of the MCB distribution board.

47.5.4 Distribution Fuseboard, MCCB Distribution Board and MCB Distribution Board

(a) The distribution boards shall be fixed on wall or metal frame securely by non-
ferrous metal screws and bolts.

(b) All distribution boards shall be clearly labelled, and marked with phase and
neutral identification with Brown, Black, Grey and Blue colour respectively.

(c) Inside each distribution board door, a circuit record card shall be provided.
The card shall be renewable and protected by transparent material for
recording the title, cable size and actual current rating of each outgoing circuit,
the rated current of the distribution board, the designation of the outgoing
circuits served by each protective device.

(d) Gaskets with necessary insulation board shall be provided to all openings for
connection to trunkings or metal cable change boxes.

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Section 47 – Sub-Mains Electrical Distribution Equipment
47.5.5 Busbar Chamber

(a) The busbar chambers shall be fixed on wall or metal frame securely by non-
ferrous metal screws and bolts.

(b) Switchgear shall be joined to busbar chambers by galvanized steel busbar

chamber connection flanges or conduit couplers and male bushes.

(c) Each busbar shall be marked with the appropriate phase colour at intervals of
not more than 600mm. Busbar chambers shall be marked with phase and
neutral identification with brown, black, grey and blue colour respectively, and
clearly labelled to indicate the ratings and functions.

47.5.6 Watt Hour Meter and Meter Chamber

(a) Current Transformers (CTs), if required, shall be mounted inside the meter
chambers, but in separate compartments so that opening of the front cover to
gain access to the meters does not expose the current transformers.

(b) Meter boards, labels and all necessary accessories shall be provided to the
satisfaction of the power supply company to facilitate the installation of kWh
meters. In case metering current transformer (CT) is required for metering,
cable termination block shall be provided to facilitate the future installation of
CT.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 47 – Sub-Mains Electrical Distribution Equipment
[this page not used]
SECTION 48 WIRING AND CABLES

48.1 GENERAL

(a) Cable and wiring shall comply with the requirement of the Code of Practice for
the Electricity (Wiring) Regulations issued by EMSD and BS 7671.

(b) Power cables are mainly for electric power supply and distribution. They shall
be manufactured under BASEC license or under equivalent quality
surveillance scheme (e.g. CENELEC Harmonization Scheme) bearing BASEC
marking or the appropriate marking of equivalent quality surveillance schemes
(e.g. CENELEC Harmonization Scheme).

(c) Non-sheathed copper cables shall be used for wiring in conduits or trunkings.
For three phase circuits, the cables shall be 450/750V grade or above.

(d) Sheathed copper cables shall be used for wiring on cable trays, on cable
ladders or surface mounted as specified on the Employer’s Drawings. For
three phase circuits, the cables shall be 450/750V grade or above.

(e) Armoured copper cable shall be used for wiring on cable trays, on cable
ladders, surface mounted, in cable trench, in cable ducts or directly buried in
ground as specified on the Employer’s Drawings. For three phase circuits, the
cables shall be 600/1,000V grade or above.

(f) XLPE/SWA/PVC cables shall be used for main feeders from the main
electrical low voltage cubicle switchboard/main distribution boards in main
switch room to sub-main distribution board.

(g) PVC non-sheathed cables shall be used for final sub-circuits except for fire
services equipment. Whenever specified on the Employer’s Drawings, the
final circuit wiring shall have the property of low smoke zero halogen to BS
7211.

(h) Cables for fire services equipment such as smoke extraction fans and smoke
curtains etc shall be of fire resistant cables on cable trays, on cable ladders or
surface mounted or as specified on the Employer’s Drawings.

48.2 RELEVANT CODES AND STANDARDS

The relevant Codes and Standards applicable to this Section include but not limited
to the following:-

BS 4066 : Part 3 / IEC Tests on electric cables under fire conditions. Tests on
60332-3 bunched wires or cables
BS 4579 Specification for performance of mechanical and
compression joints in electric cable and wire connectors
BS 5467 Specification for cables with thermosetting insulation for
electricity supply for rated voltages of up to and including
600/1000V and up to and including 1900/3300V
BS 6004 Specification for PVC-insulated cable (non-armoured) for
electric power and lighting
General Materials & Workmanship Specification 1/16 January 2011
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Section 48 – Wiring & Cables
 BS 6207 Mineral insulated cables with a rated voltage not exceeding
750V. Guide to use
BS 6346 Specification for PVC-insulated cables for electricity supply
BS 6360 Specification for conductors in insulated cables and cords
BS 6469 Methods of test for insulation and sheaths of electric cables
BS 6724 Specification for armoured cables for electricity supply
having thermosetting insulation with low emission of smoke
and corrosive gases when affected by fire
BS EN 10257-1 Zinc or zinc alloy coated non-alloy steel wire for armouring
either power cables or telecommunication cables. Land
cable
BS EN 50265-1 Common test methods for cables under fire conditions. Test
for resistance to vertical flame propagation for a single
insulated conductor or cable. Apparatus
BS EN 50265-2-1 Common test methods for cables under fire conditions. Test
for resistance to vertical flame propagation for a single
insulated conductor or cable. Procedures. 1 kW pre-mixed
flame
IEC 227 Polyvinyl chloride insulated cable of rated voltages up to and
including 450/750V
IEC 228 Conductors for insulated cables
IEC 502 Extruded solid dielectric insulated power cables for rated
voltages from 1 kV up to 30 kV
IEC 702 Mineral insulated cables and their terminations with a rated
voltage not exceeding 750V
IEC 811 Common test methods for insulating and sheathing materials
of electric cables

48.3 MATERIALS

48.3.1 PVC Insulated Cables

(a) Cables of this type shall be 450/750V grade complying with BS 6004, copper
core and PVC insulated.

(b) Conductors shall be plain annealed copper conductors complying with BS

6360.

(c) The cables shall comply with BS EN 50265-1 or BS EN 50265-2-1 for flame
retardance.

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Section 48 – Wiring & Cables
 (d) The phase of the cables shall be identified by the colour as specified below
throughout the whole of the insulation:

Phase : Brown, Black and Grey

Neutral : Blue
Earth : Green or Yellow

(e) The current carrying capacities and voltage drops of cables shall be in
accordance with Code Of Practice For The Electricity (Wiring) Regulations
issued by EMSD and BS 7671. Ratings shall be adjusted to suit local
conditions.

(f) The minimum cable sizes shall be as specified below, unless otherwise
specified:

Lighting : 1.5 mm2;

Small Power : 2.5 mm2; and
Control Wiring : 1.5 mm2.

48.3.2 XLPE Insulated PVC Sheathed Cables

(a) Cables of this type shall be 600/1000V grade complying with BS 7889, copper
core and XLPE insulated.

(b) Conductors shall be plain annealed copper conductors complying with BS

6360.

(c) Each core of the cable shall be identified by the appropriate colour as
specified in BS 6346 throughout the whole of the insulation.

48.3.3 PVC Insulated Steel Wire Armoured Cables

(a) Cables of this type shall be 600/1000V grade complying with BS 6346, copper
core, PVC insulated, extruded PVC bedded, steel wire armoured and PVC
sheathed (PVC/SWA/PVC).

(b) Conductors shall be plain annealed copper conductors complying with BS

6360, and each conductor core shall be of the same cross-sectional area.

(c) Each core of the cable shall be identified by the appropriate colour as
specified in BS 6346 throughout the whole of the insulation.

(d) Wire armour shall consist of a single layer of galvanized steel wires of the size
in the appropriate table in BS 6346 and comply with BS EN 10257-1.

(e) Single-core cables shall have aluminum armour when used for AC supplies.

(f) The oversheath of the cables shall be an extruded layer of black PVC
complying with the requirements of BS EN 50265-1 or BS EN 50265-2-1 for
flame retardance.

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Section 48 – Wiring & Cables
48.3.4 Cross-linked Polyethylene Insulated Steel Wire Armoured Cables

(a) Cables of this type shall be 600/1000V grade complying with BS 5467, copper
core, cross-linked polyethylene insulated, extruded PVC bedded, steel wire
armoured and PVC sheathed (XLPE/SWA/PVC).

(b) Conductors shall be plain annealed copper conductors complying with BS

6360. For multi-core cables, each conductor core shall be of the same cross-
sectional area.

(c) The insulation of cores shall be cross-linked polyethylene complying with BS

6469.

(d) Each core of the cable shall be identified by the appropriate colour as
specified in BS 6346 throughout the whole of the insulation.

(e) Wire armour shall consist of a single layer of galvanized steel wires of the size
in the appropriate table in BS 6346 and comply with BS EN 10257-1.

(f) Single-core cables shall have aluminum armour when used for AC supplies.

(g) The oversheath of the cables shall be an extruded layer of black PVC
complying with the requirements of BS EN 50265-1 or BS EN 50265-2-1 for
flame retardance.

48.3.5 Prefabricated Branch Cables

(a) Cables of this type shall be 600/1000V grade, copper core, crosslinked
polyethylene insulated and PVC sheathed (XLPE/PVC).

(b) The length of the tee-off cable shall be at least 1.5m per phase for connection
to the electrical equipment. The tee-off cable shall be connected to the main
cable with a purpose design connector by compression and the connected
part shall be covered with PVC injection molding completely. All cable ends,
including the tee-off cables, shall be factory sealed before delivery to Site.

(c) Conductors shall be plain annealed copper conductors complying with BS

6360 or IEC 228.

(d) The core of the cable shall be identified by the appropriate colour as specified
in BS 6346 throughout the whole of the insulation.

(e) The oversheath of the cables shall be extruded layer of black PVC complying
with the requirements of BS EN 50265-1 or BS EN 50265-2-1 for flame
retardance.

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Section 48 – Wiring & Cables
48.3.6 Mineral Insulated Cables

(a) Cables of this type shall be 750V heavy duty grade complying with BS 6207 or
IEC 702, copper core, magnesium oxide insulated, seamless copper sheathed
and PVC oversheathed.

(b) Conductors shall be plain annealed copper conductors complying with BS

6360 or IEC 228 and each conductor core shall be of the same cross-sectional
area.

(c) The oversheath of the cables shall be an extruded layer of PVC complying
with the requirements of BS 4066 : Part 3 or IEC 60332-3 for flame retardance.

48.3.7 Fire Resistant Cables

(a) Unless otherwise specified, cables of this type shall be 600/1000V grade,
copper core, steel wire armoured cables insulated with fire resistant materials
designed to maintain circuit integrity under fire conditions. These cables shall
be category CWZ (i.e. resistance to flame temperature of 950°C for 1 hour
minimum and water spray as defined in BS 6387).

(b) Conductors shall be plain annealed copper conductors complying with BS

6360, and each conductor core shall be of the same cross-sectional area.

(c) Each core of the cable shall be identified by the appropriate colour as
specified in BS 6346 throughout the whole of the insulation.

(d) Wire armour shall consist of a single layer of galvanized steel wires of the size
in the appropriate table in BS 6346 and comply with BS EN 10257-1.

(e) Single-core cables shall have aluminum armour when used for AC supplies.

(f) The oversheath of the cables shall be an extruded layer of black PVC
complying with the requirements of BS 4066 : Part 3 or IEC 60332-3 for flame
retardance.

48.3.8 Flexible Cords

Flexible cords shall be 300/500V grade, PVC insulated and sheathed flexible copper
cable with conductor operating temperature not exceeding 70°C to BS 6500. With
reference to Section 48.5.1 (i), these shall not be used under normal circumstances
except for particular situations such as a final connection to equipment from a spur
unit. They shall not be used for normal cable installations in conduit and trunking.

48.3.9 Low emission of smoke and corrosive gases thermosetting sheathed cable

(a) For armoured cables, it shall be 600/100V grade, low smoke; low emission of
smoke and corrosive gases cross-linked thermosetting (XLPE) insulated and
sheathed copper cable with armour, single or multi-core with conductor
operating temperature not exceeding 90°C complying with BS 6724.

(b) For PVC cables without armour, it shall be 450V/750V grade, low emission of
smoke and corrosive gases thermosetting insulated, sheathed or non-
sheathed, single or multi-core copper cable with solid or stranded conductor
with conductor operating temperature not exceeding 90°C complying to BS
7211.
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Section 48 – Wiring & Cables
 (c) Conductors shall be plain annealed copper conductors complying with BS
6360, and each conductor core shall be of the same cross-sectional area.

(d) Each core of the cable shall be identified by the appropriate colour as
specified in BS 6346 throughout the whole of the insulation.

(e) Wire armour shall consist of a single layer of galvanized steel wires of the size
in the appropriate table in BS 6346 and comply with BS EN 10257-1.

(f) Single-core cables shall have aluminum armour when used for AC supplies.

48.3.10 Busducts

(a) All the busducts shall be of low impedance all insulated type with copper
conductors housed in a totally enclosed non-ventilated galvanised steel housing,
protected against mechanical damages and dust accumulation.

(b) All fittings such as elbows, flanges and connection accessories shall be from
the same proprietary manufacturer compatible with each other and having the
required current ratings. Hangers and brackets shall be supplied together with
busducts. Flange end units shall be provided as required.

(c) All the busducts shall be all insulated, totally-enclosed, non-ventilated and
shall be of weatherproof type, in compliance with the degree of protection of
not less than IP54 to BS EN60529. All the busducts shall be triple pole and
neutral with integral earth busbar unless otherwise specified and the busbars
shall be tinned hard drawn high conductivity copper.

(d) The busducts shall be fitted with earthing studs suitable for connection to an
external earth bar/tape. The Contractor shall provide and install earthing
system for each busduct by independent copper tape.

(e) A composite busduct support system shall be provided for multi-runs of

busducts. The support system shall be supplied by the same manufacturer of
the busduct and it shall be suitably designed to provide supports and fixing for
other electrical services which are installed along the same routing of the
busducts. It is a requirement that the design of the busduct support should
take into consideration the maintenance requirements of the busduct
installation as well as other electrical services such as cable tray, cable
trunking, etc.

(f) The Contractor shall use the tools as recommended by the manufacturer for
busduct erection. All the contacts shall be securely fixed, electrically and
mechanically sound of the best quality. All the contacts shall be checked and
tested to be securely fixed by the Contractor, and results shall be submitted to
the Project Manager for his acceptance before energising the installation.

(g) The Contractor shall note that the long-term reliability of a busduct system
relies a great deal on the method and conditions under which the busducts
are erected, and the conditions under which the busducts are stored before
erection.

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Section 48 – Wiring & Cables
48.4 SUBMISSIONS

48.4.1 Particulars of wiring and cable system

(a) The following particulars of the wiring and cable system shall be submitted to
the Project Manager for review without objection :

(i) detailed schedule of materials, schedule of equipment and

components, manufacturer's data and relevant certificates; and

(ii) drawings showing the cable schedules, numbers of cables and the
electrical schematic wiring diagram

48.4.2 Samples

(a) The following samples of the wiring and cable system shall be submitted to the
Project Manager together with the particulars referred to in Section 48.4.1
above:

(i) power cables, including flexible cords with the appropriate certification or
standard number (BS or IEC) marked on the cable.

48.5 WORKMANSHIP

48.5.1 General

(a) Cables shall be delivered on robust cable drums with cable ends treated to
form an effective seal. When a cable is cut from a drum, all cable ends shall
be sealed immediately in an effective manner to prevent the ingress of
moisture.

(b) Cables shall be laid by means of normal hand running off the cable drum. The
cable drum shall be mounted on a spindle and allowed to turn freely as the
cable is pulled. Roller guides shall be used throughout and draw cables
through by hands. Cable winches shall not be used for cable laying.

(c) Single core cables where three phase power shall be run , arrange and tie the
cables in a single layer and separate from cables of other circuits by at least
two times the cable diameter of the largest cable in the adjacent group of
cables. Not more than one circuit of single core cables shall be grouped
together.

(d) The spacing between groups of single core cables or multi-core cables shall
be at least two times the diameter of the largest cable in the adjacent group of
cables.

(e) Where cables pass through any fire rated element, appropriate pipe sleeves
shall be provided and the opening shall be sealed with approved fire-resistant
material to maintain the same fire rating as the element penetrated. Section 41
of this GMWS shall be referred.

(f) Where cables pass through holes in metalwork, precautions shall be taken to
prevent abrasion of the cables on any sharp edges.

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Section 48 – Wiring & Cables
 (g) Where cables pass through expansion joints, a cable loop shall be formed in
adequate size to allow any movement in the joint without imposing any stress
to the cables.

(h) Cable joints in a run of cable is not allowed unless reviewed without objection
by the Project Manager.

(i) Flexible cables or flexible cords shall be used for connection to apparatus,
appliances or equipment via an appropriate wiring accessory. Flexible cables
or flexible cords shall not be used in fixed installation, except for final
connection to appropriate fixed equipment. They shall be in short length and
exposed.

(j) The Contractor shall be responsible for the supply and installation of cable
changing boxes to facilitate the cable termination at all switches, circuit
breakers, and isolators etc.

(k) The Contractor shall supply and install the cables according to the New Cable
Colour Code for Fixed Electrical Installations published by the EMSD.

(l) Unless otherwise specified, all final circuit distribution wiring shall be single
core LSOH insulated copper cable and run in steel trunkings or conduits. All
final circuit distribution wiring for essential circuits shall be single core
FR/LSOH insulated copper cable and run in steel trunkings or conduits.

(m) All cables for essential circuits shall be run in separate trunking or conduits for
segregation.

48.5.2 Cable Installation in Conduits

(a) The number of cables drawn into a conduit shall be in the way that no damage
will be caused to the cables or to the conduits during installation.

(b) Cables shall be drawn into the conduits by using approved draw-in tape or
steel wire of appropriate size. Under no circumstances shall the use of
lubricants such as grease, graphite, talc powder etc. be permitted to assist in
drawing the cables.

(c) Cables of different categories or of different voltage levels used shall be wired
in different conduits.

(d) Each cable in a run shall be of one continuous length and wired on the
“looping-in” system without any joints in cable run.

(e) For conduits serving final circuits direct from a distribution board or from an
adaptable box used as a final distribution point, all live cables of one final
circuit shall be installed in one conduit, except lighting final circuit. For conduits
serving lighting final circuits, two circuits with 1.5mm2 cables will be permitted
in a 20mm diameter conduit.

(f) The neutral cable of a lighting final circuit using single core cables may be
routed in the conduit direct to the lighting point without passing through the
switch box.

(g) Final circuits of three phase shall be run in separate conduits.

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Section 48 – Wiring & Cables
 (h) Cables shall be fed into the conduit in such a manner as to prevent any cables
crossing, and also to avoid them being pulled against the sides of the opening
of the draw-in box.

(i) The sum of all cable factors in a conduit shall not be greater than the conduit
factor as stipulated in Code 14 of Code Of Practice For The Electricity (Wiring)
Regulations issued by EMSD.

For sizes and types of cables and sizes of conduit other than those given in
Code 14 of Code Of Practice For The Electricity (Wiring) Regulations issued
by EMSD, the number of cables installed shall be such that the resulting
space factor does not exceed 40%. The space factor is expressed as the ratio
(expressed as percentage) of the sum of the overall cross-sectional areas of
cables to the internal cross-sectional area of the trunking in which the cables
are installed. The effective overall cross-sectional area of a non-circular cable
is taken as that of a circle of diameter equal to the major axis of the cable.

(j) LSOH and FR/LSOH copper cables shall be properly wired in conduits /
trunkings and accessories. In no circumstance shall the luminaire be used as
a cable route for cables connecting to other lighting or small power points.

48.5.3 Cable Installation in Trunkings

(a) Cables for each final, sub-main or control circuit in trunking system shall be
individually bunched and tied or clipped together. Precautions shall be taken
in the case where high temperature cables may be touched or where they may
touch other materials.

(b) Where more than one circuit of single-core cables or more than one multi-core
cables are enclosed in a common trunking, suitable correction factor for
grouping, as recommended by Code Of Practice For The Electricity (Wiring)
Regulations issued by EMSD and BS 7671, shall be applied in determining the
size of the cables to be installed.

(c) Cables penetrating through trunking shall be protected by conduits except

insulated and sheathed cables, if such cables form part of a surface wiring
system. In such case, the holes in the trunking, through which such cables
penetrate, shall be fitted with suitable rubber grommets or insulated bushes

(d) The number of cables put into a trunking shall be such that no damage is
caused to the cables or the trunking during their installation.

(e) The sum of all cable factors in a trunking shall not be greater than the trunking
factor as stipulated in Code 14 of Code Of Practice For The Electricity (Wiring)
Regulations issued by EMSD.

(f) For sizes and types of cables and sizes of trunking other than those given in
Code 14 of Code Of Practice For The Electricity (Wiring) Regulations issued
by EMSD, the number of cables installed shall be such that the resulting space
factor does not exceed 40%. The space factor is expressed as the ratio
(expressed as percentage) of the sum of the overall cross-sectional areas of
cables to the internal cross-sectional area of the trunking in which the cables
are installed. The effective overall cross-sectional area of a non-circular cable
is taken as that of a circle of diameter equal to the major axis of the cable.

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Section 48 – Wiring & Cables
48.5.4 Cable Installation on Surface

(a) Surface mounted power cables on the surface of wall or ceiling or other
building structure. They shall be cleated in position by approved type cable
cleats or cable saddles. Cable cleats or cable saddles shall be provided
along the entire cable route in accordance with the requirement stated in Code
Of Practice For The Electricity (Wiring) Regulations issued by EMSD.

(b) For vertical cable runs exceeding 100m, tension releasing sections shall be
provided in accordance with the recommendation of the cable manufacturer,
failing which, a tension releasing section shall be provided for every 100m
vertical run.

(c) Generally the power cables on surface shall run at least 150mm clear of all
non-electrical services unless otherwise specified.

48.5.5 Cable Installation on Cable Tray and Cable Ladder

(a) Saddles shall be used for securing multi-core cables to the cable tray or cable
ladder. The saddles shall be made from PVC covered metal strip, and shall
be shaped to the form of the cables to be secured. Cable cleats and tie
warps are also acceptable subject to the approval of the Project Manager.

(b) The saddles shall be fixed to the cable tray or cable ladder by means of
corrosion resistant cheese-headed screws and nuts. The shanks of the
screws shall not protrude beyond the nuts by more than three threads. Where
saddles exceed 150mm in length, intermediate fixings shall be provided such
that the maximum spacing between screws shall not exceed 150mm.

(c) Single-core cables shall be secured to the cable tray or cable ladder by
clamps made of wood or other non-ferrous materials specially designed to suit
the dimension of the cables. The clamp shall be secured to the cable tray or
cable ladder by means of bolts, washers and nuts.

(d) Cable saddles or cable clamps shall be provided along the entire cable route
with their spacings in accordance with the manufacturer’s recommendation.

(e) Where cables turn down to motor control panels or switchboard, drop out
accessories shall be used with cable ladder to support the cables. The
accessories shall comprise of 125mm radius curved plate with a 60mm return
flanged and stop, which shall “hook” on to a rung at the cable exit points.

(f) For cable trays or cable ladders across any expansion joint, the cable trays or
cable ladders shall be truncated at the joint and fixed on each side of the joint.
Tension releasing sections of cable passing through the joint shall be provided
to allow for the movement of joint. A separate bonding conductor shall be
provided to connect the cable trays or cable ladders for electrical continuity.

48.5.6 Cable Installation in Enclosed Trench

(a) When more than one power cable shall be laid in an enclosed cable trench,
the cables shall be installed in accordance with the recommendation in Code
Of Practice For The Electricity (Wiring) Regulations issued by EMSD and BS
7671.

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Section 48 – Wiring & Cables
48.5.7 Cable Installation in Ducts

(a) In general the cables in ducts shall be free laid. Where the ducts are formed
from wood, cables shall be fixed in position by clips, saddles or approved
fixing methods.

(b) Prior to the drawing-in of the cables, the cylindrical ducts shall be cleaned with
a cylindrical brush of appropriate size.

(c) Attachment to facilitate the pulling of cables through a duct shall be made to
the cores, insulation, inner and outer sheathed and not to the armour in order
to avoid twisting. Attachment to the armour shall only be permitted for small
cables reviewed without objection by the Project Manager.

(d) When pulling power cables into small ducts, an emulsion of graphite powder
and soft soap in water may be used for brushing onto the cable surfaces
where they enter the duct to reduce friction during pulling. The use of “French
Chalk” or other methods shall not be precluded provided that such materials or
methods shall not damage the cables and reviewed without objection by the
Project Manager.

(e) When pulling-in lead-sheathed insulated power cables, the following

precautions shall be taken:

(i) maximum stress in sheath - 10,000 kPa (with stocking pulling grip);

(ii) maximum stress in conductors - 70,000 kPa (with pulling eye attached to
conductors); and

(iii) maximum pull force shall be limited to 220,000 Newtons.

(f) Separate ducts shall be provided for cables of different circuit categories.
However, cables of different categories may be allowed to pass through the
same draw-in pit provided that they are properly and appropriately segregated.

48.5.8 Cable Buried Directly in Ground

(a) Armoured cables shall be buried at a depth of not less than 450mm for LV
cables and 900mm for HV cables and shall be protected by means of
approved cable cover tiles. The bottom of the excavated cable trench shall be
covered, to a depth not less than the diameter of the largest cable, with a
bedding layer of sand or fine soil. On top of the cables, an after layer of sand
or fine soil, to a depth of 100mm, shall again be provided. The sand or fine
soil shall not be larger than 13mm sieve.

(b) Particular care shall be taken to make sure there shall be no pebbles or small
stones in the bedding layer or after layer of the fine sand or soil.

(c) The cables shall then be covered, throughout the entire route, by approved
type cable cover tiles which shall be laid on top of the after layer. Cable
marker tapes shall be used to cover the cables tiles with wordings : "DANGER
- HKAA LV ELECTRIC CABLES BELOW" for LV cables and “DANGER –
HKAA HV ELECTRIC CABLES BELOW”.

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Section 48 – Wiring & Cables
 (d) The route of all power cables buried direct in ground shall be clearly indicated
by cable markers laid on the ground. The cable markers shall be made of
durable materials such as stainless steel to the approval by the Project
Manager and engraved with the following wording : "DANGER - HKAA LV
ELECTRIC CABLES BELOW" for LV cables and “DANGER – HKAA HV
ELECTRIC CABLES BELOW”.

(e) Cable markers shall be placed at regular intervals not exceeding 60m apart
and also at positions where the cable route changes direction.

(f) At the position of each underground junction box, a cable marker shall also be
installed. Such markers shall be engraved, in addition to the wordings
mentioned above, the appropriate information on the top, such as "3 way Joint
Box".

48.5.9 Cable Joints

(a) Joints of all power cables shall be made by skilled cable jointers and reviewed
without objection by the Project Manager before work commences.

(b) Joints shall be appropriate to the size and type of cables with which they are
to be used. No reduction in the number of strands of a cable core shall be
allowed at a cable joint.

(c) Ferrules, compression connectors and bare portions of cable core resulting
from a jointing or terminating process shall be insulated with an approved type
of insulating tape or heat shrinkable tubing after completion of process. Such
insulating tape or heat shrinkable tubing shall have equal or better electrical
and mechanical properties as those of the original insulation removed, and
shall be adhered to the cores, securely and permanently. The final thickness
shall be in a smooth contour throughout the whole length.

(d) Every compression joint shall be of a type which has been the subject of a test
certificate as described in BS 4579. When a compression joint is made, the
appropriate tools specified by the manufacturer of the joint connectors shall be
used.

(e) Plastic shells fitted with suitably sized armour bond and filled with approved
type cold pouring encapsulating compound may be used as alternative for
jointing all types of insulated power cables. The complete jointing kit,
including plastic shell, compound, insulating tape, etc. shall be from the same
proprietary manufacturer who is specialized in manufacturing products for this
purpose. The jointing method and procedure as laid down by manufacturer
shall be followed strictly.

(f) A circuit protective conductor having adequate cross sectional area shall be
installed and connected to maintain the effectiveness of the earth continuity
across every cable joint.

(g) For straight-through joint of copper conductors, the two conductors shall be
jointed by means of compression ferrule.

(h) Bonding clamps in joints shall be electrically connected with a bond having a
conductance at least equal to that of an equal length of the complete armour
of the cable, and with adequate thermal capacity to avoid excessive
overheating under short circuit conditions.
General Materials & Workmanship Specification 12/16 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 48 – Wiring & Cables
 (i) Alternatively as reviewed without objection by the Project Manager, the
conductors to be tee-jointed shall be secured by means of proprietary
designed compression type mechanical connectors, enclosed in plastic
protective shell and filled with acrylic resin.

(j) At each joint, a non-ferrous metallic label shall be fixed to the cable giving the
size and identification of the cable.

(k) Other methods for jointing a power cables apart from the above will not be
precluded provided that the method used are proven to be capable of
affording the degree of safety and efficiency not less than that achieved by the
above-mentioned methods. The methods shall satisfy the requirements of BS
7671 and prior agreement of the Project Manager must be obtained.

48.5.10 Cable Terminations

(a) No reduction in the number of strands of a cable core shall be allowed at a

cable termination.

(b) Ferrules, compression connectors and bare portions of cable core resulting
from a terminating process shall be insulated with an approved type of
insulating tape or heat shrinkable tubing after completion of process. Such
insulating tape or heat shrinkable tubing shall have equal or better electrical
and mechanical properties as those of the original insulation removed, and
shall be adhered to the cores, securely and permanently. The final thickness
shall be in a smooth contour throughout the whole length.

(c) PVC-insulated or XLPE-insulated cables with armour shall be terminated in a

gland fitted with an armour clamp and brass earth lug for earthing connection.
Provision shall be arranged to enable a watertight seal to be made between
the gland and inner sheath. The gland body shall be provided with an internal
conical seating to receive the armour clamping cone and a clamping nut which
shall secure the armour clamping cone firmly to the armour wires ensuring that
the armour wires are tightly clamped between the armour cone and conical
armour seating. A shroud of PVC or alternative approved materials shall be
fitted to cover the body of the gland and the exposed armour wires.

Cable conductor terminations shall be by means of heavy duty solderless

cable lugs. The lugs shall be of high conductivity copper electro-tinned and
applied to the conductor by means of a hydraulic crimping tool unless
otherwise specified.

(d) For mineral insulated cables, cable terminations shall generally comply with
BS 6207.

The cable to be terminated shall be cut, screwed, sealed with cold compound
and fitted with brass terminating glands, nuts, compression ring, gland body,
sealing pot, disc and sleeves. The conductors shall be carried unbroken
through the sealing pot to the terminal sockets or clamping screws.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 48 – Wiring & Cables
 Sealing shall be properly carried out to protect the cable ends from moisture
and the insulation shall be thoroughly dry before the sealant is applied. The
sealing material and material used to insulate the conductors when they
emerge from the insulation shall have adequate insulating and moisture-
proofing properties which shall be retained throughout the range of
temperature they may be subjected to in service.

Where a mineral insulated cable is terminated at an insulating casing or rust

proof metal casing, the sealing pot shall be provided with a copper circuit
protective conductor, complying with the requirements of BS 6360, and of an
appropriate size in accordance with BS 6207.

Where more than one cable terminate at a galvanized or zinc coated

enclosure, the gland plate shall be of brass or insulating materials.

PVC shrouded terminating glands shall be used when the cables are fitted
with PVC outer covering.

Only tools recommended by the manufacturer of the cables shall be used and
the manufacturer's recommended methods of cable termination shall be
adopted in all cases.

(e) Cable Identification

(i) cable identification markers shall be provided at each end of the cable,
at entry and exit points of buried ducts, and in such other positions as
are necessary to identify and trace the route of any cable. Where
cables are not enclosed in ducts and are of multiple runs, provide
markers at intervals not exceeding 60m;

(ii) cable identification shall be assembled from elliptical profiled PVC

markers, carrier strip and nylon ties. The complete assembly shall be
suitable for a maximum service temperature of 70°C.

(f) Heat Shrinkable Tubing

(i) if reviewed without objection by the Project Manager, heat shrinkable

tubing and accessories may be used for cable joints or terminations.
All tubing and accessories shall be specially designed for this purpose
and shall be suitable for use with the type and construction of cable to
be jointed or terminated;

(ii) heat shrinkable materials shall have electrical and mechanical

properties equal to or better than those of the cable insulation and
sheath, where applicable. After the application of the heat, the heat
shrinkable materials shall seal the interfaces between the heat
shrinkable materials or between the heat shrinkable materials and the
cable surfaces;

(iii) whenever heat shrinkable tubing and accessories are used, the
complete kit shall be from the same proprietary manufacturer who is
specialized in manufacturing products for this purpose. The method
and procedures adopted shall be strictly as those laid down by the
manufacturer.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 48 – Wiring & Cables
48.5.11 Bending Radius of Cables

The internal bending radius of every power cable shall not be less than the
appropriate value given in the following table:

Types of Cable Overall Diameter Minimum internal

(To BS 5467, BS 6346, BS 6387, (D) bending radius
BS 6724 or BS 7889)
Circular copper conductor, non- 10mm to 25mm 4D
armoured
above 25mm 6D
Circular copper conductor, Any 6D
armoured
Shaped copper conductor, Any 8D
armoured or non-armoured

The above table also apply to control cables whenever appropriate.

48.5.12 Busducts

(a) At every location where the busduct passes through floor or wall, the
Contractor shall supply and install a feeder section in such a way that the
busduct can be removed from either side of the floor/wall opening without
affecting the remaining installation.

(b) A composite busduct support system shall be provided for multi-runs of

busducts. The support system shall be supplied by the same manufacturer of
the busduct and it shall be suitably designed to provide supports and fixing for
other electrical services which are installed along the same routing of the
busducts. It is a requirement that the design of the busduct support should
take into consideration the maintenance requirements of the busduct
installation as well as other electrical services such as cable tray, cable
trunking, etc.

(c) The Contractor shall closely liaise with all parties on the timing of delivery and
erection of the busduct system. A busduct system shall only be installed after
the building works related either directly or indirectly to the busduct installation
has been completed and the corresponding building works is ready for
busduct installation in a dry and clean condition complete with all necessary
provisions such as doors, locks, kerbs, and with walls finished. Stored and
erected busducts shall be protected against water ingress, especially that of
cement water and corrosive fluid ingress. All wetted and / or damaged
busducts must be replaced.

(d) The Contractor shall use the tools as recommended by the manufacturer for
busduct erection. All the contacts shall be securely fixed, electrically and
mechanically sound of the best quality. All the contacts shall be checked and
tested to be securely fixed by the Contractor, and results shall be submitted to
the Project Manager for his acceptance before energising the installation.

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Section 48 – Wiring & Cables
 (e) To prevent any problems on the installed busduct system, the Contractor shall
strictly observe the following points. Failure of the Contractor to observe
and/or comply with any of the followings shall render the whole busduct
installation to be rejected and the Contractor shall be liable of all the possible
consequences: -

(i) All the busducts shall be so installed that any one section can be easily
removed for repair or maintenance.

(ii) Busducts shall not run close to or traverse any pipework. The
Contractor shall fully co-ordinate with all parties on the routings of the
busduct system.

(iii) Adequate clearance around any busducts shall be provided for future
maintenance and repair.

(iv) Stored and erected busducts shall be protected against water ingress,
especially that of cement water and corrosive fluid ingress.

(v) The Contractor shall use proper sealing compound for through wall or
floor sealing.

(f) The Contractor shall construct the waterproof concrete curb around the
locations where busducts pass through floor slabs. The waterproof concrete
curb shall be of not less than 200mm high (minimum) or at least 100 mm
higher than that of any other curbs in the same room, whichever is the higher.

(g) Should wetting of the busduct occur during transportation, storage, and
construction and prior to the installation being handed over to the Employer,
the Contractor shall immediately inform the Project Manager the damage to
the busduct. All the wetted and/or damaged busduct must be replaced. The
Contractor shall be liable of all the possible consequences.

(h) Expansion fittings of the busducts shall be supplied and installed across the
building expansion joints.

48.5.13 The Contractor shall comply with the minimum bending radius of the cables that are
to be laid and clearly indicate in the Contractor’s drawings how this will be achieved.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 48 – Wiring & Cables
SECTION 49 CABLE MANAGEMENT SYSTEMS

49.1 GENERAL

(a) The cable management systems shall be read in conjunction with Section 48
of this General Materials and Workmanship Specification for the cable
installed in cable management systems.

(b) In general the cable management systems include cable tray, cable ladder,
trunking, conduit and accessories, and cable duct and draw-in pit.

(c) In general the cable management system shall be run horizontally, vertically
and parallel to building members, unless otherwise specified on the
Employer’s Drawings.

(d) Electrical continuity shall be maintained for all joints of metal cable
management systems by copper connectors of adequate size or other
permitted means.

(e) In general PVC conduits and accessories shall not be used unless otherwise
specified in the Employer’s Drawings and reviewed without objection by the
Project Manager.

49.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as at the date of the Letter of Acceptance.

BS 731 : Part 1 Flexible steel conduit for cable protection and flexible steel
tubing to enclosure flexible drives
Part 1 Flexible steel conduit and adapters for the protection
of electric cable.
BS 1449-1.1 Steel plate, sheet and strip. Carbon and carbon-manganese
plate, sheet and strip. General specification
BS 3505 Specification for unplasticized polyvinyl chloride (PVC-U)
pressure pipes
BS 3382 : Part 2 Specification for electroplated coatings on threaded
components. Cadmium on steel components. Zinc on steel
components
BS 4568 Specification for steel conduit and fittings with metric threads
of ISO form for electrical insulations
Part 1 Steel conduit, bends and couplers
BS 4607 : Part 1 Non-metallic conduits and fittings for electrical installations.
Specification for fittings and components of insulating
material
BS 4662 Specification for boxes for the enclosure of electrical
accessories

General Materials & Workmanship Specification 1/16 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 49 – Cable Management Systems
 BS 4678 : Part 1 Cable trunking. Steel surface trunking
BS 4678 : Part 2 Cable trunking. Steel underfloor (duct) trunking
BS 7671 Requirements for electrical installations. IEE Wiring
Regulations. Sixteenth edition

BS EN 50086-2-1 Specification for conduit systems for cable management.

Particular requirements. Rigid conduit systems
BS EN 50086-1 Specification for conduit systems for electrical installations.
General requirement
BS EN ISO 1461 Hot dip galvanized coatings on fabricated iron and steel
articles. Specifications and test methods
ISO 683/13 Heat-treatable steels, alloy steels and free-cutting steels;
Part 13 : Wrought stainless steels

49.3 MATERIALS

49.3.1 Cable Tray System

(a) Metal cable trays shall be perforated, formed from plain steel sheet complying
with BS 1449 : Part 1, and shall be hot-dip galvanized to BS EN ISO 1460 and
BS EN ISO 1461 after perforation.

(b) Cable trays shall be corrosion-resistant not less than Class 2 to BS 4678 : Part
1.

(c) Perforation shall be the admiralty pattern.

(d) Cable trays shall have the following typical dimensions:

Nominal Minimum Height Thickness of Minimum Height

Width of Upstand Steel Sheet of Returned
(mm) Flange
(mm) (mm)
(mm)
100 12 1.2 -
150 12 1.2 -
225 12 1.5 -
300 20 1.5 12
450 20 2.0 12
600 20 2.0 12
800 20 2.0 12
1,000 20 2.0 12
1,200 20 2.0 12

(e) Bend pieces shall be standard fittings of the same material, thickness and
finish as the main body of the cable tray and shall have an inner radius of
50mm and a straight length of 100mm at each end.

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Section 49 – Cable Management Systems
 (f) No perforation shall be made in the circular portion of all bend pieces having a
nominal width of 150 mm or 100 mm. Perforation may be allowed in bend
pieces having a nominal width of 225 mm or above provided that the
perforation is made along a line passing through the centre of curvature of the
bend pieces and set at an angle as stated below　to the normal of the axis of
the cable tray.

For cable tray with nominal width of 225 mm and 300 mm, the angle　 shall
be 45°.

For cable tray with nominal width of 450 mm or above, the angle　 shall be
30° and 60°.

(g) Tee pieces shall be standard fittings of the same material, thickness and finish
as the main body of the cable tray. The distance measured between the point
of inter-section and the end of the tee piece shall not be less than 100 mm.

(h) Manufacturer's standard items of accessories shall be used. Site fabrication of

accessories will only be allowed upon approval of the Project Manager and
shall be kept to a minimum. Where special sections are required, the material,
thickness and finish shall be as specified for the standard items.

(i) All the steel cable tray used shall be heavy duty return flange type and hot
dipped galvanised.

(j) All support system, screws and nuts for cable trays at external area shall be
made of stainless steel.

49.3.2 Cable Ladder System

(a) Cable ladder and cable ladder fittings and accessories shall be manufactured
from 2mm thick mild steel with horizontal slotted struts and shall be hot-dip
galvanized to BS EN ISO 1460 and, BS EN ISO 1461 after perforation.

(b) For heavily corrosive environments where specified in the Employer’s

Drawings, cable ladder fittings and accessories shall be manufactured from
stainless steel 316S31 to ISO 683/13.

(c) Unless otherwise specified or reviewed without objection by the Project

Manager, the rungs shall be 51 mm wide with return rails of 28 mm and shall
be supported at 300 mm centres by 127mm channel side rails with 32 mm
return flanges. Slots of 63 x 12 mm shall be provided along the length of rungs.

(d) Unless otherwise specified or reviewed without objection by the Project

Manager, the rungs shall be set at 88 mm from the top of the side rails and the
coupling of ladders shall be by means of flanged fishplates, splined bolts, nuts
and locking washers. The ladders shall not be jointed together at structural
expansion joints.

(e) The rungs shall be suitable for various cable fixing methods including nylon
tiles, saddles and perforated strips, cable clamps and cleats.

(f) The complete cable ladder system shall be designed so that drilling shall not
be necessary on Site and cutting shall be kept to a minimum.

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Section 49 – Cable Management Systems
 (g) All fittings and accessories applied to the same cable ladder system shall be
supplied by the same manufacturer to the same finish. Factory standard right-
angle bends, tee junctions, off-set reducers, straight reducers shall be used for
horizontal bends, vertical bends, branching out and reduction of cable ladder
width. Factory standard expansion splice plate shall also be provided to allow
for expansion and contraction of the cable ladders.

(h) All the cable ladder used shall be heavy duty return flange type and hot
dipped galvanised.

49.3.3 Trunking and Accessories

(a) Steel surface trunking and fittings shall be compatible to the requirements laid
down in BS 4678 : Part 1 and shall be fabricated with sheet steel having a
nominal thickness as indicated below:

Nominal Nominal Nominal Thickness of Nominal

Size Thickness of Body Material without Thickness of
(mm) Body Material returned flange Cover
with returned (mm) Material (mm)
flange (mm)
50 × 50 1.0 1.0 1.0
75 × 50 1.2 1.2 1.2
75 × 75 1.2 1.2 1.2
100 × 75 1.2 1.2 1.2
100 × 100 1.2 1.4 1.2
150 × 100 1.2 1.4 1.2
150 × 150 1.4 1.6 1.2

Preferred lengths : 3 m (Minimum : 2 m, Maximum : 3 m)

Nominal thickness of partitions or dividers : 1.0 mm

The tolerance of the trunking dimensions shall be as follows:

Dimension (mm) 37.5 50 75 100 150 200

Tolerance (mm) +5 +5 +5 +6 +7 +8

For size not listed above, the sizes and the corresponding body material
thickness shall be reviewed without objection by the Project Manager.

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Section 49 – Cable Management Systems
 (b) Steel underfloor trunking shall be compatible to the requirements laid down in
BS 4678 : Part 2 and shall be fabricated with sheet steel having a nominal
thickness as indicated below:

External dimension Number of Nominal thickness of Nominal

excluding flange Compartment body with compartment thickness
projections s width (mm) of
Width (mm) x Depth Up to Over 100mm partitions
(mm) includin up to and and
g including connector
100mm 150mm materials

75 ± 4 x 25 ± 1.2 1 1.2 - 1.0

75 ± 4 x 37.5 ± 2 1 1.2 - 1.0
100 ± 5 x 25 ± 1.2 1 or 2 1.2 - 1.0
100 ± 5 x 37.5 ± 2 1 or 2 1.2 - 1.0
150 ± 7.5x 25 ± 1.2 2 or 3 1.2 1.6 1.0
150 ± 7.5 x 37.5 ± 2 2 or 3 1.2 1.6 1.0
150 ± 7.5 x 25 ± 1.2 1 - 1.6 1.0
150 ± 7.5 x 37.5 ± 2 1 - 1.6 1.0
225 ± 11.2 x 25 ± 1.2 2 1.2 1.6 1.0
225 ± 11.2 x 37.5 ± 2 2 1.2 1.6 1.0
225 ± 11.2 x 25 ± 1.2 3 1.2 1.6 1.0
225 ± 11.2 x 37.5 ± 2 3 1.2 1.6 1.0
Preferred lengths : 3m (Minimum : 2m, Maximum : 3m)

Notes:

(i) The thickness of the base may be reduced to 1.0mm minimum if

reviewed without objection by the Project Manager.
(ii) Where a body has more than one compartment and is not made up
from smaller size, the nominal thickness is that specified for the largest
compartment.
(iii) Trunking to special order having dimensions differing from the above
table may be used provided that they met all the other requirements as
stated in this General Materials and Workmanship Specification.

(c) Steel surface trunking and steel underfloor trunking and associated fittings
shall have Class 3 protection against corrosion in accordance with BS 4678:
Part 1.

(d) Manufacturer’s standard fittings such as tee or angle pieces, connectors, etc.
shall be used throughout unless reviewed without objection by the Project
Manager.

(e) Steel surface trunking shall be of square or rectangular cross section. One
side of the trunking shall be removable or hinged. No projection from screw or
other sharp object will be allowed inside the trunking.

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Section 49 – Cable Management Systems
 (f) Steel underfloor (duct) trunking shall be so designed and constructed as to
permit the laying of the trunking on a structural floor without ingress of water or
cement whilst the floor is screeded.

(g) Trunking and fittings shall have removable or hinged covers extending over
the entire length. The covers shall be of the same material and finish as those
of the trunking body.

(h) Screws used for securing a cover or connector and for fixing a trunking shall
have ISO metric threads. They shall be of brass or steel. Steel screws shall be
protected against corrosion by a finish at least equal to the zinc coating
specified in BS 3382: Part 2. Electro-brass plated screws or self tapping
screws shall not be used. Projection of screws inside a trunking or a trunking
fitting will not be allowed.

(i) Whenever floor boxes are used in underfloor trunking system, the lids of the
floor box, including those under floor tiles or under carpet, must be capable of
withstanding the weight of normal passage of pedestrian traffic and trolleys
without buckling.

(j) All support system, screws and nuts for cable trunkings at external area shall
be made of stainless steel.

(k) All the three compartments steel skirting trunkings (for power, data and
communication cables) shall be completed with busbars, base units, covers,
bends, tees, end caps, socket outlets, data outlets, telephone socket outlets,
and the associated accessories.

49.3.4 Conduit and Conduit Accessories

(a) Steel conduits, except flexible conduits, shall be of heavy gauge, screwed,
and longitudinally welded. All steel conduits shall be hot-dip galvanized and
shall comply with BS 4568 : Part 1 with Class 4 protection against corrosion.

(b) Steel flexible conduits and solid type brass adaptors shall comply with BS 731 :
Part 1. The flexible conduits shall be of the metallic water tight pattern and
PVC oversheathed. PVC oversheath shall not be required for installations
within ventilated ceiling void.

(c) The flexible conduit adaptor shall comprise two parts, an inner core and an
outer ferrule. The inner core shall be screwed into the bore of the conduit
together with an outer ferrule which caps off the end of the conduit to provide
an extremely strong joint by the adaptor. The outer ferrule shall be locked
against the core to isolate any sharp cut edges in the conduit.

(d) All steel conduit fittings and components shall comply with BS 4568 : Part 2
with Class 4 protection against corrosion.

(e) Adaptable boxes complete with covers shall be of cast iron or galvanized steel.
Boxes of the preferred sizes as given in BS 4662 shall be used. Bushes and
tube ends shall be of brass.

(f) Circular boxes, dome covers and hook covers shall be of galvanized malleable
cast iron. Ceiling mounted boxes shall be of deep pattern type having an
internal depth of not less than 60 mm.

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Section 49 – Cable Management Systems
 (g) Distance (spacing) saddles shall be of galvanized cast iron.

(h) Solid or inspection tee-pieces, couplers or elbows shall not be used on any
conduit installation.

(i) Metal boxes complete with covers for enclosure of electrical accessories in
conduit installation shall comply with BS 4662 and shall have heavy protection
both inside and outside in accordance with BS 4662. Boxes used to house
accessories such as domestic switches, socket outlets, spur units, etc. shall
be 35 mm and 47 mm deep. The depth chosen shall be suitable for the
accessories to be housed.

(j) Screws used for fixing boxes and spacing saddle, and for tightening covers
and spacing saddles shall have ISO metric threads. They shall be of brass or
steel and if of steel they shall be protected against corrosion by a finish at
least equal to the zinc coating specified in BS 3382: Part 2. Electro-brass
plated screws or self tapping screws shall not be used.

(k) The minimum internal diameter of steel conduit shall be ∅20 mm.

(l) All flexible conduits shall be steel flexible conduit with Low Smoke Zero
Halogen (LSOH) sheath except the flexible conduits to be used in the MOE
corridors and ventilated ceiling/elevated floors as a means for conveying air,
bare steel conduit should be used to comply with FSD regulations.

49.3.5 Cable Duct and Draw-in Pit

(a) Cable ducts shall be formed from concrete, PVC, metal, or such other
materials as shown on the Employer’s Drawings or specified in the Contract.

(b) Ducts cast in-situ in concrete shall be so formed that the radial thickness of
the concrete or screed surrounding the cross-section of the complete ducting
shall not be less than 15 mm at every point.

(c) Metallic ducting shall comply with the same requirement as metal trunking.

(d) PVC ducting shall comply with BS 3505 Class E unless otherwise specified.

(e) Draw-in pit for armoured cables shall be concrete or brick lined and shall be
fitted with a waterproof heavy cast iron lid with materials and pattern matching
the surrounding surface. Draw-in pits shall not be filled with sand or other
materials.

49.3.6 Underfloor Trunking System

(a) All underfloor trunkings shall be three compartments (for power, data and
communication cables). For size refer to the Employer’s Drawings.

(b) The floor trunking system shall be made of galvanized sheet of BS 4678
Class 3.

(c) Floor boxes shall be heavy duty type of rectangular shape incorporating a
recess to accommodate a carpet tile and complete with a hinged lid. The lid
shall be such that cables can protrude from the floor box without risk of
damage when the lid is closed.

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Section 49 – Cable Management Systems
 (d) The box base frame, trap and frame, and outlet panel are made of hot
dipped galvanized steel sheets which conform to BS 2898. The trap, frame
and outlet panel are powder coated to provide a good finish and protection
to visible parts. The side plates of the box base are designed to be used for
trunking and conduit entries, recessed 6mm and 9mm to enable it to accept
carpet or vinyl tile floor finishes.

49.4 SUBMISSIONS

49.4.1 Particulars of Cable Management System

(a) The following particulars of the cable management system shall be submitted
to the Project Manager for review without objection :

(i) detailed schedule of materials, schedule of equipment and

components and manufacturer's data; and

(ii) certificates showing the compilation with the relevant standards.

49.4.2 Samples

(a) The following samples of the cable management system be submitted to the
Project Manager together with the particulars referred to in 49.4.1 above:

(i) cable tray, cable ladder, cable trunking, conduits and accessories; and

(ii) supporting brackets and accessories.

49.5 WORKMANSHIP

49.5.1 Cable Tray Installation

(a) Connections between adjacent lengths of tray, tee or bend pieces, shall be
made by butt joints and fixed by mushroom-head steel roofing bolts and nuts
complying with BS 1449-1.1. The connection shall be mechanically strong so
that no relative movement between the two lengths can occur.

(b) Cable trays shall be cut along a line of plain metal only, i.e. they shall not be
cut through the perforation. All cut edges of the galvanized cable tray shall be
prepared and treated with a cold galvanized paint.

(c) Holes cut in a cable tray for the passage of cable shall be provided with
grommets. Alternatively, they shall be bushed or lined.

(d) Cable trays shall be fixed securely to the walls, ceiling or other structure by
means of hot-dip galvanized mild steel hangers or brackets of adequate
mechanical strength. Hanger rods shall not be less than ∅6mm.

(e) Fixings of cable trays shall be disposed at regular intervals not exceeding
1.2m for straight run and at a distance not exceeding 225mm on both sides
from a bend or intersection. A minimum clear space of 20mm shall be left
behind all cable trays.

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 (f) Cable tray shall not be bent for change in direction of run. Manufacturer's
standard fittings such as tees, 90 degree bends, reducers, etc. shall be used
throughout.

(g) Bends and tee pieces etc. in cable tray installation shall be such that the
bending radius of the largest cables to be clipped to the tray shall not exceed
the bending radius limit as specified in accordance with BS 7671.

(h) Wherever cable tray is installed, a minimum of 450mm clearance shall be

provided for future maintenance access.

49.5.2 Cable Ladder Installation

(a) Cable ladder shall be fixed securely to the walls, ceiling or other structure by
means of hot-dip galvanized mild steel hangers or brackets of adequate
mechanical strength. Hanger rods shall not be less than ∅8 mm.

(b) Fixings of cable ladder shall be disposed at regular intervals not exceeding
1.5m for straight run and at a distance not exceeding 225 mm on both sides
from a bend or intersection.

(c) Cable ladder shall not be bent for change in direction of run. Manufacturer's
standard fittings such as tees, 90 degree bends, reducers, etc. shall be used
throughout.

(d) Bends and tee pieces etc. used in cable tray installation shall be such that the
bending radius of the largest cables to be fixed to the ladder shall not exceed
the bending radius limit as specified in accordance with BS 7671.

(e) Dropout plate of width same as the cable ladder shall be provided to support
the cables locally as they exit a ladder down between the rungs.

(f) The cable ladders shall be jointed by flexible (expansion) couplers across the
expansion joints of the building structure. The selection and installation details
of such flexible couplers shall be in accordance with the recommendation by
the manufacturer and reviewed without objection by the Project Manager.
Rigid fitting across the expansion joints shall not be allowed.

(g) Proprietary ladder covers (ventilated or closed as specified) shall be fixed onto
the cable ladder following the installation details recommended by the
manufacturer whenever specified on the Employer’s Drawings.

(h) The end of a run of cable ladder shall be fixed to the wall or slab with
proprietary end connectors. If it is far from the wall or slab, a proprietary “stop
end” connector shall be fixed to the end of a cable ladder run to give a neater
appearance.

49.5.3 Trunking Installation

(a) Connection between adjacent lengths of surface trunking, tee or angle pieces,
accessories, etc. shall be made by means of butt joints. The two adjacent
ends of trunking shall be fixed so that no relative movement can occur
between them. Electrical continuity shall be achieved by means of connecting
a copper continuity connector of adequate size across the two adjacent ends
of the surface trunking.

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Section 49 – Cable Management Systems
 (b) Connectors for underfloor trunking shall also provide adequate mechanical
strength. One connector shall be provided per length of trunking. Electrical
continuity shall be achieved by means of continuity bonding links which shall
be of such materials so as to prevent electrolytic corrosion.

(c) Removable covers shall be held in position on the trunking either by the
natural elasticity of the material of the cover (e.g. spring capped trunking) or
by means forming an integral part of the cover (e.g. retaining screws) which
hold the covers tightly onto the trunking body and cause no damage to the
cables inside.
Bends, tee junctions, etc. shall also be fitted with removable or hinged covers
of the same construction as that of the trunking.

(d) Trunkings shall be installed neatly on the surface of the walls, columns, beams
or flushed with floor screeding and shall be installed along a vertical or a
horizontal plane.

(e) Surface trunking, which is installed in such a position that the cables might fall
out when the cover is removed, shall be fitted with cable retaining bars or
other suitable devices to prevent the cables from falling out.

(f) Surface trunking installed vertically with length exceeding 5 m shall contain
sufficient supporting devices such as pin racks within the trunking to prevent
strain on the cables due to the weight of the cables, and to prevent vertical
movement of the cables. These pin racks shall consist of steel pins sheathed
with insulating material mounted on backing-plates. Internal suitable fire
barriers shall be provided between floors or at intervals of 5 m apart,
whichever is the less.

(g) Where a common trunking is used to accommodate cables for different circuit
categories, they shall be effectively segregated by means of partitions or
dividers except in the case where trunking is manufactured using two smaller
pieces of trunking attached together with a common cover. The partitions or
dividers shall be of the same material as the body of trunking and shall be
adequately secured to the body of the trunking.

For underfloor trunking, the partitions or dividers shall also be of full depth to
provide support and strength to the top surface of the assembly.

Partitions shall remain continuous at joints, sets, saddle sets, cross overs, tee
off points and/or any change of direction of the trunking.

(h) Connection between trunking and equipment shall be by a screwed coupler

and brass male bushes, or a standard flange coupling or an adaptor neck,
fabricated or cast. For direct attachment of trunking to equipment, cable
entries shall be provided with smooth bore bushes or grommets and the return
edge of the lid of the trunking shall be left intact.

(i) Where connection is made between trunking and a distribution board, the
connectors for cable entry shall be sized to accept all cables from all available
circuits including circuits marked as “spare” or “space”.

(j) Trunking mounted overhead shall be suitably supported by means of hot-dip

galvanized mild steel hangers, brackets or other means reviewed without
objection by the Project Manager so that no visible sag is observed when
loaded with cables.
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Section 49 – Cable Management Systems
 (k) Individual pieces of trunking shall be independently supported by means of at
least two fixed points per piece. On straight runs, supports for trunking shall be
fixed at regular intervals with maximum spacing as given in the following table.
For runs with bends, supports shall be fixed as near to the bend as practicable.

Cross Sectional Area of Maximum Distance between Supports

Trunking, A (mm2) Horizontal Vertical
2
A ≤ 2,500 mm 1.25 m 1.5 m
2,500 mm2 < A ≤ 6,000 mm2 1.75 m 2.0 m
6,000 mm2 < A ≤ 10,000 mm2 2.3 m 2.5 m
2
A > 10,000 mm 3.0 m 3.0 m

Notes:
(i) The spacing tabulated above assume that the trunking is not exposed
to mechanical stress other than that due to the weight of the enclosed
cables, and the trunking and fittings.

(ii) The above figures do not apply to trunking which is used for supporting
luminaires or other equipment.

(l) All frayed and sharp edges shall be removed from trunking before installation
to prevent abrasion of cables. The exposed edges shall be painted with two
coats of anti-rust paint such as cold galvanized paint or reviewed without
objection by the Project Manager while the work proceeds.

(m) Holes in trunking shall be drilled, punched or cut by ring saw.

(n) Ends of trunking runs shall be fitted with removable end caps to permit future
extension.

(o) Where trunking crosses expansion joints, the trunking system shall allow for
expansion while maintaining earth continuity.

(p) Where a trunking passes through a fire resistant structural element, such as
floor and wall, having specified fire resistance, the opening thus formed shall
be internally and externally sealed with suitable fire resisting material
according to the appropriate degree of required fire resistance.

(q) Where a trunking is installed in a damp situation, or where a trunking is likely

to be exposed to weather, the trunking shall be kept away from other
metalwork with which electrolytic action is liable to incur.

(r) Every entry to a trunking shall be so placed as to prevent or to be protected

against ingress of water.

(s) Where the protective coating on a steel trunking has been damaged after
installation, such surface shall be effectively restored by at least two coats of
anti-rust paint or other suitable coating reviewed without objection by the
Project Manager to prevent corrosion.

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Section 49 – Cable Management Systems
49.5.4 Conduits and Conduit Accessories Installation

(a) Conduit system within false ceiling void, electrical and mechanical plant rooms
shall be surface mounted on wall or ceiling slab. They shall be fixed by
distance (spacing) saddles, and shall run in a vertical or horizontal direction.
Conduit boxes, adaptable boxes and metal boxes for accessories shall be
securely fixed to walls, ceilings or other substantial parts of a structure by
means of suitable brass screws correctly spaced. The fixing of these boxes
shall be independent of the fixing of the associated conduits.

(b) In any other areas shall conduits shall be concealed in walls, columns, beams,
floor slabs, screedings, partitions etc., unless otherwise specified and
reviewed without objection by the Project Manager. Chase for conduit to be
concealed shall be vertical or horizontal.

(c) Conduits cast in concrete shall be so formed that the radial thickness of
concrete or screed surrounding the cross-section of the completed conduit is
not less than 15 mm at every point. Parallel conduits cast in concrete shall be
separated by a spacing of not less than 25 mm.

(d) Where conduits are laid direct on the shuttering of the reinforced concrete slab,
deep pattern circular conduit boxes shall be used to raise the run of conduit to
between the top and bottom reinforcement. Attendance shall be provided
whilst the concrete pouring or screeding operation is being carried out in order
to avoid damage being caused to the conduits and also to ensure that the
conduit work is in sound condition, properly and efficiently maintained during
this installation period.

(e) Conduits installed in chases of walls and floors shall be firmly secured by
wrought iron pipe hooks or crumpets and these fixings shall in themselves be
sufficient to hold the conduits in place.

(f) A complete set of conduit routing drawings for each of the door mullions
requiring for Airport Systems showing all power and data concealed conduits,
adaptable boxes and all necessary holes, recesses and openings for interface
with Airport Systems to be submitted for review without objection by the
Project Manager.

(g) Steel conduits laid direct in ground or buried in soil shall be painted with two
coats of bituminous paint and wrapped with self-amalgamating tapes or other
wrapping materials for protection against corrosion reviewed without objection
by the Project Manager.

(h) Joint in steel conduits shall be made by means of a solid coupler into which
the adjacent ends of the two conduits shall be inserted to approximately half
into it and screwed up tightly in order to make the conduit run mechanically
and electrically continuous. No threads on either conduit shall be exposed.

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Section 49 – Cable Management Systems
 (i) Running couplings shall not be used. In case where such a coupling cannot be
avoided, it shall be reviewed without objection by the Project Manager before
it is adopted. In this case, the coupler shall be screwed up tightly onto the
short threaded portion of one conduit, the threaded portion of which shall
project approximately half way into the length of the coupler. The threaded
portion of the mating conduit shall also project approximately half way into the
coupler. Electrical continuity shall be ensured by tightening up a hexagon
locknut against the coupler. Any exposed threads on either conduit shall be
painted with at least two coats of anti-rust paint.

(j) An adequate number of suitably sized adaptable boxes shall be provided in all
conduit runs to enable cables to be drawn in and out easily without damage.
Adaptable boxes shall be provided immediately after every two bends, or after
a bend plus a maximum straight run of 10 m, or after a maximum straight run
of 15 m.

(k) An extension ring shall be fitted to a conduit box where the plaster wall finish
(including plaster) is more than 35 mm from the conduit box. Only extension
rings of the correct depth shall be used. Under no circumstances shall
multiple extension rings be permitted.

(l) Where a steel conduit terminates at a metal casing, a coupler and a brass
male bush shall be used. The brass male bush shall be screwed into the
coupler or adaptor from the inside of the metal casing through a clearance
hole drilled in the metal casing to suit the bush. Both the conduit and the bush
shall be screwed tightly into the coupler or adaptor so as to grip the metal
casing securely for mechanical and electrical continuity. Threads on the steel
conduit shall be at least half the coupler length. Connection between flexible
conduit and the adaptor shall be securely fixed. No threads on the metal
casing shall be allowed.

(m) In the case of flexible steel conduit, a brass adaptor together with a brass
male bush shall be used. The brass adaptor shall comprise two parts, an
inner core and an outer ferrule. The inner core shall screw into the bore of the
conduit together with an outer ferrule which caps off the end of the conduit, so
that the adaptor can provide an extremely strong joint. The core shall lock
against the outer ferrule and isolate any sharp cut edges in the conduit.

(n) Where conduits terminate at boxes, trunkings and accessories not fitted with
spout entries, they shall be terminated by means of smooth bore male brass
bushes, compression washers and sockets to obviate damage to the cables.
All conduit entries to adaptable boxes, outlet boxes and switchgear shall be
made with coupling and hexagon male bush.

(o) The steel conduit installation shall be mechanically and electrically continuous
throughout and effectively earthed. Where a metal casing is painted or
enamelled, the electrical continuity between the conduit and the casing shall
be achieved by means of a separate circuit protective conductor connecting
the conduit and an earth terminal of the casing. Alternatively, a copper
continuity connector may be placed between the bush and the metal casing.

(p) The cross-sectional area of the separate circuit protective conductor or the
copper continuity connector shall have the same current carrying capacity as
the largest live conductor drawn into the conduit in accordance with the BS
7671. Neither the paint nor the enamel shall be damaged or removed in order
to achieve the electrical continuity.
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Section 49 – Cable Management Systems
 (q) Saddles, for the support of surface conduits, shall be provided throughout the
entire route at regular intervals. The spacing between adjacent saddles for
steel conduits shall not be more than the values listed in the table below:

Maximum Distance between Supports (m)

Conduit Size Rigid Steel Conduit Flexible Conduit
(mm) Horizontal Vertical Horizontal Vertical
20 1.75 2.0 0.4 0.6
25 2.0 2.25 0.6 0.8
32 2.0 2.25 0.6 0.8

(r) Each bend of a surface conduit shall be supported by a saddle on either side
of the bend, and the saddles shall be fixed as near to the bend as practicable.

(s) Saddles shall be fixed with brass screws in expanding plugs or other purpose-
designed fixing devices reviewed without objection by the Project Manager.

(t) Flexible conduit shall be used as short as possible and in any case shall not
exceed a conduit run of 2 m.

(u) Where steel conduits are installed outdoors or in damp situations, all conduit
fittings and conduit accessories shall not be placed in contact with other
metals with which they are liable to set up electrolytic action. In addition,
where the conduit installation is subject to weather, the conduit fittings and
conduit accessories shall be provided with weatherproof sealant or other
materials to ensure that the installation is completely weatherproof.

(v) During the building construction, all open ends of the conduit termination,
which are liable to be filled with water, moisture or other foreign matters, shall
be plugged with approved conduit stopping plug. Paper, rag or similar
materials shall not be used for this purpose. Steel conduit boxes in similar
circumstances shall also be similarly plugged to prevent concrete aggregate or
plaster from entering into the boxes during building construction.

(w) The conduits shall be so laid to prevent accumulation of condensed moisture

and the ingress of water in any part of the installation. Approved type of
sealant for the prevention of condensed moisture shall be applied to ceiling
conduit outlets installed in a cooled space subject to the influx of warm air.

(x) Where a conduit passes through fire resistant structural elements, such as
walls and floors designated as fire barriers, the opening made shall be sealed
according to the appropriate degree of fire resistance of the wall and/or floor.
In addition, where a conduit is installed in a channel, duct, ducting, trunking or
shaft which pass through such elements, suitable fire-resistant barriers shall
also be provided to prevent the spread of fire.

(y) Where a conduit crosses an expansion joint, special arrangement (e.g.

telescopic conduit system) shall be employed to allow relative movement to
occur on either side of the expansion joint.

(z) Conduit system shall be completely erected before cable is drawn in and there
shall be adequate means of access for drawing cables in and out. The number
of cables drawn into a conduit shall be such that no damage will be caused to
the cables or to the conduits during their installation.

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Section 49 – Cable Management Systems
 (aa) Conduits shall be swabbed out and free from moisture before wiring work is to
commence. Suitable draw-in tape or steel wire of appropriate size and
absorbent cloth reviewed without objection by the Project Manager shall be
used.

(ab) Where the protective coating on a steel conduit has been damaged after
installation, such surface shall be effectively restored by at least two coats of
anti-rust paint or other suitable coating to prevent corrosion.

(ac) Conduit bends shall be formed on a suitable bending machine, and the
conduits shall not be flattened or with protective coating damaged at the
bends. Conduit shall not be bent with an acute angle. The internal radius of
the bend shall not be less than 2.5 times the outside diameter of the conduit.

(ad) Holes in metal work for the termination of conduits shall be drilled on site with
a twist drill of the correct size or by means of a suitable hole cutting device.

(ae) All frayed and sharp edges shall be removed from conduit before installation.

(af) Particular care shall be taken when setting out conduit runs to outlet points
which are to be fitted to furniture and equipment.

(ag) Where empty conduits are provided for other services, draw wires shall be
provided. Where a break line between contracts occurs along the conduit
system, conduits shall be terminated by means of coupler and brass bush,
and shall be provided with draw wires.

(ah) Conduits, where required to be distinguished from pipelines or other services,

shall use orange (BS colour reference No. 06 E 51 to BS 4800) as the basic
identification colour in compliance with BS 1710 or to be reviewed without
objection by the Project Manager.

49.5.5 Cable Enclosure Installation

(a) In every vertical cable enclosure, which is designed as totally enclosed without
ventilation, internal barriers shall be provided to prevent the air at the top of
the duct from attaining an excessively high temperature. The distance
between adjacent barriers shall be the distance between floors. If the floor-to
floor distance exceeds 5 m, additional barriers shall be installed at an interval
not exceeding 5 m.

(b) Where a cable enclosure passes through fire resistant structural elements,
such as walls and floors designated as fire barriers, the opening made shall be
sealed according to the appropriate degree of fire resistance of the structural
elements. In addition, suitable fire-resistant barriers shall also be provided. An
internal fire barrier may also serve as an internal barrier described in clause
49.5.5(a).

(c) Where a change in direction in a duct occurs, provision shall be made via
chambered bends to enable the cable in the duct to bend in accordance with
the required radii of curvature according to Section 48 of this General
Materials and Workmanship Specification.

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Section 49 – Cable Management Systems
 (d) Where cables in a duct are inaccessible for the greater part of their length,
adequate number of draw-in pits shall be provided at every turning point and
at regular intervals of not greater than 60 m in general, or reviewed without
objection by the Project Manager. Sufficient room shall be available in the
draw-in pits to enable the cables to be maneuvered without damage.

(e) Duct joints shall not be permitted within the thickness of walls or floors.

(f) Welding shall not be permitted on hot-dip galvanized steel pipe.

(g) After the cable has been installed, both the cables and the exposed duct end
shall be sealed to form a gas, water and fire barrier. Open ends of spare ducts
shall be closed with tapered hardwood plugs and then sealed similarly.

(h) UPVC cable ducts shall be jointed in accordance with the manufacturer’s
recommendations.

(i) Steel cable ducts shall be jointed using screwed galvanized sockets and spun
yarn. Internal rags and burrs shall be removed to provide a smooth bore
through joints in the cable duct system.

(j) Where a change in direction in a duct occurs, provision shall be made in such
a manner that the communication cables in the duct will have radii of
curvature of at least 500 mm.

(k) Where cable ducts are to be mounted on surface, the cable ducts shall be
secured by galvanized steel clamps or saddles at spacing not exceeding 3 m.

49.5.6 Underfloor Trunking System

(a) Trunking shall be installed such that adequate clearance is provided for
access to the wiring.

(b) Crossovers, tees, bridges, lids, conduit brackets and mounting brackets shall
be supplied with any additional components required for a completely
segregated installation.

(c) Site cutting / fabrication of the containment system to form crossovers, tees
etc., shall not be permissible.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 49 – Cable Management Systems
SECTION 50 WIRING ACCESSORIES AND MISCELLANEOUS ELECTRICAL
EQUIPMENT

50.1 GENERAL

(a) Wiring accessories and miscellaneous electrical equipment shall comply with
the requirement of Code of Practice for the Electricity (Wiring) Regulations
issued by EMSD.

(b) Unless otherwise specified, switch, socket outlet or connection unit mounted
outdoor, or in positions where it may be exposed to rain or water, shall be of
watertight construction with minimum IP 54 protection in accordance with BS
EN 60529.

(c) Unless otherwise specified, socket outlets shall be designed for flush
mounting onto pattresses or BS 4662 boxes.

(d) The front plate of each switch socket or control switch feeding an essential
circuit or a fixed electrical appliance, such as water heater, hand dryer and
exhaust fan etc., shall be engraved according to the appliance being
controlled.

(e) All accessories with their boxes and front plates shall provide a minimum
degree of protection of IP 41 when used inside buildings, and IP 54 when
used external to the building.

(f) Where a notice is required in accordance with Code of Practice for the
Electricity (Wiring) Regulations issued by EMSD, the accessory plate shall be
engraved “DANGER” and filled red.

(g) Where pilot lamps are detailed they shall comprise a neon lamp and resistor
with a red coloured lens.

50.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as at the date of the Letter of Acceptance.

BS 476 Fire tests on building materials and structures

BS 546 Specification. Two-pole and earthing-pin plugs, socket-
outlets and socket-outlet adaptors
BS 1362 Specification for general purpose fuse links for domestic and
similar purposes (primarily for use in plugs)
BS 1363 : Part 1 & 2 13 A plugs, socket-outlets and adaptors. Specification for
rewirable and non-rewirable 13 A fused plugs
BS 1363 : Part 2 13 A plugs, socket-outlets and adaptors. Specification for 13
A switched and unswitched socket-outlets
BS 3535 : Part 1 & 2 Isolating transformers and safety isolating transformers.
General requirements
General Materials & Workmanship Specification 1/9 January 2011
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Section 50 – Wiring Accessories & Misc. Electrical Equipment
 BS 3535 : Part 2 Isolating transformers and safety isolating transformers.
Specification for transformers for reduced system voltage
BS 3676 : Part 1 Switches for household and similar fixed electrical
installations. Specification for general requirements
BS 4662 Specification for boxes for the enclosure of electrical
accessories
BS 5733 Specification for general requirements for electrical
accessories
BS 7671 Requirements for Electrical Installations
BS EN 55014 Electromagnetic compatibility
BS EN 60309-2 Plugs, socket-outlets and couplers for industrial purposes.
Dimensional interchangeability requirements for pin and
contact-tube accessories
BS EN 60529 Specification for degrees of protection provided by
enclosures (IP code)
BS EN 60947 Specification for low-voltage switchgear and control gear
BS EN 60947-3 Specification for low-voltage switchgear and control gear.
Switches, disconnectors, switch-disconnectors and fuse-
combination units
BS EN 60947-4-1 Specification for low-voltage switchgear and control gear.
Contactors and motor-starters. Electromechanical contactors
and motor-starters
IEC 60947-3 Low voltage switchgear and control gear. Switches,
disconnectors, switch disconnectors and fuse combination
units
IEC 60947-4-1 Low voltage switchgear and control gear. Electromechanical
contactors and motor-starters

50.3 MATERIALS

50.3.1 Socket Outlets and Plugs

(a) Socket outlets and plugs rated at 13A and 15A for general application shall
comply with Code of Practice for the Electricity (Wiring) Regulations issued by
EMSD.

(b) Socket outlets and plugs rated at 13A and 15A shall comply with BS 1363 :
Part 1 & 2 and BS 546.

(c) Fuses for use in plugs shall comply with BS 1362.

(d) Socket outlets shall be of 3 pin shuttered type and shall be type-tested for
complete compliance with BS 1363 : Part 2 by an Independent Accredited
Laboratory or an Independent Short-Circuit Testing Organisation

(e) Weatherproof type socket outlets shall comply with BS EN 60309-2 and be
provided with a push-on cap and cap retaining ring or a screw-on cap with a
rubber gasket. The socket outlets shall have a degree of protection of at least
IPX4 to BS EN 60529.
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Section 50 – Wiring Accessories & Misc. Electrical Equipment
50.3.2 Integral Switch For Socket Outlets

(a) Socket outlets used to supply appliances mounted at high level shall be
unswitched, otherwise all socket outlets shall be fitted with an integral switch.
The integral switch shall be of single pole, forming part of the same front plate
as the socket outlet.

50.3.3 Industrial Socket Outlets and Plugs

(a) Industrial socket outlets shall be rated at 6A, 32A, 63A or 125A as specified on
the Employer’s Drawings and shall comply with BS EN 60309-2.

(b) Current carrying conductor including earthing conductor shall be made of

brass, copper or other suitable material.

(c) Socket outlet and plug shall have pilot pins and sleeves shorter than other
sleeves and pins of the unit such that pilot circuit makes last and breaks first.

(d) Industrial socket outlets shall be fed by radial circuits.

(e) Each socket outlet shall be provided with plug.

50.3.4 Shaver Supply Units

(a) Electric shaver supply units shall comply with BS 3535 : Part 1 and BS 3535 :
Part 2 and shall be insulated, suitable for both flush and surface mounting.

(b) Each unit shall comprise two outlets one for 110V and the other for 220V
obtained from a double wound transformer.

(c) Each unit shall be provided complete with reversible 2 pin shuttered socket
outlet and isolating transformer restricted to 200 mA.

50.3.5 Fused Connection Units (Switched or Unswitched)

(a) In addition to the above requirements for connection units, fused connection
units shall be of double pole type with neon indicator incorporating flexible
cord and cartridge fuse-links to BS 1362 of AC rating either 2A or 13A as
shown on the Employer’s Drawings.

(b) The plug shall only be removable by the use of a tool.

(c) The unit shall be clearly marked with the word “FUSE” or “FUSED” in a
conspicuous position on the front plate.

(d) Fuses shall comply with BS 1362.

(e) Where fused connection units are flush mounted final connection to fixed
equipment shall be flush via back entry.

(f) Surface mounted/ flush mounted fused connection units shall incorporate a
flex outlet with a clamp for anchoring the flexible cord.

(g) Final connection from surface mounted fused connection units to fixed
equipment shall be via flexible cord.

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Section 50 – Wiring Accessories & Misc. Electrical Equipment
50.3.6 Double Pole Switches

(a) Double pole switches shall be 20A or 45A, as indicated, with red neon
indicator complying with BS 3676.

(b) The equipment served shall be engraved on the cover plate.

50.3.7 Isolating Switches

(a) Isolators and equipment isolating switches shall comply with BS EN 60947
and shall be complete with double pole switching arranged to give the
separation distances required by BS 7671 to be classified as an effective
isolating device.

50.3.8 Lighting Switches

(a) Lighting switches for general purposes shall comply with BS 3676 : Part 1.

(b) Lighting switches shall be type-tested for complete compliance with BS 3676 :
Part 1 by an Independent Accredited Laboratory or an Independent Short-
Circuit Testing Organisation.

(c) Lighting switches shall be of the microgap type suitable for use on AC circuits,
and shall be of quick make-and-break type when used in DC circuits.

(d) Lighting switches shall be single pole rated at 10A or as shown on Employer’s
Drawings.

(e) All lighting switches shall be of 10A single pole.

(f) Each switch plate shall have a maximum of 3 gang switches unless otherwise
specified.

(g) Only lighting switches connected to the same phase shall be mounted on a
common switch plate and adaptable box.

(h) Weatherproof lighting switches shall be either of IP44 to BS5420 for pump
rooms plant area where weatherproof conditions shall be achieved and
outdoor areas as shown on the Employer’s Drawings.

(i) Flameproof lighting switches shall be designed to IP66 and zone 1 protection
for fuel oil pump room and fuel oil tank room where flameproof condition had
to be achieved.

(j) All lighting switches inside the plant rooms shall have local control with an
integral timers and by-pass switches.

General Materials & Workmanship Specification 4/9 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 50 – Wiring Accessories & Misc. Electrical Equipment
50.3.9 Dimmer Units for Tungsten and Fluorescent Lamps

(a) Dimmer units shall be of modular design and shall comprise of thyristors and
associated control and wiring circuitry. Hard firing circuitry shall also be
provided for control of fluorescent lamps to eliminate the need for load
resistors. When a fluorescent dimmer is in the OFF position, the lamp heater
circuit shall be disconnected.

(b) Dimmer units shall be designed for local or remote control as indicated on the
Employer’s Drawings. For the latter case, remote control stations shall be
provided. The control voltage shall be extra low voltage generated from the
dimmer units.

(c) Dimmer units shall be designed to eliminate radio frequency interference in

compliance with BS EN 55014.

50.3.10 Time Switches

(a) The time switch shall be 24 hours dial type suitable for use on an AC supply of
220V ± 6%, 50 Hz, or 24V, 50 Hz single-phase supply as specified.

(b) Each time switch shall be supplied in a complete set including the time switch
itself, metal or strong molded box and other accessories as specified.

(c) The dial shall be calibrated in 15-minute graduations.

(d) Time switches shall be single pole, single throw, and current rating of not less
than 16 amperes, unless otherwise specified.

(e) A reserve with a carry over period of at least 100 hours shall be included

(f) All component parts shall be of robust design, constructed from durable
materials capable of maintaining proper function and reasonable accuracy
without submission to easy wear and tear during normal operation.

(g) A day omitting device with enables switching operation to be omitted on any
pre-determined day or days of the week shall be provided.

(h) The metal or moulded box shall be suitable for wall mounting. An inspection
glass window and quick action fastener shall be fitted on the front lid. The box
shall be suitable for ∅20mm conduit entry.

(i) It shall be capable of 8 prograrnme and each programme shall consists of

“On” and “Off” and the allocation of any day of the week or a combination of
days.

(j) Each time switch shall consist of manual advance/override (on/off), automatic
override (on/off) for holidays and weekend.

(k) The accuracy shall be 5 seconds per day.

General Materials & Workmanship Specification 5/9 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 50 – Wiring Accessories & Misc. Electrical Equipment
50.3.11 Contactors

(a) Contactors for lighting control, either locally, remotely or through timers, shall
comply with BS EN 60947-4-1 or IEC 60947-4-1, utilization category AC-2,
Class 3 intermittent duty, and shall have a current rating of not less than that
of the outgoing switchgear to which they are connected, and in any case not
less than 20A.

50.3.12 Fireman’s Emergency Switches

(a) Fireman's switches shall comply with BS EN 60947-3 or IEC 60947-3,

utilization category AC-23.

(b) Fireman's switches shall have cast iron weatherproof enclosures finished in
red and shall have fixed on or near to it a nameplate marked with the words
“FIREMAN'S SWITCH”. The plate shall have a minimum size of 150 × 100
mm with lettering easily legible but not less than 13 mm high in any case.

(c) Fireman's switches shall have its “ON” and “OFF” positions clearly indicated
by lettering legible to person standing on the ground, and the “OFF” position
shall be at the top.

(d) Fireman's switches shall be of quick make and break type with a pole
operated ring handle which shall automatically lock in the “OFF” position.

50.3.13 Low Voltage Transformer

Low voltage transformers are used for powering miscellaneous equipment and
should be provided with a three-pin variety suitable for connection with standard 13-
amp sockets. Non- standard design and two-pin connections are not acceptable.
Low voltage transformers shall be provided under normal situations together with
the miscellaneous equipments to be powered by the low voltage transformers.

50.3.14 Photo Sensors

(a) The photo sensors shall be adjustable according to the site conditions in order
to achieve the required lighting levels.

(b) The photo sensor shall be complete with photocell sensing element and
measurement and output circuit boards all be housed in a weather proof base
unit suitable for outdoor use. The complete unit shall be mounted with holder
bracket at a position free from sky obstruction.

(c) The photo sensor shall be suitable for continuous accurate operation in
condition of 5 to 50 °C and 0% to 100% RH. The sensor output values shall
be calibrated corresponding to the illumination levels for direct input to the
intelligent controller. The input values shall then be mathematically converted
to illumination levels in lux for direct comparison with the set values for lighting
on/off control.

(d) Photo-electric controllers shall be of electronic fail-safe type, have an inherent

time delay of 30 seconds to prevent operation by extraneous light, and comply
with BS 5972. For the lighting control to the Architectural Lighting System, the
photo-electric controllers shall have an inherent time delay of 20 minutes.

General Materials & Workmanship Specification 6/9 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 50 – Wiring Accessories & Misc. Electrical Equipment
50.4 SUBMISSIONS

50.4.1 Particulars of Wiring Accessories and Miscellaneous Electrical Equipment

(a) The following particulars of wiring accessories and miscellaneous electrical

equipment shall be submitted to the Project Manager for review without
objection :

(i) detailed schedule of materials, schedule of equipment and

components and manufacturer's data;

(ii) details of the inscription;

(iii) the intended control and details of remote control stations for approval
prior to ordering; and

(iv) Contractor’s Drawings and detailed wiring and control diagrams.

50.4.2 Samples

(a) The following samples of the wiring accessories and miscellaneous electrical
equipment shall be submitted to the Project Manager together with the
particulars referred to in 50.4.1 above:

(i) socket outlets and plug;

(ii) fused connection units;

(iii) lighting switches; and

(iv) double pole switch.

50.5 WORKMANSHIP

50.5.1 Socket Outlets and Plugs

(a) The type of outlet shall be determined as a function of its location and as
follows:

(i) in public areas, all electrical outlets and devices other than those
specified below up to a height of 3,000 mm shall be flush mounted
complete with 316 satin grade stainless steel cover plate with 320 grit
finish, and all other outlets in these areas shall have mould plastic type
covers;

(ii) in plant rooms, services corridors and the like, all outlets shall be
surface or flush mounted, industrial, high impact mould polycarbonate
type, or, alternatively, subjected to review by the Project Manager,
shall have metal clad type finish with ‘polyester paint coating’; and

(iii) in non public areas, all outlets shall be flush mounted complete with
mould plastic covers.

General Materials & Workmanship Specification 7/9 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 50 – Wiring Accessories & Misc. Electrical Equipment
 (b) Unless otherwise specified, socket outlets shall be mounted at 300 mm from
finished floor level, 75 mm from surface top measured from bottom of socket
outlets.

(c) Socket outlets and plugs for one voltage system shall not be interchangeable
with those for use at other voltage and/or frequency systems in the same
installation.

(d) Unless detailed otherwise on the Employer’s Drawings and/or distribution

schedule, all 13A socket outlets shall be wired in a ring formation.

(e) Each ring final circuit shall incorporate 30 mA RCD protection, by means of
MCB/RCD units operating in series or combined MCB/RCD units (RCB).

(f) Unless otherwise specified, the socket outlets to be installed at public area
shall be supplied and installed with the satin stainless steel plates.

50.5.2 Lighting Switches

(a) Lighting switches, installed adjacent to a door shall be located on the handle
side of the door and shall be as near to the door as practicable.

(b) Unless otherwise specified, all lighting switches shall be white or ivory in
colour.

(c) When lighting switches are mounted adjacent to one another, they shall be
grouped in a single enclosure and shall share a common switch plate, subject
to a maximum of three lighting switches per plate.

(d) They shall be mounted at a height of 1350 mm above finished floor level
unless otherwise specified.

(e) Lighting switch for switch or plant rooms shall complete with an adjustable
electronic timer with time adjustment range from 30 minutes to 2 hours. The
timer shall turn the load on when the push button is initially pressed once. A
dual colour, red and green, LED shall show green to indicate the timer is in
operation. This situation shall remain until the preset time delay has elapsed
at which time the load turns off automatically and LED shall change to red to
indicate the timer is now returned to standby state.

(f) Subsequently, if the push button is pressed once more before the time delay
has completely elapsed. The timer shall reset and again go into the standby
state. The timer shall also work like an ON-OFF switch when the push button
is successively operated.

(g) Unless otherwise specified, the lighting switches to be installed at public area
shall be supplied and installed with the satin stainless steel plates.

50.5.3 Low Voltage Transformer

Low voltage transformers shall be installed in accordance with the requirements for
other wiring as specified in Section 48 of this General Materials and Workmanship
Specification. The units shall be installed according to the best workmanship. Rack-
mounted equipment shall have either built-in power supply units or industrial type
power supplies.

General Materials & Workmanship Specification 8/9 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 50 – Wiring Accessories & Misc. Electrical Equipment
50.5.4 Fused Connection Units

(a) The mounting level of fused connection units for exhaust fans, fan coil units
and A/C units shall be at the levels specified and within 500 mm of the
equipment to be connected.

(b) Unless otherwise specified, the fused connection units to be installed at public
area shall be supplied and installed with the satin stainless steel plates.

50.5.5 Isolating Switches

(a) Single pole and neutral or triple pole and neutral isolating switch with
appropriate rating shall be provided for shutter and equipment as indicated.
Unless otherwise specified, all isolators for shutters units shall be at high level.

(b) The Contractor shall also provide phase indication colour labels and engraved
labelling for the double pole switch to indicate the function of the switch.

(c) Unless otherwise specified, the isolating switches to be installed at public area
shall be supplied and installed with the satin stainless steel plates.

General Materials & Workmanship Specification 9/9 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 50 – Wiring Accessories & Misc. Electrical Equipment
[this page not used]
SECTION 51 GENERAL LIGHTING SYSTEMS

51.1 GENERAL

(a) The luminaires, including the control gear, shall be suitable for operation at
220V ±6%, 50 Hz ±2%, single phase, AC supply.

(b) The overall power factor of the luminaire shall not be less than 0.85 lagging.
Better power factor shall be provided whenever specified.

(c) Unless otherwise specified, the components of the luminaire shall be

manufactured in accordance with the relevant British Standard Specifications
and shall carry the BSI Kitemark or the mark of an equivalent Quality
Surveillance Scheme.

(d) Internal wiring shall be appropriately colour coded, neatly wired and properly
terminated. The luminaires excluding the fluorescent lamp shall be supplied in
complete set comprising control gear, lampholders, cable terminal block, etc.

(e) The general operation condition shall refer to Section 44.7 of this General
Materials and Workmanship Specification.

51.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as at the date of the Letter of Acceptance.

AS/NZS 2107 Acoustics – Recommended design sound level

and reverberation times for building interiors
BS 1075 Specification for tungsten halogen lamps (non
vehicle)
BS 1362 Specification for general purpose fuse links for
domestic and similar purposes (primarily for use in
plugs)
BS 1449 Steel plate, sheet and strip. Carbon and carbon-
manganese plate, sheet and strip
BS 1853 Tubular fluorescent lamps for general lighting
service
BS 4533 Luminaires
BS 4533 : Part 101 Luminaires. Specification for general requirements
and tests
BS 4533 : Part 102 Luminaires. Particular requirements. Specification
for fixed general purpose luminaires
BS 4683 : Part 1 Specification for electrical apparatus for explosive
atmospheres. Classification of maximum surface
temperatures

General Materials & Workmanship Specification 1/21 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 51 – General Lighting Systems
 BS 4683 : Part 2 Specification for electrical apparatus for explosive
atmospheres. The construction and testing of
flameproof enclosures of electrical apparatus
BS 5225 : Part 1 Photometric data for luminaires. Photometric
measurements
BS 5266 : Part 1 Emergency lighting. Code of practice for the
emergency lighting of premises other than
cinemas and certain other specified premises
used for entertainment
BS 5499 : Part 1 Graphical symbols and signs. Safety signs,
including fire safety signs. Specification for
geometric shapes, colours and layout
BS 5499 : Part 3 Fire safety signs, notices and graphic symbols.
Specification for internally-illuminated fire safety
signs
BS 5750 Quality systems
BS 6201 Fixed capacitors for use in electronic equipment
BS 6231 Specification for PVC-insulated cables for
switchgear and controlgear wiring
BS 6345 Method for measurement of radio interference
terminal voltage of lighting equipment
BS EN 55015 Limits and methods of measurement of radio
disturbance characteristics of electrical lighting
and similar equipment
BS EN 60061-1 Specification for lamp caps and holders together
with gauges for the control of interchangeability
and safety. Lamps caps
BS EN 60061-3 Specification for lamp caps and holders together
with gauges for the control of interchangeability
and safety. Gauges
BS EN 60079-14 Electrical apparatus for explosive gas
atmospheres. Electrical installations in hazardous
areas (other than mines)
BS EN 60081 Double-capped fluorescent lamps. Performance
specifications
BS EN 60155 Glow-starters for fluorescent lamps
BS EN 60188 High-pressure mercury vapour lamps.
Performance specifications
BS EN 60400/IEC 60400 Specification for lampholders for tubular
fluorescent lamps and starterholders
BS EN 60432-1 Safety specification for incandescent lamps:
Tungsten filament lamps for domestic and similar
general lighting purposes.
BS EN 60432-2 Safety specification for incandescent lamps:
Tungsten halogen lamps for domestic and similar
general lighting purposes.

General Materials & Workmanship Specification 2/21 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 51 – General Lighting Systems
 BS EN 60529 Specification for degrees of protection provided by
enclosures (IP code)
BS EN 60598-1 Luminaires. General requirements and tests

BS EN 60598-2-22 Luminaires. Particular requirements. Luminaires

for emergency lighting
BS EN 60662 Specification for high-pressure sodium vapour
lamps
BS EN 60920 Ballasts for tubular fluorescent lamps. General
and safety requirements
BS EN 60921 Specification for ballasts for tubular fluorescent
lamps. Performance requirements
BS EN 60927 Specification for auxiliaries for lamps. Starting
devices (other than glow starters). Performance
requirements
BS EN 61047 Specification for DC or AC supplied electronic
step-down convertors for filament lamps.
Performance requirements
BS EN 61048 Specification for capacitors for use in tubular
fluorescent and other discharge lamp circuits.
General and safety requirements
BS EN 61049 Specification for capacitors for use in tubular
fluorescent and other discharge lamp circuits.
General and safety requirements
BS EN 61347 Lamp controlgear
BS EN 61347-1 Lamp controlgear. General and safety
requirements
BS EN 61347-2-2 Lamp controlgear. Particular requirements for DC
or AC supplied electronic step-down convertors for
filament lamps
BS EN 61347-2-3 Lamp controlgear. Particular requirements for AC
supplied electronic ballasts for fluorescent lamps
BS EN 61558 Safety of power transformers, power supply units
and similar devices.
BS EN 62035 Discharge lamps (excluding fluorescent lamps).
Safety specifications
ICEL 1001 Scheme of Product and Authenticated
Photometric Data Registration for Emergency
Luminaires and Conversion Modules
IEC 60926 Starting devices (other than glow starters) –
General and safety requirements
IEC 60927 Starting devices (other than glow starters) –
Performance requirement
ISO 9000 Quality assurance

General Materials & Workmanship Specification 3/21 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 51 – General Lighting Systems
51.3 MATERIALS

51.3.1 Tubular Fluorescent Tubes

(a) Tubular fluorescent lamps with preheated cathode, for general lighting service,
shall be manufactured and tested to BS EN 60081 and BS 1853. Lamps shall
start satisfactory with switch-start control gears operated on 220V 50 Hz
single-phase supply.

(b) Fluorescent lamps shall be of T5 high efficient energy saving type with bi-pin
end caps to BS EN 60400, BS EN 60061-1 and BS EN 60061-3.

(c) Fluorescent lamps shall have the colour appearance of warm white with a
colour rendering index of 85 unless otherwise specified. Initial lumen output
shall not be less than that shown in the table below:

∅26 mm tubular fluorescent lamps

Rated Lumen output
power of 3,000K
lamp 3,800K 5,400K
2,700K (Warm 6,500K
(W) (Cool white) (Day light)
white)
18 1,350 1,350 1,350 1,300 1,000
36 3,350 3,350 3,350 3,250 2,300
58 5,200 5,200 5,200 5,000 3,700

Circular fluorescent lamps

Rated Lumen output
power of 3,000K
lamp 3,800K 5,400K
2,700K (Warm 6,500K
(W) (Cool white) (Day light)
white)
22 1,350 - 1,000 - 1,050
32 2,050 2,000 2,000 - 1,750
40 2,900 2,800 2,300 - 2,500

∅38 mm U-tube fluorescent lamps

Lumen output
Rated power
of lamp 3,000K 3,800K
2,700K
(W) (Warm white) (Cool white)

20 - 1,150 950
40 - 2,700 2,400
65 - 4,500 3,900

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 51 – General Lighting Systems
 ∅16 mm tubular fluorescent lamps
Lumen output
Rated power
of lamp 3,000K
4,000K 6,000K
(W) (Warm white)

14 1,350 1,350 1,300

21 2,100 2,100 2,000
24 2,000 2,000 1,900
28 2,900 2,900 2,750
35 3,650 3,650 3,500
39 3,500 3,500 3,325
49 4,900 4,900 4,650
54 5,000 5,000 4,750
80 7,000 7,000 6,650

(d) All fluorescent lamps shall have average rated life not less than those listed
below at 50% failure:

Average Rate Life for Fluorescent Lamp

Fluorescent Lamp Type Average Rated Life (Hour)
∅26 mm fluorescent lamp 12,000
∅16 mm fluorescent lamp 20,000
Circular fluorescent lamp 12,000
U-tube fluorescent lamp 8,000

51.3.2 Compact Fluorescent Lamps

(a) The energy saving lamps shall be of a compact low-pressure mercury

discharge lamp, consisting of two or four narrow fluorescent tubes welded
together.

(b) The lamp base shall from an integral housing for the integrated starter to
provide almost instant starting characteristics and radio interference
suppressor.

(c) Compact fluorescent lamps shall have the colour appearance of warm white
with a colour rendering index of 85 unless otherwise specified. Initial lumen
output shall not be less than that shown in the table below:

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 51 – General Lighting Systems
 Compact fluorescent, single-ended, 4-pin base lamps
Lumen output
Rated power
of lamp 3,000K 3,800K 5,400K
2,700K
(W) (Warm white) (Cool white) (Day light)

5 250 - 250 -
7 400 400 400 -
9 600 600 600 -
11 900 900 900 -
18 1,200 1,200 1,200 750
24 1,800 1,800 1,800 1,200
36 2,900 2,900 2,900 2,400
40 3,500 3,500 3,500 2,200
55 4,800 4,800 4,800 3,000

Compact fluorescent, single-ended, 2-pin base

with built-in starter lamps
Lumen output
Rated power
of lamp 3,000K 3,800K 5,400K
2,700K
(W) (Warm white) (Cool white) (Day light)

5 250 250 250 -

7 400 400 400 375
9 600 600 600 565
11 900 900 900 850

Compact fluorescent, twin independent single-ended,

2-pin base with built-in starter lamps
Lumen output
Rated power
of lamp 3,000K 3,800K
2,700K
(W) (Warm white) (Cool white)

10 600 600 600

13 900 900 900
18 1,200 1,200 1,200
26 1,800 1,800 1,800

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 51 – General Lighting Systems
 Compact fluorescent, triple independent single-ended,
2-pin base with built-in starter lamps
Lumen output
Rated power
of lamp 3,000K 3,800K
2,700K
(W) (Warm white) (Cool white)

13 900 900 900

18 1,200 1,200 1,200
26 1,800 1,800 1,800

Compact fluorescent, twin independent single-ended,

4-pin base lamps
Lumen output
Rated power
of lamp 3,000K 3,800K
2,700K
(W) (Warm white) (Cool white)

13 900 900 900

18 1,200 1,200 1,200
26 1,800 1,800 1,800
32 2,400 2,400 2,400
42 3,200 3,200 3,200

Compact fluorescent, four independent single-ended,

2-pin base with built-in starter lamps
Lumen output
Rated power
of lamp 3,000K 3,800K
2,700K
(W) (Warm white) (Cool white)

8 350 - -
10 600 600 -
13 900 900 900
18 1,200 1,200 1,200
26 1,800 1,800 1,800

(d) The lamp shall be type-tested in accordance with BS EN 60081 for lamp
ageing test and BS 5225 : Part 1 for lamp lumen output.

(e) All compact fluorescent lamps shall have average rated life not less than
8,000 hours at 50% failure

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 51 – General Lighting Systems
51.3.3 Discharge Lamps

(a) Discharge lamps covered in this Section include the following:

(i) Tubular high pressure sodium vapour discharge lamp (SON-T)

(ii) Elliptical high pressure sodium vapour discharge lamp (SON-E)

(iii) Linear high pressure sodium vapour discharge lamp (SON-TD)

(iv) Elliptical high pressure mercury vapour discharge lamp (MBF)

(v) Linear metal halide discharge lamp (MBIL)

(b) High pressure sodium vapour discharge lamps shall be manufactured and
tested in accordance with BS EN 60662. Elliptical mercury vapour discharge
lamp shall be manufactured and tested in accordance with BS EN 60188.
Linear metal halide discharge lamp shall be manufactured and tested in
accordance with BS EN 62035.

(c) The manufacturing process of the lamps shall comply with the quality standard
BS EN ISO 9000-4 or BS 5750.

(d) Tubular and elliptical high pressure sodium vapour discharge lamps shall
consist of a high pressure sodium discharge operating within a sintered
alumina arc tube. The arc tube shall be mounted in a clear glass bulb
complete with an E40 cap. Linear high pressure sodium vapour discharge
lamps shall be double-ended and shall consist of an arc tube made of sintered
aluminium oxide and mounted in a clear tubular quartz outer bulb having a
single contact ceramic cap of Rx7s at each end.

(e) MBF lamp shall consist of a high pressure mercury discharge operating within
a quartz arc tube. The arc tube shall be mounted in an elliptical glass bulb
coated with a fluorescent phosphor and complete with a cap of the type
compatible with the respective lamp wattage type.

(f) MBIL lamp shall consist of an arch burning between tungsten electrodes in an
atmosphere of mercury and additional metal halides enclosed in a double-
ended quartz arch tube. The caps shall be standard Rx7s ceramic type.

(g) The correlated colour temperature and colour rendering index of the lamp
shall be following unless otherwise specified:

Colour Temperature Colour Rendering Index

SON-T, SON-E, SON-TD 2,000 K to 2,100 K 25 to 35

MBF 3,400 K to 4,000 K 50 to 57

MBIL 5,200 K 65

(h) The discharge lamps shall have a universal operating position and shall be
suitable for use with external ignitor when appropriates.

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Section 51 – General Lighting Systems
 (i) The light output of the lamp shall be constant and shall not be less than the
following figures for the respective wattage type in the initial 2,000 hours:

Nominal Lamp Wattage Initial Light Output (lumens)

(W)
High pressure
150 16,000
sodium
250 28,000
400 48,000
High pressure
50 1,800
mercury
80 3,700
125 6,500
250 13,000
400 22,000
Linear metal halide 750 67,000
1,500 120,000

(j) The rated average life of the lamps shall no be less than the figures in the
following table with respect to the selected nominal lamp wattage at 50%
failure:

Rated Average Lift (Hours)

SON-T, SON-E, SON-TD 24,000
MBF 16,000 to 24,000
MBIL 6,000

(k) Where standby auxiliary lamp is used for the emergency illumination of the
gas discharge luminaire, an adjustable time delay relay circuit shall be
provided for the auxiliary lamp for illumination. When the mains power fails,
the auxiliary lamp shall operate instantaneously for emergency illumination.
Upon restoration of mains power, the auxiliary lamp shall be maintained to be
“ON” until the gas discharge lamp on the normal mains circuit has run to 90%
of full brightness.

51.3.4 Tungsten Halogen Lamp

(a) General

(i) Tungsten halogen lamps shall meet the safety requirements as

specified in BS EN 60432-2. The manufacturing process shall comply
with the relevant quality standard of ISO 9000 series standards.

(ii) The colour temperature of the lamp shall be within the range between
2,800°K and 3,200°K. The colour rendering index shall not be less
than 90.

(iii) The rated average life of the lamp shall not be less than 2,000 hours at
10% failure. The light output of the lamp shall not be diminished by more
than 5% throughout the guaranteed life.
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Section 51 – General Lighting Systems
 (b) 220 Voltage Tungsten Halogen Lamp

(i) The lamp shall comply with BS 1075 or other equivalent international
standards.

(ii) The luminous efficacy shall not be less than 13 lumens/lamp watt.

(c) Extra Low Voltage Tungsten Halogen Lamp

(i) The lamp shall be suitable for operation at 12V single phase AC
through a compact electronic step-down transformer. The output shall
be 12V AC; and

(ii) The transformer:

- The transformer shall be supplied together with the 12V lamp as an

integral package by the same manufacturer or supplier;

- The general and safety requirements shall be comply with BS EN

61347-1, BS EN 61347-2-2 and BS EN 61558 or other equivalent
international standards; and

- The performance requirements shall comply with BS EN 61047 or

other equivalent international standards;

- The radio interference suppression shall comply with BS EN 55015

or other equivalent international standards;

- The transformer shall be suitable for use with dimmers so that the
luminance of the lamp can be adjusted if required. In addition, the
transformer shall be able to be used with DC supplies for
emergency lighting purpose.

(iii) The overall size of the lamp bulb shall be about 50 mm in diameter and
the height shall be about 45 mm, with bi-pin end cap.

(iv) The design lumen output of the lamp bulb shall not be less than the
schedule under:

Rated
Beam Beam Angle Peak Candelas
Wattage
50 narrow 10° 12,000
50 medium 21° 3,700
50 wide 38° 1,550

51.3.5 Fluorescent Luminaire

(a) Fluorescent luminaires and all their accessories shall be radio interference
suppressed to limits specified in BS 6345. Slight hum which occurs in ballasts
shall not be amplified by resonance in the luminaires.

(b) The luminaires shall be classified, as a minimum requirement, to Class I and

IP 2X for indoor use to BS EN 60529 and BS 4533 : Part 102.

(c) The luminaire shall be operable up to 45°C as minimum.

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Section 51 – General Lighting Systems
 (d) Each luminaire shall be supplied as a complete set comprising the main part,
end plates, cover plate/reflector/diffuser, ballast, starter and starter-holder,
power factor correction capacitor, bi-pin lampholder, fused terminal block,
integral earthing terminal and internal wiring. Electronic ballast shall be used
unless otherwise specified.

(e) A fused terminal block, fitted with a suitably rated fuse to BS 1362, shall be
properly fixed to the body in such a way as to be easily accessible for fuse
replacement.

(f) The main part of the luminaire shall be made of substantive sheet steel of
minimum thickness 0.5 mm, cold rolled general grade to BS 1449, pretreated
to prohibit corrosion on both sides and finish coated in gloss white stoved
enamel or colour as specified to BS EN 60598-1 or epoxy powder on the
outside surface. It shall be formed and suitably shaped into one continuous U-
channel piece to give a fairly rigid structure on its own, but can be further
strengthened by ribs where necessary.

(g) The luminaire shall be provided with cover plate, reflector, or diffuser as
appropriate. The cover plate and reflector shall be of the same material and
finish as the main part, but the reflector shall be finish coated on both inside
and the outside surfaces. The cover plate and reflector shall be of one
continuous piece formed and suitably shaped to give adequate mechanical
strength. The fixing screw for the cover plate and reflector shall be captive
with the main part. The diffuser shall be made of clear prismatic plastic
material unless otherwise specified.

(h) For back entry installation, if the basic batten cannot fully cover the circular
conduit box, a pattress block cover made of 0.5 mm thick mild steel, finished
in white stoved enamel shall be supplied with each basic batten to shield the
conduit box outlet. The basic batten shall be capable to accept the metal cover
plate and different reflectors or diffusers.

(i) Electrical control gear shall be totally built into the luminaire assembly and
shall provide for switch start and/or dimming operation. Ballasts shall be
designed to suit nominal supply of voltage and frequency. Power factor
correction capacitors shall be provided to correct the power factor for each
luminaire to not less than 0.95 lagging after it has operated continuously. The
capacitors shall be metallized polypropylene strips would onto cylindrical
formers. The capacitors shall be rated to operate at not less than 85°C and
shall be mounted not less than 75 mm from any ballast. Capacitors shall be
connected in parallel with ballasts and tubes.

51.3.6 Weatherproof Type Fluorescent Luminaires

(a) A type-test certificate together with the associated test report(s) issued by BSI
or an Independent Accredited Laboratory shall be submitted as evidence of
compliance with the required standard.

(b) The luminaire shall be classified, as a minimum requirement to Class IP 54 as

described in BS EN 60529 and BS 4533 : Part 101.

(c) The luminaire shall be supplied as a complete set comprising the main part,
reflector/gear tray, diffuser, ballast, starter and starter-holder, power factor
correction capacitor, bi-pin lampholder, fused terminal block, integral earthing
terminal and internal wiring.

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Section 51 – General Lighting Systems
 (d) A fused terminal block fitted with a suitably-rated fuse to BS 1362 shall be
properly fixed to the body in such a way as to be easily accessible for fuse
replacement.

(e) The housing of the luminaire shall be a one piece moulded polycarbonate or
glass fibre reinforced plastic finished in light grey colour or colours as specified.
The mounting face of the main part shall be formed with a knockout for back
entry and holes for mounting screws. The two ends of the main part shall each
be provided with a hole for conduit entry which shall be sealed with a suitable
plastic plug.

(f) The reflector/gear tray shall be made of substantive sheet steel of minimum
thickness 0.5 mm, pretreated and finish coated in gloss white stoved enamel
or epoxy powder. It shall be of one continuous piece formed and suitably
shaped to give adequate mechanical strength. The ballast, power factor
correction capacitor, starter-holders and bi-pin lampholder shall be
conveniently positioned and securely fixed onto the tray.

(g) The reflector/gear tray shall be securely mounted to the main part by screws,
or other suitable means, which shall remain captive with the main part, or the
tray, when the tray is detached from the main part. In the detached position,
the tray shall be securely strapped or hinged to the main part.

(h) The diffuser shall be of one piece injection moulded, internally pattern clear
polycarbonate material and fixed to the housing against a gasket by hinged
polycarbonate toggles held captive to the housing. The diffuser shall be
vandal proof and have a service temperature limit of at least 1,100°C and shall
have negligible yellowish tendency with UV radiation.

(i) A neoprene or silicone gasket shall be provided between the main part and
the diffuser and shall be retained firmly in the purposely formed groove in the
main part.

(j) The capacitor shall be metabolized polypropylene dry film unit, or approved
equivalence, internally fused to BS EN 61048 and BS EN 61049, and radio
frequency suppressed to BS 6201. The capacitor shall be properly protected
from corrosion effect.

(k) The starting circuit shall be either of switch start or electronic start as specified.

51.3.7 Flameproof Fluorescent Luminaires

(a) The luminaires shall be designed and constructed in accordance with BS

4683 : Part 2,, flameproof enclosure Ex ’d’ and certified flameproof by an
approved independent testing authorities. The choice, installation and
maintenance of the fittings shall comply with BS EN 60079-14. Temperature
classes shall be T6 complying with BS 4683 : Part 1.

(b) The luminaires shall be classified, as a minimum requirement, to Class II and

IP 66 of BS EN 60529, and shall also comply with all the safety, electrical,
thermal and mechanical requirements of BS 4533 in general.

(c) The starting circuit of the luminaire shall be of electronic start and the control
gear components shall be installed on a removable metal tray enclosed in a
separate housing which shall be provided with at least 20 mm E.T. entries for
through connections.
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Section 51 – General Lighting Systems
 (d) The body casting, control gear housing and end covers shall be constructed
with cast aluminium at least to ISO 3522 Al-Si5Cu3 and with suitable coating
for increased protection against corrosion. The fluorescent lamp shall be
housed in a cylinder of borosilicate glass and flamesealed at the end of the
casing.

(e) The luminaire shall be supplied as a complete set comprising the main
housing, reflector gear tray, vandal, flame and explosion proof diffuser,
switchgear, power factor correction gear, lampholder, fused terminal block,
integral earth terminal, internal wiring, and other accessories housed within
the flameproof body but easily accessible for servicing, and the respective
fluorescent tube.

(f) The luminaires shall be suitable for both 20 mm diameter conduit suspensions
and direct-on-ceiling mounting which shall comprise cast iron boxes rigidly
supported by metal connecting tube and a reflector. The control gear shall be
installed on a removable metal tray enclosed in the main casting. One of the
entries shall be fitted with a hexagonal headed flameproof plug.

(g) The reflector-gear tray shall be made of substantive sheet steel of minimum
thickness 0.5 mm, pretreated to prohibit corrosion on both sides and finish
coated in gloss white stove enamel on the outside surface. The reflector-gear
tray shall be of one continuous piece formed and suitably shaped to give
adequate mechanical strength for the mounting of all accessories and be
securely fixed to the housing with captive screws. In the detached position, the
tray shall be securely strapped or hinged to the main part.

(h) The incoming terminal chamber shall be an integral part of the body casting
complete with who phase and earth terminal block. The cover of chamber
shall be provided with weatherproof gasket and with at least 20 mm entries
fitted with hexagonal headed flameproof plug.

51.3.8 Self-Contained Fluorescent Luminaires

(a) The luminaires shall be of self-contained maintained type. The battery supply
system shall comprise of NiCd battery, charger, detector, inverter, changeover
switch, radio frequency suppressors, indicator, integrated test switch etc. The
luminaire shall be designed and constructed in accordance with BS 4533 and
BS 5266 : Part 1.

(b) A type test certificate together with the associated test report(s) issued by BSI
or an approved internationally recognized testing authority shall be submitted
to verify compliance with the required standards.

(c) Each luminaire shall be classified, as a minimum requirement, Class I to BS

4533 : Part 101, and shall also comply with all the safety, electrical, thermal
and mechanical requirements of BS 4533.

(d) The luminaire shall be supplied as a complete set comprising the main part,
battery supply system, end plates, cover plate, ballast, starter and starter-
holder, power factor correction capacitor, bi-pin lampholder, fused terminal
block, integral earth terminal, internal wiring etc. housed within the main body
but easily accessible for servicing, and the respective fluorescent tubes.

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Section 51 – General Lighting Systems
 (e) An independent circuit including a separate set of starter and ballast etc. shall
be provided for each fluorescent lamp.

(f) The main part of each luminaire shall be constructed from substantive mild
steel sheet of minimum thickness of 1 mm, cold rolled general grade to BS
1449. It shall be pretreated to prohibit corrosion on both sides, with hot alkali
degreasing, and with a layer of iron or zinc phosphate, two coats of primer and
a finish paint of gloss white stove enamel or epoxy polyester powder. It shall
be formed and suitably shaped into one continuous U-channel piece to give a
rigid structure on its own, further strengthened by ribs where necessary.

(g) Under normal supply, a battery unit shall be charged to maintain in a fully
charged state ready to supply power as required and the fluorescent lamp
shall be operated by the mains supply through a separate circuit. When mains
supply failure occurs the unit shall switch instantaneously to battery-powered
operation. Upon restoration of mains supply the lamp shall be switched back
to mains supply operation and the battery shall be re-charged again. The
whole operation shall be performed automatically.

(h) Batteries shall be sealed nickel-cadmium rechargeable type certified to ICEL

1001: Part 2 and shall be capable of continuous operation at cell wall
temperature of 60°C. The battery shall have ample capacity to maintain the
fluorescent lamps for up to 2 hours after the mains supply fails. Throughout
the 2 hours of discharge period, the lumen output of the luminaires shall not
be less than 20% of those under mains supply condition.

(i) The charger shall be fully automatic, solid state constant voltage type, with
electronic circuitry to protect the batteries against over-charge and over-
discharge. The charging system shall be capable of recharging the battery to
full capacity in not more than 24 hours after a total discharge of the battery.

(j) Test switch and indication lamps shall be provided externally on the housing
for the purpose of testing the proper functioning of the battery supply system
and indicating the discharge of battery. These shall be positioned to be visible
and accessible when the luminaire is installed.

(k) The control circuits shall be suitable for mains operation and shall be designed
to enable the luminaires to operate exactly like normal conventional luminaires.

(l) A fused terminal block fitted with cartridge fuses of appropriate rating shall be
provided separately for both the charge and the maintained circuit.

(m) Light output throughout the average mid-tube life when using “daylight”
4,500°K tube shall be throughout the 2-hour discharging period when mains
fails. Light output shall not be less than 50% of the nominal light output under
the maintained mode.

(n) The battery shall be protected against over-discharge by a low voltage “cut-
out” device which shall disconnect the battery from the load once the
discharging voltage of the nickel cadmium cell drops below 1V.

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Section 51 – General Lighting Systems
51.3.9 Self-Contained Exit Signs

(a) EXIT signs shall meet the requirements of circular letters of Fire Services
Department, HKSAR.

(b) The EXIT signs shall be internally illuminated by fluorescent lighting fitting or
incandescent lamp, acceptable to the Fire Services Department, HKSAR and
suitable to use on 220V, 50Hz, single phase AC supply.

(c) The complete EXIT signs shall, where applicable, meet the requirements of
BS 5499 : Part 1, BS 5499 : Part 3 and BS EN 60598-2-22.

(d) Self-contained exit signs which are either licensed with ICEL Approval scheme
of BSI Kitemark scheme are deemed to have satisfied the requirements of the
preceding paragraph. Alternatively, exit signs may be accepted whose
illuminants are assembled from either ICEL Approved self-contained
emergency batten fluorescent fitting with its battery set and transistorized
ballast placing outside the casing of the batten fitting but contained within the
exit sign enclosure, or ICEL approved self-contained emergency lighting
conversation module/kit installed in conditions as approved by ICEL.

(e) Batteries used in the emergency illuminant shall be sealed nickel cadmium
batteries. To comply with sub-clause 22.6.3 of BS 4533 : Section 102.22,
batteries with excess initial capacity shall be chosen to compensate for the
loss of effective capacity during operation such that the “four years” minimum
interval between batteries replacement will be achieved.
(f) The complete lighting fitting contained inside the EXIT sign shall consist of a
normal fluorescent luminaire plus an emergency lighting modification unit as
specified.

(g) All components in connection with emergency fluorescent tube such as

batteries, transistorized ballast, mains power failure detector, automatic
changeover relay, low voltage “cut-out” battery protective device, etc. shall be
contained inside the exit sign box.

(h) The following accessories shall be provided on the surface of the EXIT sign
box:

(i) a self-returning switch to be switched on to simulate failure of normal

supply to test the emergency operation of the emergency lighting fitting.

(ii) A red neon light to show “mains supply healthy” of the emergency
lighting fitting.

(i) Operation of Exit Signs:

(i) under normal conditions, the 220V AC mains shall power the
fluorescent lamp and charge a sealed nickel cadmium battery through
a battery charger. On failure of mains supply, the emergency lighting
modification unit shall instantaneously switch to battery power
operation. Upon restoration of mains supply, the unit shall switch back
to normal power and the batteries shall be re-charged again. The
changeover operations shall be automatic;

(ii) the duration of emergency operation shall be at least 2 hours after the
mains supply fails with a light output up to the end of the duration;

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Section 51 – General Lighting Systems
 (iii) the charging system shall be capable of recharging the battery to full
capacity in 24 hours after a total discharge of the battery; and

(iv) The battery shall be protected against over-discharge by a low voltage

“cut-out” device which shall disconnect the battery from the load once
the discharging voltage of the nickel cadmium cell drops below 1V.

51.3.10 Ballast

(a) All electronic ballasts shall be preheat start design. They shall be of the high
frequency (>25 kHz) electronic type comply with the performance and safety
requirements of BS EN 60929 or BS EN 61347-1 & BS EN 61347-2-3, the
EMC immunity and emission requirements of BS EN 61000-6-1 & BS EN
50082-1, and BS 6100 : Part 2 or BS EN 55015. They shall be suitable for
operation on a 220V, 50 Hz supply and mainly used in tubular fluorescent
luminaires unless otherwise specified.

(b) Ballasts for discharge lamps shall be of the auto-stabilized type with lead
peaked circuiting, with a power factor not less than 0.9 lagging. A 10%
variation in line voltage shall vary the lamp wattage by no more than +10%.
Ballasts shall provide an adequate voltage at the lamp with a source voltage
drop voltage drop of up to 20% below nominal to prevent the lamp from being
extinguished.

(c) The overall sound pressure levels in dB(A) at 1m position of ballasts shall not
exceed values of the room noise rating criterion NC minus 10 dB, where the
relevant or equivalent standards on Noise Criterion (NC) values shall be taken
latest issues from ASHRAE, CIBSE or AS/NZS 2107 publications.

(d) All electronic ballasts shall comply with the general and safety requirements of
BS EN 60928. The electronic ballasts shall be suitable to operate at an
ambient temperature range from 0oC to 50oC and at a maximum relative
humidity of 95%.

(e) All electronic ballasts shall be selected from “List of Electronic Ballasts
Meeting EMSD’s Minimum Technical Requirements” issued by the Electrical
and Mechanical Services Department of the HKSAR.

(f) The minimum efficiency of the electronic ballasts shall be 90%. In case of
dimmable electronic ballast, the minimum efficiency shall not be less than 85%
at its lowest dimmable range.

(g) The electronic ballasts shall be rapid or instant start and the lamp operating
frequency shall be above 30kHz.

(h) The complete electronic ballasts shall be housed in a single front-access

enclosure with appropriate terminal blocks for easy connection of wiring. The
maximum case temperature of the electronic ballast shall be 70oC.

(i) The rated life of the electronic ballasts shall not be less than 50,000 hours at
the test point of 70oC.

General Materials & Workmanship Specification 16/21 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 51 – General Lighting Systems
51.3.11 Earth Leakage Currents

Earth leakage currents from luminaries shall be within the limits specified in Section
10.3 BS 4533, as follows:

All luminaries Class O and Class II 0.5 mA;

Portable luminaries Class I 1 mA; and
Fixed luminaries Class I 1 mA
Up to 1 kVA rated input Increasing by 1 mA/kVA up to a maximum of 5
mA.

51.3.12 Luminaires and Lamps

(a) The Contractor shall supply and install luminaires in the Luminaire Schedule.
Luminaires shall comply with the requirements of BS 4533. Lighting circuits
shall be connected on the ‘loop-in’ principle unless otherwise specified.

(b) All luminaires shall be installed complete with lamps and all the necessary
control gears. Multiple lamp fluorescent luminaires shall be fitted with separate
control gear for each lamp.

(c) For fluorescent luminaire, high frequency electronic control gear shall be used.
Fluorescent lamp shall be 4000k colour temperature and Ra 85 colour
rendering index unless otherwise specified.

(d) For high pressure discharge luminaire, a power factor greater than 0.9 shall
be achieved. Control gear shall be housed in the control gear enclosure.

(e) All lamps shall be suitable for use on 220 volt 50 Hz single phase supply.

(f) ‘T5’ energy saving fluorescent lamp shall be used.

(g) All luminaires shall have a power factor greater than 0.9.

51.3.13 Emergency Lighting

(a) All emergency fluorescent fittings shall be equipped with self contained
maintained type battery/inverter/charger kits to provide 2 hour maintained
output during power supply failure. Wherever a multi-lamp luminaire is
identical as an emergency luminaire, all the lamps in the luminaire shall be
equipped with a battery pack unless otherwise specified. The lighting output
shall be 50% of nominal lighting output when the lamp is supported by the
self-contained battery pack.

(b) The battery/inverter/charger kits shall be fitted to the body of the emergency
luminaires. A red LED shall be fitted to each emergency luminaire to indicate
the charging status. The position of the LED shall be such that it is clearly
visible through the diffuser.

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Section 51 – General Lighting Systems
 (c) All high pressure discharge luminaires for emergency purpose shall be
equipped with auxiliary tungsten halogen lamp arrangement consisting of an
electronic relay circuit to operate an auxiliary tungsten halogen lamp. This
lamp shall provide instant light during the warm up period of the main
discharge lamp and after a momentary power interruption. The tungsten lamp
shall remain energised until the main discharge lamp had run up to at least
50% of its normal light output. The central battery systems (CBS) shall be
provided to support 2 maintained output from the auxiliary lamp during power
supply failure. The lighting output shall be 100% of nominal lighting output
when the lamp is supported by the CBS.

51.3.14 Exit Sign

The general specifications of the exit signs shall be in accordance with Section 86
of the GMWS or amendments thereof. The Contractor shall obtain approval from
FSD for the exit sign construction prior to submitting details to the Project Manager
for review without objection. The specifications of the exit sign boards shall be
referred to the PTS.

51.3.15 Directional Sign

The general specifications of the directional signs shall be in accordance with

Section 86 of the GMWS or amendments thereof. The Contractor shall obtain
approval from FSD for the directional sign construction prior to submitting details to
the Project Manager for review without objection. The specifications of the exit sign
boxes shall be referred to the PTS.

51.3.16 Lighting Control

(a) The Outgoing circuits from MCB boards shall be connected to lighting points
through normally closed contacts of contactors located next to the respective
MCB boards as shown on the Employer’s Drawings. All contactors shall be
completed with all necessary auxiliary contacts required.

(b) The current rating of the main contacts shall not be less than the up-stream
protective device.

(c) All the relay contacts provided shall be suitable for 220V ac and 2A inductive
currents. All the contactors auxiliary contacts, relay, terminals etc shall be
housed in dust proof metal boxes located next to the respective MCB board.
All the boxes shall be made of steel sheet not less than 1.5mm in thickness
and complete with finish to be reviewed without objection by the Project
Manager. Plastic labels engraved with the lighting zones being controlled shall
be provided on the metal boxes adjacent to each remote on/off switches.

(d) Photo sensors shall be supplied and installed to control the lighting systems at
the Departures Concourse and above the driveway.

(e) Lighting switches completed with timers shall be supplied and installed to
control the lighting installations in the plant rooms and fixed link bridges.

General Materials & Workmanship Specification 18/21 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 51 – General Lighting Systems
51.4 SUBMISSIONS

51.4.1 Particulars of General Lighting System

(a) The following particulars of the proposed general lighting system shall be
submitted to the Project Manager for review without objection:

(i) catalogue, detailed schedule of equipment and components and

manufacturer's data. When requested by the Project Manager,
manufacturer's type test certificates and testing documents shall also
be submitted for inspection;

(ii) the wiring diagram, scale plans, and details showing the method of
installation of lampholders, lamps, reflectors, transformers, control
gear and secondary feeds mounting bracket and support assembly
detailing leveling adjustment facilities as well as a complete bill of
materials; and

(iii) complete photometric data for the luminaries, including optical

performance rendered by an independent testing laboratory approved
and licensed by the British Standards Institute (BSI) or an equipment
testing laboratory reviewed by the Project Manager. This data shall be
developed according to methods of the International Commission of
Illumination (CIE) and shall include the following information as a
minimum:

- coefficients of utilization;

- luminance control table with data presented numerically and

graphically, showing maximum luminance of the fitting measured
at the shielding angles. Readings should be taken both crosswise
and lengthwise in the case of fluorescent fittings or in fittings with
an asymmetric distribution;

- candela distribution data, presented graphically and numerically, in

5° increments (i.e. 5°, 10°, 15°, etc.). Data developed for up and
down quadrants normal, parallel, and at 22-1/2°, 45°, 167-1/2° to
lamps if light output is asymmetric;

- zonal lumens stated numerically as shown in the photometric

specification; and

- overall efficiency.

(iv) Computerised lighting calculation to substantiate that the selected light

fitting can achieve the required illuminance and uniformity.

(b) The Contractor shall be responsible for preparing and submitting the
Contractors Drawings showing the exact locations, mounting levels together
with the mounting details of the luminaires for Project Manager’s review
without objection prior to the actual installation.

(c) The installation method and details shall be in compliance with manufacturer’s
recommendations and submitted to the Project Manager for review without
objection.
General Materials & Workmanship Specification 19/21 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 51 – General Lighting Systems
51.4.2 Samples

(a) The following samples of the proposed general lighting materials shall be
submitted to the Project Manager together with the particular referred to in
clause 51.4.1:

(i) samples of fluorescent luminaire as specified; and

(ii) sample of EXIT signs.

(b) Sample shall be an actual working unit of equipment to be supplied.

51.5 WORKMANSHIP

51.5.1 General

(a) All luminaires shall be fixed properly, securely and appropriately to the
structural elements, supporting frames, beams or columns.

(b) All recessed luminaires inside false ceiling shall be installed matching with the
adjacent grids and panels, air conditioning ductwork, pipeworks, other
services and ceiling support brackets but independent of them. The luminaries
shall be adequately supported from the structural ceiling but not on the false
ceiling, or other services, and in accordance with the manufacturer’s
recommendations and to the satisfaction of the Project Manager. They shall
only be allowed to be supported from the ceiling systems where these are
specifically designed to provide such support and reviewed without objection
by the Project Manager.

(c) The pendant modular luminaires shall be hanged by a proprietary hanging unit
comprising casing, galvanized steel internal bracket and steel rods / wires.

(d) For luminaires suspended or hanged at high level without false ceiling (e.g.
high bay lighting) or mounted on high level on beams or brackets (e.g. outdoor
floodlight), safety chains, reviewed without objection by the Project Manager,
of sufficient strength shall be provided to prevent accidentally falling during
servicing.

(e) Adjustment bolts and nuts of a luminaire which is mounted on high level shall
be captive to prevent accidental loss during servicing.

(f) All metal casing of the luminaries shall be properly earthed.

(g) Liminaires, other than those using tungsten filament lamps or fluorescent
lamps with electronic ballast, installed over rotating machinery, shall be
arranged so that at least two luminaires connected to different phases are
used to illuminate the moving parts of the machinery. Alternatively where
different phases are not available or the use of which is impracticable,
separate tungsten filament lamps shall be used in additional of discharge
lamps to eliminate the stroboscopic effect.

(h) All luminaires and lighting equipment, except self-finished (e.g. stainless steel
or anodized aluminium) shall have factory-finish unless otherwise specified.

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Section 51 – General Lighting Systems
 (i) A luminaire installed in a location within hand reach shall be of robust
construct, fitted with an impact-resistant transparent or diffusing front panel,
and shall have secret key fixings for the panel to the body of the luminaire.
Where necessary and specified, wire guards shall be fitted over the front panel
to give extra protection.

(j) All luminaires shall be fixed in a manner recommended by the manufacturers.

(k) All other conduits for the lighting installation shall be concealed or cast-in
concrete.

(l) LSOH and FR/LSOH copper cables shall be properly wired in conduits /
trunkings and accessories. In no circumstance shall the luminaire be used as
a cable route for cables connecting to other lighting or small power points.

51.5.2 Labelling of Luminaires

(a) Each luminaire shall be provided with a durable self-adhesive label which shall
clearly detail the unique no. with bar code and the manufacturers type. The
text on the labels shall be 10 mm high, coloured black on a white background.
The labels shall be located to the exterior of the luminaires in positions hidden
from normal view.

General Materials & Workmanship Specification 21/21 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 51 – General Lighting Systems
[this page not used]
SECTION 52 UNINTERRUPTIBLE POWER SUPPLY SYSTEM (UPS)

52.1 GENERAL

(a) UPS systems shall be designed to supply continuous electrical power under
normal operating conditions and to provide supply on failure or deterioration of
the normal mains and standby supplies.

(b) Protection

(i) the UPS shall have built-in self-protection against:

- over and under voltage power line surges;

- over voltage and voltage surges introduced at the output terminals by

parallel sources;

- load switching and circuit breaker operation in the distribution system;

- sudden changes in output load exceeding the rating limit; and

- short circuits at the output terminals.

(ii) information shall be generated within the UPS to maintenance personnel

regarding the reasons for tripping, with built-in self-protection against:

- power semiconductors in the UPS shall be fused with fast acting

fuses so that the loss of any one power semiconductor shall not
cause cascading failures. Each fuse shall be provided with a blown
fuse indicator on the control panel; and

- thermostats shall be fitted to monitor the temperature of the power

semiconductors, such that when over-temperature is sensed and
alarm should be raised first at intermediate temperature, the UPS
shall automatically be shut down and the critical load transferred to
the bypass source via the static bypass switch.

(c) Electrical Characteristic and UPS Performance

(i) operating input power:

the UPS shall be designed to receive power from the following sources:

mains input voltage 380V AC ±10%;

wiring 3-Phase, 4 wire and earth; and
frequency 50 Hz ±5%;

(ii) input power factor:

the power factor of the UPS as a load, with 100% full load, battery fully
charged, and input voltage ±10% of nominal, shall be from 0.85 lagging
to unity;

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Section 52 – Uninterruptible Power Supply System(UPS)
 (iii) system efficiency:
the efficiency of the UPS shall be at least 90% from half load to full load
with the battery fully charged; and 70% minimum for rated load while
recharging the battery;

(iv) harmonics on input voltage:

relative harmonic content shall not exceed 10% and harmonic
components shall not exceed values given in IEC;

(v) reflected input harmonics:

the RMS sum of all harmonics in the input current waveform contributed
by the rectifier shall not exceed 5% of the RMS value of the fundamental
with the UPS operating at rated voltage and current;

(vi) load unbalance capacity:

the UPS shall have the capability to accept up to 50% load unbalance, in
which the ratio of current in the most loaded phase to the current in the
least loaded phase does not exceed 1.5, provided the most loaded
phase current does not exceed the rated line current;

(vii) overload capabilities:

the UPS shall be able to supply 125% rated load for at least 10 minutes
and 150% rated load for at least 1 minute;

(viii) electromagnetic interference:

the equipment shall include screening as necessary for the suppression
of radiated interference; and

(ix) noise level:

the noise level shall not exceed 60 dB(A) measured.

(d) The UPS shall be designed for continuous reliable operation such that the
“Mean-Time-Between-Failures” (MTBF) for individual modules of the UPS viz.
rectifier/charger unit, inverter unit and static switch etc. shall be more than
8,760 hours.

(e) The “Mean-Time-To-Repair” (MTTR) of the UPS shall not exceed 1 hour. The
MTTR shall be the time excluding travelling time required to diagnose the fault
and restore the UPS to normal working condition by means of module
replacement at Site.

(f) Minimum Life of Service:

Unless otherwise specified, each UPS supplied shall be suitable for operation
with at least 15 years service life for major electrical components and 7 years
service life for major electronic components under Section 44.8 of this General
Materials and Workmanship Specification.

General Materials & Workmanship Specification 2/9 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 52 – Uninterruptible Power Supply System(UPS)
52.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document stated below, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 88/IEC 60269 Cartridge Fuse for Voltage up to and including 1000V AC

and 1,500V DC
BS EN 60076/IEC76 Power Transformers
BS 727 Specification for Radio Interference Measuring Apparatus
BS 800 Radio – Interference Limits
BS 5372 Specification for dimensions of cable terminations for multi-
core extruded solid dielectric insulated distribution cables of
rated voltages 600/1000V and 1900/3300V having copper or
aluminium conductors
BS EN 61558-2 Isolating Transformers and Safety Isolating Transformers
BS 6290 : Part 4 Lead-acid Stationary Cells and Batteries : Specification for
classifying valve Regulated Types
BS EN 61000-4-1/IEC Electromagnetic Compatibility for Industrial-Process
61000-4-1 Measurement and Control
BS 60146-1-1/IEC Semi-conductor Converters
60146-1-1
BS 60529/IEC529 Specification for Degrees of Protection Provided by
Enclosures (IP Code)
BS EN 60896 Stationary Lead-acid Batteries – General Requirements and
Methods of Test
BS EN ISO 3746 Determination of Sound Power Level of Noise Sources
Using Sound Pressure
BS EN 55014 Limits and Methods of Measurement of Radio Disturbance
Characteristics of Electrical Motor-Operated and Thermal
Appliances
BS 7430 Code of Practice for Earthing

52.3 MATERIALS

52.3.1 General

(a) The UPS shall consist of a rectifier/charger section, an inverter section, a

static bypass switch, manual by-pass switch, and all necessary controls. The
UPS shall be provided with a battery bank.

(b) All active electronic devices shall be solid state. All semiconductor devices
shall be hermetically sealed. All relays shall be dust tight.

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Section 52 – Uninterruptible Power Supply System(UPS)
 (c) The maximum working voltage, current and di / dt of all solid state power
components and electronic devices shall not exceed 75% of the ratings
established by their manufacturer. The operating temperature of solid state
component cases shall not be greater than 75% of their ratings. Electrolytic
capacitors shall be computer grade and be operated at no more than 75% of
their voltage rating.

(d) The UPS solid-state power switching circuits and control systems shall be
modular in construction for ease of maintenance and to minimize down time.
All solid-state power switching modules shall be draw-out type removable from
the front of the UPS.

(e) The UPS shall be designed to permit ready access to modules and
assemblies. The placement of parts, test points and terminals shall be such
that they are accessible for circuit checking, adjustment and maintenance
without the removal of any adjacent module or assembly.

52.3.2 Inverter

(a) The inverter unit shall be a solid state device capable of accepting the output
of the rectifiers/ chargers or battery and providing rated output within specified
limits.

(b) DC over-voltage trip and DC undervoltage alarms shall be provided. Inverters

shall be protected from excessive overloads by current limiting fuses.
Inverters shall be mechanically connected and disconnected from the critical
load by non-automatic, moulded case circuit breakers located inside each
module.

(c) The inverter shall be sized to supply the load in accordance with the following
requirements:

(i) output voltage:

- rated voltage = 380V, 3-phases, 4-wire and earth; and

- steady state voltage regulation = ±1% for a load between 0 and 100%
of full rated value irrespective of normal mains supply and DC voltage
levels within the limits specified;

(ii) transient voltage regulation, output voltage transients shall not exceed
±5% of rated voltage for a 100% load step change;

(iii) in all cases, the voltage shall return to within steady state tolerance in
less than 20 milliseconds;

(iv) output voltage adjustment:

±5% of nominal voltage;

(v) harmonic distortion: the inverter shall be provided with an output filter to
limit single and total distortion to less than 4% with no single harmonic
greater than 3%, irrespective of load and normal mains supply within the
limits specified;

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Section 52 – Uninterruptible Power Supply System(UPS)
 (vi) voltage unbalance, steady state (difference from the arithmetic average
of the three phases). Balanced loads: 1%; 50% unbalanced load as
described above: ±3%;

(vii) phase displacement: 120°±1/2° for balanced load; 120°±3° for 50%
unbalanced loads; and

(viii) output frequency:

- rated frequency = 50 Hz;

- in normal operation, the output frequency of the inverter shall be

synchronized to that of the bypass power supply (mains 2) within the
limits of 0.5 Hz;

- for mains 2 frequency variations exceeding these limits, the inverter

shall switch over to free running mode, with regulation providing an
output frequency to within: ±0.1% of the rated value; and

- frequency slew rate = 1 Hz/second minimum.

52.3.3 Rectifier/Charger

(a) Incoming AC power shall be converted to regulated DC output by

rectifiers/chargers which shall be the solid-state type with constant voltage or
constant current control circuitry.

(b) Output voltages from rectifiers/chargers shall not deviate by more than plus or
minus 1% due to primary input voltage and frequency variations and ambient
temperature variations.

(c) Rectifiers/chargers shall be capable of supplying an overload current not less

than 125% of full load current. Rectifiers shall be current limited against
greater loads demand. Input current limits shall be adjustable over the range
of 100 to 125% of the full load input under nominal operation conditions.

(d) Initial magnetization inrush surges shall be limited to 600% of the

rectifier/charger full load current.

(e) Rectifiers/chargers shall have a minimum power factor of 0.85 with nominal
input voltage and frequency and the inverters operating at full-rated load.

(f) Modules shall be provided with input circuit breakers and fuses for
disconnecting the rectifier/charger and overload protection.

(g) Rectifier/chargers shall have sufficient capacity to simultaneously supply full

load to the inverter and recharge a fully discharged battery to 100% capacity
within 10 hours.

(h) The rectifier/charger shall be equipped with a filter limiting the DC ripple
voltage to a value less than 1% of the DC voltage.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 52 – Uninterruptible Power Supply System(UPS)
52.3.4 System Bypass Switches

(a) System Mechanical Bypass Switch

The UPS shall be provided with an external mechanical bypass switch to

manually bypass the entire UPS for maintenance and service purposes. Load
transfer to and from the bypass source shall be a “make-before-break” type
switching such that disturbances seen by the load during a bypass shall not be
greater than that specified in this Specification.

(b) Static switch and bypass shall be provided as an integral part of the UPS.
Bypass switches shall include transfer control logic which shall automatically
transfer the load to bypass upon the following conditions:

(i) output overvoltage or undervoltage;

(ii) overload condition of a duration longer than 10 minutes;

(iii) overtemperature; and

(iv) inverter failure.

(c) Return to UPS mode of operation upon restoration of normal operating

conditions shall be automatic except for overload or inverter failure which
require a manual restart. Electromechanical transfers shall be break-before-
make.
The cubicle and controls shall:

(i) be free-standing, floor mounting;

(ii) require front access only for installation and maintenance;

(iii) be complete with the system mimic diagram, controls and metering in
the front face;

(iv) be all the same height and depth, suitable for bolting together in a suite;

(v) have top cable entry with removable undrilled gland plates;

(vi) be of reasonably insect, duct and waterproof, consistent with adequate

ventilation of all internal components;

(vii) be protected to IP 31 BS EN 60947-1 / IEC 144;

(viii) have lifting facilities;

(ix) have front doors that:

- are capable of opening 120 degrees;

- are fitted with a positive limit to opening; and

- do not distort when open, particularly if mounted components are

fitted; and

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Section 52 – Uninterruptible Power Supply System(UPS)
 (x) have terminations in accordance with BS 5372 Cable.

(d) Module control panels shall be furnished for modules equipped with the
following meters, controls, and indicators.

(i) metering of the following functions:

- AC input voltage;

- AC input current;

- AC input frequency;

- DC battery current;

- DC battery voltage;

- AC inverter voltage;

- AC inverter current;

- AC inverter frequency; and

- elapsed time;

(ii) controls:

- AC input breaker;

- DC battery breaker;

- AC output breaker;

- UPS module on;

- UPS module off;

- lamp test;

- horn silence;

- audible alarm volume control; and

- manual restart;

(iii) alarm monitoring:

- system normal;

- alarm;

- low battery;

- battery discharge;

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Section 52 – Uninterruptible Power Supply System(UPS)
 - output overload;

- synchronous loss;

- AC input failure;

- overtemperature;

- shutdown imminent; and

- on bypass;

(iv) a horn which shall be activated upon any UPS alarm or when the
inverter is on and the battery breaker is open; and

(v) fully automatic operation of the UPS shall be provided through the use of
microprocessor controlled logic. Operating and protection parameters
shall be computer controlled, to eliminate the need for manual
adjustments to compensate for component tolerances. The logic shall
include system and battery test capability to facilitate maintenance and
troubleshooting. Start-up, transfers, and battery recharge shall be all
automatic functions.

(e) Storage Batteries

(i) storage batteries shall be furnished for the UPS as a stored energy
source. The batteries shall be of heavy duty industrial type designed for
power services and have a proven serviceable life of at least 10 years.
Battery cells shall be rechargeable, low maintenance, high performance
lead-acid valve regulated type with cell containers of high impact plastic
to give a leak-proof seal. The ampere hour rating shall be sufficient to
maintain the UPS rated output at rated voltage for a period of 1 hour
minimum. The discharging and charging curves of the battery proposed
and calculations to substantiate that the battery bank provided is of
adequate ampere hour capacity shall be submitted. The battery shall
also be sized to operate throughout the range of ambient temperatures
as specified;

(ii) all battery cells shall be equipped with safety vent caps to prevent
internal cell explosions caused by internal pressure developed during
battery discharge or recharge. All terminal pillars, connectors and bolt
sets of the battery bank shall be coated with petroleum jelly; and

(iii) batteries shall be supplied with the following:

- rack protected with electrolyte resistant paint;

- intercell and inter-tier connectors protected with anti-corrosive plastic

covers; and

- special tools and fittings required to assemble the batteries.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 52 – Uninterruptible Power Supply System(UPS)
52.4 INSTALLATION

52.4.1 General

(a) All equipment, cabling etc. shall be installed in locations as indicated on the
Employer’s Drawings or as specified.

(b) All equipment except portable equipment shall be firmly held in place.
Fastenings and supports shall be adequate to support their loads with a safety
factor of at least three.

(c) The requirements on the provisions of cables, cable trays, conduit and
trunking etc. shall be in accordance with the relevant sections of the
Specification.

52.4.2 Equipment Earthing

All cabinet(s) shall be solidly bonded to a good earth in accordance with BS 7430
using adequate section of cable or busbar. The earth connection at the cabinet(s)
shall be made to the frame earth terminal provided l.

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Section 52 – Uninterruptible Power Supply System(UPS)
[this page not used]
SECTION 53 MOTORS

53.1 GENERAL

(a) All electric motors shall be of the high efficiency squirrel-cage induction type
and used for the application to the following areas or as specified:

(i) Fans;

(ii) Compressor; and

(iii) Pumps

(b) Noise and Vibration:

(i) all motor rotors shall be dynamically balanced. The vibration and noise
level generated by the motors shall not exceed the recommended
limits; and

(ii) operating noise of motors installed in plant rooms and air conditioning
ducts shall not exceed the sound power levels given below for all
conditions of loading:

Rating (kW) 0.75 4.0 7.5 15.0 37.0 75.0 150.0

Sound 64 69 74 79 86 91 94
Power (dBA)

(c) Minimum Motor Efficiency:

(i) unless otherwise specified, all motors shall have the minimum
efficiency in compliance with the Code of Practice for Energy Efficiency
of Electrical Installations.

Output Power (kW) 0.18 0.25 0.37 0.55 0.75 1.1 1.5 2.2

Minimum Efficiency 74.9 77.0 79.2 81.3 82.8 84.6 85.9 87.4
(%)

Output Power (kW) 3.0 4.0 5.5 7.5 11.0 15.0 18.5 22.0
Minimum Efficiency 88.5 89.4 90.4 91.3 92.2 93.0 93.4 93.8
(%)

Output Power (kW) 30 37 45 55 75 90 110 132

Minimum Efficiency 94.3 94.7 95.0 95.3 95.8 96.0 96.3 96.5
(%)

General Materials & Workmanship Specification 1/10 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 53 – Motors
53.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document stated below, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 88 Cartridge fuses for voltages up to and including 1,000V AC

and 1,500V DC
BS 88 : Part 2 Cartridge fuses for voltages up to and including 1,000V AC
and 1,500V DC. Specification for fuses for use by authorized
persons (mainly for industrial application)
BS 3790 Specification for endless wedge belt drives and endless V-
belt drives
BS 4941 Specification for motor starters for voltages up to and
including 1000 V AC and 1200 V DC
BS 5420 Specification for degrees of protection of enclosures of
switchgear and control gear for voltages up to and including
1000 V AC and 1200 V DC
BS 5512 Method of calculating dynamic load ratings and rating life of
rolling bearings
BS EN 60034-5 Rotating electrical machines. Degrees of protection provided
by the integral design of rotating electrical machines (IP
code). Classification
BS EN 60947-1 Specification for low-voltage switchgear and controlgear.
General rules
IEC 60034 Rotating electrical machines
IEC 60085 Thermal evaluation and classification of electrical insulation

53.3 MATERIALS

53.3.1 Motor Starters

(a) General Requirements

(i) starters shall be air break triple pole electro-magnetic contactor type.
Any no-volt release mechanism must be of the automatic resetting
type such that on the restoration of the supply the motor can re-start
automatically. A phase failure protective device shall be incorporated;

(ii) starters shall be provided complete with enclosures except where

required to be mounted upon composite control panels and shall be in
accordance with BS 4941. Enclosures shall provide protection of
person against contact with live or moving parts;

(iii) inside the enclosure, protection against ingress of dust and liquid and
protection against mechanical damage shall be in accordance with BS
4941 and BS 5420;

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 53 – Motors
 (iv) star/ delta starters shall have timers for automatic transition, calibrated
and adjustable; and

(v) all components shall be of non-hygroscopic, non-corroding material

and tropicalized. Operating coils shall be wound on nylon or similar
bobbins and vacuum impregnated with non-organic varnish or plastic
encapsulated.

(b) Type

(i) motors of more than 0.5 kW rating shall be provided with a starter
designed to perform the following functions efficiently and safely:

- to start the motor without damage to the drive or driven equipment

whilst regulating the starting current to the satisfaction of the
requirements of CLP Supply Rules and ensuring that at all stages
of starting, the motor will develop sufficient torque to accelerate the
load;

- to stop the motor;

- to prevent damage to the motor due to overload, under voltage,

disconnection of one phase, etc.;

- to prevent damage to reduced voltage started motors and danger

to personnel due to resumption of the electricity supply following a
failure;

- to limit the damage to the motor due to stalling or internal electrical

or mechanical faults by quickly disconnecting the supply; and

- to prevent damage to the motor or the starter itself due to improper

unskilled or hesitant operation or failure to complete a starting
sequence once it is connected.

(ii) in general, the following types of motor starters will be accepted

subject to conformation to the CLP Supply Rules:

Motors up to 0.5 kW output “ON/OFF” switch or

Direct-on-line starter
Over 0.5 kW and up to 7.5 kW Direct-on-line starter
Over 7.5 kW and up to 55 kW Star-delta starter
Over 55 kW Auto-transformer starter

where otherwise specified or shown on the Employer’s Drawings, soft-

start motor starter can be used in lieu of the starters mentioned above
to start motors over 2 kW;

(iii) each motor starter assembly shall comprise fused switchgear,

contactors, protection relays and associated accessories. For starter to
be installed in motor control switchboard, the whole unit shall be
enclosed in the switchboard from which no access can be gained to
adjoining sections of the switchboard;

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Section 53 – Motors
 (iv) all starters shall be of the electrically held-on pattern and shall not
release until the voltage falls below 75% of nominal value;

(v) all contactors shall be of the electro-magnetic type and shall comply
with BS EN 60947-1, utilization category AC-3. The duty rating of the
contactors shall not be less than intermittent duty class 0.1 60% on-
load factor;

(vi) control circuits shall be operated on mains supply derived from the
control panel or switchboard, and protected by fuse to BS 88 : Part 2;
and

(vii) where duplicate equipment is provided, the starter for each equipment
shall be housed in a separate panel. Unless otherwise indicated,
where equipment is provided with duplicate motors, two starters shall
be supplied.

(c) Direct-on-line (DOL) Starters

(i) motors rated below 7.5 kW shall be direct-on-line started provided that
the maximum starting current does not exceed six times the rated
motor full load current, otherwise star-delta starters shall be provided;

(ii) the starters shall be equipped as the following provisions:

- fused switchgear;

- a triple pole motor protection unit incorporating over-current and

single-phasing protection with manual reset facilities. The over-
current protection unit shall be of the thermal type, with minimum
setting of 110% of full load current;

- triple pole air break contactor;

- under-volt release protection device: unless otherwise specified, it

shall be arranged to provide automatic restart on restoration of
mains voltage;

- current transformers with suitable ratio, output and accuracy for

motor protection;

- local/off/remote control selector switch lockable in each position;

- start and stop push buttons;

- indicating lamps for motor running, off and tripped on fault;

- dry contacts wired to terminals for remote indication of, motor

running, off, tripped on fault and summary alarm to supervisory
control panels;

- terminals wired to provide for connection to emergency stop push

button and remote start/stop of the motor;

- hour run meter;

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Section 53 – Motors
 - lamp test button; and

- any other items required to effect satisfactory motor starting and

control.

(d) Star-delta Starters

(i) motors rated at and above 7.5 kW and up to 55 kW shall be star-delta

started to limit the maximum starting current to within 2.5 times the
rated motor full load current;

(ii) star-delta starters shall be equipped as per the DOL starters specified
above, with the following provisions:

- triple pole air break contactors with electrical and mechanical

interlock arranged for automatic star-delta transition;

- calibrated and adjustable solid state timer for automatic star-delta

transition; and

- a triple pole motor protection unit incorporating over-current,

single-phasing and earth leakage protection with manual reset
facilities. The over-current protection unit shall be of the thermal
type, with a minimum setting of 110% of full load current. The earth
leakage protection unit shall be selected to isolate the motor circuit
with a maximum fault disconnection time of 5 seconds in case of
earth leakage without causing nuisance tripping of the motor circuit
due to motor starting and transient current transformer saturation.

(e) Auto-transformer Starters

(i) motors rated above 55 kW shall be reduced voltage started by means

of auto-transformer to limit the maximum starting current to within 2.5
times the rated motor full load current;

(ii) reduced voltage starters shall be equipped as per the star-delta

starters specified above, with the following additional provisions:

- triple pole air break contactor with electrical and mechanical

interlock arranged for automatic reduced voltage transition;

- air-cooled copper winding auto-transformer with class F insulation

enclosed in an earthed metal casing suitably ventilated by splash
proof IP 55 louvres. Suitable tappings shall be arranged for closed
transition reduced voltage motor starting; and

- calibrated and adjustable solid state timers for switching over from
reduced voltage to full voltage connection.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 53 – Motors
 (f) Soft-start Motor Starters

(i) soft-start motor starters shall be equipped with the following provisions:

- enclosure of softstarter shall be protected to at least IP44 for

indoor and IP55 for outdoor application by a single front-access
enclosure and shall be suitable for operation without derating
under ambient temperature of up to 50℃ and relative humidity of
up to 95%;

- heat sink of the softstarter shall be of good quality aluminium

construction and shall provide sufficient thermal inertia to permit
successful starting of the motor without exceeding the solid state
AC switches permitted junction temperature;

- softstarter shall provide auxiliary contacts for end of starting (by-

pass) and fault condition. The output relay contact shall be suitable
for 220V AC operation in category AC11 and DC operation in
category DC11;

- semiconductor fuses shall be available as an option and have the

characteristics suitable to protect the softstarter; and

- an isolation contactor or isolator shall be available as an option to

isolate the supply in the ‘Off’ stage to the softstarter for the safety
of the operator.

53.3.2 Motor Overload Protection Devices

(a) All motors shall be protected by three pole bimetallic overload protection
devices incorporating inherent ambient temperature compensation and single
phasing protection with different action. Overloads shall be adjustable within a
range of plus or minus 10% of the thermal setting.

(b) Overload protection relays shall be manual reset.

(c) Overload protection relays shall have the following additional features:

(i) block type for mounting direct to the contactor up to a rating of 15 kW

and separate mounting above that size;

(ii) current rating to suit contactor sizes;

(iii) same manufacture as contactor; and

(iv) short circuit proof.

(d) All motors rated above 15 kW and variable speed motors rated above 2.2 kW
shall also incorporate thermistors monitoring all phase windings of motors;

(e) Thermistors shall be wired in series to a thermistor protection unit and shall be
manual reset.

(f) Thermistor protection units shall compensate for fluctuations in supply voltage
and shall be compatible with the thermistors embedded in the motor windings.

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Section 53 – Motors
 (g) The thermistor protection unit shall be incorporated in a motor protection relay
and have the following protective features:

(i) thermal overload protection, pre-warning and indication;

(ii) single phasing and phase asymmetry protection and indication;

(iii) thermistor protection and indication;

(iv) adjustable time/current characteristic curves to allow for motor

acceleration times from 2 to 29 seconds ensuring full motor protection
during start up;

(v) inbuilt or remote current transformer on each phase;

(vi) overcurrent indication;

(vii) fitted with test and manual reset button;

(viii) the power supply to the motor protection relay shall be from a source
which is not interrupted by normal stop-start operations; and

(ix) Plant shall also incorporate protection recommended by the relevant

manufacturer.

53.3.3 Low Voltage Electric Motors

(a) Motors shall be rated for continuous operation.

(b) Minimum power factor shall be 0.85.

(c) Motors shall be totally enclosed fan cooled.

(d) Eye hooks shall be provided for all motors over 10 kg.

(e) All electric motors shall comply with the relevant parts of IEC 60034.

(f) The motors shall be insulated IEC 60085 with Class F as the minimum
insulation.

(g) Motor enclosures shall be in accordance with BS EN 60034-5 and the 'degree
of protection' shall be appropriate to the location in which the motors are
operating and the environment indicated. Unless otherwise specified, motors
shall be protected with enclosures to at least IP 44 for indoor and IP 55 for
outdoor application.

(h) Motors of 2.2 kW output or above shall be suitable for operation from three-
phase supply. Single-phase motors could be used for output power under
2.2kW and whenever in appropriate applications.

(i) Unless otherwise specified, the synchronous speed of the motor shall be 1450
rpm or 2900 rpm.

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Section 53 – Motors
 (j) Starting Torque and Current:

(i) Motors shall have starting torque characteristics to suit the connected
load and the type of starting, in particular where reciprocating
compressors will be used and not fitted with starting unloaders.

(ii) Starting current conditions shall conform to the requirements as

stipulated in the CLP Power Supply Rules.

(k) Tachometers

(i) All cases of direct drive (except hermetic), an application point shall be
provided for speed checking by a tachometer.

(l) Terminal Box

(i) Terminal boxes shall be mounted on the starter casing only. Each
phase of stator shall be brought out to a terminal in the box.

(ii) Terminal boxes shall be constructed of cast iron or a non-ferrous

material, drilled and tapped to accept conduit or cable glands.

(iii) Terminal blocks shall be constructed out of high grade insulating

material of sufficient strength to support the incoming cables and
terminations under fault conditions.

(iv) Terminal boxes shall be capable of being rotated 360° to allow at least
4 different orientations for cable entry.

(v) Terminals for thermistor elements and anti-condensation heaters shall

be segregated from power terminals by insulating barriers or separate
compartmentation.

(vi) Terminals blocks shall be arranged to enable ease of access for

maintenance.

(m) Anti-condensation Heater

(i) Anti-condensation heaters shall be provided in pump and motors

located inside any deep or damp conditions, or motors above 30 kW.

(n) Belt Drives and Pulleys

(i) Belt drives shall comply with BS 3790 and be capable of transmitting at
least the rated power output of the driving motor with one belt
removed. A minimum of two belts per drive shall be used and all multi-
belt drives shall use matched sets.

(ii) Slide rails shall be provided for all motors driving through belts.
Purpose-made adjusting devices shall be provided to enable belt
tension to be altered and motors to be secured.

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Section 53 – Motors
 (iii) Belt driven fans shall be fitted with pulleys suitable for the belt drive
used. Pulleys shall use split taper bushings for drives up to 30 kW. For
drives rated at above 30 kW, pulleys shall be secured to the fan and
motor shafts by keys fitted into machined keyways. Keys shall be
easily accessible so that they can be withdrawn or tightened.

(o) Protective Guards

(i) Protective fixed guards shall be provided at all open intakes and
exhausts from fans, for all forms of open power transmission systems
including belt drives and drive couplings, and to dangerous parts of
machinery to avoid inadvertent access or contact. Guards shall comply
with the safety requirements stipulated by the Labour Department.

(ii) For belt drives, the guards shall be of galvanized steel wire of not less
than 2.5 mm diameter attached to a rigid galvanized steel rod or angle
framework. The mesh size and the location of the guard shall prevent
finger contact with any enclosed danger point. Removable access
panels shall be provided in guards to allow tachometer readings to be
taken on both driving and driven shafts and also belt tension to be
tested. The sizes of guards including the dimensions and locations of
access panels shall allow for the limits of motor position.

53.3.4 Motor Bearings

(a) Motors up to and including 4 kW shall be fitted with ball bearings at both ends.
Motors over 4 kW shall be fitted with roller or deep groove ball bearings at the
driving end and deep groove ball bearings at the non driving end. Motors
driving equipment that develops end thrust and motors operating with shafts in
a vertical position, shall be equipped with bearings designed to counter
unbalanced end thrust.

(b) Bearings shall have a minimum L10 life of 100,000 hours at design conditions.
Rolling bearings shall be selected in accordance with BS 5512.

(c) Bearings shall be located in suitable housings with efficient shaft seals to
prevent the entry of impurities and the escape of grease. Housings shall be
fitted with accessible, capped grease nipples and relief plugs to enable
bearings to be lubricated without the removal of end caps and without the risk
of pressure build up. Motors shall be delivered with bearings lubricated using a
lithium based grease suitable for minimum bearing temperatures of 150°C.

53.3.5 Variable Frequency Drives

(a) All Variable Frequency Drives (VFD) shall be purpose built for fans and
pumps, individually factory tested packaged units and shall include but shall
not be limited to the following:

(i) Power rectifier;

(ii) Variable frequency inverter with a sine weighted Pulse Width

Modulating (PWM) output suitable for the control of IEC 3 phase
induction motors without requiring the motors to be de-rated or causing
the motor’s temperature to rise above the class B rise;

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Section 53 – Motors
 (iii) Microprocessor based control system with local display;

(iv) Local manual controls;

(v) Fault Protection Facilities; and

(vi) MBMS interface facilities.

(b) The Contractor shall submit to the Project Manager, for review without
objection, full technical details of the VFD proposed demonstrating the
suitability of the proposed connected loads before the VFD are ordered.

(c) A separate isolation contactor shall be provided in the corresponding motor

control centre for each VFD. The Contractor shall isolate the VFD main
supply and associated motor whenever the relevant system is shutdown
automatically or manually. The control signal to the VFD shall not be isolated
when the VFD main supply contractor is de-energised.

(d) Function of the blower motor shall be driven by variable frequency drive (VFD)
for maximum efficiency.

(e) The VFD shall vary the output frequency based on the demand imposed by
the programmable controller to adjust the speed of the blower motor.

(f) The VFD shall intercept the inrush of staring current from reaching the blower
motor and bring the blower up to operating speed gradually thus reducing
inrush current.

(g) The VFD shall be completed with a cooling fan to provide heat dissipation for
the internal components.

(h) VFD shall be constructed to conform with IP42 (or IP55 in exposed locations)
in accordance with IEC 529.

(i) VFD for the unit shall be suitable for mounting internally inside the unit and
shall withstand the vibration whilst in service.

53.4 SUBMISSIONS

53.4.1 Particulars of Motors

(a) The following particulars of the proposed motors shall be submitted to the
Project Manager for review without objection :

(i) description of motor and its components;

(ii) Contractor’s drawings including outline dimensions, weight, mounting

and fixing details of motors;

(iii) Contractor’s drawings including electrical control wiring diagrams

showing the details of all wiring in the motor control panel, panel layout
with all dimensions, and mounting details of the panel; and

(iv) motor speed-torque, current, efficiency and power factor curves

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Section 53 – Motors
SECTION 54 HIGH VOLTAGE ELECTRICAL SERVICES

54.1 GENERAL

(a) The HV electrical services specified in this General Materials & Workmanship
Specification include:

(i) HV switchgear;

(ii) Distribution Transformer; and

(iii) HV cable

(b) High voltage shall refer to voltage above 1kV and up to 11kV. All equipment
specified here shall be capable of operating continuously, in normal situation
at voltage of 11 kV.

54.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as at the date of the Letter of Acceptance.

BS 142 Electrical protective relay

BS 171 Specification for power transformers
BS 171 : Part 5 Power transformers. Specification for ability to withstand
short circuit
BS 923 Guide on high-voltage testing techniques
BS 2692-2 Fuses for voltages exceeding 1,000V AC expulsion fuses
BS 3941 Specification for voltage transformers
BS 5311 Specification for high-voltage alternating-current circuit-
breakers
BS 5691 : Part 2 Guide for the determination of thermal endurance
properties of electrical insulating materials. Choice of test
criteria
BS 6121 Mechanical cable glands
BS 6360 Specification for conductors in insulated cables and
cords
BS 6436 Specification for ground mounted distribution
transformers for cable box or unit substation connection
BS 6622 Specification for cables with extruded cross-linked
polyethylene or ethylene propylene rubber insulation for
rated voltages from 3.8/6.6 kV up to 19/33 kV
BS 6724 Specification for 600/1,000V and 1,900/3,300V armoured
electric cables having thermosetting insulation and low
emission of smoke and corrosive gases when affected by
fire
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Section 54 – High Voltage Electrical Services
 BS 7655 Specification for insulating and sheathing materials for
cables
BS 7671 Requirements for electrical installations. IEE Wiring
Regulations. Sixteenth edition
BS 7806 Dry-type power transformers
BS 7844-2 Three-phase dry-type distribution transformers 50 Hz,
from 100 to 2,500 kVA with highest voltage for equipment
not exceeding 36 kV.
BS 7888 Test requirements for MV accessories
BS EN 50267 Common test methods for cables under fire conditions
BS EN 60044 Instrument transformers
BS EN 60076 : Part Power transformers. Determination of sound levels
10
IEC 551 Measurement of transformer and reactor sound level
IEC 726 Dry-type power transformers

54.3 HV SWITCHGEAR

54.3.1 Vacuum Circuit Breaker (VCBs) and Trucks

(a) All VCBs shall comply with BS 5311 and shall be of trip-free, totally enclosed,
metal clad, vertical isolation and horizontal draw-out type and shall meet the
following requirement:

Characteristics of circuit-breaker
Number of poles: 3
Class: Indoor
Rated voltage: 12kV
Rated lightning impulse withstand 75kV (peak)
voltage:
Rated one-minute power frequency 28kV
withstand voltage:
Rated frequency: 50Hz
Rated normal current: As shown on the Employer’s
Drawing
Rated short-circuit breaking current: 20kA (3 second)
Rated short-circuit making current: 50kA
Rated operating sequence: 0-3 min-close open-3 min-close
open
Rated duration of short-circuit: 3 seconds
Rated transient recovery voltage for as per BS 5311
terminal faults:

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Section 54 – High Voltage Electrical Services
 Characteristics of circuit-breaker
Power supply characteristics
Operating voltage: 11kV + 10% and –2.5%
Operating frequency: 50Hz ± 2.0%
Characteristics of the operating mechanism of circuit-breaker:
Method of closing operation: motor-charging spring-powered
stored energy type/solenoid
closing
Rated supply voltage: 220V AC for closing 110V DC
for tripping

(b) The moving portion of each circuit breaker, in the form of a four wheeled truck
which carries the circuit breaking system, operating mechanism, moving
isolating contacts, controls, indicators and all the necessary control wiring,
shall have 3 distinct positions; “disconnect”, “test” and “service”. Connection
to the trip and close coils, motor circuits and control/indication devices on the
moving portion shall be via auxiliary contacts which shall automatically engage
when the truck is in the “service” and “test” positions.

(c) The moving portion of each circuit breaker shall be earthed in an effective way
which shall be submitted to the Project Manager for review without objection.
Apart from the current carrying parts, the carriage and all metal parts of the
circuit breaker truck shall be solidly earthed via the fixed portion.

(d) Circuit breakers of the same current rating shall be fully interchangeable.
Means shall be provided to prevent circuit breakers from being placed into
housings of different ratings. This device shall also prevent damage to the
isolating and other contacts.

(e) The circuit-breaker shall be provided with interlocks of the mechanical type to
prevent the following operations:

(i) withdrawal or engagement of a circuit breaker when it is closed.

Attempted isolation shall not trip the circuit breaker;

(ii) closing of the circuit breaker unless the movable portion is correctly
plugged in or isolated from the equipment;

(iii) circuit breaker being closed in the “service” position without completing
the appropriate auxiliary circuits, or the auxiliary circuits from being
interrupted when circuit breaker is in the “service” or “test” position;
and

(iv) the movable portion being withdrawn or replaced unless the circuit
breaker is isolated and in the appropriate position.

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 (f) The circuit breaker operating mechanism shall be of the motor-charging spring
powered stored energy type, mechanically and electrically trip-free, suitable
for operation within 70 to 110% of its rated operating voltage. The closing
spring shall be automatically recharged after the circuit breaker is closed. The
time required for spring recharging shall not exceed 5 seconds at rated supply
voltage. It shall also be provided with means for charging the springs by hand
in the event of a power supply failure. Mechanical indication shall be provided
to indicate the status of the spring.

(g) The circuit breaker operating mechanism shall be fitted with an electrical
closing and shunt trip coil and a mechanical hand tripping device. The device
shall be a TRIP/NEUTRAL/CLOSE control selector switch, spring returned to
neutral position. The switch shall be lockable in the neutral position. In
addition, anti pumping devices shall be incorporated to ensure positive
operation.

(h) Integral earthing facilities shall be provided for both incoming/outgoing cables
and busbars and shall be of the transfer circuit breaker arrangement. Labels
shall be provided to show whether the equipment is prepared for “service”,
“busbar earth” or “circuit earth”.

(i) For each circuit breaker a mechanically operated indicating device shall be
provided that indicates the breaker positions.

(j) Provide a contact wear gap indicator for each circuit breaker.

(k) Each circuit breaker shall include a mechanical counter to register the number
of breaker operations. The counter shall be non-reversible with the indication
of 4 digits or above.

54.3.2 Protective Relays

(a) Protective relays shall comply with BS 142.

(b) Protective equipment and relays shall be designed to disconnect faulty circuits
effectively, without interfering with other healthy circuits. The Contractor shall
ensure full discrimination throughout the HV electrical system and submit for
review without objection by the Project Manager the recommended relay
settings, supported by design calculations, for all protective relays being
supplied. Liaise with the power company and coordinate with their incoming
supply system.

(c) Protective circuits shall be designed to reduce the standing load on the DC
supply to the minimum.

(d) The housing of all relays shall be dustproof cases. All metal bases and
frames of the relays shall be earthed except where the latter must be insulated
for special requirements. All principle protection relays shall be of a draw-out
pattern, and flush mounted on the front of the relay compartment. A filter
shall be fitted which shall equalize the pressure inside and outside the case
without admitting dust. For over-current relays, three single-phase units in
one horizontal plane shall be housed in a common casing. Auxiliary relays
accommodated internally shall be mounted so as to be easily accessible for
inspection and wiring.

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 (e) “Current Transformer” (CT) operated relays shall be provided with shorting
contacts which shall short circuit the associated current transformers on
withdrawal of the relays.

(f) Operation indicators shall be provided for all relays that are designed to trip
the circuit breakers to identify the type or phase of the fault condition. The
relays shall preferably be of the electro-mechanical type, capable of being
reset by hand without opening the relay case.

(g) All relay contacts shall be capable of making and breaking the maximum
current that may occur under fault conditions in the circuits in which they are
connected.

(h) One set of test plug, universal test block and sufficient plugs and flying leads
shall be provided to facilitate testing of the principle relays in draw-out cases.

(i) Furnish all the necessary protective relays, control and auxiliary relays to
provide for local and remote indications and/or control of the circuit breakers.

(j) Particular requirements for inverse definite minimum time overcurrent and
earth fault relay shall be as follows:

(i) the relay shall have an inverse definite minimum time/current

characteristic according to BS142. The relay shall be calibrated to 50Hz
and falls into error class index E7.5. The frequency error shall be less
than 8% for frequency variation of 2 Hz;

(ii) shunt reinforcing auxiliary attracted armature unit with a hand reset
operation indicator shall be used;

(iii) the relay shall have the following characteristics:

Current setting:
For overcurrent relay - 50 to 200% of 5A, adjustable in 7 equal
steps
For earth fault relay - 10 to 40% of 5A, adjustable in 7 equal steps
Time setting:
0 to 3 seconds at 10 times current setting; and

(iv) auxiliary unit operation voltage: 110V DC.

(k) Particular requirements for inverse time undervoltage relay shall be as follows:

(i) the relay shall have an adjustable inverse time/voltage characteristic

manufactured to BS 142. Shunt reinforcing auxiliary armature units
with a hand reset operation indicator shall be used;

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Section 54 – High Voltage Electrical Services
 (ii) the relay shall have the following characteristics:

Current setting:
50 to 90% of 11kV adjustable in five equal steps.
Time setting:
0 to 5 seconds at zero voltage; and

(iii) auxiliary unit operation voltage: 110V DC.

(l) Particular requirements for trip circuit supervision relay shall detect the failure
of trip supply, trip coil and trip circuit wiring open circuit and failure of circuit-
breaker tripping mechanism. It shall be able to detect trip circuit abnormalities
with circuit-breaker in either opened or closed states except for earthing
positions. The relay shall have 2 pairs of normally closed and 1 pair of
normally open contacts.

54.3.3 Current Transformer (CT)

(a) All CTs shall be designed to operate at a system voltage of 11kV and comply
with BS EN 60044.

(b) CTs shall be suitable for the operation of protective relays, instruments and
metering equipment and the characteristics shall be of a type reviewed without
objection by the Project Manager.

(c) All CTs shall be of low reactance type and bar-primary design, epoxy resin
moulded type, and shall be able to withstand the anticipated short circuit
current for the associated circuit breaker as well as a 1 minute open circuit on
the secondary with the primary carrying the rated current.

(d) CTs shall have an output rating adequate to cater for all the loads connected
to them. They shall have sufficient rating, terminal voltage, accuracy and
overcurrent performance for the satisfactory operation of their associated
equipment.

(e) All connections from the secondary windings shall be brought out and taken
by means of separate insulated leads to a terminal board mounted in an easily
accessible position. All current transformers shall be adequately labeled to
indicate the polarity, ratio, class and duty of each transformer. For multi-ratio
secondary windings CTs, the Contractor shall provide labels to indicate the
connections required for each ratio.

(f) The secondary windings of each set of CTs shall be earthed. The earth
connection shall be made via a removable link.

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 (g) Notwithstanding the above, the CTs shall meet the following minimum
requirements:

Class of insulation: Class B

Rated one-minute power frequency 28 kV
withstand voltage:
Rated lightning impulse withstand voltage: 75 kV (peak)
Rated secondary current: 5A
Rated short time current: Primary current of 20 kA
for 3 seconds
Rated dynamic current: Primary current of 50 kA
(peak)
Accuracy class for measuring current Class 1
transformers:
Accuracy class for protective current Class 5P (for O/C & E/F)
transformers:
Class X (for pilot wire
feeder protection relays)

(h) The product of the rated output and rated accuracy limit factor of the CT shall
be not less than 150.

54.3.4 Voltage Transformer (VT)

(a) All VTs shall be designed to operate at a system voltage of 11 kV and comply
with BS 3941.

(b) Voltage transformer shall be suitable for the operation of protective relays,
instruments and metering equipment.

(c) All VTs shall be of epoxy resin moulded type and shall be able to carry 50%
load above their rated load indefinitely without damage.

(d) VTs and their associated primary fuses shall be of withdrawable type, and
shall be provided with an automatically operated safety shutter in an
independent compartment. VTs shall have the “service” and “disconnected”
positions with a mechanical indicator visible from the outside. Facilities for
padlocking in the primary fuses, a mechanical interlock shall be provided so
that the access lid can be opened only when VTs are in the “disconnected”
position.

(e) All connections from the primary and secondary windings shall be brought out
and taken by means of separate insulated leads to separate terminal boards
mounted in an easily accessible position. All terminals shall be adequately
labeled to indicate their function, phase, ratio, class and duty of each
transformer.

(f) Each phase end of the secondary winding shall be brought out to fuses, and
the neutral end shall be brought out to insulated links. Each of the neutral
leads shall be connected together at a single point and earthed through a link
which can be removed for insulation testing.

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 (g) VTs for measurement shall be connected star-star with the neutral points
earthed. The earthing of VTs shall be of a design reviewed without objection
by the Project Manager.

(h) Notwithstanding the above, VTs shall meet or exceed the following
requirements:

Class of insulation: Class B

Rated one-minute power frequency withstand voltage: 28 kV
Rated lightning impulse withstand voltage: 75 kV (peak)
Accuracy Class: Class 1

54.4 DISTRIBUTION TRANSFORMER

54.4.1 General

(a) The requirements for the resin encapsulated, dry type power transformers are
as detailed herein.

(b) The rating of transformers covered by this General Materials & Workmanship
Specification shall be 1500 kVA except where otherwise noted on the
Employer's Drawings.

(c) The transformers shall be designed and suitable for a 25 years life. The
transformer manufacturer shall provide a 5 year warranty from initial
energisation. The form of the warranty shall be reviewed without objection by
the Project Manager.

(d) The transformers shall be of robust construction to BS 171 and capable of

being transported, installed and removed without damage.

(e) Suitable facilities for “securing” the transformers during transport shall be
provided.

(f) The bearing surface of all bolt heads and nuts shall be parallel to the surface
onto which they tighten. Where necessary, angled washers shall be provided
to meet this requirement.

(g) All metal parts, except core laminations shall be hot dipped galvanised.

54.4.2 Operating Conditions

(a) Transformers will be installed indoors.

(b) The service conditions shall be as specified in this General Materials &
Workmanship Specification with the exception that the maximum air
temperature shall be 45°C and the average daily and annual air temperature
shall not exceed 35°C and 25°C respectively.

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 (c) The transformers shall be manufactured and tested in accordance with the
requirements of BS 171 Power Transformers parts 1 to 5 inclusive.

(d) The transformers shall be entirely suitable for continuous operation under the
conditions specified herein at full rated output and shall include all equipment
necessary for the safe and convenient installation, operation and maintenance
of the plant.

54.4.3 Rated Voltage Ratio

(a) The transformers shall be capable, when the primary windings are energized
at 50 Hz with three phase 11,000 voltage, of giving 380 volts between phases
and 220 volts between each phase and neutral, at no load, at the secondary
terminals.

54.4.4 Insulation Level

(a) The insulation of the HV windings shall be designed to withstand impulse

voltage testing, including chopped waves in accordance with BS 171.

(b) The impulse voltage withstand and the power frequency voltage withstand of
the HV windings and connected parts for each transformer shall be 75 kV
peak and 28 kV rms respectively.

(c) The highest voltage on the 11 kV system is 12.0 kV.

(d) All insulation components shall be Class F (155°C).

54.4.5 Cooling

(a) Transformer design shall ensure compliance with the permitted temperature
rise requirements specified in Part 2 or BS 171.

(b) The method of cooling each transformer shall be AN. Transformers shall
however be designed and manufactured to facilitate the future addition of fans
for forced cooling to allow the transformer rating to be increased by a
minimum of 33.3% (i.e. to a minimum rating of 2,000 kVA).

(c) The transformers shall be manufactured with all mounting attachments and
components necessary to facilitate the future addition of cooling fans including
control and wiring provision for fans and alarm circuits. Items and/or
components which cannot be easily retrofitted shall be installed during
manufacture of the transformer, electrical connections associated with the
future forced cooling system shall be prewired to terminals.

(d) The Contractor shall include with their submission, all technical information
and modifications required to the proposed transformers for incorporation of
the forced ventilation system. Details shall be submitted assuming the
modifications will be carried out during the service life of the transformer, i.e.
subsequent to commissioning.

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54.4.6 Noise

(a) The design and construction of each transformer shall be such that its noise
level is kept as low as possible. In any case it shall not exceed an audible
sound level of 59db(A) at one metre from the surface of the transformer
enclosure, measured in accordance with IEC 551.

54.4.7 Tappings

(a) Each transformer shall be capable of off-circuit tap changing by means of links
on the HV winding.

(b) Five tappings shall be provided on the high-voltage winding. The principal
tapping shall correspond to the rated voltage as specified above. The tapping
range shall be ±5 percent of the rated voltage with voltage steps of 2.5 percent.
(i.e. ±5%, ±2.5%, 0%).

(c) Each tapping position shall be clearly identified to show which tapping of the
transformer is in use. Tapping position no. 1 shall correspond to the full
winding in circuit, that is, the maximum “plus” tapping.

(d) Tapping links shall be tin plated to provide resistance against corrosion.

(e) A warning notice shall be installed adjacent to the tapping links, worded as
follows:

“-Warning-“
“Isolate HV and LV supplies to transformer before changing tapping
position”

54.4.8 Impedance

(a) The impedance of the transformers at rated current on the principal tapping
shall be

(i) 6% for the 1500 kVA transformers; and

(ii) 10% for the 2500 kVA transformers; except where otherwise noted on
the Employer's Drawings.

(b) The above impedance values shall be guaranteed and shall be subject to the
allowable tolerances as set out in BS 17l. Details shall be submitted to the
Project Manager.

54.4.9 Flux Density

(a) The maximum flux density at any point in the core shall be such that with
normal primary voltage of sinusoidal waveform applied to the primary
terminals with the transformer on maximum negative tapping, the magnitudes
of the 5th and 7th harmonic currents shall not exceed 15% and 5%
respectively of the fundamental value of the magnetising current.

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54.4.10 Winding Connections

(a) The transformers shall have electrically separate primary and secondary
windings. They shall be connected Delta-Star in accordance with the vector
group Dyn11.

54.4.11 Core and Windings

(a) Cores shall be cold rolled, grain orientated non-ageing transformer silicon
steel. The complete core shall be protected from the environment by the resin
coating.

(b) The core and all metalwork shall be electrically bonded to the transformer
frame. A bolted connection shall be provided in the core earthing strap to
enable disconnection and testing of the core insulation.

(c) Transformers with copper windings shall be offered, but details shall be
submitted clearly stating the type of windings proposed and whether they will
be of foil or radial wire construction. The winding shall be coated with epoxy
resin and fibre-glass filler, wound as in the "RESIBLOCK" method or applied
under vacuum at a high temperature to avoid formation of undesirable gas
bubbles. After encapsulation, the winding shall be maintenance free, damp
proof and fire retardant. If fire occurs, no toxic or explosive gases are to be
generated.

(d) HV connections to the tapping switch shall be reinforced by means of cup

washer.

(e) The core and coils of each transformer shall be substantially supported and
mechanically braced, to prevent distortion and to withstand the effect of
vibration, transportation and all mechanical shocks which may occur under
working conditions, including those produced by short circuits.

(f) The core and winding assembly shall be readily removable from the
transformer enclosure for inspection and shall be secure from movement
inside the enclosure during normal handling or transport.

(g) The windings shall be designed to withstand ail dielectric, electro-magnetic

and thermal stresses which might occur in service including those produced
by shortcircuits.

(h) The LV winding shall be manufactured with the conductor and insulating
material bonded together by heat treatment to form a compact unit which is
sealed against moisture.

(i) The maximum temperature rise limit for the HV/LV windings shall be the same
as the temperature rise limits given in BS 171: Part 2 : 1978 but reduced by
10°C to compensate for the higher average annual temperature in Hong Kong.
The maximum temperature rise will be the value at peak ambient of 45°C
inside the substation when the transformer delivering full load.

(j) The transformer shall include surge diverters or other methods reviewed
without objection by the Project Manager to protect windings from switching
surges.

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54.4.12 Temperature Monitoring

(a) Each transformer shall be protected from undue high temperature rise by a
temperature warning system comprising resist sensitive thermal sensors
located in the upper region of each low voltage winding (hot spot). Two
sensors shall be provided for each phase, each linked to a relay and wired in
series to a terminal block, mounted on the upper core clamp.

(b) These relays shall provide facilities for alarm and tripping and shall include
relays with one pair of N/C contacts for alarm purposes and one pair of N/O
contacts for tripping purposes.

(c) A temperature indication system, incorporating facilities for control of the

future cooling fan, shall be provided comprising a capilliary thermostat with a
0-175°C thermometer, complete with adjustable 10A rated, 220 volt, contacts
for the starting and stopping of the cooling fan. The contacts shall have a
50oC differential between making on rising temperature and opening on falling
temperature. The thermometer shall be mounted on the outside of the
enclosure.

(d) Output contacts shall be adjustable and shall be connected to a terminal block,
accessable from outside the enclosure, enclosed in a sheet steel adaptable
box and suitable for termination of 4mm2 cables and complete with knock outs
in the box for termination of cable glands.

(e) The setting of the various temperatures for the alarm, tripping and control
contacts shall be to the manufacturers recommendations. Details of proposed
settings shall be submitted to the Project Manager for review without objection.

54.4.13 Losses

(a) The transformer losses shall not exceed the following parameters.

(b) Maximum allowable losses are as follows, except where otherwise noted on
the Employer's Drawings, subject to the tolerances specified in BS 171 - IEC.
726:

(i) kVA rating 2500 kVA 1500 kVA

(ii) maximum allowable 4.5 kW 3.0kw

no load losses

(iii) maximum allowable 20kW 11.1kw

load losses

(iv) required impedence 10% on 2500 kVA base 6% on 1500 kVA base

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54.4.14 Dimensional Limitations

(a) Dimensions shall be as compact as practicable. The transformer dimensions,

complete with enclosures shall not exceed the following maximum dimensions;
full details of dimensions shall be submitted to the Project Manager for review
without objection.

(i) L=2400 mm max;

(ii) W=2000 mm max; and

(iii) H = 2500 mm max.

54.4.15 Rating and Terminal Marking Plates

(a) The appropriate designating letter and subscript numbers assigned to the
windings and tappings in accordance with BS 171 shall be deeply stamped or
engraved on plates affixed to the transformer upper frame. Phase colours
shall not be used, adhesive type labels are not acceptable.

(b) The rating and terminal marking plates shall be located on the transformers
remote from the high voltage termination in such a position that they can be
easily and safely read with the transformers in service.

(c) All quantities shall be stated in metric units.

(d) The rating and diagram plates shall be manufactured from either non-ferrous
metal or stainless steel with the lettering etched or otherwise formed in relief.

(e) The terminal working plate shall show a diagram of internal connections, a
legend stating which tappings are connected at each of the five tapping
selector switch positions and a voltage vector diagram.

(f) The rating plates shall show the measured value of impedance voltage at the
principal tap as obtained by test on each transformer.

54.4.16 Lifting Facilities

(a) Lugs shall be provided suitable for lifting the transformer when fully fitted out
and ready for service. They shall be positioned so that any slings attached
thereto do not foul with any part of the transformer and when suspended by
them, the transformer shall hang without tilting.

(b) All parts of the transformer, which must be removed for inspection or repair,
shall be fitted with lifting facilities suitable for use with slings and shackles.

54.4.17 Earthing Lug

(a) An earthing stud of 12 mm diameter with 50 mm of thread for connecting an

earth conductor shall be provided near the bottom of the transformer as close
as practicable to vertically below the secondary neutral terminal. The earth
stud shall be welded direct to the transformer frame. There are to be no bolted
connections in the electrical path between the stud and the transformer frame.

(b) The stud shall be of stainless steel. Painting and other non-conductive
coatings are not acceptable.
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54.4.18 Mounting Arrangement

(a) The transformers shall be skid mounted.

(b) Jacking lugs shall be provided at a height of 250 mm from the underside of the
base. A channel iron base shall be provided and fitted under the clamping
frame, with a set of 150 mm diameter wheels suitable for forwards and
sideways movement. It shall be possible to fit and remove the wheels without
entering the enclosure.

(c) Noise reduction anti vibration bearing blocks shall be built into the base to
provide effective isolation of vibration from the building structure. Blocks
designed for use under the wheels are not required, because wheels will
normally be removed.

54.4.19 Protective Housing

(a) Protective housing to a minimum of IP20 shall be provided. The enclosure

shall be constructed generally in accordance with the requirement for the
switch panel assemblies. Access to the enclosure shall be key interlocked with
the HV circuit breaker in the RMU. The housing shall be mounted onto the
transformer base at the manufacturer's works with the design suitable for site
assembly if substation location presents access entry problems. The bottom
part of the housing on the HV cable termination side shall be provided with an
access slot to allow the HV cable to be "rolled" into position. For maintenance
and periodic cleaning the side panels shall be easily removable. Bach panel
shall weigh not more than 10kg, have 2 handles for lifting and fixing holes
along the top edge shall be punched out to key hole shape for easy hanging
prior to screw fixing. Ventilation openings shall be suitably screened with wire
mesh to prevent vermin entry. The Contractor shall submit details of the
removable panels to the Project Manager for review without objection.

(b) Anti condensation heaters shall be included if required by the manufacturer for
operation in the specified ambient conditions.

(c) Lifting lugs for whole transformer and towing lugs shall be made available
outside the protective housing.

(d) The protective housing should incorporate all the necessary provisions for
future forced air (AF) operation such as louvers/grilles for intake and exhaust
air, space and mounting provisions for fans etc.

(e) Cable gland plate for HV cables and duct flange for LV bus duct connection
shall be included on the protective housing based on the following positions:

(i) HV - top or bottom; and

(ii) LV - top.

General Materials & Workmanship Specification 14/22 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 54 – High Voltage Electrical Services
54.4.20 Painting

(a) In addition to the requirements of Section 44.10 of the General Materials and
Workmanship Specification the following shall apply:

(i) the painting system provided shall be adequate to protect the core,
frame, housing, base, wheels etc against corrosion;

(ii) paint shall be applied by the flood or spray method as appropriate. The
inside and outside of the protective housing panels shall be treated in
the same manner;

(iii) the spacing of all adjacent pans, shall allow sufficient room for their
proper inspection, cleaning and painting;

(iv) after each section of equipment is completed and before any paint is
applied, the surface of all parts usually painted shall be thoroughly
cleaned to remove all rust, oil, grease, dirt and other foreign matter, by
shotblasting or an equivalent process reviewed without objection by
the Project Manager;

(v) two priming coats of zinc chromate-iron oxide paint, each of a different
colour, shall be applied to the cleaned metal surfaces, to provide a
minimum combined thickness of 0.075 mm. The first protective coat
shall be applied on the same day, immediately after shot blasting and
without outdoor exposure;

(vi) three finishing coats of acrylic micaceous iron oxide paint, colour
No.632 (Dark admiralty grey), to BS 381C or equivalent to a minimum
film thickness of 0.15 mm;

(vii) all paint and varnish shall be non-corrosive, heat and oil resistant. It
shall be made by a reputable paint manufacturer and shall be applied
in accordance with the manufacturers recommendations for this
particular application;

(viii) each coat shall cover completely and evenly the surface to which it is
applied; and

(ix) the Contractor shall submit details of the method of preparation of the
surfaces for painting as well as the make, type and method of
application of the paints and varnishes to be used, to the Project
Manager for review without objection.

54.4.21 HV Terminations

(a) The transformers are to be supplied fitted with terminal palms rigidly bolted to
the core frame within the transformer enclosure and suitable for use with a
proprietary brand of withdrawable "Load Break Elbow" facilitating
disconnection of HV cables and utilising proprietary heat shrink terminations.
A cable way and support structure shall be provided suitable for
accommodating a 3 core XLPE insulated, copper tape screened, LSF
sheathed and nylon jacketed cable.

General Materials & Workmanship Specification 15/22 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 54 – High Voltage Electrical Services
 (b) The terminal shall preferably be in the form of a 50mm wide flat bar with single
l4mm diameter hole for connection of the cable load break elbow assembly.
The HV cable shall be made off in front of the HV terminals and substantially
completed before the termination including gland is moved into the final
position where it will be mounted on a gland plate within the protective housing.

(c) Each cable box shall be fitted with a detachable and undrilled split gland plate.
The cable gland plate shall be designed for easy withdrawal of a trifurcated
cable complete with gland to facilitate transformer changes. The gland plate
shall be supplied complete with bolts, spring washers, nuts and lock nuts for
mounting of the gland. The position of the gland plate shall be at 900mm
distance from a horizontal line drawn through the MV terminals and at not less
than 600mm distance above the floor in the case of bottom entry units. The
Contractor shall also provide a 100 mm2 tinned dropper earthing tape from the
armour clamps which fit over the cable gland to the transformer unit earthing
terminal.

(d) A cable support bracket shall firmly clamp the incoming cable at a suitable
distance from the terminations.

(e) Minimum phase to phase and phase to earth clearances within the cable box
shall be 184 mm and 160 mm minimum respectively.

(f) The minimum horizontal distance between the centre line of each phase
termination shall be 260 mm.

(g) The minimum vertical distance between the centre line of the phase
termination and the top of the gland plate shall be 800 mm.

(h) The cable box shall be fitted on a side of the transformer frame parallel to the
plane of the core and shall be opposite the LV bushings.

54.4.22 LV Terminations

(a) Each transformer shall be fitted with an air insulated cable box.

(b) The cable boxes shall be suitable for the termination of busduct up to 3,000
Amp rating. The connection shall be either top or bottom entry. The details
shall be subject to review without objection by the Project Manager prior to
manufacture.

(c) All cable boxes shall be supplied complete with expansion joints suitable for
use with the bus duct listed above to allow the movement of the transformer to
be accommodated.

(d) Each cable box shall be fitted with a detachable and undrilled split brass gland
plate.

(e) A link chamber or neutral bushing external to the cable box is not required.

General Materials & Workmanship Specification 16/22 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 54 – High Voltage Electrical Services
54.4.23 Terminations Heights

(a) LV and HV terminal heights shall be as indicated on the Employer's Drawings.

(b) LV connections shall be top entry.

(c) HV connections shall be either top or bottom entry depending on location. The
transformer shall accommodate both top and bottom cable entry.

54.5 HIGH VOLTAGE CABLE

54.5.1 General

(a) This section specifies the requirements for 6.35/ 11 kV high voltage AC power
cables.

54.5.2 Construction requirements

(a) The cable conductors shall be of stranded construction, and shall consist of
plain annealed high conductive copper, complying with the requirements of BS
6360 Class 2. Conductor screening shall be a layer of extruded semi-
conducting compound having a nominal thickness of 0.7 mm.

(b) A conductor screen consisting of an extruded layer of semi-conducting

compound shall be applied over the conductor. The extruded layer shall be
continuous and shall cover the surface of the conductor completely. The
resistivity of the extruded conductor screen shall not exceed 500 ohm-m at
90°C as specified in BS 6622.

(c) The insulation shall be extruded XLPE in accordance with BS 6622 and water
free retardant. The nominal thickness of the insulation shall be as specified in
BS 6622.

(d) The insulation screen shall have the following requirement:

(i) an insulation screen shall be applied to all XLPE insulated cables and
shall consist of an extruded semi-conducting layer in combination with
a metallic layer;

(ii) the semi-conducting layer shall be continuous and shall cover the
surface of the insulation of each core completely;

(iii) the resistivity of the extruded insulation screen shall not exceed 500
ohm-m at 90°C as specified in BS 6622;

(iv) the extruded insulation screen shall be of a type that can be stripped
easily. The force required to remove the screen, when tested in
accordance with the method given in BS 6622, shall not be less than
18N and not more then 80N; and

(v) the metallic portion of the insulation screen applied over each core
shall be helically applied cover tape.

General Materials & Workmanship Specification 17/22 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 54 – High Voltage Electrical Services
 (e) The bedding of the cable shall consist of an extruded layer with flame
retardant characteristic tested to BS 4066. It shall be water resistant and
compatible with the operating temperature of the cable.

(f) Armour for three core cables shall consist of a single layer of round galvanised
steel wires. Armour for single core cables shall consist of a single layer of
round aluminium wires. The armouring dimensions shall be in accordance with
BS 6622. The armour of the cable shall be rated to carry the maximum earth
fault current that may flow under fault conditions. Armour shall be applied
helically in a single layer with a left-hand lay.

(g) The oversheath of the cable shall be an extruded layer of anti-corrosion, flame
retardant compound. An outer graphite coating shall be applied to serve as an
electrode for the voltage test on the oversheath of the cable. The colour of the
oversheath shall be red.

(h) Cables shall not be bent during installation to a radius smaller than the table
below:
(D = Overall diameter of cable)

During installation Adjacent to joints &

termination
Single core
- Unarmoured 20D 15D
- Armoured 15D 12D
Three core
- Unarmoured 15D 12D
- Armoured 12D 10D

54.5.3 Properties of Cable Sheathing Materials

(a) The physical properties of the cable sheathing materials shall include the
following when tested in accordance with BS 6469:

Property Requirement
- Tensile strength at break ≥ 10 Nmm-2
- Elongation at break ≥ 100%
After ageing for 7 days at 100°C
- Tensile strength at break ≥ 10 Nmm-2
- Elongation at break ≥ 100%
- Maximum variation of tensile strength ± 40%
- Maximum variation of elongation at break ± 40%
- Tear resistance ≥ 8 Nmm-2
Hot pressure test
- Test temperature 80°C
- Indentation ≤ 50%
Cold elongation test
- Test temperature -15°C
- Elongation ≥ 20%
General Materials & Workmanship Specification 18/22 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 54 – High Voltage Electrical Services
54.5.4 Fire Performance Requirements

(a) The bedding and oversheath of the cable shall have a minimum oxygen index
of 35 when tested in accordance with BS 2782.

(b) The temperature index of the bedding and overhseath of the cable shall not
less than 280°C when tested in accordance with BS 2782.

54.5.5 Corrosive and Acid Gas Emission

(a) The level of hydrochloric acid of the insulation, fillers, binder tapes, bedding
and oversheath of the cable shall not be greater than 0.5% by weight of
material when tested in accordance with BS EN 50267.

54.5.6 Smoke Emission

(a) The value of the smoke generated shall meet the requirements of BS 6724
when a sample of the complete cable is tested in accordance with BS 6724
Appendix F (3m cube test chamber).

54.5.7 Cable Termination

(a) Cable termination shall be designed to allow for top or bottom cable entry.
Where top cable entry for any equipment is used, particular attention shall be
given to the possibility of water ingress to the equipment and only designs that
completely eliminate the possibility of water ingress shall be adopted.

(b) Cable terminations for switchgear and transformers shall be completely

enclosed in a sheet fabricated cable box complete with cable glands suitable
for the type of the cable being used. The cable box shall be of air filled type
reviewed without objection by the Project Manager.

(c) The terminations within the cable box shall be suitable for compression typed
terminal lugs, and terminations using heat shrink proprietary kit type reviewed
without objection by the Project Manager.

(d) Cable terminations of switchgear and transformer shall have the following
minimum basic impulse level:

- 11 kV termination: 75 kV

(e) The minimum distance between lug termination and cable gland plate shall be
600mm.

(f) Where more than one cable enters a terminal box, the clearance between
adjacent glands shall be sufficient to permit satisfactory cable installation.

(g) All terminal boxes shall be fitted with screwed or tapered glands which shall be
insulated to withstand DC voltage test for extruded anti-corrosion reduced
flame propagation sheaths, and for leakage to frame protection.

(h) A removable earthing strip shall be positioned on all cable boxes terminating
metal sheathed cables, and combined armour and earthing clamps shall be
fitted to all cable boxes terminating armour cables. Provision shall be made
for earthing the body of the cable box.

General Materials & Workmanship Specification 19/22 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 54 – High Voltage Electrical Services
 (i) If by reasons of the cable size or number of cables, direct termination of
cable(s) to the distribution equipment specified is not possible, a cable
extension box shall be provided to terminate the incoming cable(s). The
incoming cable(s) shall in turn be connected to the distribution equipment with
cables of smaller cross-sectional area where such cable extension boxes are
required, detailed proposals on the intended cable size rating of the equipment
shall be submitted to the Project Manager for review without objection prior to
carrying out the installation.

54.5.8 Cable Gland

(a) Cable gland shall be manufactured and tested to comply with the
requirements of BS 6121 type “E2”.

(b) Cable gland shall be of a type that seals the cable against the ingress of dirt
and moisture, and provides adequate mechanical support.

54.5.9 Cable Cleat

(a) Cable cleats shall be single way cleats or trefoil cleats depending on the type
of cables being installed.

(b) Cable cleats shall be made from materials that have no deleterious effect on
the cable, and shall be compatible with the cable supports.

54.5.10 Cable Joint

(a) The joint boxes shall be watertight, free from sharp points or ridges,
thoroughly clean internally, and designed to retain the filling medium and/or
cable compound at all times without leakage. The metallic screen(s) and the
armouring wires of the cable shall be efficiently bonded to the box. The joint,
insulation of cores and method of jointing shall be designed to prevent
migration of compound and interchange of compound between cable and joint.

(b) Where joints are designed to be filled with fluid or semi-fluid compound,
suitable connections shall be provided for exhausting, filling or pressure filling
joints.

(c) For compound filled joints, the design of the box and the composition of the
filling compound shall provide an effective seal to prevent moisture gaining
access to the conductor connector and armour and screen(s) connections.
The filling compound shall be compatible with the materials of the cable
components with which it comes into contact. Account shall be taken of the
pouring temperatures or the temperature resulting from exothermic reaction.

(d) The semi-conducting insulation screen shall be removed from the core(s) and
any remaining semi-conducting coating or semi-conducting particles shall be
thoroughly removed before application of the stress control components.

(e) Before the work of jointing is commenced, copies of the jointing instructions
together with details of the physical and electrical characteristics of the filling
medium shall be submitted to the Project Manager for review without objection.

General Materials & Workmanship Specification 20/22 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 54 – High Voltage Electrical Services
 (f) For normally-bonded circuits, the metallic screen of all single core cables shall
be bonded across each joint by means of a copper bond, and an additional
copper bond shall be installed to connect together the bonds on each three
phase circuit.

(g) The armour of all galvanised steel armoured or aluminium armoured cables
shall be bonded across each joint by means of a copper bond or the
aluminium bond having a conductance at least equivalent to that of an equal
length of the complete armour and metallic screen(s) of the cable, and with
adequate thermal capacity to avoid excessive overheating under short circuit
conditions.

(h) Copper bonds shall have a cross sectional area of not less than 120 mm2.
Aluminium bonds shall be of aluminium stranded conductor sheathed with
flame retardant and low smoke halogen free material, and shall have a cross
sectional area of not less than 185 mm2.

(i) All joint sleeves and any bonding leads associated therewith shall be
externally insulated.

(j) All cable conductor connectors shall be of the compression type, crimped with
the aid of the hydraulic compression tool and appropriate die set.

(k) Joint boxes shall be installed as directed, and shall be protected by an outer
box of design reviewed without objection by the Project Manager, filled with
compound, sand or other suitable material.

(l) All joints shall be capable of carrying the rated load and fault currents without
overheating and with mechanical strength to prevent movement.

(m) All joints installed shall have flame retardant, low smoke halogen free
characteristics when affected by fire.

(n) The positions of all cable joints along the cable routes shall be submitted to
the Project Manager for review without objection. All joints shall not exceed
300mm wide. No joint shall be made in the cable route of a trench at platform
level, and no joint shall be made within 4m of a bend. No joint shall be made
on a vertical cable.

54.6 PILOT CABLES

All pilot cables shall be stranded plain copper conductors with XLPE insulated, LSOH
bedded, steel wire armoured and LSOH oversheath to BS 6724. Each cable shall
have not less than 38-cores and the cross-sectional area of copper conductor per
each core shall be not less than 2.5 mm2.

General Materials & Workmanship Specification 21/22 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 54 – High Voltage Electrical Services
54.7 SUBMISSIONS

54.7.1 High Voltage Electrical Services

(a) The following particulars of the proposed high voltage electrical services shall
be submitted to the Project Manager for review without objection:

(i) details of equipment and components and manufacturer’s data;

(ii) certificates showing the compliance with the relevant standards;

(iii) Contractor’s drawings showing outline dimensions, weight, mounting

and fixing details of distribution transformers;

(iv) Contractor’s drawings showing outline dimensions, mounting and fixing

details of HV switchboards;

(v) Contractor’s drawings including electrical control wiring diagrams

showing the details of all wiring in the HV switchboards, the details of
current transformer ratios, class, and terminal markings, internal
connections of all apparatus, position of all equipment on panel faces,
and colour of indicating lamps and push button switches;

(vi) Contractor’s drawings showing the layout of the HV switch rooms

General Materials & Workmanship Specification 22/22 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 54 – High Voltage Electrical Services
SECTION 55 NOT USED

General Materials & Workmanship Specification 1/1 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 55 – Not Used
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SECTION 56 NOT USED

General Materials & Workmanship Specification 1/1 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 56 – Not Used
[this page not used]
SECTION 57 EARTHING AND BONDING SYSTEM

57.1 GENERAL

(a) Earthing and bonding system shall comply with the requirement of Code Of
Practice for the Electricity (Wiring) Regulations issued by EMSD.

(b) All metal works associated with an electrical installation but not forming part of
a live conductor, including exposed conductive parts and extraneous
conductive parts shall be solidly and effectively bonded and earthed.

(c) All exposed conductive parts of the electrical installation shall be securely
bonded by means of circuit protective conductor, metal trunking, conduit
and/or copper earth tape with sound electrical continuity to the main earth
terminals in the main switchboards.

(d) Supplementary bonding conductors shall be provided for bonding extraneous

conductive parts and simultaneously accessible exposed conductive parts
such as metal work of windows, doors, water taps, pipes, etc., this bonding
when using conductor shall be kept to a minimum length and connected to
adjacent earth terminal, conduit or alike. Concealed conduit shall be brought
down to a connection box on the wall under the sinks, pipes etc. so that
bonding can be made more neatly.

57.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as at the date of the Letter of Acceptance.

BS 1432 Specification for copper for electrical purposes: high

conductivity copper rectangular conductors with drawn or
rolled edges
BS 4662 Specification for boxes for the enclosure of electrical
accessories
BS 7430 Codes of Practice for Earthing
BS 7671 Requirements for electrical installations. IEE Wiring
Regulations.
BS EN 12165 Copper and copper alloys. Wrought and unwrought forging
stock
BS EN 12420 Copper and copper alloys. Forgings
IEEE 1100 Recommended Practice for Powering and Grounding
Sensitive Electronic Equipment

General Materials & Workmanship Specification 1/10 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 57 – Earthing & Bonding System
57.3 MATERIALS

57.3.1 Main Earthing Terminal

(a) A solid copper main earthing terminal of ample size shall be provided for every
electrical installation at a position near the main incoming switch or
switchboard for the connection of the circuit protective conductors, the main
equipotential bonding conductors and the earthing conductors to create the
equipotential zone. The main earthing terminal shall be connected to earth via
an earthing conductor to an earth electrode or a group of electrodes.

(b) Where an installation distributes to a number of buildings or units, a separate

main earthing terminal shall be provided for each individual building or unit at
the point of intake thereby creating a separate equipotential zone in each
building or unit.

57.3.2 Earth Electrode

(a) The following types of earth electrode shall be used unless otherwise specified
in the Employer’s Drawings:

(i) Rod electrode

- rod electrode shall be mild steel inner core with a bonded hard drawn
copper sleeve of an approved type. The overall diameter of the rod
shall not be less than 15 mm and the thickness of the copper sleeve
shall not be less than 0.25 mm. The minimum length shall be 2.4m.
Additional lengths, whenever required, shall each be of 1.2m; and

- in the event that one rod does not produce a low earthing resistance,
additional lengths or rods shall be installed. For the latter application,
additional rods shall be driven into the ground outside the resistance
area of the previously installed rod(s). Under normal circumstances,
a mutual separation of 3.5m is considered adequate.

(ii) Tape Electrode

- tape electrode shall be untinned copper strip of not less than 25 × 3

mm in cross section. Tape electrode shall be used only if specified by
the Project Manager; and

- in case where several tapes are required for connection in parallel to

achieve a low earthing resistance, they may be installed in parallel
lines or they may radiate from a point.

(iii) Plate Electrode

- plate electrode shall be of copper not less than 3 mm in thickness,

having dimensions as indicated on the Employer’s Drawings or
subject to a maximum of 1200 × 1200 mm.

57.3.3 Earth Conductor

(a) Earthing conductors shall be tinned copper tapes of 25 × 3 mm in cross

section. Whenever specified, they shall be with PVC insulation.
General Materials & Workmanship Specification 2/10 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 57 – Earthing & Bonding System
57.3.4 Equipotential Bonding Conductor

(a) Unless otherwise specified, equipotential bonding conductor shall be of

copper.

(b) The cross sectional area of a main equipotential bonding conductor shall not
be less than half of the cross-sectional area of the associated earthing
conductor of the installation subject to a minimum of 6 mm2 and a maximum of
25 mm2.

(c) The cross sectional area of a supplementary bonding conductor shall be

determined in accordance with BS 7671

(d) Main equipotential bonding conductors shall be provided and shall connect to
the main earth bar all the extraneous conductive parts including but not limited
to the following:

(i) main gas pipes;

(ii) main water pipes;

(iii) other service pipes and ductings;

(iv) risers and exposed metallic part of the building structure;

(v) air-conditioning system; and

(vi) cable trays, cable ladders and cable trunkings.

57.3.5 Supplementary Bonding Conductor

(a) Unless otherwise specified, supplementary bonding conductor shall be of

copper.

57.3.6 Circuit Protective Conductor

(a) General

(i) Circuit protective conductors (CPC) may be formed by a separate cable,

the metallic sheath or armour of a cable, part of the same cable as the
associated live conductor, rigid steel conduits, trunking or ducting, or the
metal enclosure of the wiring system. Flexible conduits and the exposed
conductive parts of equipment shall not form part of the circuit protective
conductor.

(ii) The cross section of a protective conductor, excluding equipotential

bonding conductors, shall be determined by the formula given in BS
7671.

General Materials & Workmanship Specification 3/10 January 2011

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Section 57 – Earthing & Bonding System
 (iii) Where a protective conductor shall not form part of a cable and shall not
formed by, or not contained in, steel conduit, trunking, ducting or other
metallic enclosure of a wiring system, the cross sectional area shall not
be less than 2.5 mm2 or equivalent if protection against mechanical
protection is provided (e.g. sheathed cable) and 4 mm2 copper or
equivalent if mechanical protection is not provided (e.g. non-sheathed
cable). When a separate cable is used as a CPC, the cable shall be
insulated to BS 6004 or better.

(iv) For surface conduit installation, the supplementary bonding conductors

shall be terminated at the nearest conduit or conduit box forming an
integral part of the conduit installation.

(v) For concealed conduit installations, the supplementary bonding

conductors shall be terminated at a copper earthing terminal fitted inside
a metal box forming an integral part of the conduit installation. The
metal conduit box shall be located as near as possible to the bonding
position and the exposed part of the supplementary bonding conductor
shall be made as short as possible.

(vi) When metal enclosures for cables are used as protective conductors,
they shall have cross-sectional area equivalent to that of copper, not
less than the requirement as stipulated in BS 7671.

(b) CPC for Socket Outlet

(i) For every socket outlet, a separate circuit protective conductor shall be
provided connecting the earth terminal of the socket outlet and that
inside the enclosure accommodating the socket outlet.

(c) CPC for Flexible Conduit

(i) For every length of flexible conduit, a separate circuit protective

conductor shall be provided inside the conduit to ensure the earth
continuity of the installation between the two ends of the flexible conduit
for the whole circuit.

(d) CPC for Busbar Trunking and Busway

(i) A copper tape, 25 × 3 mm in cross section shall be provided for the

entire length of a busbar trunking or busway. The copper tape shall be
bonded to the busbar trunking or busway at intervals not exceeding 3m
and at the position of each tap-off point.

(ii) Subject to the prior agreement of the Project Manager, the provision of
copper tapes for a busbar trunking or busway may be exempted
provided that the enclosure of the busbar trunking or busway can be
proven to satisfy the full requirements of the circuit protective conductor
in accordance with relevant regulations of Code Of Practice For The
Electricity (Wiring) Regulations issued by EMSD.

General Materials & Workmanship Specification 4/10 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 57 – Earthing & Bonding System
 (e) CPC for Final Ring Circuit

(i) For wiring system using PVC insulated, the circuit protective conductor
of every ring final circuit shall also be run in the form of a ring having
both ends connected to the earth terminal at the origin of the circuit.

57.4 EARTHING RESISTANCE

(a) On completion of the electrical installation the earthing resistance shall be

tested in accordance with Code Of Practice For The Electricity (Wiring)
Regulations issued by EMSD and CLP supply rules.

57.5 EARTH FAULT LOOP IMPEDANCE

(a) Automatic Disconnection Time

(i) For the purpose of automatic disconnection, means of protection shall

be provided at the main switch. The type and setting of the protective
devices shall be so selected that they can properly discriminate from the
China Light and Power’s ingress protection.

(ii) For installation other than socket outlet circuits where protection against
indirect contact is afforded by an overcurrent protective device, the earth
fault loop impedance of a final circuit and the characteristic of the
protective device shall be co-ordinated that the automatic disconnection
of supply shall occur within 5 seconds in case of an earth fault of
negligible impedance.

(b) Maximum Earth Loop Impedance

(i) For installation other than the socket outlet circuits where protection
against indirect contact is afforded by overcurrent protective device, the
earth fault loop impedance of any final circuit shall not exceed the
maximum values given in the relevant tables in the Code Of Practice For
The Electricity (Wiring) Regulations issued by EMSD for automatic
disconnection time of 5 seconds.

(ii) For circuits using residual current devices, the following formula shall be
fulfilled:

RAIa < 50V where:

RA is the sum of the resistances of the earth electrode and the protective
conductor(s) connecting it to the exposed conductive part; and

Ia is the current causing the automatic operation of the protective device

within 5 seconds. When the protective device is a residual current
device, Ia is the rated residual operating current.

General Materials & Workmanship Specification 5/10 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 57 – Earthing & Bonding System
57.6 SUBMISSIONS

57.6.1 Particulars of earthing and bonding system

(a) The following particulars of the earthing and bonding system shall be
submitted to the Project Manager for review without objection:

(i) detailed schedule of materials, schedule of equipment and components

and manufacturer's data;

(ii) detailed Contractor’s Drawings of earthing schematic diagram and

installation; and

(iii) test report and certificates.

57.6.2 Samples

(a) The following samples of the earthing and bonding system shall be submitted
to the Project Manager together with the particulars referred to in 57.6.1
above:

(i) copper strip, copper tape, copper connector clamps, earth rods and
other accessories.

57.7 WORKMANSHIP

57.7.1 Earthing Equipment

(a) Main Equipotential Bonding Conductors

(i) main equipotential bonding conductors shall be provided and connected

to the extraneous conductive parts of other services within the premises
to the main earthing terminal of the installation. Such extraneous
conductive parts shall include main water and gas pipes, other service
pipes and risers and exposed metallic parts of the building structure
liable to transmit a potential. Connection shall be made as near as
practicable to the point of entry of the non-electrical services into the
premises concerned, and shall be on the installation side of the possible
breaks in the system, such as gas meter or water meter. Where
practicable, the connection shall be made within 600 mm from the meter
outlet union or at the point of entry to the building if the meter is outside
the building.

(ii) Main equipotential bonding conductor shall be securely and reliably

connected to extraneous conductive parts of the non-electrical services
by means of a copper connector-clamp of an approved type suitable for
the particular application.

(b) Supplementary Bonding Conductor

(i) In a room containing a fixed bath or shower, all simultaneously

accessible conductive parts (either exposed or extraneous) shall be
locally connected by means of supplementary bonding conductors.

General Materials & Workmanship Specification 6/10 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 57 – Earthing & Bonding System
 (ii) Supplementary bonding of extraneous conductive parts shall be required
whenever such conductive parts are likely to be accessible
simultaneously with other extraneous conductive parts or exposed
conductive parts, and are not electrically connected to the main
equipotential bonding by means of permanent and reliable metal-to-
metal joints of negligible impedance.

(iii) Supplementary bonding conductor shall be solidly and effectively

connected to the extraneous or exposed conductive parts by means of a
copper connector-clamp of an approved type suitable for the application.

(iv) For surface steel conduit installation, the supplementary bonding

conductor shall be terminated at the nearest steel conduit or conduit box
forming an integral part of the conduit installation.

(v) For concealed steel conduit installation the supplementary bonding

conductor shall be terminated at, via a telephone cord outlet plate, a
copper earth terminal fitted inside a BS 4662 metal box forming an
integral part of the conduit installation. The BS 4662 metal conduit box
shall be located as near as possible to the bonding position and the
exposed part of the supplementary bonding conductor shall be made as
short as possible.

(c) Each individual earthing system shall be connected to separate earthing

electrode system by tinned copper tapes each of 25 × 3 mm cross section.

(d) At the earthing terminal, a permanent copper label marked with the words
“SAFETY ELECTRICAL EARTH – DO NOT REMOVE” in English and
Chinese shall be permanently attached to the final earthing lead connection.
Lettering shall be 5 mm high and fixing details shall be referred to the
Employer’s Drawings.

(e) The main earth terminal in the form of earth electrodes shall be driven into
solid ground at earth pits. A test clamp shall be provided for earth resistance
testing.

(f) Joints in the earthing system shall have a resistance not exceeding that of an
equivalent length of conductor.

(g) No drilling of the earth conductor shall be made except for jointing or
terminating to the requirements of BS 7671, unless approved by the Project
Manager without objection otherwise.

(h) All Joints and connections shall be so effected as to avoid reduction of the
current-carrying capacity of the earth bar. Special precautions shall be taken
to ensure that the available contact area is fully utilized in all connections to
plants and apparatus.

(i) All contact faces of each terminal shall be cleaned and free from non-
conducting materials, such as grease or paint, before connections are made to
the earthing system.

General Materials & Workmanship Specification 7/10 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 57 – Earthing & Bonding System
 (j) Earthing leads shall be clamped to the earth electrode by bolted clamps as
approved and supplied by the same earthing electrode manufacturer. The
method shall allow the disconnection, testing and remaking as many times as
necessary.

(k) For each earth electrode, the clamping arrangements shall be contained within
a small concrete lined pit complete with an easily removable lid to enable
inspection.

57.7.2 LV Electrical Earthing

(a) For earthing system provided for LV electrical earthing shall have the resulting
earth resistance not greater than 0.3 ohm unless otherwise specified.

(b) The electrical earthing system shall be installed both vertically and horizontally
along the routes as shown on the Employer’s Drawings and shall form a
network bonding all switchboards, control panels, distribution boards, all
exposed conductive parts and extraneous conductive parts to the building's
main earth bar.

(c) The requirement shall not apply in the following instances:

(i) Steel reinforced concrete poles in which the steel reinforcement is not
accessible.

(ii) Exposed conductive parts which owing to their reduced dimensions or

their disposition cannot be gripped or cannot be contacted by a major
surface of the human body, provided that connection of these parts to a
protective conductor cannot readily be made or cannot be reliably
maintained. This item applies to small isolated metal parts such as bolts,
rivets, nameplates and cable clips. A major surface of the human body
shall be 50 × 50 mm or greater.

(iii) Fixing screws for non-metallic accessories provided that there is no

appreciable risk of the screws coming into contact with live parts.

(iv) Short lengths of metal conduit for mechanical protection of cables having
a non-metallic sheath.

(d) The minimum size of the principal protective conductors shall be as indicated
below:

(i) Earthing conductor between the earthing bed and the main earth bar at
LV Switchroom: 50 × 6 mm.

(ii) Circuit protective conductor between main earth bar and the LV
switchboard: 50 × 6 mm.

(iii) Circuit protective conductor for equipment/circuits protected by

overcurrent protective devices rated 630A or above: 25 × 6 mm.

(iv) Circuit protective conductor for equipment/circuits protected by

overcurrent protective devices rated below 630A: 25 × 3 mm.

General Materials & Workmanship Specification 8/10 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 57 – Earthing & Bonding System
 (v) A main earth bar shall be provided in the LV Switchroom to connect all
the circuit protective conductors and the main equipotential bonding
conductors to the earthing conductor. The main earth bar shall be 50 ×
6 mm cross-section, hard drawn high conductivity copper not less than
600 mm in length and the main earth bar shall be connected to the
principal earthing conductor.

(e) All armoured cables shall be terminated with purpose made cable gland and
earthing lugs. Busbar plug-in units shall be provided with earthing
connections to earthing conductors of the busbar risers which shall be
engaged before the live contacts are made.

(f) Cable link boxes shall be provided with earthing connections between the
incoming and outgoing connections.

(g) Cable trays and cable ladders shall have a tinned copper earth conductor of
not less than 25 × 3 mm installed along their entire length, fixed to the tray at
2m intervals by means of bronze clamps. The intervals of fixing shall be
decreased as necessary to ensure that individual section of tray is fixed to the
earth conductor. Individual sections of any trunking, whether it is ceiling or
underfloor/flushfloor or other types, shall be electrically bonded together with
tinned copper earth conductors of not less than 25 × 3 mm and of sufficient
lengths.

(h) Main equipotential bonding conductor shall be securely and reliably connected
to extraneous conductive parts of the non-electrical services by means of a
copper connector-clamp of an approved type suitable for the particular
application. All contact surface shall be cleaned and free from non-conducting
materials, such as grease or paint, before the connector-clamp is installed.

57.7.3 Generator Neutral Earth

(a) An earth bar of 50 × 6 mm shall be provided in the generator room. The

generator frame, generator switchboard, fuel tank, generator neutral, etc. shall
be connected to the earth bar by conductors. The sizing of conductor shall be
accordance with Code Of Practice for the Electricity (Wiring) Regulations
issued by EMSD. The resulting earthing resistance shall not be greater than
0.5 ohm unless otherwise specified on the Employer’s Drawings.

(b) A continuous earthing conductor shall be provided in the generator room and
along the route as shown on the Employer’s Drawings for the bonding of the
generator set.

57.7.4 Earthing For Electronic Systems

(a) Electronic systems shall include but not limited to security system,
communication system, computer system and Supervisory Control and Data
Acquisition (SCADA) system etc which utilizing communication electronic
signals at high frequencies.

(b) The earthing system for electronic systems shall be independent of the LV
electrical earthing system except the main earth terminals, where the different
earthing systems shall be connected together before connecting to the ground
by earth electrodes.

General Materials & Workmanship Specification 9/10 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 57 – Earthing & Bonding System
 (c) The earthing system shall provide a conductive path for spurious common-
mode currents and minimize interference and other electromagnetic
anomalies.

(d) The common earth connection shall be made via a high-conductivity copper
cable of no less than 8 strands and of minimum conductor cross-sectional
area of 35 mm2 connected to the nearest point of the building common earth
system provided by the Contractor.

(e) All equipment racks and/or sub-racks mounted within outdoor enclosures shall
be properly earthed to the metallic enclosure via internal braided copper
straps of minimum practical length or to the earthing terminal inside the non-
metallic enclosure via internal braided copper straps of minimum practical
length.

(f) For metal moving parts such as metal doors and metal cabinet openings,
braided copper straps with proper labels used for earth connections shall
comply with BS 1433, and shall have a minimum cross-sectional area of 16
mm2.

(g) Braided copper straps shall be terminated in crimped copper or bronze lugs
plated with tin or zinc. Lugs shall have a minimum cross-sectional area greater
than that of the attached braided copper strap, and shall be suitable for bolting
to enclosure frames and items subject to earthing.

(h) The contact faces between earthing lugs, enclosure frames and earthed items
shall be cleaned and free of paint, and shall exhibit a maximum resistance of
less than 0.3Ω.

(i) The main earthing conductor shall be 25 × 3 mm copper tape. The copper
tape shall be PVC sheathed throughout in grey colour.

57.7.5 Identification and Labelling

(a) Colour Identification

(i) All cables used as protective conductors, including earthing conductors,

main equipotential bonding conductors, supplementary bonding
conductors and circuit protective conductors shall be identified by the
colour combination “green and yellow”. Such colour combination shall
not be used for other identification purposes.

(ii) Bare conductor used as protective conductor shall also be made

similarly identifiable, where necessary, by the application of tapes,
sleeves or discs, or by painting with the above colour combination.

(b) Label for Earthing and Bonding Connections

(i) Every point of connection for earthing and bonding shall be provided
with a warning notice in accordance with the Electricity Ordinance and
the Code Of Practice For The Electricity (Wiring) Regulations issued by
EMSD.

General Materials & Workmanship Specification 10/10 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 57 – Earthing & Bonding System
SECTION 58 LIGHTNING PROTECTION SYSTEM

58.1 GENERAL

(a) The lightning protection system shall convey lightning discharges to ground
without electrification of the structure.

(b) The complete lightning protection system shall consist of a network of air
terminals at roof level, interconnected by horizontal tapes. The whole air-
termination system shall be connected to down conductors, which shall
preferably run outside of the building. The down conductors shall be bonded
to a number of dedicated earth electrodes, which do not make contact with
any part of the structures or buildings. A bond should be mechanically and
electrically effective and protected from corrosion in and erosion by the
operating environment. The earth electrode design shall comply with the
relevant requirements for earthing in Section 57 of this GMWS.

(c) Any protrusion from the sides of a structure, which may obstruct the vertical
path of the down conductor, shall be sleeved to allow the down conductor to
pass through.

(d) The lightning protection system shall be designed and installed to provide
protection coverage over the entire building and associated apron area,
including but not limited to, metallic projections, ducts, vent pipes, railings,
gutters and the like, which may be extended from the main building.

58.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as at the date of the Letter of Acceptance.

BS 1433 Specification for copper for electrical purposes. Rod and bar
BS 6651 Code of Practice for Protection of Structures against Lightning
BS 7430 Code of Practice for Earthing
BS 7671 Requirements for Electrical Installations

58.3 MATERIALS

58.3.1 Air Termination

(a) An air termination shall consist of vertical conductors, horizontal conductors or

a system of vertical and horizontal conductors;

(b) Vertical conductors shall have overall length not less than 450 mm and ∅12
mm rods made of hard drawn or annealed copper;

(c) Horizontal conductors shall be of 25 x 3 mm annealed strips made of PVC

sheathed copper.

General Materials & Workmanship Specification 1/5 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 58 – Lightning Protection System
 (d) Air Termination with Electronic Device

(i) The air termination shall be of the type equipped with an electronic
device which emits a high pulse voltage of known and controlled
frequency and amplitude enabling the early formation of the upward
leader which is then continuously propagated towards the lightning
downward leader.

(ii) The air termination shall be non-radioactive.

(iii) The air termination shall not be dependent upon batteries or external
power supplies for any part of its operation.

(iv) The materials of the air termination shall be non-corroding in normal

atmosphere.

58.3.2 Down Conductor

(a) The dimension of down conductors to be used shall be either if the following:

(i) annealed tinned copper strip 25 x 3 mm;

(ii) annealed copper rod ∅12 mm; and

(iii) steel reinforcement bar ∅12 mm.

58.3.3 Test Joint

Test joints shall be of phosphor bronze, gunmetal or copper. They shall comprise a
heavy circular base, to which a heavy circular cover of the same material shall be
bolted. The flat copper conductor shall be overlapped and placed so that they are
clamped between the cover and the base by means of at least four screws or studs.

(a) Earth Termination

An earthing system shall be provided for the lightning protection system. The
Contractor shall investigate the site conditions and submit installation details
for Project Manager’s review without objection.

(b) Spacer Saddle

(i) Spacer saddles shall be of high quality metal. For copper conductors,
brass or gunmetal shall be used.

(ii) Non-metallic spacer saddles shall only be used when down conductors
are provided with non-metallic sheathing.

General Materials & Workmanship Specification 2/5 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 58 – Lightning Protection System
58.3.4 Submissions

(a) Particulars of Lightning Protection System

(i) The following particulars of the proposed lightning protection system

shall be submitted to the Project Manager for review without objection:

- detailed schedule of equipment and components and

manufacturer's data; and

- installation detail and layout plan of lightning protection system.

(b) Samples

(i) The following samples of the proposed lightning protection materials

shall be submitted to the Project Manager together with the particular
referred to in 58. 3.4 (a) (i) above:

- copper tape;

- square tape clamp; and

- copper tape clip.

58.3.5 WORKMANSHIP

(a) Air Termination

(i) For a roof of larger horizontal dimensions, the outer perimeter and the
flat roof shall be covered by an air termination network mesh of
approximately 10 x 20m, so that no part of the roof shall be more than
5m from the nearest horizontal conductor. All salient points of the roof
structure shall be incorporated in the air termination network. All
metallic projections, ducts, vent pipes, railings, gutters, etc., on or
above the main surface of the roof of the structure, shall be fixed to,
and form part of, the air termination network. Horizontal conductors
shall be fixed to the roof structure at regular intervals of not more than
1m by means of suitable spacer saddles.

(ii) Vertical conductors shall be mounted on a gunmetal base plate.

(b) Down Conductor

(i) When down conductors mounted on the external wall, down

conductors shall be fixed at regular intervals of not exceeding 1m apart
by means of heavy gauge non-ferrous spacer saddles. They shall
follow the most possible direct path between the air termination and
the earth termination.

(ii) Where the steel work of the structure is used as down conductor, the
Contractor is required to ensure the continuity of the steel work. In this
connection the ends of the steel work shall be connected to the lighting
protection system by “Thermoweld” jointing method or other methods
agreed with the Project Manager. A test joint shall be provided at each
connection.

General Materials & Workmanship Specification 3/5 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 58 – Lightning Protection System
 (iii) The number of down conductors to be installed shall depend on the
building base area or the building perimeter. At least two down
conductors shall be installed. The number of down conductors shall
be one for each 20m or part thereof of the perimeter at roof level or
ground level, whichever is the greater. For building over 20m high,
one per 10m or part thereof shall be provided.

(iv) Each down conductor shall be complete with test joint and connecting
to an earth termination.

(v) PVC sleeve from 2 m above ground to the earth pit shall be provided
for the down conductor.

(vi) Joints in copper tapes shall be avoided wherever possible, if joints are
inevitable the copper tapes shall be wiped clean while hot, then
riveted, and sweated using a non-corrosive flux.

(vii) Down conductors shall not be bonded to structure metalwork, as pipes,

water pipes etc. unless otherwise reviewed without objection by the
Project Manager.

(viii) The use of coaxial cables as down conductors shall not be allowed.

(c) Test Joint

The test joints shall be positioned so that they shall not be tampered with by
unauthorised persons. In cases where this is not possible, the earth tape/rod
connector clamp shall be used as an alternative test point in place of the test
joint.

(d) Earth Termination

Each earth termination shall have a resistance to earth not exceeding the
product given by 10Ω times the number of earth termination to be provided.
The whole of the lightning protective system shall have a combined resistance
to earth not exceeding 10Ω. Where it is difficult, due to local conditions to
obtain a value of less than 10Ω by the sole use of rod electrodes, alternative
or additional methods, e.g. the installation of tape of plate electrodes may be
used subject to review without objection by the Project Manager.

(e) Connection to Earth Termination

Down conductors and bonding conductors shall be connected to the earth

electrode in accordance with Section 57 of this GMWS. Each connection shall
be separately clamped and shall be fitted with a warning notice.

General Materials & Workmanship Specification 4/5 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 58 – Lightning Protection System
 (f) Bonding to Other Services

Lighting protection systems shall normally be kept segregated from the

metalwork of other services. Minimum isolation clearances as given in BS
6651 shall be maintained. However, in certain circumstances, e.g. where
fortuitous contact with other systems cannot be avoided, earth electrodes for
lightning protection may, reviewed without objection by the Project Manager,
be bonded to each other services including the metal sheath and amouring of
low voltage cables, the consumer’s low voltage earth system, metal water
pipes and steel reinforcing the foundation and structure. Cables and earthing
systems belonging to the Supply Authorities, The Telephone Company and
other authorities shall not be bonded except with the written permission of
such authorities. Gas pipes shall not normally be connected to any earth
electrode.

(g) High Mast Lighting

Vertical conductor shall be installed at the highest point of the high mast
lighting, connected to 25 x 3 mm copper tape as down conductor concealed
inside the lamp pole.

(h) Surge Protection Design Criteria

All plant shall be properly protected against lightning induced voltage surges
occurring on any connected cables and shall sustain no physical damage,
excepting under conditions of direct strike where the particular design
measures shall be such as to reasonably minimise any damage incurred. (An
allowance of lightning flash densities of twenty (20) flashes per square
kilometre per year shall be included in the design of the system.)

(i) Air Termination with Electronic Device

(i) The air termination shall be fixed on the mounting base on the top of
the high mast lighting pole and on the roof of the plant deck. No part
of the air termination shall extend above the air port height restrictions
for the given location.

(ii) The lightning protection system shall provide complete protection

coverage to the whole building and associated apron, including but not
limited to, metallic projections, ducts, vent pipes, railing, gutters etc
which extended from the building, and all the aprons.

General Materials & Workmanship Specification 5/5 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 58 – Lightning Protection System
[this page not used]
SECTION 59 ELECTROMAGNETIC COMPATIBILITY

59.1 GENERAL

(a) Electromagnetic compatibility (EMC) is defined as the ability of an item of

equipment or a system to function satisfactorily in its electromagnetic
environment without introducing intolerable electromagnetic disturbances to
other equipment or systems in that environment.

(b) Equipment shall operate reliably in terms of performance and functionality in

the electromagnetic environment.

59.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as at the date of the Letter of Acceptance.

BS EN 61000-6-2 Electromagnetic compatibility (EMC). Generic standards.

Immunity for industrial environments
BS EN 61000-6-4 Electromagnetic compatibility (EMC). Generic standards.
Emission standard for industrial environments
BS EN 55011 Limits and methods of measurement of radio disturbance
characteristics of industrial, scientific, medial (ISM) radio-
frequency equipment.
BS EN 55022 Information technology equipment. Radio disturbance
characteristics. Limits and methods of measurement
BS EN 55014 Electromagnetic compatibility. Requirements for household
appliances, electric tools and similar apparatus. Emission.
Product family standard
BS EN 55015 Limits and methods of measurement of radio disturbance
characteristics of electrical lighting and similar equipment
IEC 61000-4-2 Electromagnetic compatibility (EMC) Part : 4-2 : Testing and
measurement techniques - Electrostatic discharge immunity
test

59.3 ELECTROMAGNETIC COMPATIBILITY (EMC)

59.3.1 Electromagnetic compatibility

All electrical and electronic apparatus, including such items as thyristor controlled
propulsion equipment, sensors, contactors, starters etc., shall be fitted with means
for suppressing the radio interference frequencies caused by it, shall be immune to
interference fields and comply with the relevant National Standards of any of the
EEC Member States, the reference numbers of which have been published in
accordance with the provisions of Council Directive 89/336/EEC.

General Materials & Workmanship Specification 1/2 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 59 – Electromagnetic Compatibility
59.3.2 Radio Frequency Interference

(a) Radio frequency noise generated by the operation of the system shall not
result in any improper functioning of the system and the system shall not be
susceptible to the normal electromagnetic emission by other airport equipment
provided in the building.

(b) The system shall not interfere with nor be affected by RF systems on the
airport.

(c) Industrial control equipment, for example, PLC, relay assemblies, contactor
panels and convertors, etc., shall be type-tested to the limits specified in BS
EN 55011.

(d) Information technology equipment, for example, PC based monitors or signal

equipment transmitting data over LANs shall be type-tested to satisfy BS EN
55022.

59.3.3 Harmonics and Voltage Surges

(a) Industrial control equipment shall be type-tested to satisfy the limits specified
in BS EN 61000-6-4 for emissions and BS EN 61000-6-2 for immunity
standards. The level of harmonic emissions shall be reviewed without
objection by the local electricity supply Authority.

59.3.4 Electromagnetic Interference

(a) The Plant shall not interfere with aviation navigation systems or aircraft
maneuvering operations in any way.

(b) The Plant shall be designed to the requirements of the electromagnetic

compatibility as referred in this section.

(c) The design and/or selection of all equipment shall take into account the effects
of possible electromagnetic interference from nearby high voltage and current
supplies, automatic people mover (APM), Airport Express train (AEL), heavy
current plant and machinery, discharge and other lighting equipment, direct
current signaling and control systems, radio transmitters and radar which are
likely to be installed within the Project Site.

General Materials & Workmanship Specification 2/2 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 59 – Electromagnetic Compatibility
SECTION 60 INSPECTION, TESTING AND COMMISSIONING ELECTRICAL SERVICES

60.1 GENERAL

(a) The Plant shall be inspected, tested and commissioned to confirm that Plant
performance complies with the requirements of the Contract.

(b) All such Inspection, Testing and Commissioning shall, in particular but without
limitation, be planned, carried out and documented in accordance with:

(i) General Conditions of Contract;

(ii) the construction quality plans and inspection and test plans prepared by
the Contractor in accordance with the relevant ISO standard and
reviewed without objection by the Project Manager; and

(iii) General Specification.

60.2 TERMINOLOGY

(a) In this Contract, and in all programmes, quality plans, reports and other
documents produced in the course of this Contract, the following terms shall
be used:

(i) Manufacturing Phase - the period during which the manufacture,

fabrication and assembly of the Plant, or a discrete element of the Plant,
is carried out off-Site;

(ii) Installation Phase - the period during which the fabrication, assembly
and installation of the Plant, or a discrete element of the Plant, is carried
out on-Site;

(iii) Pre-Commissioning Phase - the period when, in relation to the Plant or a

discrete element of the Plant, Component Tests and Commissioning are
carried out in preparation for the Plant Commissioning Phase;

(iv) Plant Commissioning Phase - the period when Commissioning and

Reliability Tests are carried out to ensure that the Plant fully complies
with the design and operational requirements of this Contract;

(v) Plant Integration Phase - the period prior to issue of the Completion
Certificate when Plant Integration Tests and Commissioning are
conducted to integrate the Plant with existing plant and systems and all
work completed or being undertaken by Other Contractors in full
compliance with the design and operational requirements of this
Contract;

(vi) Confidence Trial Phase - the period after issue of the Completion
Certificate when the Confidence Trials are carried out;

(vii) Phase - one or other of the phases identified in (i) - (vi) above;

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Section 60 – Inspection, Testing & Commissioning –
Electrical Services
 (viii) Type Tests - tests undertaken on similar equipment or components in
lieu of individual unit tests;

(ix) Factory Tests - tests carried out on items of Plant at the manufacturer's
works or elsewhere before they are dispatched to Site;

(x) Site Tests - tests on static items of Plant and systems (e.g. inspection
and testing of welds and hydraulic testing of pipeworks) to ensure
correct and safe installation before Setting to Work;

(xi) Component Tests - tests on components to be incorporated in the Plant;

(xii) Commissioning - the advancement of the Plant or an element of the

Plant from the stage of static completion to full working conditions and to
meet the specified design requirements. This shall include Setting to
Work and Regulation;

(xiii) Setting to Work - the process of setting a static system into motion;

(xiv) Plant Integration Tests - the measuring, recording and proving of correct
integration between the Plant and all other systems, whether installed by
Other Contractors or existing, as detailed in the Specification;

(xv) Regulation - the process of adjusting a system (e.g. the rates of fluid
flow and heat transfer in a distribution system) within specified
tolerances;

(xvi) Reliability Tests - tests carried out over set trial periods and under
simulated operating conditions to prove reliability;

(xvii) Confidence Trials - tests undertaken after the issue of the Certificate of
Completion when the Plant is operational and being operated by the
Employer under the supervision of the Contractor;

(xviii) Inspection, Testing and Commissioning Programme - the sub-network of

the Works Programme prepared by the Contractor in accordance with
section 10 of the General Specification and reviewed without objection
by the Project Manager, detailing the programme for the inspection,
testing and programme for the inspection, testing and commissioning of
the Plant;

(xix) Phase Notice - a notice prepared by the Contractor in accordance with

the requirements of this General Materials & Workmanship Specification
Section 60.5;

(xx) Phase Report - a report prepared in accordance with the requirements of

this General Materials & Workmanship Specification Section 60.7; and

(xxi) Test Results Form - a form prepared in accordance with the

requirements of this General Materials & Workmanship Specification
Section 60.6.

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Section 60 – Inspection, Testing & Commissioning –
Electrical Services
 (b) The term “Tests on Completion” as defined and used in the General
Conditions of Contract refers to the Plant Integration Tests and such other
tests, if any, identified as such in the Specification.

(c) The term “Performance Tests” as defined and used in the General Conditions
of Contract refers to the Confidence Trials and such further tests, if any,
identified as such in the Specification.

60.3 TESTING AND COMMISSIONING PHASES

(a) In order to facilitate the orderly management of the testing and commissioning
of Plant and the Project Manager's monitoring of progress of the Project as a
whole, the Contractor shall structure his construction quality plans (see
Section 14 of the General Specification), inspection and test plans (see
Section 15 of the General Specification, and the Inspection, Testing and
Commissioning Programme (see Section 10 of the General Specification) into
the following Phases with the tests to be carried out during each Phase
identified under the following categories:

(i) Manufacturing Phase:

- Factory Test; and

- Type Tests.

(ii) Installation Phase:

- Site Tests.

(iii) Pre-Commissioning Phase:

- Component Tests; and

- Commissioning of elements of the Plant.

(iv) Plant Commissioning Phase:

- Integration of elements of the Plant;

- Commissioning; and

- Reliability Tests.

(v) Plant Integration Phase:

- Plant Integration Tests.

(vi) Confidence Trials Phase.

(b) Any Deferred Seasonal Tests shall also be clearly identified in all plans and
programmes.

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Section 60 – Inspection, Testing & Commissioning –
Electrical Services
 (c) For the duration of the Defects Liability Period operational and safety controls
shall be sealed if adjustment beyond defined limits could result in malfunction
and give rise to a defect.

(d) The Contractor shall provide attendance and technical support during the
Confidence Trials Period in accordance with Section 60.16 of this General
Materials & Workmanship Specification Confidence Trials Phase.

60.4 QUALITY PLANS

(a) The Contractor shall identify in his construction quality plans and division of
the Plant into discrete elements to facilitate the preparation and service of
Phase Notices as called for in this General Materials & Workmanship
Specification Section 60.5.

(b) The Project Manager, in reviewing any inspection and test plan, may require
additional inspection, testing and commissioning documentation as may be
considered reasonably necessary to record these processes.

60.5 PHASE NOTICES

(a) For each element of the Plant identified in the Contractor's construction quality
plans or, as the case may be, for the Plant as a whole:

(i) the Contractor shall prepare and submit to the Project Manager for
review a Phase Notice at the end of the Manufacturing Phase, the
Installation Phase and the Pre-Commissioning Phase;

(ii) each Phase Notice shall contain a statement by the Contractor

confirming that all inspections and tests required during the relevant
Phase have been performed satisfactorily or identifying any non-
conformities or tests that have been failed and confirming that all
reports of such inspections and tests have been filed in his Records
Office (in accordance with Section 15 of the General Specification);

(iii) the Phase Notice relating to a Manufacturing Phase shall confirm that
the Contractor is satisfied that the relevant equipment or system or
part of a system is ready for release from the manufacturer's works;

(iv) the Phase Notice relating to an Installation Phase shall confirm that the
Contractor is satisfied that the equipment or system or part of a system
is ready for starting the pre-commissioning tests; and

(v) the Phase Notice relating to a Pre-Commissioning Phase shall confirm

that the Contractor is satisfied that the system or part of a system is
ready for Commissioning and Reliability Tests.

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 (b) Upon receipt of an application for a Completion Certificate or Stage Certificate,
the Project Manager may carry out a detailed inspection of each element of
the Plant in the presence of the Contractor to check the soundness and state
of the Plant and identify the extent of any rectification work required. The
Contractor shall ensure that, prior to such inspection, all work has been
properly and thoroughly cleaned, painted where specified and generally tidied
up to present a clean and workmanlike installation.

60.6 TEST RESULTS FORMS

(a) In addition to the requirements of Section 15 of the General Specification,

each report of an inspection or test shall indicate the following:

(i) the system or item being tested;

(ii) the identification reference for an item being performance tested;

(iii) the test acceptance criteria;

(iv) the tolerances;

(v) the test units of measurement;

(vi) the actual test results;

(vii) pass /fail;

(viii) whether a concession shall be requested under Section 14 of the

General Specification;

(ix) any concessions or variations made pursuant to Section 14 of the

General Specification; and

(x) whether a design review is requested.

(b) Test acceptance criteria shall be prepared by the Contractor in accordance

with this General Materials & Workmanship Specification and included as part
of each Test Results Form. Acceptance criteria may not be changed by the
Contractor except with the consent of the Project Manager in writing.

(c) The Contractor shall prepare and submit his proposed test Results Forms as
part of his submission of the relevant Inspection, Testing and Commissioning
Plan.

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60.7 PHASE REPORTS

(a) Without prejudice to the Contractor's obligations to produce summaries of test

data and other information under the General Conditions and Section 15 of the
General Specification, the Contractor shall upon completion of each Phase
complete and submit to the Project Manager for his information a Phase
Report setting out and detailing the test results including performance figures
obtained, graphs, charts, tabulated computer output, and supporting narratives
describing any special events, occurrences and other discrepancies or
deviations not expected in the original plan or programme.

(b) In particular, the Phase Report shall include a chronological diary of findings
and incidents including:

(i) workmanship;

(ii) plant operating peculiarities and observations;

(iii) any measurement and checks which may be required by operating and
maintenance personnel; and

(iv) results of any statutory testing and inspection, e.g. earth grid
measurements.

(c) All hazardous conditions shall be corrected by the Contractor prior to or during
Commissioning. Comments shall be included on any observed deficiencies in
Plant design and performance.

(d) Any modifications to circuitry, instrumentation, etc. carried out at any time shall
be recorded in detail in the Phase Reports and shown on the Contractor’s
Drawings.

(e) Any conclusions that shall be helpful to the Employer's operating and
maintenance staff shall be summarised at the end of the Phase Reports.

(f) The Phase Reports shall be prepared and submitted in the Employer's
standard format as soon as practicable after the completion of each Phase.

60.8 RELEVANT CODES, STANDARDS AND REGULATIONS

(a) All testing and commissioning carried out by the Contractor shall be
undertaken using the International System of Units (S.I.) and shall comply, as
appropriate, with the latest and most up to date edition at the date of the Letter
of Acceptance, of the following standards, regulations and guides:

(i) the relevant “British Standard” published by the British Standards

Institution or other relevant international standards;

(ii) BS 7671 - Requirements for Electrical Installation;

(iii) “Code Of Practice for Electricity (Wiring) Regulations” published by

EMSD HKSAR;

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 (iv) “Code Of Practice for minimum fire services installations and
equipment and inspection, testing and maintenance of installations and
equipment” published by the HKSAR; and

(v) the relevant circular letters issued by the Fire Services Department
(FSD).

60.9 CONTRACTOR’S TESTING AND COMMISSIONING STAFF

(a) All testing and commissioning shall be undertaken by the Contractor's

appropriate testing and commissioning specialist or by a competent
independent commissioning specialist nominated by and acting for the
Contractor and reviewed without objection by the Project Manager.

(b) The Contractor shall provide all necessary skilled labour and assistance for
testing, operating, adjusting, commissioning and verifying the performance of
all Plant.

(c) The Contractor's testing and commissioning staff shall have had previous
experience with testing and commissioning similar Plant of comparable duty.

(d) The Contractor's relevant specialist testing and commissioning staff including
supervisors shall be available on Site at all times during testing and
commissioning of the Plant.

60.10 TESTING AND COMMISSIONING EQUIPMENT AND INSTRUMENTS

(a) The Contractor shall provide all portable and supplementary instrumentation,
recording facilities, consumables and the like required for all Factory Tests
and testing and commissioning on Site.

(b) Testing and commissioning instrumentation shall be designed for field use and
to minimize field measurement errors through the use of electronic sensors,
digital displays and similar devices.

(c) The calibration of instruments shall be demonstrated immediately prior to, and
after completion of testing and commissioning, and current calibration
certification submitted to the Project Manager for record purposes.

(d) At least one complete set of testing and commissioning instrumentation,

including all accessories, fittings, attachments and purpose built carrying
cases, shall be made readily available in a calibrated and operational
condition for retesting by the Contractor for the duration of the Defects Liability
Period.

60.11 NOTIFICATIONS

(a) The Contractor shall, in accordance with Section 15 of the General

Specification, give the Project Manager notice in writing, when tests or trials
shall be ready to commence provided that, notwithstanding Section 15 of the
General Specification, not less than 48 hours' notice of all tests and trials
carried out on Site shall be given.
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60.12 INSPECTIONS AND TESTING

(a) Prior to any inspection and testing by the Project Manager, the Contractor
shall inspect and test the Plant himself to ensure that equipment and facilities
are clean and complete and can reasonably be expected to meet successfully
all inspection and/or testing criteria.

(b) Prior to Setting to Works, testing and Commissioning, the Contractor shall
clean all Plant and shall confirm in writing to the Project Manager that all
relevant work, if any, by Other Contractors is complete and satisfactory for the
purpose of testing and commissioning.

(c) In the event that the Contractor considers that any testing is not appropriate or
required, the Contractor may submit alternative proposals to the Project
Manager for his review without objection.

60.13 SPECIFIC INSPECTION, TESTING AND COMMISSIONING REQUIREMENTS

60.13.1 General

(a) General electrical Site Tests and Commissioning shall include but not be
limited to the following:

(i) all equipment, cabling, etc. is electrically and mechanically safe;

(ii) all interlocks, isolators and door and cover securing mechanisms are
properly fitted and adjusted;

(iii) all exposed metal work is properly bonded and earthed in accordance
with BS 7671 and statutory requirements and that all connections and
points required to be earthed for safety and satisfactory operation are
properly earthed in accordance with the manufacturer's requirements;

(iv) all cables, cores and terminations are properly made off, secure,
properly supported and correctly identified and coloured;

(v) all phases, polarities, neutral and common connections are correctly
switched as required, that power is correctly available at all points and
that voltage and frequency at all equipment are correct and in
accordance with requirement for correct working;

(vi) all supplies are properly fused, or otherwise protected to give

satisfactory discrimination and safe disconnection under fault
conditions;

(vii) all contacts are properly aligned and not subject to excessive wear or
erosion;

(viii) all protective covers are properly fitted, all warning and designating
labels are correct and in position and the inside of all boxes and
cubicles are clean and free of “swarf” and cable strippings;

(ix) batteries, if provided, are properly ventilated, installed, connected and

fitted, and that battery chargers are working correctly;
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 (x) all instruments and meters are energised with correct polarity and
working properly;

(xi) all fault indications and alarms are working correctly;

(xii) all essential equipment fed from battery systems continues to function
correctly and without disturbance during all supply failure, restoration
and standby sequences;

(xiii) all interlocks, sequences and protection for normal and emergency
operations are in order; and

(xiv) compliance of performance as required by BS 7671.

60.13.2 LV Switchboard

(a) Factory Tests shall include the following:

(i) Visual Checks

- visual inspection of the general construction of the switchboard, the

busbar system, switchgear, instrumentation, cabling provisions, etc.
to determine if the switchboard is ready for further testing and
subsequent delivery to Site;

(ii) Dielectric Test

- this shall be carried out at power frequency as defined in BS EN

60439-1;

(iii) Insulation Test

- this shall be carried out by means of a 1,000V “Megger” tester or

similar instrument;

(iv) Secondary Injection Test

- this shall be carried out using AC and shall check that protection
relays or devices function in accordance with their performance
curves by a test at the lowest setting and two further tests of
current and timing;

(v) Primary Injection Test

- this shall be carried out to prove the correct operation of protective

devices or system when set at the agreed setting;

(vi) Polarity Check for CT

- this shall be carried out to ensure that all CTs are correctly
connected’

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 (vii) Functional Test

- this shall be carried out to ensure that the overall functionality

operate properly as intended;

(viii) Contact Resistance Test

- this shall be carried out by means of “Ductor” tester or similar

instrument to ensure that contacts and joints for switchgears,
cables, busbars as well as the contacts and joints for outgoing
cables and busbars are maintained in good condition; and

(ix) Temperature Rise Limits Test

- this shall be carried out as defined in BS EN 60439-1.

(b) On site test shall be carried out including visual check and as following above
tests ii) to viii) in Section 60.13.2 (a) of this General Materials & Workmanship
Specification.

(c) Battery Test shall include the following:

(i) inspection of the charger that it is connected to the mains supply

through a suitable rated fuse;

(ii) inspection of the battery connections;

(iii) inspection of instruments, indicating lamps, fuses, relays and labels on

battery charger have been carried out;

(iv) for initial set-up, charge the batteries at the manual highest rate until
the charging current remains constant. Record the starting and
finishing time. Check the capacity of charger is capable of recharging
the batteries from fully discharged to fully charge within the specified
duration;

(v) measure charger output on load with batteries disconnected, this

should be between 110% and 115% of the normal batteries voltage
and within the operating voltage limits of all connected devices;

(vi) measure charger current on load with battery disconnected, this should
be less than the maximum recommended continuous charge current
for the batteries;

(vii) interrupt mains input to the charger and check that proper operation of
connected devices continues on standby batteries. In the case of
switch tripping in Switchboard, interrupt mains input to check whether
the capacity of the batteries is adequate to trip the associated air
circuit breaker consecutively at least 20 times or up to twenty air circuit
breakers simultaneously, whichever the greater;

(viii) confirm correct function of charger fail/mains fail/battery

disconnected/charge indications as specified; and

(ix) restore mains supply and check that charger fail/mains fail indications
are off and that mains on indication is restored.
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60.13.3 UPS

(a) Factory Test shall include:

(i) The assembly shall undergo factory test prior to installation. Carry out
a 72 hours continuous “burn-in” test for the total system, including
functional and full load tests prior to shipment.

(b) Commissioning shall include :

(i) In addition to the above, carry out the following tests:

- full load and half load efficiency tests;

- frequency and voltage limits over the whole range of load;

- over voltage and short circuit protection;

- voltage and frequency regulation during sudden load application;

- overload performance;

- instruments calibration;

- output tests while being supplied from batteries only;

- battery charging and discharging tests;

- simulation tests to all alarms and faults;

- system by-pass, mains failure simulation tests; and

- any other functional tests necessary to demonstrate that the

system constructed are fully in compliance with the Specification.

60.13.4 Lighting

(a) Commissioning shall include:

(i) illuminance measurements; and

(ii) test to establish correct operation of switching control.

60.13.5 Lightning Protection System

(a) Component Tests shall include:

(i) continuity between air and earth terminations; and

(b) Commissioning shall include:

(i) earth electrode resistance.

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60.13.6 Low Voltage Testing and Inspection

(a) Inspection of Low Voltage Installations

(i) A visual inspection shall be carried out accordance with Code 21A in
“Code Of Practice for Electricity (Wiring) Regulation” by EMSD

(b) Testing of Low Voltage Installations

(i) The following tests shall be carried out in the order specified:

- continuity of right final circuit conductors;

- continuity of protective conductors, including main and

supplementary equipotential bonding;

- earth electrode resistance;

- insulation resistance;

- polarity;

- earth fault loop impedance;

- functions of all protective devices; and

- functions of all items of equipment.

(ii) The details of above tests shall be accordance with Code 21B in “Code
of practice for Electricity (Wiring) Regulation” by EMSD.

60.13.7 Test Certificates and Documentation

(a) Work completion certificate shall be provided accordance with Code 19 in

“Code of practice for Electricity (Wiring) Regulation” by EMSD, after the
installations are completed.

60.14 HV DISTRIBUTION CABLES

(a) Factory tests certificate from the manufacturer shall be provided.

(b) Type tests shall be included the following:

(i) construction test;

(ii) dielectric test;

(iii) conductor resistance test;

(iv) insulation resistance test;

(v) insulation resistance test – steam degradation test;

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 (vi) tensile strength and elongation test;

(vii) weight loss test;

(viii) immersion test;

(ix) accelerated aging test;

(x) cold bend test;

(xi) ozone resistance test;

(xii) flame propagation test;

(xiii) copper mirror corrosion test;

(xiv) partial discharge test;

(xv) bending test, plus partial discharge test;

(xvi) loss angle measurement;

(xvii) impulse withstand test, followed by a power frequency voltage test;

and

(xviii) high voltage AC test.

(c) Site Tests:

(i) checking for proper connection of the cables to the equipment;

(ii) pressure test;

(iii) insulation resistance test; and

(iv) polarity test.

(d) Testing and Commissioning during Plant Commissioning Phase:

(i) checking for proper laying of the cable;

(ii) insulation resistance test;

(iii) earth test; and

(iv) pressure test.

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60.15 HV DISTRIBUTION TRANSFORMER

(a) The contractor shall carry out tests of transformers of the same type and rating
as the transformer being offered as per BS EN 60076 and BS IEC 60076-8 (or
other equivalent international standard). Type test certificates for each type
test complete with reports and drawings shall be submitted.

(b) Testing shall include the following:

(i) measurement of insulation resistance;

(ii) measurement of winding resistance;

(iii) measurement of voltage ratio;

(iv) check of voltage vector relationship;

(v) no load test;

(vi) impedance test;

(vii) measurement of zero sequence impedance;

(viii) temperature rise test;

(ix) lightning impulse test;

(x) power frequency voltage withstand test;

(xi) measurement of audible sound level;

(xii) tests on magnetizing current;

(xiii) harmonic measurements;

(xiv) functional test and calibration of protective device, high temperature

alarm and trip;

(xv) test on tap changer operation;

(xvi) magnetic circuit insulation test;

(xvii) short circuit test;

(xviii) induced overvoltage withstand test to BS EN 60076-3 (200% nominal

voltage at 315 Hz); and

(xix) partial discharge test.

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 (c) Site Tests

(i) inspection of the workmanship and the effectiveness of the outgoing

connections; and

(ii) testing of insulation resistance of winding to winding and winding to

earth.

(d) Testing and Commissioning During Plant Commissioning Phase

(i) tests to verify correctness of voltage ratio and vector group; and

(ii) functional test and calibration of protective device, high temperature

alarm and trip.

60.16 CONFIDENCE TRIALS PHASE

(a) On or after the date of issue of the Certificate of Completion, the Contractor
shall conduct a Confidence Trial under full live traffic conditions. The
Confidence Trial shall continue for a minimum period of 3 months. Availability
measurements shall be taken during the test and the test shall be restarted on
any test failure. Testing shall continue until the required availability is
achieved. If during the Confidence Trials and the Defects Liability Period the
service availability is not achieved and/or a trend indicates it shall not be met,
the Contractor shall promptly undertake design reviews and a review of the
maintenance and operations procedure and immediately correct the default or
potential default.

60.17 EMERGENCY GENERATORS

(a) Tests shall be carried out on the major components of the emergency
generator systems during manufacture and certified records in quadruplicate
of all such tests shall be submitted. The completed and fully assembled
emergency generator sets shall be tested at the manufacturer’s works before
dispatch, including governor trials, full load and overload performance, over-
voltage protection, under-voltage protection, engine over-speed protection,
overload trip protection, and fuel consumption tests, in accordance with BS
5000 and BS 5514. Certified records of the tests and type test certificates of
items for protection and alarm shall be submitted in quadruplicate before
shipment.

(b) Performance tests shall be carried out for all equipment and systems installed.
This shall include the necessary adjustment and setting of all controls,
checking the operation of all overload protection and safety devices and the
commissioning of the completed installation.

(c) All apparatus, fuels, tools and instruments necessary for testing the
installation shall be supplied. The accuracy of the instruments shall be proved.
Calibration certificates of all instruments shall be submitted before carry out
the test. Test methods and measurements shall be in accordance with
BS5514, Part 2 and Part 3.

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 (d) Performance tests shall be carried out on the emergency generators after
installation. Diesel fuel, water, lubricants, etc. shall be provided for all tests
including dummy load test, actual load test and other fire services test shall be
provided. Sufficient quantities of these consumables shall be topped up before
carrying out such tests.

(e) Full load test in the first instance shall use dummy load which shall be carried
out. This shall be followed by the actual full load tests. Transportation shall be
arranged to deliver the dummy loads to the Site and temporary power
connection from the generator to the dummy load shall be provided.

(f) The engine shall be run consecutively at no load, 25% load, 50% load, 100%
load, 110% load and 80% load each for at least one hour under worst ambient
condition. The following data shall be recorded for every 15 minutes:

(i) Engine speed, both panel reading and with tachometer

(ii) Output voltage, frequency, current and power factor

(iii) Oil pressure and temperature

(iv) Cooling water temperature

(v) Fuel level at every half hour by manual sounding and gauge reading

(vi) Ambient temperature, exhaust gas temperature

(vii) Temperature rise (compliance with BS 5000)

(viii) Voltage regulation

(g) The engine speed control shall be tested by applying consecutively step load
of 25% and 50% of rated capacity and the transient speed drop recorded.

(h) Four copies of certified results of the tests shall then be submitted to the
Project Manager.

(i) All the fuel tanks shall be topped up after satisfactory completion of all the
above tests.

60.18 DAILY AND UNDERGROUND FUEL TANKS

(a) Hydraulic testes for the daily fuel tanks, underground storage tanks and the
completed pipework for a period of time not less than 2 hours without undue
deformation and leaking. The following test pressure shall be used :

(i) 70 kPa for the daily service tanks and the underground fuel storage tanks.

(ii) 700 kPa for the completed pipework, valves and fittings.

(b) The pressure gauges employed for the test shall be tested and calibrated by
approved laboratory before use. Pressure gauges with full scale deflection
readings more than 3 times the test pressures shall not be used.

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 (c) Immediately after the hydraulic testing, the daily service tanks and underground
fuel storage tanks must be drained and dried out and a thick coat of linseed oil or
equivalent coating shall be applied on the interior surfaces of the tanks to
prevent rusting. All pipework, fittings and valves after tests shall be drained dried
and flushed out with linseed oil to remove all traces of water to prevent rusting.

(d) The following information shall be permanently and clearly marked on a

nameplate to be attached to the daily service tanks and underground fuel
storage tanks in an agreed position:

(i) Contractor's name

(ii) Gross capacity in litres

(iii) Date of hydraulic test

60.19 PILOT CABLES

All the cable type tests and routine tests for pilot cables shall be carried out in
accordance with BS 6387, BS 4066, BS 6425, and BS 6724.

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[this page not used]
SECTION 61 AIR HANDLING UNITS

61.1 GENERAL

(a) The air handling units shall be supplied by manufacturers experienced in the
design and construction of similar equipment and who have made air handling
units for similar duties for at least five years.

(b) No ex-factory fabrication or assembly of air handling unit components shall be

commenced without prior review without objection by the Project Manager.
Works shall be carried out by the manufacturer and covered by both a test
report and a warranty from the manufacturer showing that the performance of
the AHU has not been degraded.

(c) Mounting and fixing details shall include details and dimensions of air handling
unit bases, fixing bolts, flexible connections, vibration isolators and any
installation requirements.

(d) Air handling units (AHU's) shall include, but not be limited to, the following
components.

(i) sheet metal housing including fan, cooling coil, filter and air mixing
sections;

(ii) fans;

(iii) motors and drives;

(iv) cooling coils;

(v) drain pans and pipework;

(vi) air filters;

(vii) outside and return air dampers;

(viii) access doors;

(ix) thermal insulation;

(x) vibration mounts; and

(xi) flexible connections.

(e) The Contractor shall comply with other relevant sections of this General
Materials & Workmanship Specification including, but not limited to the
sections which specify:

(i) Section 63 “Fans”;

(ii) Section 66 “Air Cooling Coils”;

(iii) Section 67 “Dampers and Air Volume Control Devices”;

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 (iv) Section 69 “Air Filters”;

(v) Section 70 “Ductwork and Fittings”;

(vi) Section 72 “Pipework, Fittings and Valves”;

(vii) Section 73 “Thermal Insulation”;

(viii) Section 75 “Noise and Vibration Control”;

(ix) Section 76 “Electrical Equipment and Installation”;

(x) Section 77 “Automatic Controls”;

(xi) Section 78 “Instruments”; and

(xii) Section 79 “Testing, Inspection and Commissioning – Mechanical

Services”;

(f) Air handling units and associated components shall be factory fabricated and
assembled, factory tested and pre-commissioned prior to shipment. Work to
be undertaken at the factory prior to delivery to Site shall include, but not be
limited to:

(i) mounting dampers and associated damper motors;

(ii) mounting sensors and control devices;

(iii) cabling up sensors, controllers and dampers; and

(iv) testing and commissioning control algorithms.

No accessories are allowed to be installed directly onto the AHU’s casing

unless shown on the manufacturer’s fabrication drawings.

(g) All AHUs shall incorporate filter differential pressure switch regardless of
whether or not the pressure switch is monitored by the mechanical BMS
(MBMS).

(h) All air handling units and/or primary air handling units shall incorporate a
600mm long empty section to allow the future installation of air treatment
plant.

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Section 61 – Air Handling Units
61.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, at the date of the Letter of Acceptance.

BS 848 Fans for general purposes

BS EN ISO 9001 Quality systems. Model for quality assurance in design,
development, production, installation and servicing
ARI 430 Central-station air-handling units
DW/144 Specification for sheet metal ductwork

All air handling units and/or primary air handling units shall be constructed in
accordance with BS EN 1886:1998 - Ventilation for buildings.

Each AHU shall be provided with a factory assembled air mixing plenum at the air
intake as shown on the Employers Drawings. Each opening on the mixing plenum
shall be provided with an integral factory assembled volume control damper.

61.3 SELECTION

(a) Static pressure of the fan performance shall meet the total system
requirements, including but not limited to, pressure drops across wet cooling
coils, dirty filters, sound attenuators, dampers, plenums, ductwork, door grilles
and the like.

(b) Scheduled external fan static pressures affecting the final selection of fans,
motors and associated plant are approximate. Fans shall be selected based
on the Contractor’s static pressure calculations to ensure the duties are
compatible with the installed plant, materials used and the final ductwork
layout.

(c) Units shall be tested and rated in accordance with ARI Standard 430.

61.4 MATERIALS

61.4.1 General

(a) AHU assemblies shall be rigid double skin fully modular construction
incorporating a solid sheet metal outer casing and base frame, insulation and
a solid sheetmetal internal lining. All individual components and sections shall
be assembled using proprietary fastening techniques which have been
reviewed without objection by the Project Manager. Locking devices shall be
used with all fastenings that are subject to vibration. Air leakage of the
assembled unit shall be to HVCA Standard DW144 Class B.

(b) Air handling units shall be horizontal draw through.

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Section 61 – Air Handling Units
 (c) The unit housing shall be fabricated from heavy gauge, hot dipped galvanised
structural members and heavy gauge galvanised folded sheet steel panels.
Base frame shall not be less than the height of 100mm. Casing materials
shall not be less than the thickness as shown in the table below and methods
of strengthening and fastening shall ensure that air-handling assemblies are
not less but preferably more rigid in operation than the distribution duct to
which they connect.

Component Minimum material

thickness (mm)
Steel framework 2.0
Cooling coil casing 1.6
Acoustic and thermal 0.8
insulation
Other 1.2

(d) Unit casings shall withstand, without damage, a positive or negative pressure
differential of 2500 Pa, or the shut off pressure of any fan capable of
influencing the unit, whichever is the greater.

(e) All metal surfaces shall be properly treated and suitably painted. Galvanised
sheet metal finish is not acceptable. External wall shall be galvanised steel,
chemically treated, pre-coated with primer and plastisol topcoat in accordance
with the manufacture’s recommendations.

(f) The channel and/ or angle framework sections shall be of galvanised steel and
be easily bolted/ welded together on site. All bolts and nuts etc. shall be
stainless steel metal or bright metal cadmium coated steel.

(g) Each air handling units and/or primary air handling units shall be supplied to
site as a complete factory assembled unit direct from the original
manufacturer’s works. Each unit shall include, but not be limited to, motors,
bearings, pulley drives, eliminators, filters, cooling coil, ducted mounted
electric heater, and other components and accessories. All components shall
be arranged such that they are readily accessible for repair, maintenance and
replacement.

(h) The Contractor shall submit to the Project Manager, for review without
objection, Contractor’s drawings detailing the proposed delivery routes and
access requirements to allow the future replacement of the complete air
handling units and/or primary air handling units, of part thereof.

61.4.2 Acoustic and Thermal Insulation

(a) As a minimum, the entire unit housing shall be internally insulated with 50 mm
of 48 kg/m3 fiberglass within the double skin. The insulation shall comply with
FSD regulations.

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Section 61 – Air Handling Units
 (b) The unit shall be cold bridge free without sweating even under ambient
conditions of 40°C and 98% RH. Thermal insulation shall be 50mm thick 48
kg/m3 fibreglass having a thermal conductivity not greater than 0.02 W/m°C
rated at the operating temperature and reviewed without objection by the
Project Manager. The insulation shall provide a high degree of noise
attenuation. Insertion loss through the panels shall be sufficient to achieve a
25 dB and 27 dB reduction at 63 Hz and 125 Hz octave bands respectively.

61.4.3 Access Doors and Panels

(a) The unit shall be provided with rigid, insulated, gasketted, non-leaking doors
and panels to provide access to items which may require inspection,
adjustment, maintenance and/or removal.

(b) Hinged doors of cool room construction or similar shall be used for access on
all air handling units with an internal height exceeding 0.6 m. Doors shall be
operable from inside and outside the AHU.

(c) For smaller air handling units, access panels shall be provided with sash
clamps or similar fasteners for ease of panel removal. Panels screwed in
position will not be accepted.

(d) Doors and access panels shall be a minimum 600 mm wide and shall be the
full height of the air-handling unit up to a maximum of 1500 mm.

(e) A minimum of 2 hinges and 2 catches shall be provided on access doors and
a minimum of 4 clamps on access panels.

(f) Access doors and panels shall be designed to open in a direction opposite to
that of the pressure produced by the fan.

(g) Fan chamber access doors shall be key locked and interlocked with fan motor
to automatically stop the fan if the door is opened.

61.4.4 Fans, Motors and Drives

(a) Fan and motor assembly shall be mounted on a common framework inside the
fan section.

(b) The fan discharge shall be isolated from the casing by a flexible connection.

(c) Fan shall be driven by at least a two-belt arrangement.

(d) Selection of the fan and motor shall be such that they are operating at their
peak efficiency. Fan and motor shall be supplied together by the AHU
manufacturer, unless otherwise specified.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 61 – Air Handling Units
61.4.5 Vibration Isolation and Flexible Connections

(a) Flexible connections shall be fitted between the fan discharge and the main air
supply ductwork. Flexible connections shall be constructed of two layers of
fire resistant glass cloth with aluminum foil interleaf or equivalent to provide a
pressure seal. Both the internal and external faces of the connection shall be
moisture proof. Exposed flanged joints shall be sealed with vapour barrier
mastic and capped all around with a 0.8 mm galvanised sheet metal painted to
match the air handling unit colour.

(b) Neoprene padding shall be installed continuously between the air handling
unit and the mounting frame as vibration absorption media.

61.4.6 Anti-Corrosion Treatment

(a) Where units incorporate humidifying plant and/or cooler batteries, the internal
surfaces of the units liable to be affected by moisture shall be of non- ferrous
materials or galvanized mild steel sheet. The GI metal sheets shall be
protected by at least two coats of anti-corrosion epoxy resin paint, colour coat,
or other finish reviewed by the Project Manager and applied in the factory.
Field painting after the installation is not accepted.

61.5 SUBMISSIONS

61.5.1 Particulars of AHU

(a) The Contractor's Drawings shall clearly indicate the construction and
assembly of all air handling unit components including accessories. This
includes the details of supporting framework such as height of base frame and
steel channel and the details of the maintenance space for access.

(b) The Contractor shall submit the make and type of each fan giving values of
sound power levels and fan efficiency at the selected duty together with the
'type' test certificate for review without objection by the Project Manager.

(c) Fan performance curves.

(d) System static calculation supporting the selection of equipment and confirming
the system will meet the requirements of the specification.

61.6 WORKMANSHIP

(a) Unless otherwise noted on the Employer's Drawings and reviewed without
objection by the Project Manager, air-handling units, including structural
support bases, shall not exceed 2.0 m in overall height.

(b) Panels shall be fixed to structural members by welding, bolting or metal thread
screws. Joints between sections shall be fitted with gaskets or shall be
caulked to prevent air leakage. The complete unit shall be stiffened as
necessary to ensure structural rigidity, to prevent "drumming" and to limit
deflection of the casing under all operating conditions.

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Section 61 – Air Handling Units
 (c) Bolts, screws, fixings and the like shall not penetrate or contact both interior
and exterior panels or form a "thermal bridge".

(d) Wherever possible, all plant including fans, coils, valves, dampers, filters,
heaters, motors and the like shall be accessible for inspection, adjustment,
maintenance and removal from the one side of the air handling unit. The units
shall be designed and arranged so that the location of access doors, coil
connections, fans, drives, motors and support points are compatible with the
unit locations shown on the Employer's Drawings.

(e) Units over 1.0 m high or 1.0 m wide shall be ‘walk in’ and have floors and floor
mounted condensate trays designed to carry the weight of a maintenance
person.

(f) A structural steel channel or rolled steel joist base shall be provided to support
the unit. The base shall be of sufficient depth to allow installation of the entire
condensate trap within the depth of the base. The AHU shall not directly rest
on the concrete plinth and shall be supported with steel channel of not less
than 100mm height.

(g) Capped test holes and other facilities shall be provided to suit testing and
commissioning.

(h) Unless otherwise specified, air handling unit shall be mounted on a hot dipped
galvanised I beam or U channel mounting frame which is either fixed on a
concrete plinth of 150mm height with not less than 15mm thickness neoprene
pads or ceiling mounted by suspension galvanised steel hangers. Sufficient
space shall be allowed for installation of drain trap and fall of condensate
drainpipe.

(i) For ceiling mounted air handling unit, the mounting frame and hanging rods
shall be designed to account for the operation loading of the air handling unit
and the associated ducting and piping. Hanging rods shall be threaded and
complete with locking nuts for level adjustment. All AHU supports and
supporting accessories shall be hot dip galvanised steel.

(j) Where corrosion can occur, appropriate corrosion-resistant materials and

assembly methods must be used including isolation of dissimilar metals
against galvanic interaction.

(k) Fans shall be 'type' tested in accordance with the requirements of BS 848

(l) All gauges and meters other than insertion type shall not be mounted on the
casing of the air handling unit but shall be purpose designed and installed
within the AHU at the manufacturer’s works.

(m) The Contractor shall adequately protect the surface of the coil fins with
wooden covers which shall remain on the coil until system balancing
commences.

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Section 61 – Air Handling Units
 (n) Each AHU shall have a specification plate which shall show full details of the
fan size, r.p.m., amperes, impeller diameter, fan characteristics, lubricants, air
flows at specified duty, pulley and belt sizes, coil duties, filter media, water
flow rates, design flow temperatures and any other information as may be
required by the Project Manager. This plate shall be labeled in English and
securely fixed to the air handling unit casing.

(o) The air handling units shall bear the manufacturer’s nameplate giving
manufacturer’s name, serial and model number and date of manufacture.

General Materials & Workmanship Specification 8/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 61 – Air Handling Units
SECTION 62 FAN COIL UNITS

62.1 GENERAL

(a) The Permanent Works and materials specified below shall comply with the
sections stated, unless otherwise stated in this section:

(i) Section 63 “Fans”;

(ii) Section 66 “Air Cooling Coils”;

(iii) Section 69 “Air Filters”;

(iv) Section 70 “Ductwork and Fittings”;

(v) Section 72 “Pipework, Fittings and Valves”;

(vi) Section 73 “Thermal Insulation”;

(vii) Section 75 “Noise and Vibration Control”;

(viii) Section 76 “Electrical Equipment and Installation”; and

(ix) Section 79 “Testing, Inspection and Commissioning – Mechanical

Services”.

(b) Fan coil units shall comply with the requirements for air handling units and
cooling coil specified in this General Materials and Workmanship Specification
except that:

(i) externally mounted motors are acceptable subject to compliance with

specified noise levels for the corresponding space;

(ii) casings designed to withstand a minimum positive or negative

pressure differential of 2,500 Pa; and

(iii) as a minimum, the entire housing shall be internally insulated with 25

mm of 32 kg/m³ fibreglass.

(c) All FCU insulation shall comply with FSD requirement.

(d) FCU shall be controlled either locally or by MBMS and the proposed control
methodology shall be submitted to the Project Manager for review without
objection. If it is controlled by MBMS, local mechanical BMS (MBMS)
controllers shall be mounted on the side of the FCU.

(e) Exposed fan coil units visible to the public shall be finished with a decorative
casing and provided with an adjustable discharge grille.

General Materials & Workmanship Specification 1/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 62 – Fan Coil Units
62.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as the date of the Letter of Acceptance.

BS 4856 Methods for testing and rating fan coil units, unit heaters and
unit coolers
BS EN 779 Particulate air filters for general ventilation. Requirements,
testing, marking
ANSI/ASHRAE 79 Methods of testing for rating room fan-coil air-conditioners
ARI Standard 430 Central station air handling units
ARI Standard 440 Room fan-coils

62.3 MATERIALS

62.3.1 General

(a) The capacity of fan coil units and air flow rate shall be selected based on the
performance of the units at medium fan speed.

(b) In selecting the fan coil units, allowance shall be made for the actual
resistance imposed on the air flow of the units due to ducts and grilles. The
added resistance shall be applied to all fan coil units whether shown to have
ducts connected or not, and shall be taken as not less than 50Pa external to
the unit.

(c) Fan coil units (FCU's) up to 700 L/s shall be tested in accordance with
ASHRAE 79 and rated in accordance with ARI Standard 440. All other fan coil
units shall be tested and rated in accordance with ARI Standard 430.

(d) The thermal, volumetric and acoustic performance of fan coil units shall
comply with the testing and rating criteria in accordance with BS 4856.

62.3.2 Fans

(a) Fans shall be of the DIDW forward curved centrifugal or tangential flow types
and shall be of mild steel, aluminium, reinforced glass fibres or rigid plastics
material.

62.3.3 Air Filters

(a) Air filters shall be of FM-C type or as indicated in the relevant clauses of
Section 69 but with an efficiency of not less than 50% when tested in
accordance with BS EN 779.

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Section 62 – Fan Coil Units
62.3.4 Motors

(a) Motors shall be quiet running and have sleeve bearings factory lubricated for
life. Motor windings and electrical components shall be protected from
condensation. The fan motor shall be of the single phase permanent split
capacitor type provided with three speed tapped windings.

62.3.5 Casings

(a) Casings shall be of G.I. sheet metal with thickness not less than 0.8 mm.
Casings shall not “drum” (that is produce noise) or vibration and shall be
protected against corrosion and finished inside and outside with stoved primer.
All corners shall be rounded off without sharp edges. Casings shall be lined
with material to act as both thermal and acoustic insulation.

62.3.6 Components

(a) All units shall include an easily removable filter capable of treating the total air
volume. Filters shall be washable.

62.3.7 Drain Pans

(a) Drain pans shall be made of one piece stamped stainless sheet steel with no
weld and protected against corrosion, or, review without objection by the
Project Manager, made of plastics or reinforced glass fibre materials insulated
with a minimum of 13 mm thick flexible closed cell elastomeric insulation in
compliance with relevant FSD codes.

62.3.8 Controls, Dampers and Grilles

(a) Fan coil units shall have a combined room temperature sensor complete with
3-speed controller and cooling mode selector as specified. Where indicated
they shall have connections for both fresh and re-circulated air and shall
include a damper which shall be adjustable to give up to 25% of the fan
capacity drawing from the fresh air source. Outlet grilles shall be capable of
adjusting the direction of airflow without adversely affecting pressure drop. On
floor mounted units, supply grilles shall be on the top of the unit.

62.3.9 Exposed Type Fan Coil Unit

(a) All FCU’s which are exposed shall be of proprietary ceiling mounted type,
combining the supply air grille, return air grille, fan, cooling coils, filters,
acoustic treatments and the like. The unit shall be complete with a GI sheet
metal casing with minimum thickness 1mm suitably stiffened to minimise
drumming and vibration. No connection of ductwork shall be allowed except
for outside air.
(b) The Contractor shall submit to the Project Manager details of the exposed
type FCU for review without objection prior to procuring the units.
(c) The casing shall be protected against corrosion and finished inside and
outside with stoved primer. All corners shall be rounded off without sharp
edges. The air supply direction shall be horizontally discharged.
(d) Fan coil units shall be selected to provide the required design duty with the
fan running at medium speed.

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Section 62 – Fan Coil Units
 (e) Each fan coil unit shall be provided with a stainless steel drain pan situated
beneath the cooling coil. The drain pan shall be arranged so that all moisture
can be collected and drained from the pan. Each drain pan shall be fitted with
a drain pipe which shall be connected via suitable runs (correctly laid to fall) to
the drainage system.

62.3.10 Condensate Pumps

(a) Condensate pumps shall be provided for removal of condensate from all fan
coil units where it is not possible to achieve a natural fall (of at least 1:100) to
the nearest gravity condensate stack. A sensing system, complete with low
and high water warning limits, shall be provided to control the operation of the
condensate pump.

(b) An additional high water limit switch shall be included to set off an alarm to
warn the user of a system failure. When the water level reaches the warning
limit, the sensing system shall cut off the chilled water supply to the FCU to
prevent further cooling. Audio and visual alarm signals shall be provided
locally and relayed to the MBMS.

(c) Condensate pumps shall be designed to run continuously once the high water
level signal is activated. The power source for condensate pumps and the
associated control systems shall be independent from the associated fan coil
unit such that the pump can still be operated after the unit has been switched
off. The power supply for the condensate drain pump shall be completed with
a switched fuse-spur unit and changeover switches.

(d) A wall mounted monitoring panel shall be provided complete with pump fault
common alarm, buzzer, indicating lamp and reset switch for each pump set.
The panel shall be mounted on wall (inside plant room) or ceiling void with
easy access.

(e) The pump set shall be completed with integral float switch, pump and motor
assembly all housed in a thermally insulated PVC pit/tank. The pumps shall be
in-line centrifugal type or equivalent to be submitted to the Project Manager
for review without objection.

(f) The Contractor shall submit calculations to the Project Manager for review
without objection, to confirm the condensate pump flow rate and pressure
head. The condensate pump shall be completed with PVC casing and
impeller, stainless steel shaft. The pump speed shall not be greater than
1000rpm. If the pump set is located in any area other than a plant room, the
noise level limit shall be NC35. The minimum vibration isolation efficiency
shall be 95%

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 62 – Fan Coil Units
62.4 SUBMISSIONS

62.4.1 Particulars of Fan Coil Units

The following particulars of the proposed fan coil unit shall be submitted to the
Project Manager for review without objection:

(a) contractor’s drawings detailing the location, position and fixing details of all fan
coil unit and access panels;

(b) make and type of “type” test certificate; and

(c) noise data based on the tests in accordance with this General Materials and
Workmanship Specification, and full details of the testing technique and
procedure. The data shall include an octave band analysis of the sound
power level of each unit when operating at its full or the stated design speed.

62.5 WORKMANSHIP

(a) Threaded suspension rods with lock nut and washer shall be used for ceiling
mounted fan coil units for level adjustment.

(b) Sufficient access panels shall be provided at the supply air duct and the return
air plenum for servicing the blower and duct heater. Demountable return air
grille of minimum dimensions 600 mm × 600 mm shall be considered as an
access panel subject to review without objection by the Project Manager.

(c) The location of the control box shall be within 600 mm from the terminal box of
the fan coil unit and the duct heater.

(d) All units shall be selected to suit the limited space within the false ceiling, with
due consideration to access for maintenance and servicing.

(e) All blowers and motors of fan coil units shall be demountable from the ceiling
void for maintenance purposes without causing damage to the associated
ductwork and insulation. The motor and fan shall be mounted on a detachable
mounting chassis that is able to be removed from the fan coil enclosure as
one assembly (with extended cables) to facilitate fan and motor cleaning. It
shall then also be possible to remove the fan impeller scroll casing in order to
properly clean the fan blades. Fan and motor assemblies shall be complete
with neoprene rubber anti-vibration mountings.

(f) The condensation drain pan shall have insulation of a class approved by FSD.

(g) For fan coil units rated at less than 700 l/s:

(i) fans and motors shall be mounted on a detachable mounting plate to

facilitate removal for inspection and cleaning. Extended cables shall
be provided to suit; and

(ii) blow through cooling coils are acceptable.

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Section 62 – Fan Coil Units
 (h) Casings shall include space for pipework connections and valves, and there
shall be ready access to the fan and motor, filter, damper, drain pan, pipework
connections and valves, for maintenance purposes.

(i) Air filter shall be supported in a stiff aluminium/stainless steel withdrawable

frame.

General Materials & Workmanship Specification 6/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 62 – Fan Coil Units
SECTION 63 FANS

63.1 GENERAL

(a) Unless otherwise indicated, the requirements of this Section shall not apply to
individual fans having a duty air flow rate of 1.0 m3/s or less.

(b) Hot smoke extraction fans, motors and associated plant shall comply with
Relevant Authority requirements for dynamic smoke extraction systems
including the requirement that plant shall be suitable for continuous operation
at 250°C for at least 1 hour.

(c) Kitchen exhaust fans, whilst not part of dynamic smoke extraction system,
shall also be suitable for continuous operation to 250°C for at least 1 hour.

(d) Belt driven fans shall use a V-belt drive rated at not less than 150% of actual
full load and shall have a minimum of two belts. Provision shall be made for
belt adjustment.

(e) A 1.6 mm thick perforated galvanized sheet metal or 12.5 mm galvanized wire
mesh belt guard to protect belts and pulleys shall be provided. A 40 mm
diameter hole shall be provided in the belt guard opposite each fan and motor
shaft to allow for the insertion of a tachometer.

(f) Pulleys shall be selected and installed in accordance with the manufacturer’s
recommendations. Selections shall ensure that fans start without belt squeal
and without excessive belt tension. Fan and motor shafts shall be keyed to
the mating pulleys. Fans selected for 4.5 kW shaft power and above, shall be
fitted with fan and motor pulleys of standard taper lock style. Pulleys shall be
exactly aligned and all holding down bolts grouted in by the Contractor,
positioned to the correct alignment. Provision shall be made for positive
adjustment of the tension in V-belt drives.

(g) Fan guards shall be provided for:

(i) open unprotected intakes to centrifugal flow fans;

(ii) unprotected intakes to and exhausts from axial flow fans;

(iii) open unprotected and easily accessible intakes to and exhausts from
propeller fans;

(iv) V-belt drives; and

(v) drive couplings.

(h) Bearings shall have a minimum L10 life of 100,000 hours at operating
conditions. Rolling bearings shall be selected in accordance with BS 5512.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 63 – Fans
 (i) Bearings shall be located in dust tight housings with efficient shaft seals to
prevent the entry of impurities and the escape of grease. All housings shall be
fitted with accessible grease nipples and relief plugs to enable bearings to be
lubricated without the removal of end caps and without the risk of pressure
build up. Fans shall be delivered with bearings lubricated using a lithium
based grease suitable for minimum bearing temperatures of 120°C. Sealed for
life housings may be fitted on fans with a duty up to 1.0 m3/s.

(j) Fan wheels shall be statically and dynamically balanced after fabrication.

(k) A plugged drain hole shall be provided in the bottom of fan casings.

(l) Kitchen exhaust fans shall have clean out doors.

(m) Ventilation fans, and associated fan motors, serving rooms which contain lead
acid batteries and which are operated in extraction mode, shall be of the
totally enclosed fan cooled (TEFC) type in accordance with FSD
requirements. All components shall be made of corrosion resistant material.

(n) Where the room served is used for battery charging, the fan motors shall be
electrically interlocked with the battery charger so that the charger cannot be
operate when, for whatever reason, the ventilation fan is not running. The
power supply for the ventilation fan(s) shall be taken from an independent
circuit other than that of the battery charger. The interlock control relay shall
be protected by an independent fuse.

(o) The ventilation fans serving the fuel pipe duct shall be of the explosion proof
type complying with BS EN 60079.

63.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, at the date of the Letter of Acceptance.

BS 848 Fans for general purposes

BS 2757 Method for determining the thermal classification of electrical
insulation
BS 3790 Specification for endless wedge belt drives and endless V-
belt drives
BS 5512 Method of calculating dynamic load ratings and rating life of
rolling bearings
DW/144 Specification for sheet metal ductwork
ARI 670 Fans and blowers
ASHARE Standard 51 Laboratory methods of testing fans for aerodynamic
performance rating
ASHARE Standard 68 Laboratory method of testing to determine the sound power
in a duct

General Materials & Workmanship Specification 2/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 63 – Fans
63.3 MATERIALS

63.3.1 General

(a) Fans shall be tested in accordance with ASHRAE 51 (General) and ASHRAE
68 (Noise).

(b) Fans shall be rated in accordance with ARI Standard 670.

(c) Fans shall comply with quality standard ISO9000-1 to 9000-4 and be ‘type”
tested in accordance with the requirements of BS 848.

(d) Motor insulation for hot smoke extraction fans, kitchen exhaust fans and fans
running 24 hours non stop operation shall be Class H to BS 2757 minimum.

(e) Fan V-belt drives shall comply with BS 3790 and shall be capable of
transmitting at least the rated output with one belt removed. Unless otherwise
indicated, not less than two belts per drive shall be used.

63.3.2 Axial Flow Fans

(a) Axial flow fans shall be either the single-stage type or the multi-stage contra-
rotating type with each impeller mounted on an independent motor.

(b) Fan casings shall be of galvanized steel and braced to obviate drumming and
vibration. Cast iron or fabricated steel feet shall be provided where necessary
for bolting to the base or supports.

(c) Impellers shall be of steel or die cast aluminium.

(d) Axial flow fans shall be factory assembled and flanged for duct mounting or
attachment to inlet and discharge cones.

(e) The length of duct casing shall be sufficient for housing the fan(s) & motor(s)
and it shall be removable without disturbing adjacent ductwork for
maintenance.

(f) Fans shall have variable pitch blades capable of being re-adjusted on Site but
factory set for the design duty. Blades shall have aerofoil sections and shall
be suitable for horizontal or vertical spindle operation as installed.

(g) Blades shall be secured to the hub or the blades and the hub shall be formed
in one piece. The hub shall be keyed to a substantial mild steel shaft carried
on two bearings and the whole shaft, hub & blades shall be statically
balanced.

(h) Inspection doors of adequate size to facilitate inspection, cleaning and other
maintenance shall be provided on the fan casing.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 63 – Fans
 (i) Electrical connections to the motor(s) shall be through electrical terminal
boxes externally mounted on the fan casing.

(j) Reversible axial fans shall provide at least 60% of the specified air quantity in
reverse mode.

63.3.3 Centrifugal Fans

(a) Centrifugal fans for air handling units or for high-velocity high pressure
systems as defined within HVCA Specification DW/144, shall be of the
backward bladed type.

(b) Centrifugal fans consuming 7.5 kW or more at the fan shaft shall be of the
backward bladed type having a fan total efficiency of at least 75%.

(c) Forward curved or backward inclined blades shall only be used for fan coil
units and packaged air conditioning units where it is demonstrated and
reviewed without objection by the Project Manager that the developed fan
static and selection point on the fan performance curve is suitable for the
application under all operating conditions.

(d) Fan casings and fan wheels shall be constructed of galvanized steel. Fan
casings shall be constructed to allow withdrawal of the fan impeller after fan
installation.

(e) Fans, except those in factory constructed air handling units, shall be provided
with flanged outlet connections and spigoted inlet connections. Spigoted inlet
connections shall be suitable for flexible joint connections except those for use
with negative pressures greater than 500 Pa in which case the inlet
connection shall be flanged.

(f) All fan casings of 900 mm diameter or greater shall be provided with
removable access panels complete with air seals and of a size suitable for
cleaning and maintenance of the impeller but in any case not smaller than 600
mm X 600 mm.

(g) Kitchen extract ventilation fans shall have a removable access panel of width
equal to the diameter of the impeller. The access panels shall be fitted to the
scroll casing in an easily accessible position for inspection and cleaning. A
plugged drain point shall be fitted at the lowest point in the fan casings.

(h) Impellers shall be of galvanized steel of riveted or welded construction, with

spiders or hubs of robust design, and shall be capable of running continuously
at ten percent in excess of normal speed. Impellers shall be keyed to a
substantial mild steel shaft.

(i) Fan shafts shall allow pulleys to be mounted at both ends. Shaft bearings of
belt driven single inlet fans shall be truly aligned and rigidly mounted on a
pedestal common to both bearings. Double inlet, double width fans shall have
a pedestal mounted bearing at each side of the fan. Fan bearings shall be
ring oiling sleeve type or the ball or roller type. Where silence is important the
bearing pedestal shall not be attached to the fan casing and ring oiling sleeve
type bearings shall be supplied.
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Section 63 – Fans
 (j) Permanent indication shall be provided to show the correct direction of rotation
of the fan impeller. Fan designation and fan number shall be clearly marked
on the fan casing.

(k) Centrifugal fans shall be driven by electric motors through V-belt drives.

(l) Single phase powered variable flow centrifugal fans where specified shall be
fitted with variable inlet vanes which shall be matched to the fan performance
to give stable control. Vanes shall be closely interlocked to ensure movement
in unison. Operation shall be manual or automatic as indicated. Where manual
control is indicated, the operating device shall be facilitate positive locking in at
least five different positions. Vane blades shall not vibrate or flutter throughout
their operational range.

(m) Three phase powered variable flow centrifugal fans where specified shall be
variable speed driven.

63.3.4 In-Line Centrifugal and Mixed Flow Fans

(a) Fan casing shall be of galvanized sheetmetal or aluminium alloy, stiffened and
braced where necessary to obviate drumming and vibration. Mounting feet
shall be provided where necessary for bolting to a base or supports.

(b) Inlets and outlets shall terminate in flanges to facilitate removal.

(c) Stator vanes shall be of mild steel or aluminium alloy.

(d) Inspection doors of adequate size, with purpose made air seals to facilitate
inspection and cleaning shall be provided on the fan casing.

63.3.5 Propeller Fans

(a) Mounting plates shall be of galvanized steel and impellers shall be of die cast
aluminium.

(b) The blades shall be fastened to the hub, or the blades and hub shall be
formed in one piece.

(c) The bearings may be ball, roller, or sleeve type.

(d) Propeller fans shall be mounted in a suitable housing complete with wire mesh
guards, automatic shutters and decorative finish.

(e) The tip speed of propeller fans shall not exceed 20 m/s.

General Materials & Workmanship Specification 5/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 63 – Fans
63.3.6 Domestic Exhaust Fans

(a) The unit shall be driven by a totally enclosed, single phase, indicator motor.

(b) The unit casing, outlet grille, fan blade and shutters shall be moulded in rigid
flame-retardant plastic. This shall also apply to the motor casing if not
manufactured in metal.

(c) The unit shall be complete with in-built draught excluding shutters suitable for
remote control through an on/off switch.

(d) The whole unit shall be finished in white or ivory colour or alternatively to
manufacturer’s standard light colour.

(e) The fan shall be of single speed and be capable of being switched on and off
by a remote 5A switch.

(f) The fan shall be provided with two meters of 0.75 mm2, 3 core, PVC insulated
and sheathed flexible cable.

63.3.7 Kitchen exhaust air fan

(a) Kitchen exhaust air fans shall incorporate backward inclined wheels,
constructed in heavy gauge steel. Blades shall be of single thickness and
welded to a heavy gauge back plate and wheel cone. Each wheel shall be
statically and dynamically balanced.

(b) Kitchen exhaust air fan shall be of the centrifugal type. The fan motor shall be
installed outside the air stream in all cases.

(c) The fan shall be listed for grease removal in accordance with UL/cUL 762 or
equivalent standard submitted to the Project Manager for review without
objection.

(d) Machined cast iron motor pulleys shall be factory set to the required RPM and
adjustable on site for final system balancing. Drives shall be sized for a
minimum of 150% of horsepower.

(e) Heavy duty ball bearing motors shall be carefully matched to the fan load.
Open drip proof, total enclosed and explosion proof enclosures shall be used.

(f) Shafts and bearings shall be precision tuned, ground and polished solid steel
shafts. The shafts shall be sized so that the first critical speed is at least 25%
above the maximum operating speed. Heavy duty, self aligning pillow block
ball bearings shall be selected for a minimum L50 life in excess of 200,000
hours at the maximum catalogued operating conditions.

63.3.8 Smoke Extraction Fans

(a) Smoke Extraction Fans shall comply with Section 5.23 of the FSD COP. Fans,
motors, drives, etc. handling smoke shall be suitable for continuous operation
at 250 deg. C for not less than 1 hour.

General Materials & Workmanship Specification 6/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 63 – Fans
63.3.9 Air Curtain

(a) Air curtains shall have a pleasant appearance, silent in operation and shall be
operated on single phase supply.

(b) Exact length of air curtains shall be decided on site to suit the actual door
dimension. The total length of any air curtain set shall extend minimum 300
mm beyond each side of the doorway or as far as practicable.

(c) Air curtains provided shall be capable of creating an effective air barrier at the
door. The air speed achieved on the floor of the doorway shall not be less
than 4 m/s.

(d) Air curtain casings shall be of galvanized steel construction with spigots for
duct connections. Fan scrolls of cross-flow design together with fan motors
mounted on a common drive shaft shall be housed within the casing. Fan
motors and bearings shall be accessible for maintenance.

(e) Air curtains shall be equipped with two-speed ("HI" and "LO") plus "OFF"
selector switches.

(f) Support beams, support legs, platforms, hangers and anchor bolts shall be
provided as required for the proper installation of equipment. Vibration
isolators shall be provided as recommended by the manufacturer. Equipment
shall be operated without noticeable vibration after installation.

(g) Access doors shall be provided for inspection and cleaning. Access doors
shall be hinged and shall be provided with air tight seals which allow quick
opening.

(h) Epoxy type protective coatings suitable for grease resistance shall be used
throughout.

(i) Factory assembled, threaded drain connections shall be provided to drain

moisture from the bottom of the fan housing.

(j) Heat slingers shall be provided in the form of an aluminium cooling disc
mounted on the fan shaft between the inboard bearing and the fan housing.
The disc shall dissipate heat that is conducted along the fan shaft.

63.4 SUBMISSIONS

63.4.1 Particulars of Fan

The following particulars of the proposed fan shall be submitted to the Project
Manager for review without objection :

(a) manufacturer’s information for each make and type of fan together with the
“type” test certificate;

(b) calculations of actual external static pressure for the total distribution system
based on the actual equipment offered and installed;

General Materials & Workmanship Specification 7/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 63 – Fans
 (c) fan performance curve giving values of sound power levels and fan efficiency
at the selected duty; and

(d) the colour of domestic exhaust fans.

63.5 WORKMANSHIP

63.5.1 Axial Flow Fans

(a) Suitable mounting plates or brackets provided from the same manufacturer
shall be used for fixing the fan.

63.5.2 Centrifugal Fans

(a) For fans mounted on the floor, the fan shall be mounted on a concrete plinth
with anti-vibration mountings.

(b) For fans mounted from the ceiling, the fan shall be mounted on anti-vibration
mountings fixed on a steel mounting frame. Threaded suspension rods with
locking nuts shall be used for level adjustment.

(c) Anti-vibration mountings shall be selected to cater for different point loads
from the fan at all four corners.

63.5.3 In-line Centrifugal and Mixed Flow Fans

(a) Galvanised steel support shall be used to mount in-line centrifugal and mixed
flow fans.

(b) Threaded steel rods with locking nuts shall be used for ceiling mounted fans.

(c) Neoprene pads shall be provided for vibration isolation.

63.5.4 Propeller Fans

(a) Propeller fan casings shall be longer than the length of the fan and motor.
The casing shall be of galvanized steel or aluminium sheet or stainless steel
as specified, and shall have flanged ends and an inspection door.

(b) A terminal box shall be mounted externally on the casing.

63.5.5 Domestic Exhaust Fans

(a) The unit shall be suitable for mounting on window glass and partitions.

(b) The unit shall have “easy-to-disassemble” design for cleaning and
maintenance.

(c) The fan shall be fitted with silent running, self-aligning, self-coil bearings.

(d) All exposed metal parts of the fan shall be earthed via a 3-pin plug.

General Materials & Workmanship Specification 8/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 63 – Fans
SECTION 64 SPLIT TYPE AIR CONDITIONING UNIT

64.1 GENERAL

64.1.1 General

(a) The Permanent Works and materials specified below shall comply with the
sections stated, unless otherwise stated in this section:

(i) Section 69 “Air Filters”;

(ii) Section 72 “Pipework, Fittings and Valves”;

(iii) Section 73 “Thermal Insulation”;

(iv) Section 75 “Noise and Vibration Control”;

(v) Section 76 “Electrical Equipment and Installation”; and

(vi) Section 79 “Testing, Inspection and Commissioning – Mechanical

Services”.

(b) Split type air conditioning units shall be factory fabricated and assembled.
The equipment shall be rated and tested in the same country of manufacture
and meet with the requirements of the American Air-conditioning and
Refrigeration (ARI) Standards 210 or other international recognized quality
assurance standards reviewed without objection by the Project Manager.

(c) All air conditioners shall be selected with dimensions suitable for maintenance
within the spaces provided as indicated on the Employer’s Drawings.

(d) Unless otherwise specified, electrical equipment of split type air conditioners
shall be suitable for use with 3-phase and neutral, 4-wire, 380/220 volts ± 6%,
50Hz ± 2% source neutral earthed system with provision of bonding.
Transformers may be used for equipment designed for operation on voltages
other those specified above. Transformers shall be installed within the unit.

(e) In the absence of published manufacturer’s rating for 50 Hertz operation, a

factor of 0.83 is to be applied to the capacity rating of unitary air-conditioners
manufacturers for 60 Hertz operation.

(f) Packaged unit – chilled water split type air conditioning unit for Computer
Rooms; Communication Rooms, etc. or any other locations as indicated on
the Employer’s Drawings.

64.1.2 Basic Units

(a) Split type air conditioning units shall be direct expansion type comprising an
outdoor unit (condensing unit), an indoor unit (evaporator), pre-charged
refrigerant pipework and fittings, insulated drain pan, and complete control
device.

(b) The outdoor unit shall be either horizontal or vertical discharge type as
scheduled, including a weatherproof cabinet suitable for outdoor use, hermetic
compressor, condenser coil, condenser fan and motor.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 64 –Split Type Air Conditioning Unit
 (c) The indoor unit shall be concealed type or exposed type, complete with
remote control panel. The remote control panel shall comprise ‘cool-fan’
selector switch and 3-speed fan switch. The indoor unit shall include factory
wired controls and factory assembled components; one/two rotary, scroll or
reciprocating compressors of either the hermetically sealed or semi-
hermetically sealed type; direct expansion cooling coil; blower; air filters; drier
of the renewable cartridge type complete with isolating valve; expansion valve;
and safety devices, all housed in sturdy painted G.I. metal casing arranged for
vertical or horizontal mounting inside the building.

64.1.3 Duties

(a) In selecting the air conditioners, the Contractor shall allow for the resistance
imposed on the air flow of the units due to filters, air grilles and air ducts. The
added resistance applied to all air conditioners shall be taken as 4 mm water
gauge or unless otherwise specified.

(b) Generally all air conditioners shall be rated at high fan speed with noise level
less than NC 45.

(c) The proposed air conditioning units shall be capable of handling the lengthy
refrigerant pipe as required to provide the right cooling capacity. Documentary
substantiation shall be submitted to the Project Manager for review without
objection.

64.1.4 Service Conditions

(a) Air-cooled condensers and condensing units for split type air-conditioners
shall be selected to give rated capacity with condensing temperature not
exceeding 50°C for the ambient condition as specified below:

(i) Climate: Hong Kong (tropical)

(ii) Ambient temperature:

Peak -5°C to +40°C (continuously 4 hours)

Average 0°C to +35°C (over 24 hours)

(iii) Altitude: up to 2000 m above sea level

(iv) Relative humidity: 99% maximum

64.1.5 Minimum Installations Requirements of Safety and Operational Control

Associated Components / Unit Cooling Capacity

Facilities Up to 7kW 7kW – 14kW Over 14kW
Self-contained safety and Yes Yes Yes
operational components of
factory standard
Pressure gauges c/w stop - Yes Yes
valves, sight glass
Renewable filter-drier c/w/ - Yes Yes
accessories

General Materials & Workmanship Specification 2/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 64 –Split Type Air Conditioning Unit
 Associated Components / Unit Cooling Capacity
Facilities Up to 7kW 7kW – 14kW Over 14kW
Externally mounted adjustable - Yes Yes
Hi-Lo pressure cutout with
hand reset for High side
Anti-recycling device Yes Yes Yes
Emergency stop switch Yes Yes Yes
Crankcase Heater - Yes Yes
Pump down function and - - Yes
facilities
Refrigerant R407C R407C R407C
Mechanical Protection to Yes Yes Yes
thermal insulation which
exposed to view

64.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as the date of the Letter of Acceptance.

BS 21 Specification for pipe threads for tubes and fittings where

pressure-tight joints are made on the threads (metric
dimensions)
BS 476 : Part 7 Fire tests on building materials and structures. Method of
test to determine the classification of the surface spread
of flame of products
BS 1387 Specification for screwed and socketed steel tubes and
tubulars and for plain end steel tubes suitable for welding
or for screwing to BS 21 pipe threads
BS 3382 : Parts 1 and 2 Specification for electroplated coatings on threaded
components. Cadmium on steel components. Zinc on
steel components
BS EN 1057 Copper and copper alloys. Seamless, round copper tubes
for water and gas in sanitary and heating applications
BS EN ISO 1461 Hot dip galvanized coatings on fabricated iron and steel
articles. Specifications and test methods
ARI 210 Unitary air-conditioning and air-source heat pump
equipment
ARI 260 Sound rating of ducted air moving and conditioning
equipment
ASHARE Standard 52.1 Gravimetric and dust-spot procedures for testing air-
cleaning devices used in general ventilation for removing
particulate matter

General Materials & Workmanship Specification 3/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 64 –Split Type Air Conditioning Unit
 ASHARE Standard 52.2 Method of testing general ventilation air-cleaning devices
for removal efficiency by particle size

64.3 MATERIALS

64.3.1 Casing

(a) The ceiling concealed unit shall be fabricated of galvanized steel, suitably
reinforced with channels and sections to form a robust cabinet. The interior
surface of the unit shall be lined with 13 mm coated fiberglass insulation. The
fan and motor assembly shall be easily removable for maintenance. 25 mm
supply duct collars shall be provided for all units.

(b) The ceiling mounted or wall mounted unit shall be fabricated of galvanized
steel or heavy duty plastic, suitably reinforced with channels and sections to
form a robust cabinet. The exterior surface shall be zinc phosphatized, with
baked enamel finish for galvanized steel casing. The interior surface shall be
lined with 25 mm coated sound-absorbing fiberglass insulation. The fan and
motor assembly shall be easily removable for maintenance. The front panel of
the unit shall be easily removable facilitating maintenance.

(c) Casing for outdoor installation shall be of weatherproof finish, preferably

galvanized, painted or anodized aluminum.

(d) Removable panel for casings shall be provided to give access to all working
components, parts, and connections for installation and servicing. The
compartment housing for the direct-expansion coil and blower shall be
adequately insulated to prevent sweating and shall contain a suitable drip pan
with a drain connection. The compartment housing for the compressor shall
be treated for effective sound insulation to ensure that the noise emitted is
within the limits as specified in Section 75 of this General Materials and
Workmanship Specification.

64.3.2 Compressors

(a) Compressors shall be rotary, scroll or reciprocating of either the hermetically

sealed type or the semi hermetically sealed type. Compressors shall be
provided complete with internal motor protection, positive lubrication, mufflers,
crank- case heater, and internal and external vibration isolation.

(b) Each compressor shall form a separate refrigerant circuit with its own
condenser, evaporator and controls.

64.3.3 Air Cooled Condensers

(a) Air-cooled condensers shall unless otherwise specified be suitable for outdoor
installation with ample capacity to dispose of the rejected heat from the air
conditioning system. Condenser coils shall be constructed with copper tube
and aluminum fins. Special corrosion resistant treatment for the condenser
coils and fins shall be considered for the equipment to be located on corrosive
environment.

(b) Condenser fans shall be propeller type installed for either horizontal or vertical
discharge as specified on the Employer’s Drawings.

General Materials & Workmanship Specification 4/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 64 –Split Type Air Conditioning Unit
64.3.4 Fans and Motors

(a) Fans shall be of double width, double inlet, centrifugal forward-curved type or
propeller type for operation against the specified static pressure. Fan wheels
shall be statically and dynamically balanced. Fan wheels and housings shall
be of galvanized steel. The fans shall be directly driven by 6-pole single phase
3-speed motor of tap wound, permanent split capacitor type with thermal
overload protection. Motor bearings shall be of the sleeve type with oil tubes
and oil reservoirs. The motor shall be high efficiency motor.

(b) All fans shall be statically and dynamically balanced. Fans shall be equipped
with self-aligning bearings suitable for the installed altitude of the fan. Motors
shall be installed in accordance with Sections 76 of this General Materials and
Workmanship Specification.

64.3.5 Cooling and Heating Coils

(a) All cooling coils shall be of direct expansion type and constructed with copper
tubes and aluminum fins to give high heat transfer performance. The coils
shall have sufficient number of rows of tubes to provide efficient
dehumidification and cooling of the air.

(b) Heating coils shall be constructed with copper tubes and aluminum fins to give
high heat transfer performance.

(c) All tubes shall be arranged horizontally and shall be stiffened. All coils shall
be encased in substantial galvanized frames. Fins shall have smooth-drawn
collars of length equal to fin spacing and mechanically bonded to tubes. Fins
shall be of plate type, corrugated to ensure maximum air contact.

(d) All coils shall be arranged within the coil section in a vertical position with the
air passing horizontally through the coil and shall be completely enclosed
within the insulated casing with only connections extended through the cabinet.
All coils shall be selected for a suitable face velocity without moisture carry-
over.

(e) Pipe connections to the coils shall be to facilitate disconnection. Fittings shall
permit sweat connections to be made.

64.3.6 Refrigerant Pipework and Fittings

(a) External refrigerant piping connecting the indoor air conditioners and the
outdoor air-cooled condensing units shall include all necessary accessories
such as stop valves, filter dryer, sight glass, pressure gauges at high and low
pressure side, fitting, and insulation; and of copper or steel pipe. All insulation
shall be properly protected with mechanical means such as metallic cladding
or cement plastering and painting. Copper pipe shall be of refrigeration quality
(i.e. material to BS EN 1057), and internally degreased and cleaned.

(b) Refrigerant piping shall be sized to avoid excessive pressure drop of the fluids
or gases they carry. The recommendations of the Chartered Institution of
Building Services Engineers (UK) and/or the American Society of Heating,
Refrigeration and Air-conditioning Engineers on the sizing of refrigerant piping
shall be complied with.

General Materials & Workmanship Specification 5/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 64 –Split Type Air Conditioning Unit
 (c) Filter dryer with stop valves shall be duplicated for each air cooled condenser.
The pressure gauges and the filter dryers (including stand-by) shall be
installed on a 4 mm thick hot dipped galvanized mild steel plate mounted on
the plinth adjacent to the respective condenser. All pressure gauges and
accessories installed outdoor shall be stainless steel and water-proof to IP55
and suitable for outdoor installation.

(d) Pipework shall be designed and run so that any oil in the compressor
discharge is carried through the system and returned. Oil traps and oil
separators where necessary shall be provided according to the position of the
outdoor and the indoor units to facilitate oil return to the compressors.

(e) All fittings shall be suitable quality copper with all joints being made either by
brazing or soldered capillary fittings.

(f) All finished joints shall be cleaned of flux. The refrigerant pipework shall be
pressurized and tested for leaks after erection.

64.3.7 Thermal Insulation

(a) All thermal insulation and vapour barrier (where required) shall be approved
by the Fire Services Department for the application intended. Unless
otherwise indicated, all thermal insulating materials used when tested in
accordance with BS 476 : Part 7 shall comply Surface Spread of Flame Class
1 and the thermal insulation requirement shall be referred to Section 73 of this
General Materials and Workmanship Specification.

(b) Unless otherwise specified, the refrigerant suction pipes and exposed
condensate drain pipes shall be insulated with respectively 20 mm thick
minimum and 13mm thick minimum fire-resistant flexible closed-cell
elastomeric material in continuous lengths. The thermal conductivity of this
material shall be 0.0375 W/mC or lower at a temperature of 24°C.

(c) All thermal insulation for refrigerant pipes installed outdoors shall be painted
with paint supplied by the manufacturer of the thermal insulation. The paint
shall form a ultra-violet protection film on the insulation materials such as to
protect the insulation from UV deterioration.

(d) The colour of the paint shall be reviewed without objection by the Project
Manager. The overall paint application on the surface of insulation shall be a
minimum three layers.

64.3.8 Air Filter

(a) 25mm thick filters of washable, permanent panel type shall be provided for
each indoor unit of concealed ceiling type air conditioning units. The filters
shall be composed of at least six cross-plated layers of crimped and expanded
aluminum foil with larger openings at the outer layers and small openings in
the inner layers all housed in an aluminum holding frame. Panel filters shall
be mounted behind the return air louvre for ease of removal. The air velocity
through the filters shall not exceed 1.3 m/s.

(b) Air filters shall unless otherwise specified be of the washable panel type and
of an average weight arrestence efficiency not less than 85% according to
ASHARE 52-76. Higher filter efficiency shall be adopted to meet with the IAQ
objective designed and the requirement shall be referred to Section 69 of this
General Materials and Workmanship Specification.

General Materials & Workmanship Specification 6/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 64 –Split Type Air Conditioning Unit
64.3.9 Condensate Drain Pans and Drain Pipes

(a) Insulated drain pans shall be provided to collect condensate from the cooling
coil including water headers and return bends where necessary. Drain pans
shall be of stainless steel construction.

(b) Condensate drain piping shall be galvanised steel pipe to BS 1387 medium
grade and lead to the nearest convenient drain as indicated on the Employer’s
Drawings or as directed by the Project Manager.

(c) The condensate drain pan shall have insulation of a class approved by FSD.

64.3.10 Control

(a) Controls shall be factory wired. Field wiring in conduit or trunking shall be
limited to interconnections between separate pieces of equipment and power
wiring. Each unit shall be protected and controlled by a factory built control
panel incorporating all necessary devices, switches, indicator, etc.

(b) Safety protection shall include low lubricating oil pressure cut-out, low
evaporating pressure cut-out, high condensing pressure cut-out, low
refrigerant temperature cut-out, high motor coil temperature cut-out, and other
protection necessary for the proper and safe operation of the unit. Overload
and motor burn-out protection shall be provided as well.

(c) The control of the ceiling concealed type air conditioning unit shall be effected
by duct mounted or wall mounted thermostat with a narrow operating
temperature range and solenoid valve/thermal expansion valve. A 3-speed
controller with ON/OFF switch and fan/cool selector shall also be provided.

(d) Remote controller shall be provided for wall mounted and ceiling mounted
indoor unit and shall be of proprietary design with the features stated in
64.3.10 (c) above as minimum.

(e) Regarding the split type air conditioning unit installed within computer room’s
communication rooms, etc, the control on those units, either chilled water type
or refrigerant type, should be interlocked with each other so that the standby
unit could be on when the room condition does not fall within the acceptable
range. The interlock control logic should be submitted to Project Manager for
review without objection.

64.3.11 Refrigerant

The refrigerant used for all split-type air conditioning units and computer room air
conditioning units shall be R407c. Alternative refrigerants should be submitted to
the Project Manager for review without objection prior to selection of the units.

General Materials & Workmanship Specification 7/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 64 –Split Type Air Conditioning Unit
64.4 SUBMISSIONS

64.4.1 Particulars of Split Type Air Conditioning Unit

The following particulars of the proposed split type air conditioning unit shall be
submitted to the Project Manager for review without objection:

(a) Contractor’s drawings detailing:

(i) the location, position and fixing details of all split type air conditioning
unit; and

(ii) the location and details of maintenance platform as necessary;

(b) details of each proposed split type air conditioning unit including design
information, manufacturer’s published information and all manufacturer’s
drawings; and

(c) noise level emissions data of indoor units in terms of dB re 10-12 watts (dB
PWL) from 125 Hz to 4,000 Hz inclusive for all available fan speeds.

64.5 WORKMANSHIP

64.5.1 General

(a) Installation and servicing of split type air-conditioners shall comply with the
practice set out in the ARI Standard 260 and the manufacturer’s
recommendation. Vibration mounting shall be installed in accordance with
Section 75 of this GMSW.

64.5.2 Supports for Equipment

(a) All supports, hangers brackets etc. shall be of hot-dipped galvanised mild steel
construction to BS EN ISO 1461 with minimum coating thickness of 85 μm and
210 μm for indoor and outdoor installation respectively.

(b) All bolts, nuts and washers shall be electro-plated with zinc or cadium to
BS3382: Parts 1 and 2 with minimum plating thickness of 25 μm.

(c) Details of supports shall be submitted to Project Manager for review without
objection.

64.5.3 Maintenance Servicing Platform

(a) Where split-type air conditioning units are installed on side walls of building at
levels that are normally inaccessible from ground, these shall be provided with
an adequately sized service platform complete with railings and steel cat
ladder with safety wings. Such platforms shall be of reasonable substantial
rigid metal construction and shall be well protected against corrosion. The
design shall be submitted to the Project Manager for review without objection.

(b) The Contractor shall comply with Labour Department Ordinance, and shall
provide working platforms for any activity carried out at a height of over 3
metres above finished floor level. This maintenance servicing platform
requirement shall apply to all equipment and installation.
General Materials & Workmanship Specification 8/8 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 64 –Split Type Air Conditioning Unit
SECTION 65 WINDOW TYPE AIR CONDITIONING UNIT

65.1 GENERAL

(a) Window type air-conditioners shall be of the completely self-contained type

with factory wired controls and factory assembled components and piping. The
unit shall include compressor, condenser fan and motor, cooling coil, blower,
air filters, drier of the renewable cartridge type complete with isolating valve,
expansion valve, controls and safety devices; all housed in a weather-proof
and metal casing of robust yet attractive appearance.

(b) The unit shall be complete with the following minimum features:

(i) On/off control

(ii) 2-speed fan control

(iii) 2-speed cooling control

(iv) Adjustable thermostat control

(v) 4-way air deflection system (adjustable front louvers with horizontal and
vertical register)

(vi) Outside air damper bypass (ventilation control)

(vii) Wireless remote controller

(viii) Slide-out chassis for easy installation

(ix) Washable air filter

(c) The wireless remote controller of the unit shall be able to perform the following
function:

(i) On/off control

(ii) Fan speed control

(iii) Cooling speed control

(iv) Temperature control

(v) Air-swing on/off control

(d) In the absence of published manufacturer’s rating for 50 Hz operation, a factor

of 0.83 is to be applied to the capacity rating of window type air conditioners
manufacturers for 60 Hz. operation.

General Materials & Workmanship Specification 1/3 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 65 – Window Type Air Conditioning Unit
65.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as the date of the Letter of Acceptance.

BS3382 : Part 1 and 2Specification for electroplated coatings on threaded

components. Cadmium on steel components. Zinc on
steel components.
ARI Standard 210 Standard for Unitary Air Conditioning and Air Source Heat
Pump Equipment
ARI Standard 260 Sound Rating of Ducted Air Moving and Conditioning
Equipment
ASHRAE Standard 52.1 Gravimetric and Dust-Spot Procedure for Testing Air-
Cleaning Devices Used in General Ventilation for
Removing Particulate matter
65.3 MATERIALS

65.3.1 General

(a) The unit shall be rated and tested in the same country of manufacturing and
meet the requirements of the American Air-conditioning and Refrigeration (ARI)
Standards 210.

65.3.2 Casings

(a) Casings of window type air conditioners shall be constructed of rigid

galvanized sheet steel complete with weatherproof finish, preferably
galvanized, painted or anodized aluminium.

65.3.3 Compressor

(a) Compressors shall be rotary hermetically sealed type with copper tube
aluminium fin evaporator and condenser

(b) Compressor shall be complete with internal motor protection, positive

lubrication, mufflers, crank-case heater, and internal and external vibration
isolation.

65.3.4 Cooling Coils

(a) Cooling coils shall be of the direct expansion type and constructed with copper
tubes and aluminum fins to give high heat transfer performance.

(b) The cooling coils shall have sufficient number of rows of tubes to provide
dehumidification of the air and its cooling.

65.3.5 Air Filter

(a) Air filters shall be washable panel type and of an average weight arrestance
efficiency not less than 85% according to ASHRAE 52.1.

General Materials & Workmanship Specification 2/3 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 65 – Window Type Air Conditioning Unit
65.4 SUBMISSIONS

65.4.1 Particulars of Window Type Air Conditioning Unit

The following particulars of the proposed window type air conditioning unit shall be
submitted to the Project Manager for review without objection:

(a) Contractors’ drawings detailing the location, position and fixing details of
window type air conditioning unit.

(b) Manufacturer data to indicate the performance to meet the requirements of

this General Materials and Workmanship Specification.

65.5 WORKMANSHIP

(a) Installation and servicing of window type air conditioners shall comply with the
practice set out in the ARI Standard 260 and the manufacturer’s
recommendation.

(b) The unit shall be completed with aluminium framework mounting.

(c) The unit shall be of size capable of fixing into the Air-Conditioning hood and
window frame which is available for installation and maintenance.

(d) All bolts, nuts and washers shall be electro-plated with zinc or cadium to BS
3382: Part 1 and 2 with minimum plating thickness of 25 μm.

General Materials & Workmanship Specification 3/3 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 65 – Window Type Air Conditioning Unit
[this page not used]
SECTION 66 AIR COOLING COILS

66.1 GENERAL

(a) The Contractor shall comply with other relevant sections of this General
Materials and Workmanship Specification including but not limited to the
sections which specify:

(i) Section 61 "Air Handling Units";

(ii) Section 62 “Fan Coil Units”;

(iii) Section 64 “Split Type Air Conditioning Unit”;

(iv) Section 65 “Window Type Air Conditioning Unit”;

(v) Section 70 "Ductwork and Fittings";

(vi) Section 73 "Thermal Insulation"; and

(vii) Section 79 "Testing, Inspection and Commissioning".

(b) Coils shall be type tested in accordance with ASHRAE 33 and rated in
accordance with ARI 410.

(c) Coils shall be selected to totally avoid moisture carryover without the use of an
eliminator. Water shall not be carried over from a cooling coil into the
remainder of the system.

(d) Coils shall be designed to shed condensate without "water clogging" or

causing an uneven air distribution across the face of the coil. The height of
the coil above a condensate drain pan shall not exceed 1.2 m. Stacked coils
with separate condensate drain pans or single coils with intermediate
condensate drain pans shall be provided as required.

(e) Chilled water coils shall be selected so that flow remains turbulent at 40% of
the design flow rate.

(f) The resistance to airflow through a cooler battery shall not exceed 125 Pa
taking into account the wet air condition. The face velocity of airflow shall not
exceed 2.5 m/s.

General Materials & Workmanship Specification 1/4 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 66 – Air Cooling Coils
66.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as the date of the Letter of Acceptance.

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

ASHRAE Standard 33 Method of Testing Forced Circulation Air Cooling and Air
Heating Coils
BS 970 : Part 1 Specification for wrought steels for mechanical and allied
engineering purposes. General inspection and testing
procedures and specific requirements for carbon, carbon
manganese, alloy and stainless steels

66.3 MATERIALS

66.3.1 Coils

(a) Coils shall be of the extended surface staggered tube type.

(b) The cooling medium shall be designed to enter the coil on the air leaving side.

(c) Chilled water coils shall be self-venting.

(d) Unless otherwise specified in the Specification, coils shall be copper tube with
copper fins electroplated with tin. Re-circulating FCU’s with no outside air
scheduled on the Employer’s Drawings and packaged air conditioning units
may have cooling coils incorporating copper tubes with aluminium fins.

(e) Cooling coils shall utilize the full unit available cross sectional area. Unless
otherwise indicated, coils shall be constructed from the following
combinations:-

(i) copper tubes expanded into aluminum fins for fan coil units;

(ii) copper tubes expanded into tinned copper fins with epoxy coating for
fresh air primary air handling units;

(iii) copper tubes expanded into tinned copper fins for air handling units and
other cooling equipment other than fresh air primary air handling unit;

(f) Tube thickness shall not be less than 0.45 mm. Fin thickness shall not be less
than 0.24 mm with maximum fin spacing of 25.4 mm. Unless otherwise
specified, cooling coils shall be constructed from copper tubes with aluminium
fins sprayed with zinc rich anti-corrosion coating of at least 0.08mm thick.

(g) The coil row for primary air handling units shall not be less than eight rows and
for other air-handling units shall not be less than six rows. For fan coil units,
cooling coils shall be a minimum of 3 rows.

General Materials & Workmanship Specification 2/4 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 66 – Air Cooling Coils
66.3.2 Casing

(a) Coil support frames shall be constructed from brass, or steel hot dip
galvanized and shall be of galvanized sheet steel not less than 1.60 mm thick
with flanged ends drilled and corrosion treated to receive counter flanges on
connecting ductwork or other associated equipment. The bottom of casings
shall be made in the form of a watertight drip tray from BS970 grade 316
stainless steel, or otherwise be manufactured of equal (or superior) corrosion
resistant materials submitted to the Project Manager and reviewed without
objection.

66.3.3 Condensate Pans and Drains

(a) Condensate drain pans shall be located beneath each coil and shall be
constructed of minimum 1.6 mm copper, stainless steel or epoxy coated
galvanised sheet steel. Unless otherwise reviewed without objection by the
Project Manager, drain pans shall not be integral with the unit casing. Drain
pans shall be separated from contact with the unit casing by a minimum of 25
mm rigid, non-hygroscopic thermal insulation.

(b) Drain pans shall extend beyond all sides of the cooling coil including headers
and shall be of sufficient dimensions to collect all condensate. Drain pans
shall be integral with cooling coils or designed and installed to allow removal
of the cooling coil without the need to dismantle or damage the drain pan.

(c) In multiple coil units, drain pans shall be inter-connected. Down pipes shall
terminate a minimum of 50 mm below the rim of the lower pan and at least 25
mm above its base. Down pipes shall be a minimum of 38 mm diameter
copper pipe.

(d) Drain pipework shall connect into the bottom of the drain pan and shall be
extended through a sealed trap to the exterior of the unit housing. The trap
shall be configured and sized to maintain a seal under full load with a dirty
filter and wet coil conditions.

(e) Condensate discharges shall be visible for inspection and maintenance from
outside of air handling units, fan coil units and packaged air conditioning units.

(f) Any insulation materials for condensate pans and drains shall be of FSD.
approved class of insulation. Please refer to the section 73 of this General
Materials and Workmanship Specification.

(g) The drain pipework shall include a water seal of adequate depth to prevent
entry or exit of air to or from the system. On stacked coils, intermediate drain
troughs shall be provided. Sealing devices shall be provided at tops and
bottoms of coils to minimize air by-pass and water carry over.

66.4 SUBMISSIONS

66.4.1 Particulars of Air Cooling Coil

(a) The make and type of the air cooling coil shall be reviewed without objection
by the Project Manager. Test reports/certificates shall be submitted to the
Project Manager for review prior to placing the order.
General Materials & Workmanship Specification 3/4 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 66 – Air Cooling Coils
66.5 WORKMANSHIP

66.5.1 General

(a) Coils shall be mounted on non-corrosive aluminum slide rails and arranged for
connection into an air handling and/or fan coil unit casing. Additional supports
shall be installed as required to suit coils. Coil sections shall be arranged to
provide removal of coils from the access side of the section.

(b) Air-cooling coils shall be supported such that their weight is not transmitted to
ductwork and they can be removed without disturbing adjacent ductwork.
Access doors with air seals shall be provided on both the upstream and
downstream of the cooling coils and shall be sized for the full height of the
connecting ductwork but need not exceed 1800 mm.

(c) Pipework shall be arranged so that coils can be easily removed, and with all
connections on the same side.

(d) Access for inspection shall be provided to both faces of all cooling coils.

(e) Coil support frames shall be constructed from brass, or steel hot dip
galvanised after fabrication.

(f) Coil connections 50mm and below shall be terminated with screwed female
connections with ground in spherical seated unions. Larger connections shall
be flanged. Coil connections shall be fitted with sealing rings and plates
where penetration of the end sandwiches panel occurs.

(g) There shall be no contact between ferrous / non-ferrous parts of the cooling
coil and / or casing.

66.5.2 Chilled Water Connections to Cooling Coils

(a) The flow and return connections and headers shall be made of heavy gauge
seamless flanged copper tube. Provision shall be made for thermal expansion
of the tubes, for effective venting of the coils and their connections and for the
draining of the headers and tubes.

(b) Coil connections shall be arranged so as to enable same side connections to

the flow and return pipework, and to have the supply and return connections to
headers to give counter flow of air and water. Equal flow of water shall be
through all the tubes in the coils.

(c) Up to and including 50 mm bore connections may be made using ground-in

spherical seated unions. Pipework of 65 mm bore and above shall be
connected using flanged joints. Isolating valves shall be provided on flow and
return connections and arranged so as to facilitate easy removal of the cooler.

(d) For rigidity, the short pipe length connecting the copper coil header and the
external GI or black steel pipe work shall be stainless steel pipe having the
same bore size as the copper header.

General Materials & Workmanship Specification 4/4 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 66 – Air Cooling Coils
SECTION 67 DAMPERS AND AIR VOLUME CONTROL DEVICES

67.1 GENERAL

(a) The respective function, types and general constructional requirements of

dampers shall be in accordance with the HVCA ductwork specification
DW/144 unless otherwise indicated, sufficient dampers shall be provided to
regulate and balance the system. Dampers on grilles or diffusers shall be used
for fine control only.

(b) Dampers and air volume control devices shall be accessible for testing,
commissioning, inspection and maintenance. Access panel size shall not less
than 300 mm × 300 mm.

(c) Dampers and volume control devices associated with smoke extraction
systems or upon which the operation of smoke extraction systems is
dependent shall comply with Relevant Authority requirements including but not
limited to FSD Circular Letter 96 and COP for Minimum Fire Service
Installations and Equipment AND Inspection, Testing and Maintenance of
Installations and Equipment.

(d) Motorized and non-return dampers associated with smoke extraction systems
or upon which the operation of smoke extraction systems is dependent
including non return dampers on plant room ventilation takeoffs shall be
designed to also operate as smoke dampers complying with UL 555S or
equivalent.

(e) Dampers shall be designed to minimize resistance to air flow when in a fully
open position.

(f) Dampers shall be multi-blade.

(g) Multi-leaf and single leaf dampers shall have the following features:

(i) damper blades shall be of the double skin airfoil design when located in
air streams with a design flow rate equal to or larger than 10 m3/s;

(ii) damper blades shall overlap by at least 10 mm;

(iii) bearings shall be of the ball or sleeve type;

(iv) dampers shall be designed to operate from a fully open to a fully closed
position and vice versa under all operating conditions;

(v) damper blades and linkages shall be designed to transmit 200% of the
torque of the actuator;

(vi) the maximum air leakage rate shall be tested according to BS EN 1751
Clause 4;

General Materials & Workmanship Specification 1/5 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 67 –Dampers & Air Volume Control Devices
 (vii) the damper assembly shall be self supporting without external supports
or bracing; and

(viii) multi-leaf damper blades shall lock against each other when closed.

(h) The motorized on/off dampers for smoke extraction make-up at ground floor
shall have the following minimum dynamic insertion loss in the closed position:

Description Octave Band Centre Frequency (Hz)

63 125 250 500 1k 2k 4k 8k

Motorized On/Off Damper 11 13 17 19 17 27 26 27

(Closed Position)

67.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as the date of the Letter of Acceptance.

UL 555S Leakage-Rated Dampers for Use in Smoke-Control Systems

BS EN 1751 Ventilation for buildings. Air terminal devices. Aerodynamic testing
of dampers and valves

67.3 MATERIALS

67.3.1 Volume Control Dampers

(a) Volume control dampers shall be designed and installed to maintain smooth
airflow and minimum regenerated noise.

(b) Air balancing facilities behind or adjacent to registers, diffusers, grilles,

terminals and the like shall be set so that the pressure drop does not exceed
it’s "fully open" pressure drop by more than a factor of 1.5. Additional
accessible balancing facilities shall be provided as required.

(c) An adjustable deflector or damper with a suitable locking device shall be

installed at each branch take off and return and at each exhaust hood neck.

(d) Manual volume control dampers shall be at least two metal gauges heavier
than the duct. Dampers shall have extended shafts and mounted lugs on the
quadrant so that damper controls can be located on the external surface of the
insulation.

General Materials & Workmanship Specification 2/5 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 67 –Dampers & Air Volume Control Devices
 (e) Unless otherwise specified, volume control dampers shall be as follows:

(i) manual and motorized zone mixing : opposed blade

and coil bypass dampers. Dampers at
registers and grilles, and on exhaust systems

(ii) two position dampers : parallel blade;

(iii) manual dampers at main duct separation dampers : splitter;

(iv) direct duct mounted registers and dampers : streamsplitter; and

(v) on minor branch ducts : rotating butterfly.

(f) Two position dampers shall be designed to fully changeover within 45 seconds.

(g) Volume control dampers shall be labelled to externally indicate the open and
closed positions.

67.3.2 Non Return Dampers

(a) Non-return dampers shall be constructed with marine grade aluminium blades,
and provided with blade tip seals or similar to minimize the generation of noise
on activation. Minimum rated face velocity shall be 12 m/s. Maximum pressure
drop at 8.0 m/s face velocity shall be 40 Pa.

(b) Where AHU(s), FCU(s) and ventilation fans are operating in pairs with the
same supply air ductwork, non-return dampers shall be provided at each AHU,
FCU or ventilation fan discharge ductwork.

(c) Bearing shall be accessible for cleaning and lubrication and shall be mounted
in a rigid galvanised steel frame. The maximum length of each blade without a
central bearing shall be 1,000 mm.

67.3.3 Fire Dampers

(a) Fire dampers shall be provided with the associated proprietary mounting
frames and shall be factory manufactured, constructed and tested to comply
with Relevant Authority requirements.

(b) Unless otherwise specified, fire dampers shall be minimum 2 hours FRP.

(c) Fire dampers shall be constructed of stainless or galvanised steel in a

multiblade offset hinge.

(d) Fire dampers shall be spring assisted and shall incorporate automatic locking
devices.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 67 –Dampers & Air Volume Control Devices
 (e) Multiblade dampers shall be ganged to ensure that all blades close
simultaneously.

(f) Unless otherwise specified, fire damper should be resettable thermal release
type with rating not exceeding 69ºC.

67.3.4 Motorized Fire and Smoke Dampers

(a) Motorized fire and smoke dampers shall be provided with the associated
proprietary mounting frames and shall be factory manufactured, constructed
and tested to comply with Relevant Authority requirements.

(b) Motorized fire and smoke dampers shall be constructed of stainless or

galvanized steel and shall comply with UL 555S.

(c) Limit switches shall be provided for monitoring both the open and the closed
positions of motorized fire and smoke dampers by the mechanical BMS
(MBMS).

(d) Fusible links shall be provided on motorized fire and smoke dampers to suit
Relevant Authority requirements.

(e) Motorized smoke and fire dampers shall be installed with an electric motor
actuator mounted externally to the damper. The actuator shall be suitable for
operation with 220V/1 phase/50Hz power supply. The actuator shall be fully
enclosed, thermally protected and positioned out of the air stream. It shall
generate sufficient torque to ensure efficient movement of the blades against
the prevailing airflow and to allow tight closure of the damper. The actuator
shall be capable of being detached from the damper to allow manual operation.

(f) The damper shall be manufactured with stainless steel aerodynamic blades
incorporating synthetic or stainless steel seals and with stainless steel blade
end bearings in a peripheral gasket. The whole motorized smoke and fire
damper and motor actuator assembly shall be capable of continuous operation
at 250oC ambient air temperatures for a minimum of one hour.

(g) The damper shall be capable of reserve operation. In the closed position the
fire damper shall provide protection to the associated fire compartments
commensurate with the specified fire resistance period.

(h) Power cables serving the dampers shall be of fire rated type to meet the
specified fire resistance period. The whole smoke and fire damper assembly
shall be endorsed by the FSD.

(i) Motorized smoke and fire dampers located at Fuel Tank Room shall be
explosion proof complying FSD requirements. These dampers shall be
activated by the detector installed inside the fuel tank room.

General Materials & Workmanship Specification 4/5 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 67 –Dampers & Air Volume Control Devices
67.3.5 Barometric Damper

(a) Barometric pressure relief dampers shall be designed to maintain a pre-

selected pressure (site adjustable) within a designated area. The damper shall
be selected to suit the pressure and the flow to be handled.

(b) The damper shall be constructed of galvanized steel and complete with
adjustable pressure setting mechanism to be submitted to the Project
Manager for review with objection.

67.4 SUBMISSIONS

67.4.1 Particulars of Damper and Air Volume Control Devices

The following particulars of the proposed dampers and air volume control devices
shall be submitted to the Project Manager for review without objection:

(a) Manufacturer’s proposed installation details

(b) Fire services certificate approved by FSD

67.4.2 Samples

The following samples of proposed materials shall be submitted to the Project

Manager together with the particulars referred to in 67.4.1 above:

(a) fire damper.

67.5 WORKMANSHIP

(a) Dampers shall be factory manufactured and unless otherwise specified in this
General Materials and Workmanship Specification shall be manufactured from
marine grade aluminium or galvanised steel.

(b) Where fire dampers, motorized fire and smoke dampers are installed in dry
wall construction they shall be supported independently of the wall and
ductwork to ensure no distortion during fire condition to maintain the integrity
of the fire barrier. Manufacturer recommended installation detail should be
strictly followed.

(c) Fire Damper, motorized fire and smoke dampers shall be supported
independently of associated ductwork.

(d) Damper actuators shall be mounted externally and shall incorporate visual
position indicators.

(e) Dampers shall be arranged and installed so that there is access for testing
and resetting the damper, including the fusible link, without dismantling any
Plant.

General Materials & Workmanship Specification 5/5 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 67 –Dampers & Air Volume Control Devices
[this page not used]
SECTION 68 REGISTERS, DIFFUSERS AND GRILLES

68.1 GENERAL

(a) The Permanent Works and materials specified below shall comply with the
sections stated, unless otherwise stated in this section:

(i) Section 70 “Ductwork and Fittings”;

(ii) Section 73 “Thermal Insulation”;

(iii) Section 75 “Noise and Vibration Control”; and

(iv) Section 79 “Testing, Inspection and Commissioning – Mechanical

Services”.

(b) The Contractor shall, at a location directed by the Project Manager, install a
register, diffuser and/or grille and notify the Project Manager that the proposed
benchmark is available for review. Upon receipt of a notice of no objection
from the Project Manager the installations shall become the benchmark for
quality of workmanship for the installation of all subsequent register, diffuser
and/or grille installations.

68.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as the date of the Letter of Acceptance.

BS 476 : Part 4 Fire tests on building materials and structures. Non-

combustibility test for materials
BS 476 : Part 6 Fire tests on building materials and structures. Method of test
for fire propagation for products
BS 476 : Part 7 Fire tests on building materials and structures. Method of test
to determine the classification of the surface spread of flame
of products
BS 476 : Part 12 Fire tests on building materials and structures. Method of test
for ignitability of products by direct flame impingement
BS 1322 Specification for aminoplastic moulding materials
BS 6399 : Part 1 Loading for buildings. Code of practice for dead and imposed
loads
ADC 1062 : GRD-84 Test code for grilles, registers and diffusers
UL-181 Factory-made air ducts and air connectors
NFPA 90A Standards for the installation of air-conditioning and
ventilating system

General Materials & Workmanship Specification 1/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 68 – Registers, Diffusers & Grilles
68.3 DESIGN AND PERFORMANCE CRITERIA

Grilles, diffusers and registers shall be designed in accordance with the following:

(a) rated in accordance with ASHRAE standard 36-72 and Air Diffusion Council
(ADC) standard 1062 : GRD-84 or equivalent;

(b) air throws to suit the dimensions of the space being served, so that air
movement in areas below 1800 mm above the floor, and more than 300 mm
from walls does not exceed 0.25 m/s;

(c) provide an air pattern which shall not 'dump' at minimum design flow when
supply air is 10°C and room air is 22°C;

(d) grilles, diffusers and registers mounted immediately in front of fire dampers
and volume control dampers shall have removable cores;

(e) shall have concealed fixing system and shall have quick release frame to
facilitate cleaning;

(f) shall be mounted on substantial frame and shall be provided with a minimum 7
mm soft rubber or felt joining ring inserted under the frame to prevent air
leakage and the formation of condensate on the fitting;

(g) plenums shall be acoustically lined with a minimum of 25 mm thick 48 kg/m³

fibreglass, or where the plenum is within 1.0 m of a fire damper, the plenum
shall be lined with 25 mm thick 80 kg/m³ rockwool. The distance between
supply air connections on elongated plenums shall not exceed 1500 mm.

(h) volume control dampers shall be installed for all grilles, diffusers and registers.
Diffusers shall be provided with volume control dampers of the iris, flap or
sleeve type which shall be adjustable from the front of the diffuser. Where the
length of a vertical duct to a diffuser is less than twice the diameter of the
diffuser an equalizing deflector shall be fitted;

(i) dimensions shall match building, cladding and ceiling modules; and

(j) light troffer diffusers shall suit the as-installed light fittings.

68.4 MATERIALS

68.4.1 General

(a) Unless otherwise specified, all grilles, diffusers and registers shall be
aluminum, and finished in a sintered powder coat.

(b) Sections of diffusers, grilles, louvres, nozzles and the like supplied and
installed but not connected to plenums or ductwork shall be fitted with a matt
black sight tight air boot, blanking plate or similar.

(c) The inside of all components and surfaces associated with registers, diffusers,
grilles, louvres, nozzles, boots, and the like shall be painted matt black.

General Materials & Workmanship Specification 2/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 68 – Registers, Diffusers & Grilles
68.4.2 Diffusers

(a) Diffusers shall incorporate an edge seal; diffusers mounted on ceilings shall
have anti-smudge rings. Pan type diffusers shall be provided except where
cone type diffusers are indicated.

(b) Square and rectangular diffuser shall be flush mounted and have a removable
core.

(c) The square face diffuser for VAV system shall be constructed of aluminum
and with large turn down ratios. Each ceiling mounted square face diffuser
shall have a factory assembled diffuser and an air plenum. The air plenum
shall be provided with dividing plates such that the diffuser back is divided into
an annulus area and a square central area. In the entry to the diffuser plenum,
the flow cross section shall also be divided into two parts, one part serving as
a bypass and the other equipped with a self contained, weight balance
damper. The damper shall be balanced with a weight in such a way that the
horizontal outlet jet velocity remains nearly constant over a flow rate range of
100 to 20% of maximum in order to prevent stagnant area.

(d) The design of the supply air diffuser shall be capable to induce adequate air
movement and provide the throw to cover the entire air-conditioning space
without causing air turbulence and cold draft.

(e) Round ceiling diffusers shall:

(i) provide uniform 360° distribution; and

(ii) have core removable and adjustable to allow variation in throw.

(f) Perforated ceiling diffusers shall:

(i) be flush face and concealed modular cores for adjusting the discharge
pattern;

(ii) have perforations 5 mm on a staggered spacing of 6.5 mm; and

(iii) have a removable perforated face.

(g) Linear diffusers shall:

(i) be constructed of extruded aluminum section and include a control

damper at the rear of the vanes giving volume control down to
complete shutoff and operated from the face of the diffuser;

(ii) have adjustable blades to providing directional air flow control;

(iii) maintain a horizontal discharge pattern at a turn down ratio of 20% of

the maximum specified air volume without air dumping;

(iv) be provided with a factory fabricated plenum with suitable inlet

connection for flexible ductwork. The plenum and diffuser neck shall
be constructed of galvanised steel sheets internally lined with 25 mm
48 kg/m3 glass cloth faced fibreglass insulation enclosed in galvanized
perforated metal liner; and

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 68 – Registers, Diffusers & Grilles
 (v) be insulated in compliance with NFPA-90A, UL-181 and BS 476 Part :
4, 6, 7 & 12 standards.

(h) Linear slot diffusers shall:

(i) unless otherwise specified, be used for ceiling mounted linear outlets ;

(ii) be constructed of extruded anodized aluminium, with multiple slot for

the required air flow rate;

(iii) be provided with a factory fabricated plenum complete with an inlet

connection suitable for flexible ductwork. The plenum and diffuser
neck shall be constructed from galvanized steel sheets internally lined
with 25 mm 48 kg/m3 glass cloth faced fiberglass insulation enclosed
in galvanized perforated metal liner;

(iv) incorporate twin 20 mm slots and where used for supply air shall
include integral facilities for full 180° discharge pattern control.

68.4.3 Jet Nozzles

(a) Jet nozzles shall comprise concentric spun aluminium nozzle elements
mounted on a flanged face plate singly or in banks of up to four.

(b) Nozzles shall be designed to allow for rotation of at least ±30°. The axis of
rotation shall be adjustable through at least 180° so that each nozzle is fully
directional.

68.4.4 Drum Louvres

(a) Drum louvres shall incorporate a truncated cylindrical core that allows rotation
about a horizontal plan of at least ±30° and individually adjustable vertical
blades at 75 mm to 125 mm spacing.

(b) A felt seal or similar shall be provided between the drum and the frame to
prevent air leakage.

(c) Drum louvre guide vanes shall be capable of being adjusted laterally to allow
full directional adjustment of the air jets. Volume control dampers shall be
mounted away from the drum louvre outlet at a distance of not less than 3
times of the drum louvre outlet diameter. The colour of the whole assembly
shall be submitted to the Project Manager for review without objection.

68.4.5 Punkah Louvres

(a) Punkah louvres shall be constructed form spun aluminum or compression

moulded plastic to BS 1322 Class A.

(b) Punkah louvres shall be designed and installed to allow rotation of the
spherical core up to 30° in any direction without affecting air quantities or air
distribution.

(c) A felt seal or similar shall be provided between the core and the frame to
prevent air leakage.

General Materials & Workmanship Specification 4/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 68 – Registers, Diffusers & Grilles
68.4.6 Grilles

(a) Grilles shall be of steel, aluminum or as otherwise indicated. Steel grilles shall
be protected against rusting and supplied in fully finished stove-enamelled or
otherwise specified condition.

(b) Double deflection grilles shall:

(i) unless otherwise specified, be double deflection having two sets of

separately adjustable louvres, one set horizontal and one set vertical,
and shall be complete with an opposed blade multi-leaf damper for
supply air grilles. The louvre and the damper or air controller shall be
adjustable from the front of the grille.

(ii) have blades at the front of grilles and aligned vertically; and

(iii) shave removable cores that can be rotated within the frame without
affecting blade settings for long throw application.

(c) Single bladed grilles and louvres shall:

(i) unless otherwise specified, incorporate fixed blades with 35° deflection
and a maximum 20 mm spacing or a rhomboidal air controller operable
for the front for return air, make up air, exhaust air and similar. The
maximum pressure drop across the grille or louvre at a 2.5 m/s face
velocity shall be 20 Pa; and

(ii) be arranged such that the central core of the grille is hinged and
demountable for access to the filter for cleaning where return air grilles
are fitted for fan coil unit. Mounting frames for these grilles shall
include provision for fixing the filter in position.

(d) Linear bar grilles shall:

(i) be made from extruded aluminum and shall be complete with flanges
suitable for mounting on the proposed cladding or ceiling as
appropriate; and

(ii) unless otherwise noted on the Employer's Drawings, be bar grilles with
3 mm bars at 12 mm spacing for wall mounted linear outlets and inlets
shall. Bar grilles shall have removable cores.

(e) Floor grilles shall:

(i) shall have a maximum gap between core elements of 6 mm and a

maximum distance between core element centers of 15 mm;

(ii) shall have removable cores;

(iii) have frames flush with the floor or cambered to minimize the effect of a
raised surface;

(iv) be suitable for heavy pedestrian traffic;

(v) shall incorporate removable diffuser elements for round floor grilles;

General Materials & Workmanship Specification 5/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 68 – Registers, Diffusers & Grilles
 (vi) be spaced a maximum of 225 mm apart for rectangular floor grilles
support bars; and

(vii) have perforations of 5 mm on a staggered spacing of 6.5 mm.

(f) Egg-Crate grilles shall:

(i) have a 12 mm grid; and

(ii) be made from anodized aluminum or equivalent.

(g) Wire mesh and insect screens shall

(i) be vermin proof and removable; and

(ii) be woven and galvanised.

(h) Grid Mesh

(i) shall comply with the requirements for catwalks in Plant areas as
detailed in BS 6399 : Part 1;

(ii) be manufactured from galvanised steel with a 12 mm grid; and

(iii) be fixed in accordance with manufacturer's recommendations.

(i) Security Bar

(i) The security bar shall be manufactured from galvanised steel with
aperture size 300 mm x 75mm and strand size 4 mm (width, facing air
stream) x 10 mm (thick). The end of strands shall be embedded into
the wall.

68.5 SUBMISSIONS

68.5.1 Particulars of Registers, Diffusers and Grilles

The following particulars of the proposed registers, diffusers and grilles shall be
submitted to the Project Manager for review:

(a) Contractor’s drawings detailing the location, position and fixing details of all
registers, diffusers and grilles;

(b) calculations supporting the selection of equipment to meet the requirements of

this General Materials and Workmanship Specification; and

(c) details of each proposed register, diffuser and/or grille including design
information, manufacturer’s published information and all manufacturer’s
drawings.

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Section 68 – Registers, Diffusers & Grilles
68.5.2 Samples

The following samples of proposed materials shall be submitted to the Project

Manager together with the particulars referred to in 68.5.1 above. Each sample
shall be mounted on a panel of the material upon which the proposed register,
diffuser or grille are to be installed.

(a) one sample of each type of register, diffuser and/or grille proposed.

68.6 WORKMANSHIP

68.6.1 General

(a) Grilles and diffusers shall be fixed on air ducts by self-tapping screw or
purposely made spring or locking devices. Fixing the grille or diffuser by self-
taping screws on the face panel exposed to view is not allowed.

(b) Where grilles and diffusers are to be incorporated into false ceilings before
any grilles or diffusers are installed into ductwork or fan coils, the Contractor
shall mark out the ceiling line on the adjacent plastered walls or columns and
also indicate where ceiling tee bars line up or the ceiling joints occur in order
to provide a clear datum for installation works.

(c) Bar grilles, linear slot diffusers and similar shall be continuous with precision
butt joints at centres to match building modules. Suitable fasteners shall be
provided to align separate sections of bar grille and linear slot. When installed,
bar grilles and linear slots shall present a continuous straight appearance
without misalignment or distortion.

(d) Corners shall be mitred and factory fabricated by the corresponding grille or
diffuser manufacturer.

(e) For up to ten grilles, one set of tools required for adjusting the louver and
dampers or air controllers shall be provided. From eleven to twenty four grilles,
two sets and above twenty five grilles, three sets of tools shall be provided.

68.6.2 Tolerances

(a) Connections between cladding mounted grilles, diffusers or registers, and

corresponding ductwork shall make due allowance for soffit slab deflections of
up to 25 mm relative to the cladding.

(b) All grilles and diffusers which are smaller than the ceiling tile into which they
will be installed, shall be positioned in the centre of the ceiling tile unless
otherwise specified or reviewed without objection by the Project Manager.
The exact location of the ceiling grilles and diffusers shall be co-ordinated on
Site.

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Section 68 – Registers, Diffusers & Grilles
[this page not used]
SECTION 69 AIR FILTERS

69.1 GENERAL

(a) The Contractor shall comply with other relevant sections of this General
Materials and Workmanship Specification including, but not limited to the
sections which specify:

(i) Section 61 “Air Handling Units”;

(ii) Section 62 “Fan Coil Units”; and

(iii) Section 70 “Ductwork and Fittings”.

69.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document stated below, including all amendments issued by the
relevant authority.

ASHRAE Standard 52.1 Gravimetric and Dust Sport Procedures for Testing Air Cleaning
Devices Used in General Ventilation for Removing Particular
Matter

UL 586 Test Performance of High Efficiency Particulate, Air Filter Units

EN-779 Particular Air Filter for General Ventilation - Requirements,

Testing, Marking.

Eurovent 4/5 Method of Testing Air Filters Used in General Ventilation.

Eurovent 4/4 Sodium Chloride Aerosol Test for Filters Using Flame
Photometric Technique.

BS 476 : Part 4 Non-Combustibility Test for Materials

BS 476 : Part 6 Method of Test for Fire Propagation for Products

UL 900 Standard for Air Filter Units

DIN 53 438 Part 3 Response to Ignition by A Small Flame, Surface Ignition.

UL-710 Standard for Exhaust Hoods for Commercial Cooking

Equipment

UL-867 Standard for Electrostatic Air Cleaner

COP (2005) Code of Practice for minimum fire service installations and
equipment and inspection, testing and maintenance of
installation and equipment

FSD Circular Letter No. 96

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Section 69 – Air Filters
69.3 DESIGN AND PERFORMANCE CRITERIA

69.3.1 General

(a) Filters shall be tested and rated in accordance with the following one of the
following standards:

(i) ASHRAE Standard 52.1;

(ii) UL 586;

(iii) EN-779;

(iv) Eurovent 4/4; and

(v) Eurovent 4/5.

(b) The fire property of air filters shall comply with the following standards and the
latest requirement of Fire Services Department:

(i) FSD Circular Letter No. 4/96 and COP (2005)

(ii) BS 476 : Part 4

(iii) BS 476 : Part 6

(iv) UL 900, Class 1 or Class 2

(v) DIN 53438 Part 3

(c) Filters shall be selected with a maximum face velocity of 2.5 m/s.

(d) Space shall be allowed for the future installation of carbon filters at all fresh air
intakes to fans and air handling units.

(e) The filters for all outside air intakes shall have a dust spot efficiency of not less
than 80%. In addition, pre-filters with dust spot efficiency of not less than 35%
shall be fitted to all AHUs and PAUs.

(f) The filters on at the air intakes to FCU’s shall have a dust spot efficiency of
not less than 35%,

(g) Filters shall be tested in accordance with ASHRAE Standard 52.1-92 or

European Standard EN-799:1993.

(h) The Contractor shall demonstrate that the installed filtration system shall be
capable of maintaining the indoor repairable suspended particulate level
below 180 μg/m³ for a 24 hour time weighted average.

(i) Local filter clog indicators shall be fitted for all filters.

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Section 69 – Air Filters
69.3.2 Bag Filters

(a) Bag filters shall be rated in accordance with ASHRAE 52.1-1992 and conform
with the following:

(i) maximum initial resistance : 75 Pa;

(ii) minimum average arrestance : 65 %; and

(iii) maximum final resistance : 250 Pa.

(b) The bag or packer shall inflate fully, shall not sag or flutter or be obstructed by
contact with other filter faces or ductwork surfaces when operating between
60-110 % of design air volume flow rate for fixed volume system.

69.3.3 Disposable Panel Filters

(a) Type FM-C filter shall be disposable panel filters

(b) Disposable panel filter shall be rated in accordance with ASHRAE 52.1-1992
and conform with the following:

(i) maximum initial resistance : 20 Pa;

(ii) minimum average arrestance : 80 %;

(iii) minimum average efficiency : 20 %; and

(iv) minimum dust holding capacity : 400 g/m2.

at design air quantity and
design final resistance of 75Pa

69.3.4 Washable Panel Filters

(a) Washable panel filter shall be rated in accordance with ASHRAE 52.1-1992
and conform with the following:

(i) maximum initial resistance : 40 Pa (50mm thick), 20 Pa (25mm

thick);

(ii) minimum average arrestance : 65 %;

(iii) minimum dust holding capacity : 1600 g/m2(50mm thick); 1500 g/m2 ;
and at design air quantity and
final resistance of 150Pa
(50mm thick)

(iv) minimum dust holding capacity : 1500 g/m2(50mm thick).

at design air quantity and final
resistance of 100Pa (25mm
thick)

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Section 69 – Air Filters
69.3.5 Electrostatic Precipitators

(a) Minimum oily fume and odour removal efficiency shall be:

Oily fume : 80%; and

Odour : 50%.

(b) Ozone generation level of the electrostatic precipitator shall be below 0.1 PPM
as recommended by the American Conference of Governmental Industrial
Hygienists.

(c) Electrostatic precipitator shall be rated in accordance with ASHRAE 52.1-1992

and conform with the following:

(i) minimum Dust Spot Efficiency : 95 %;

(ii) minimum cold DOP Efficiency : 65 %;

(iii) maximum initial resistance : 120 Pa; and

(iv) power supply : 220V/1-phase/50Hz

(d) Electrostatic precipitators for treating kitchen exhaust shall be modular two-
stage design.

(e) The electrostatic precipitator shall consist of a pre-filter, ionizer, collecting cell
and after filter.

(f) Each module shall have a pilot light to indicate that the power pack is
functional.

(g) Each power pack shall generate a minimum of 12kV for the ionizer and 6kV
for the collecting cell for effective precipitation of the oily or odour particles.
Current limiting devices shall be provided to limit the maximum current flow to
5mA.

(h) The flow of contaminated air shall be unable to by-pass the electrostatic
precipitator.

(i) Ionizing and collecting components shall have spring-loaded high voltage
contacts and there shall be no contact possible to this component. Ionizing
and collecting components shall be accessible from the side of the
electrostatic precipitator for maintenance.

(j) Spacing between unlike charged collecting plates shall be approximately 6mm.

(k) The operation of electrostatic precipitators shall be interlocked with the fan or
air handling unit in such a way that the filter is in operation whenever the fan
or air handling unit is operated.

(l) The unit shall comply with the latest requirements of the Environmental
Protection Department and Fire Services Department on the treatment of
kitchen exhaust air systems.

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Section 69 – Air Filters
 (m) The unit shall be leak proof to avoid dripping of oil.

(n) Each electrostatic precipitator shall complete with an auto-wash system. An

automatic timer control and change-over panel and associated switches shall
be provided to control the on/off, change-over and sequential operation of the
washing water supply control valve and the sub-auto-wash system. Auto-
wash water shall be taken from the cleansing water system. Washing water
supply control valves shall not be opened simultaneously.

(o) The air velocity across the electrostatic precipitator cell shall not exceed 2.5
m/s.

(p) Ceiling mounted type electrostatic precipitators shall include a circulating fan
with on/off switch, 3-speed selector and a filter clogged indicating lamp.

69.3.6 Bio-oxygen Generator Type Air Purifier

(a) The bio-oxygen generator shall be capable of reducing bacteria and airborne
contaminants within the area concerned.

(b) All components of the bio-oxygen generator, which are located within the air
stream, shall comply with the latest requirement of Fire Services Department.

(c) The bio- oxygen generator shall have a minimum removal efficiency of not
less than 95% of Total Bacteria Count (TBC) Test, 95% of cigarette smoke
particles and 80% of odours. The ozone level generated in the indoor
environment shall be less than 0.05 ppm and the background ozone level
shall not exceed the levels of the safety standards specified by Occupational
Safety and Hygienic Association (OSHA), USA.

69.3.7 Ultra Violet (UV) Sterilizer

(a) The UV sterilizer shall be installed as shown on the Employer’s Drawings.

The UV sterilizer shall be capable of disinfecting the supply air and eliminating
any health hazard from the mechanical ventilation and air conditioning system.

(b) The UV light emitted shall be of a high output germinal ultra violet device and
shall consist of UV lamp tube, tube fitting set, electrical supply unit and
monitoring unit. All components of the UV system shall comply with ENEC, CE,
UL, requirements or equivalent, submitted to the Project Manager for review
without objection.

(c) The UV sterilizers shall have one pass bacterial removal efficiency at least
90%. Equipment shall be selected on basis of UV lethal dosage requirement,
not less than 5000µW-s/cm². The Contractor shall liaise with the UV sterilizer
system supplier to ensure the correct data area used for UV system design
(e.g. air temperature, humidity, flow rate, velocity, size and material of
irradiation chamber etc.).

(d) The UV air sterilizer shall not generate ozone substances in excess of the
safety standards specified by the World Health Organization (WHO);
Occupational, Safety and Hygienic Association (OSHA), USA, Food & Drug
Association (FDA), USA, American Society of Heating, Refrigerating and Air-
Conditioning Engineers (ASHRAE), USA or equivalent and statutory
requirements.

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Section 69 – Air Filters
69.4 MATERIALS

69.4.1 Bag Filters

(a) Bag filters shall be of the high efficiency, as specified in 69.3.2 (a) (ii),
extended area, deep pleated, disposable type.

(b) The media shall be microfine glass fibre, reinforced by a laminated synthetic
backing. The media shall have a nominal width of 600mm.

(c) The filter package shall be factory assembled ready for Site installation. The
filter package shall consist of a holding frame, sealer frame, media retainer,
and the disposable element (the media, as described above).

(d) The sealer frame shall be constructed of galvanized steel and be equipped
with airtight sealing gasket and sealing mechanism on the sealer frame flange.

(e) The holding frame shall be provided with at least four heavy duty spring type
positive sealing latches for each filter cell to ensure a positive seal against
leakage of unfiltered air.

(f) For filter cells installed inside air handling unit, separate filter housing is not
required.

69.4.2 Disposable Panel Filters

(a) Disposal panel filter shall be of the disposable glass fibers media panel type.

(b) For the filter cells installed inside air handling units, separate housing is not
required.

69.4.3 Washable Panel Filters

(a) Washable panel filter frame shall be constructed of aluminium to withstand

washing by water or steam. This filter panel shall be constructed from multiple
layers of expanded aluminium mesh or glass, natural or synthetic fibre, with
the layers being corrugated or plain and arranged alternatively at right angles
to one another. Filter media shall be supported on both sides with a rigid and
thicker aluminium expanded metal mesh.

(b) Washable panel filters of 50mm thick shall be provided behind all fresh air
intake louvres or on ductwork forming the paths through which fresh air is
admitted into the building.

(c) For the filter cells installed inside air handling units, separate housing is not
required.

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Section 69 – Air Filters
69.4.4 Electrostatic Precipitators

(a) Electrostatic precipitators shall be a proprietary item.

(b) The cabinet shall be a galvanized steel structure with an epoxy enamel coated
exterior. Each module shall have it’s own components access door and power
pack. Other modules shall not be effected when inspection of other modules is
undertaken. Each access door shall have a mechanical interlock that
deactivates the power pack when the door is opened.

(c) Each module tier shall have an independent drain pan to physically isolate that
tier from others and prevent runoff of contaminant onto components below.

(d) All high voltage wiring shall be outside of the contaminated airstream.

(e) The ionizer, collecting cell and filter components shall be positioned in slide
tracks and removable without the need to dismantle any equipment, from the
side for maintenance.

(f) Pre-filter and after-filter shall be 25 mm thick, washable panel filter

construction.

(g) Each collecting cell shall have a centrally located handle and weigh no more
than 14 kg. Each collecting cell shall have a 250 mm minimum airflow depth to
maximize retention time of contaminated air. The collecting cell shall be of
aluminum construction.

(h) The ionizer and collecting cell shall be separate and independent of each
other in a single unit for cleaning and replacement.

(i) Electrostatic precipitators shall be leakage proof to avoid oil dripping.

(j) All parts shall be factory assembled into a sectioned housing having an overall
depth not greater than 1,000 mm in the direction of the airflow.

(k) Each section of the galvanized steel housing assembly shall incorporate a pair
of hinged air tight access doors providing easy access for servicing of all
internal components. A watertight, all welded, galvanized steel, drain pan
having drain connections shall be provided where appropriate.

(l) Each ionizer-collector section shall be furnished with the required number of
one-piece cells of all aluminium construction. Each cell shall be fitted with
stainless steel slides for mounting on the tracks to facilitate removal of cells for
servicing. The cell support framework shall be completely open beneath the
ionizer-collector cells to ensure complete drainage of wash water and excess
adhesive to prevent short circuits when high voltage power is restored
following completion of the wash cycle.

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Section 69 – Air Filters
 (m) Cells shall be designed so that high voltage input terminals and their high volt
rated insulators are located completely out of the moving air-stream to avoid
build up of dirt and reduce air cleaning efficiency. The high voltage bus bars
and contactors shall be inherent to the design of each cell and shall permit cell
removal without disconnecting any high voltage wiring. Insulators shall be
fully exposed, for ease of cleaning, when cells are removed for service. Cells
shall be designed for full-face ionization and shall have completely flat
collector plates to prevent build-up of residual, inaccessible dirt accumulations.

(n) Dual voltage power packs shall be designed to provide a high voltage supply
to the ionizer circuit. The plate circuit respectively shall be connected to each
ionizer-collector section. The power packs shall be of solid state design,
having multiple steps of output voltage adjustment and shall include, but not
be limited to, relays to provide remote indication of primary input and
secondary output and “fail-safe” low voltage relays to interrupt power to the
ionizer circuit in the event of a malfunction in the plate circuit.

(o) High voltage connections between the high voltage output terminals and the
bus bar terminals shall be installed. Power pack covers shall include, but not
be limited to, primary and secondary neon glow lamps, a circuit breaker, and a
manual reset button. Two time delay safety type door interlock switches, with
a suitable length of safety chain shall be provided, wired in a series circuit with
the power pack, to cut-off the power supply whenever the door is opened.

(p) The electrostatic precipitator shall be equipped with an auto-cleaning system.

Detergent shall be routed from a storage tank, through a dedicated compact
detergent dispenser and on to the water line. The wash cycle shall be initiated
and controlled to completion by the system’s wash control panel.

(q) The cleansing water system shall include but not be limited to, a non-return
valve, a ball valve, a y-strainer with mesh screen, a water pressure regulator,
a solenoid valve, an injector tee assembly, a detergent pipe and a detergent
pressure gauge.

(r) Detergent shall flow from the detergent tank and through the compact
detergent dispenser at discharge pressure, toward the water line. Detergent
shall passes through injector tee assembly which shall adjust the detergent
flow at the point where detergent is mixed with the plant water line. A
drainage pipe shall be connected from the electrostatic precipitator to the
dedicated drainage pipe.

(s) The auto-wash system shall have: a hand valve in the water line for
maintenance; a pressure gauge in the water line for pressure monitoring; and
a strainer in the water line to keep plant line debris from fouling the valve seats
in the supply lines at the precipitator.

(t) The auto-wash system shall have an individual control panel. Each cleaning
cycle shall be push-button initiated and automatically sequenced by a built-in
control accessory.

(u) The auto-wash system shall include a selector for on/off power, an “On” button
for overall starting of the auto-wash operation and a “Stop” button for
emergency stop both located in the control panel; and an operating light
signalling “cleaning is in process”.

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Section 69 – Air Filters
 (v) The washer supply water solenoid valve, the manifold drive motor, and the
manifold limit switch shall be pre-wired to an accessible, internally mounted
terminal box. The washer control enclosure access door shall incorporate a
status light to indicate when the reconditioning cycle is energized. An internal
panel shall be equipped with a combination of LED status lights and a digital
readout to indicate which part of the reconditioning cycle is in operation. The
digital readout shall be visible through a window in the control cover. The
complete automatic cleaning by reversing the polarity of the filter element, wet
washing by water spray and adhesive application shall be initiated manually or
automatically through a push button actuated, internally fused, all solid state,
program timer control, with adjustable timer to control drip and fan dry cycles.

(w) Each auto-wash system washer and adhesive applicator section shall
incorporate slide-in type, perforated, galvanized steel air distribution baffles
and a motor-driven mobile header assembly. The mobile header assembly
shall be connected to the inlet water solenoid valve and to the adhesive pump
by means of non-snag, flexible steel hose. Rotating washer arms, each
equipped with adjustable, multi-directional, 360° washer spray nozzles, shall
be driven by reactive force to the high inlet water pressure. The removable
brass adhesive nozzles shall be mounted on a separate, fixed, vertical header
forming an integral component of the mobile assembly. The filter adhesive
shall be cold water soluble and non-flammable. A rotary gear adhesive pump
with bronze impeller and sufficient adhesive for at least four reconditioning
cycles shall be furnished.

69.4.5 Bio-oxygen Generator Type Air Purifier

(a) Each bio-oxygen generator unit shall be of the ductwork mounted type and
shall consist of electrode tubes and power generator with built in output
regulator:

(i) The electrode tube shall consist of electrodes, glass tube and a threaded
connector at the base of the tube for connection with the tube socket
provided at the power generator. Each tube shall be covered with stainless
steel mesh and earthed by via the grounding leaf spring connected to the
power generator. No high voltage part shall be exposed and accessible.

(ii) All parts in contact with air shall be corrosion resistant. The output of the
electrode tubes for each air handling plant shall be in accordance with the
manufacturer’s recommendations. The output shall be sufficient to handle
the design air flow rate and the volume of the room served.

(iii) The power generator shall be able to operate on 220V/50 Hz single

phase supply and shall generate appropriate supply to match with the
operational requirements of the electrode tubes.

(iv) Each unit shall be equipped with built-in regulator for output adjustment
and shall consist of on/off indicator lamp, overload protection device, tube
sockets, control knob for regulator setting and on/off switch.

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Section 69 – Air Filters
 (b) The bio-oxygen generator shall be factory fabricated and assembled in
accordance with the manufacturer’s installation details. The Contractor shall
include all necessary electrical cables/accessories for proper operation of the
complete installation. The Contractor shall provide all necessary safety
measures including automatic cut-off switch and high voltage warning label at
each access panel for the unit to prevent any possibility of electrical shock to
personnel during operation, inspection and maintenance.

(c) The complete assembly shall be mounted onto the wall of the ductwork by the
manufacturer’s mounting flange provided by the manufacturer with the power
generator outside the air stream and the electrode tubes within the air stream.
The glass tube electrodes shall be mounted perpendicular to the direction of
air flow and installed at a minimum distance of 150 mm away from any air
distribution accessories within the ductwork. The power generator shall be
installed with all necessary support brackets and ductwork stiffeners onto the
ductwork without damaging the thermal insulation.

(d) The mounting shall be designed and installed in a manner that prevents air
leaks and avoids condensation at any surface in contact with the ductwork.
The unit shall be capable of being completely withdrawn for routine inspection
and maintenance.

(e) The bio-oxygen generator shall be installed in the return air duct and
interlocked with the fan or air handling unit so that the generator is in
operation whenever the fan or air handling unit is in operation.

69.4.6 Activated Carbon Filter

(a) Each unit shall be suitable for ductwork mounting.

(i) Filters shall comprise a removable steel cell and steel frame, sourced
from a single source supply. The steelwork shall be corrosion resistant.

(ii) The cells shall be in tray or rack formation with perforated surfaces
containing high density, high porosity, high crushing strength activated
carbon granules, selected to give optimum absorbing efficiency for the
agents specified. A minimum of 40kg shall be provided for each 1m3 of
design air volume flow rate.

(iii) At the design air flow rate the filter resistance shall not exceed 125Pa.

(iv) The cells shall be arranged so that the air stream passes uniformly and
proportionally through the activated carbon beds. Provision shall be
made to retain granules in position and prevent migration and settlement.

(v) There shall be no air leakage between cell and frame.

(vi) Each filter bank shall be provided with a detachable test unit for
prediction of service life.

(vii) Activated carbon filters shall be preceded by a dry fabric panel filter.

General Materials & Workmanship Specification 10/13 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 69 – Air Filters
69.4.7 Ultra Violet (UV) Sterilizer

(a) The UV sterilizer shall be composite unit assembled and tested in the factory
prior to delivery to site. The Contractor shall install and commission the unit in
accordance with the manufacturer’s recommendations. The Contractor shall
include all necessary electrical and control cable/accessories for proper
operation of the complete installation.

(b) The UV lamp tube shall consist of electrodes and high quartz glass tube with
ceramic bases. Each tube shall consume not more than 40W but emit pure
UV-C irradiation not less than 120µW/cm² measured at 1m from the source
after 100hr under 25°C. The total UV light intensity shall be not less than
360µW/cm² per 1 m³/s air flow measured at 1m from the source.

(c) When the UV exposure level exceeds 0.2µW/cm² after 8 hours, baffle filters
shall be installed for those air discharge louver to reduce UB light intensity
level. Safety precaution shall be taken in the installation and maintenance of
the air sterilizer to leakage of UV lighting. Operating life shall be at least
10,000 hours.

(d) The operation of UV system shall be interlocked with the respective fan such
that the disinfection only occurs when the mechanical ventilation system is in
operation. The sterilizer shall be automatically switched off with an indicator
light on when the maintenance access is opened.

(e) The UV sterilizers shall be mounted onto the wall of ductwork by an

independent mounting flange provided by the manufacturer. The mounting
shall be designed to prevent air leakage and to avoid condensation at any
surface in contract with the ductwork. The Contractor shall ensure sufficient
access space is allowed for maintenance.

(f) The UV sterilizer lamps shall be positioned perpendicular to the airflow at a air
velocity less than 5m/s. UV irradiation sections shall be provided with access
door, inspection window and safety switch to interlock with access panel.
Safety labels shall be provided on the ductwork access panel.

(g) The UV sterilizer shall be suitable for operation under supply voltage of
220V/50Hz. The system should be of high grade, non-corrosive materials. The
housing of the air sterilizers should be of high quality stainless steel and lamps
should be made from quartz glass with ceramic bases. The electric supply unit
should be allowed to mount inside the irradiation chamber. System
components exposed under moist air or condensation shall be of IP68.

(h) The Contractor shall also provide safety measurements to confirm the system
does not create direct exposure to operators. The supply unit shall include a
safety switch-off function to prevent operation after lamp breakdown. The
working range of the electronic ballast shall be linear throughout the expected
range of temperatures. The UV system shall start and continue to operate
under all unexposed and unfavourable working temperatures. The electronic
ballast shall have an over voltage cut-out to improve safety and material
protection. The surface temperature of any exposed elements shall exceed
40ºC during normal operation.

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Section 69 – Air Filters
 (i) The monitoring unit shall be in the form of an independent wall mounted unit
installed in the vicinity of the sterilization section. The monitoring unit shall be
enclosed within a casing constructed to at least IP54. The monitoring unit
shall consist of an easy to reach circuit breaker, an on/off 3 way switch
(auto/off/manual), a leakage current protective switch, hour run meter, a
visible general malfunctioning alarm lamp and an indication display with at
least two coloured functioning LED’s for each connected ultraviolet system.
The monitoring unit shall provide information about used lifespan and lamp
replacements.

(j) The UV sterilizer shall be equipped with a micro-processor base control

system. Signal shall be transmitted to the DDC controller, so that the mode of
the operation can be displayed on the MBMS workstations.

(k) On site performance testing shall be conducted to verify the total bacteria
count (TBC) removal efficiency, background UV intensity and ozone level.

(l) Safety devices listed as below shall be provided as a minimum:

(i) Electric safety interlock to prevent the dehumidifier from running with
the electrical control panel open or the mechanical access panels
removed.

(ii) Automatic shutdown in case the control system detecting a fault.

(iii) Independent thermostats for the reactivation heater shall be provided

to trigger automatic shutdown in accordance with statutory
requirements.

69.5 SUBMISSIONS

(a) The Contractor shall submit a reference to the Project Manager for the
electrostatic precipitators for kitchen exhaust air treatment. The reference shall
include details of the installations (restaurants in Hong Kong) where the
proposed electrostatic precipitator has been in service for at least 4 years.

(b) Type test certificate of air filter showing the filter characteristic.

(c) The Contractor shall include all necessary electrical cables/accessories for
proper operation of the complete installation. The Contractor shall submit
details of all necessary safety measures to be put into place including, but not
limited to, automatic cut-off switch and high voltage warning labels, to prevent
any possibility of electrical shock to personnel during operation, inspection and
maintenance of the electro air filtration systems

General Materials & Workmanship Specification 12/13 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 69 – Air Filters
69.6 WORKMANSHIP

69.6.1 Bag Filters

(a) Bag filters installed in air handling units (AHU) the holding frame shall be
factory mounted in the AHU casing shall provide access for maintenance from
the air side.

69.6.2 Disposable Panel Filters

(a) The holding frames shall be provided with fixtures for easy removal of the filter
cells without the use of any special tools.

(b) Disposable panel filters installed in AHU, the holding frames shall be factory
mounted in the AHU casing and shall provide access for maintenance from
the air side .

69.6.3 Washable Panel Filters

(a) The holding frames shall be provided with fixtures for easy removal of the filter
cells without the use of any special tools.

(b) Holding frames installed in AHU shall be factory mounted in the AHU casing
and shall provide access for maintenance from the air side.

69.6.4 Electrostatic Precipitators

(a) The complete electrostatic filter set including filter cells, holding frames and
housing shall be factory fabricated and assembled.

(b) All necessary safety measures including automatic cut-off switch and high
voltage warning label at each access panel for the electrostatic precipitators
shall be provided to ensure the safety of personnel during operation,
inspection and maintenance.

69.7 INSPECTION, TESTING AND COMMISSIONING

(a) Air conditioning and general ventilation filters shall be tested and rated in
accordance with ASHRAE Standard 52.

(b) Electrostatic precipitators shall comply with the fire and “Burnout Test” type
tests. The Burnout Test shall have been conducted in accordance with the
Standard for Grease Extractors for Exhaust Systems (UL-710), 3rd Edition.

General Materials & Workmanship Specification 13/13 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 69 – Air Filters
[this page not used]
SECTION 70 DUCTWORK AND FITTINGS

70.1 GENERAL

(a) The Permanent Works and materials specified below shall comply with the
sections stated, unless otherwise specified in this section:

(i) Section 61 “Air Handling Units”;

(ii) Section 67 “Dampers and Air Volume Control Devices”;

(iii) Section 68 “Registers, Diffusers and Grilles”;

(iv) Section 69 “Air Filters”;

(v) Section 72 “Pipework, Fittings and Valves”;

(vi) Section 73 “Thermal Insulation”;

(vii) Section 74 “Sound Attenuators”; and

(viii) Section 75 “Noise and Vibration Control”.

(b) Ductwork shall include all ducts, casings, drain pans, dampers, sound
attenuators, plenum chambers and similar for air handling plant and ducted
systems. All ducts shall be complete with all necessary supports, access
doors, cleaning point and test holes.

(c) Volume dampers and/or splitters necessary for complete balancing of all air
handling systems shall be installed.

(d) Cross breaking shall be permitted on low velocity only and in no case where
rigid external insulation will be applied.

(e) Unless otherwise specified, duct sizes given on the Employer’s Drawings are
all clear internal dimensions and allowance shall be made for both internal and
external insulation on the ducts where applicable.

(f) The Contractor shall also supply a set of proprietary type compressed air
lance, disinfection application lance and sampling probe that shall be suitable
for use with the cleaning points. All operating and servicing instruction
manuals shall be supplied with each set of equipment.

General Materials & Workmanship Specification 1/13 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 70 – Ductwork & Fittings
70.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, at the date of the Letter of Acceptance.

BS 476 : Part 6 Fire tests on building materials and structures. Method of test
for fire propagation for products
BS 476 : Part 7 Fire tests on building materials and structures. Method of test
to determine the classification of the surface spread of flame
of products

BS 476 : Part 12 Fire tests on building materials and structures. Method of test
for ignitability of products by direct flame impingement
BS EN 10142 Continuously hot-dip zinc coated low carbon steels strip and
sheet for cold forming. Technical delivery conditions
BS 4127 Specification for light gauge stainless steel tubes, primarily for
water applications
BS 5315 Specification for hose clamps (worm drive type) for general
purpose use (metric series)
DW/143 Practical guide to ductwork leakage testing
DW/144 Specification for sheet metal ductwork
DW/151 Specification for plastics ductwork
DW/191 Guide to good practice glass fibre ductwork
ISO 9692 Metal-arc welding with covered electrode, gas-shielded metal-
arc welding and gas welding -- Joint preparations for steel
NFPA 90A Standards for the installation of air-conditioning and
ventilating system
COP Codes of practice for minimum fire service installations and
equipment and inspection, testing and maintenance of
installations and equipment
FSD Circular Letter
96

70.3 DESIGN AND PERFORMANCE CRITERIA

70.3.1 General

(a) Duct pressure classifications shall be based on the more stringent of:

(i) 120% of the scheduled external static pressure of the associated fan;
or

(ii) 750 Pa (positive or negative as applicable).

General Materials & Workmanship Specification 2/13 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 70 – Ductwork & Fittings
 (b) Flexible ductwork shall be suitable for an operating temperature range of -5°C
to 90°C and shall comply with BS 476 : Part 12, Rating Class P; BS 476 : Part
6 having an index of performance not exceeding 12 of which not more than 6
should derive from the initial period of test; BS 476 : Part 7 Class 1 (surface of
very low flame spread) unless otherwise indicated.

70.3.2 Transfer Ductwork

(a) Transfer ductwork shall perform as acoustic/thermal insulation with the

following absorption coefficients (a) at different frequencies:

Hz 125 250 500 1000 2000 4000

a 0.20 0.40 0.65 0.55 0.70 0.70

70.3.3 Access Panels and Doors

(a) Gaskets shall conform to DW/143 and DW/144.

70.3.4 Flanges for Ductwork

(a) Gaskets strip shall comply with BS 476 : Part 7, Class 1.

(b) Ductwork sealant to BS 476 : Part 7, Class 2.

70.3.5 Flexible Ductwork

(a) The frictional resistance to air flow per unit length of flexible duct shall not
exceed 150% of the frictional resistance per unit length of galvanised steel
duct of similar diameter.

(b) The radius ratio R/D for bends shall be not less than 2, where R is the centre
line radius and D is the diameter of the flexible duct.

70.3.6 Cleaning Points

(a) Air leakage for cleaning points shall comply with DW/143 and all Fire Services
Department requirements.

70.3.7 Flexible Joints for Ductwork

(a) Flexible joints shall be provided to accommodate all anticipated building
movements. The Contractor shall be responsible for the design and selection
of appropriate flexible joint materials to ensure that the entire air-side system
operation will not be damaged by building movements and/or thermal
expansion.

General Materials & Workmanship Specification 3/13 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 70 – Ductwork & Fittings
70.4 MATERIALS

70.4.1 General

(a) Ductwork shall comply with the latest edition of the following HVAC
publications with additions or amendments as required by this General
Materials and Workmanship Specification:

(i) DW/144;

(ii) DW/151; and

(iii) DW/191.

(b) If any part of the installation is not covered by (a) above, then the
recommendations of the latest edition of "Low Pressure Ductwork
Construction Standards" and "High Pressure Ductwork Construction
Standards," issued by the Sheet Metal and Air Conditioning Contractors'
National Association (SMACNA) Inc. USA, shall apply.

(c) Flanges shall be of a proprietary type, tested and certified for air leakage and
deflection to DW/144.

(d) All ductwork shall be off Site pre-fabricated from best quality full sized zinc
coated hot dipped galvanised flat steel sheet to BS EN 10142, Grade
DX51D+Z, coating type Z275 unless otherwise specified in the Specification or
on the Employer’s Drawings.

(e) Sheetmetal and ductwork materials sealants, adhesives and the like shall
comply with the requirements of:

(i) FSD Circular Letter No 96 and COP (98); and

(ii) NFPA 90A.

(f) All ductwork and fittings delivered to site shall be clearly and indelibly stamped
to identify different grades, materials and manufacturers.

(g) Bends and branch vanes, dampers etc. shall be of the same material as used
for the ductwork and/or of heavier gauge, securely mounted.

70.4.2 Flexible Ductwork

(a) Flexible ductwork shall comply with FSD Circular Letter Part 11 (Vent)/96.

(b) Flexible supply air ducts shall have 25 mm thick fibreglass insulation with a
reinforced aluminium foil bonded to the internal face. The internal face shall
be bonded to and supported with spring-steel wires.

General Materials & Workmanship Specification 4/13 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 70 – Ductwork & Fittings
70.4.3 Flexible Connections

(a) Flexible joints shall consist of, or be externally protected by, material having a
fire penetration time of at least 15 minutes and shall comply with BS 476 : Part
7, Class 1 (surface of very low flame spread).

(b) Flexible connections shall be factory manufactured with UL classification or

equivalent.

(c) Flexible connections shall not be painted.

(d) Connections shall be approximately 150 mm long and shall separate items of
Plant by at least 50 mm. In any case, flexible connections shall not exceed
200 mm in length.

70.4.4 Fire Rated Ductwork

(a) Fire rated ductwork and cladding, including access panels, shall comply with
FSD requirements including but not limited to FSD Circular Letter No. 4/96
and COP (2005).

(b) Fire rated ductwork used to convey air-conditioned supply air, return air,
make-up air and similar shall be constructed from sheet metal and clad with a
2 hours fire rated material.

(c) Fire rated ductwork used to convey only hot smoke extraction air may be
constructed from a calcium silicate, GRP reinforced monolithic cement
material or similar, subject to the installation being in accordance with the
Relevant Authority requirements and the manufacturer's recommendations.
Each edge shall be protected by a minimum 40 mm × 20 mm × 0.7 mm angle
iron externally fixed to the cladding. Joints between lengths of ductwork shall
be protected by a second strip of minimum 100 mm wide fire rated board or
similar.

(d) All ductwork installed in protected areas or lobbies shall be properly enclosed
by fire rated material according to the requirement of Fire Services
Department and Buildings Ordinance. The enclosure shall have a fire rating
meeting the requirements of Fire Services Department, but shall in no case be
less than 2 hours.

(e) Fire rated flexible connections shall be manufactured from fibreglass coated
with silicone on both sides or equivalent.

70.4.5 Kitchen Exhaust Ductwork

(a) Kitchen exhaust ductwork shall be constructed using 304 grade stainless
steel.

(b) Kitchen exhaust ductwork shall have access panels every 3 m and on both
sides of every change of direction.

(c) Kitchen exhaust ductwork required to be fire rated shall be clad with a suitable
fire rated material in accordance with the manufacturer's and Relevant
Authority requirements.

General Materials & Workmanship Specification 5/13 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 70 – Ductwork & Fittings
 (d) Kitchen exhaust ductwork shall be provided with drains at all low points. Each
horizontal section of kitchen exhaust ductwork shall slope towards drainage
points located in accessible locations adjacent to access panels at a maximum
of 18 m centres. A 15 mm diameter stainless steel drain shall be run from
each low point to the nearest convenient floor gully. Drain holes shall be
minimum 25mm diameter and shall be sealed water tight with a suitable
screwed plug. The drains shall be complete with a 150 mm running rap and
the pipework shall be to BS 4127, with stainless steel compression fittings.
The drain connection to the duct shall be made by means of a trapped socket
with adaptor welded to the outside of the duct.

(e) Construction of kitchen exhaust air ducts shall comply with the HVCA DW171.

70.4.6 Kitchen Extract Hoods

(a) Hoods shall be of stainless steel. The hoods shall be rigidly formed and shall
be supported independent of the ductwork. Unless otherwise indicated, they
shall be supported either from above or from a side wall. The type and size of
hood shall be as indicated but the Contractor shall submit his proposal for its
exact position in relation to the associated item of kitchen equipment to be
covered on Site to the Project Manager for review without objection.

(b) Hoods for kitchen equipment and for the extraction of condensable vapours
shall have all joints in sheets vertical and shall have a drip gutter all round with
a drain connection plugged, to run a drain to a suitable point. Hoods in high
fire risk situations such as for working ranges in kitchen shall overlap the
equipment by a minimum of 500 mm.

(c) Stainless steel hoods shall be manufactured from 1 mm thick 304 grade
stainless steel with joints continuously welded; all external welds shall be
ground and polished. All stiffening and supported shall be hidden. The
stainless steel shall be free from scale and all surfaces shall be polished to
type 4 commercial (satin) finish.

(d) Unless otherwise specified, welding of the stainless steel shall be by inert-gas
arc welding to ISO 9692.

(e) Lighting fittings shall be provided within the hoods and fittings shall be
bulkhead design with die cast aluminium base and glass diffuser. The fittings
as well as the wiring for the fittings shall be suitable for continuous use in
ambient conditions of 100°C temperature and 100% RH.

(f) Hoods positioned over cooking appliances shall be fitted with grease filters.

70.4.7 Transfer Ductwork

(a) Transfer ductwork shall have internal linings of 50 mm thick rigid fibreglass
insulation.

General Materials & Workmanship Specification 6/13 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 70 – Ductwork & Fittings
70.4.8 Access Doors and Panels

(a) Access panels in ductwork, casings or sheet metal partitions shall be of

double skin construction with minimum 25 mm insulation of the same general
character as adjacent sections of ductwork, of not less than 0.7 mm sheet
metal, and shall have not less than 15 mm wide neoprene rubber gaskets,
around the entire perimeter.

(b) Access panels shall be 600 × 600mm minimum, or where the duct width is
smaller than 600 mm, it shall be the full width of the duct and 600 mm long.

(c) Removable access doors shall be no larger than 350 mm × 300 mm, unless
necessary for access to equipment, in which case the size shall be agreed
with the Project Manager.

(d) Access panels in sheet metal work shall be secured in the closed position by
means of wedge type catches. Panels screwed in position will not be
accepted.

(e) Access panels greater than 600 mm in height shall be hinged.

(f) Access panels shall open against the pressure of the fan.

70.4.9 Flanges for Ductwork

(a) All rectangular ductwork shall be flanged jointed. Flanges shall be a

proprietary type.

(b) Proprietary ductwork flanges shall be roll-formed from zinc coated hot-dipped
galvanised sheet metal to BS EN 10142 Grade DX51D+Z, coating type
ZF180. Flanges shall be constructed with prefabricated flange profile
consisting of manufacturer provided integral sealant with corner joints inserted
into the end of the flange profiles and the whole frame shall be firmly secured
including the corner component. All sealant used shall be fire proof and
vermin proof, non-toxic and acceptable to the Fire Services Department.

(c) Sealants and gaskets shall be provided by the flange manufacturer.

70.4.10 Hangers and Supports

(a) All supports and hangers for air duct installed shall be hot dip galvanized U-
channel construction.

70.4.11 External Ductwork

(a) Brackets, hangers, nuts, bolt and any other metallic components shall be fully
galvanised.

(b) Damaged galvansing shall be primed with at least 2 coats of anti-corrosive

paint.

General Materials & Workmanship Specification 7/13 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 70 – Ductwork & Fittings
70.5 SUBMISSIONS

70.5.1 Particulars of Ductwork and Fittings

The following particulars of the proposed ductwork and fittings shall be submitted to
the Project Manager for review without objection:

(a) test certificate / certified test data (from an approved laboratory) of equipment
confirming the selected equipment meets the requirements of this General
Materials and Workmanship Specification;

(b) hangers and support structure designs;

(c) a method statement including the method of fixing hangars and supports to
the structure;

(d) details of the source, type and properties of materials including design
information, manufacturer’s published information all manufacturer’s drawings;
and

(e) Contractor’s drawings detailing:

(i) location and position of ductwork, fittings and equipment; and

(ii) installation and fixing details of hangers, supports and access panel.

70.5.2 Samples

The following samples of proposed materials shall be submitted to the Project

Manager together with the particulars referred to in 70.5.1 above:

(a) sheet metal;

(b) flexible ductwork;

(c) flanges; and

(d) hangers and supports.

70.6 WORKMANSHIP

70.6.1 General

(a) A minimum clearance of 200 mm shall be maintained between any duct joint,
flange or duct insulation and the underside of all suspended ceilings wherever
possible.

(b) Where patented ductwork systems have been reviewed without objection by
the Project Manager, installation shall be in accordance with the
manufacturer's recommendations.

General Materials & Workmanship Specification 8/13 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 70 – Ductwork & Fittings
 (c) Ductwork shall be inspected internally prior to erection and all dirt, dust and
other foreign matter shall be removed. During construction, open ends of
ductwork stored or installed on Site shall be covered with polythene sheeting
or similar to prevent damage from moisture or debris. Any ductwork or
insulation damaged by moisture or similar shall be replaced.

(d) Ductwork including fire dampers shall be independently supported from the
structure. Blockwork, cladding, partition work and similar shall not be used to
support Plant.

(e) Internal roughness, sharp edges or obstructions to air flow (other than
dampers, splitters or diffusers) shall not be allowed. External edges and
corners formed from cleated joints shall be neatly dressed down and joints
made airtight.

(f) Dampers, doors, casings and ductwork shall be internally free of raw edges
and projections and shall be installed to minimize the generation of noise due
to vibration or leakage.

(g) Joints in air chambers and plenums shall be airtight. Bottoms of all such air
chambers resting on a masonry floor or similar shall be gasketed or caulked to
prevent air leakage.

(h) At each point where a duct passes through a roof or external wall, a weather
'cravat' or other purpose made arrangement shall ensure a waterproof and
weatherproof fixing.

(i) All intake and discharge openings to the building shall be fitted with 10 mm
mesh bird wires which is additional to any grilles or louvers indicated for these
locations.

(j) Where floor slabs are of waterproof construction, the Contractor shall not
pierce waterproofing with retaining bolts or inserts but shall use an alternative
method of securing plenums, chambers and casings.

(k) Sheet metal plenum boxes shall be provided for all ceiling mounted diffusers
and where shown on the Employer's Drawings. Plenums shall be supported
from soffits with suitable hangers. Supports shall have adjustment facilities to
allow for final positioning of registers, diffusers, and grilles.

70.6.2 Fabrication

(a) Snaplock joints shall only be used for longitudinal seams on sheetmetal with a
thickness of 0.9 mm and above subject to a maximum duct pressure
classification of 1,000 Pa.

(b) Unless otherwise reviewed without objection by the Project Manager, vertical
ducts shall have flanged angle frame connections.

(c) Exhaust systems shall use flanged connections. Drive cleat construction shall
not be used.

General Materials & Workmanship Specification 9/13 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 70 – Ductwork & Fittings
 (d) Duct connections between individual components of an air handling assembly
and connections between an assembly and a ductwork system shall be made
with angle-flanged joints. Removable sections shall be provided for cleaning
and maintenance access. All joints shall be made perfectly airtight and
proprietary duct-flanges shall be used for all cross-joints and for connection to
Plant.

(e) Perforated rivets shall not be used in manufacture or erection of ductwork. The
Contractor shall not use self tapping screws. Pop rivets shall be of the self-
sealing type.

(f) No pipes shall pass through ducts, unless specifically shown on the
Employer's Drawings. Where pipes are shown to pass through ducts, the
Contractor shall provide teardrop sheet metal fairings, carefully shaped around
pipes.

(g) Joints shall be lapped, creased and secured to ensure an airtight connection.
Slip joints shall be lapped in direction of airflow.

(h) Flanged transverse joints shall be sealed with a neoprene gasket around the
entire perimeter.

(i) Internally lined ductwork shall have flanged transverse joints only and shall not
be cross-broken.

(j) Angles shall not be fixed over cross breaks.

(k) Elbows shall be "standard radius" or "square throat, double vane".

(l) The Contractor shall paint any steel that is not galvanised.

70.6.3 Hangers and Supports

(a) All ductwork shall be securely supported by hangers, brackets and other
appropriate forms of support.

(b) All ductwork shall be securely supported so as to prevent vibrations or

movements and arranged to allow expansion due to thermal stresses without
distortion of the ductwork, rupture of insulation or damage to the supporting
structure. Ductwork supports shall be positioned close to dampers, diffusers
and all similar equipment which are not subjected to distortion. Allowance shall
be made in ductwork construction for instrument and controls connections and
adequate local stiffening shall be incorporated to provide ridge mountings.

(c) Noise and vibration shall not be transferred to the structure or any other
element through hangers and brackets.

General Materials & Workmanship Specification 10/13 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 70 – Ductwork & Fittings
70.6.4 Flexible Ductwork

(a) Flexible ductwork shall be independently supported from the underside of the
concrete slab. On all circular spigots, the flexible ductwork up to and including
140 mm diameter shall be secured with a worm drive type hose clip complying
with BS 5315. Ductwork over 140 mm diameter shall be secured with a band
clip. On rectangular connections, the flexible ductwork shall be held in place
by a mating flange with a backing plate. Backing flat shall not be less than 3
mm thick. No flexible ductwork shall be less than 50 mm long between rigid
components.

(b) Joints at flexible duct connections shall be made with a sealant that
permanently retains adhesion and elasticity throughout the design working
temperature range. The sealant and method of application shall be in
accordance with the ductwork manufacturer's recommendations.

(c) Flexible ductwork shall be neatly installed without kinks or deformation in a

manner that minimizes pressure losses.

(d) The flexible duct shall be installed in as straight a manner as possible. In

situations where bending is required, the bending radius shall be sufficient to
prevent tensioning of the bend and restriction of the throat likely to cause
deformation and/or leakage. In no case shall flexible ductwork be used to
correct misaligned ducts.

(e) Where flexible ductwork is indicated or required between rigid ductwork and
items of equipment, the internal diameter of the flexible duct shall be equal to
the external diameter of the rigid duct and equipment spigot. Flexible ductwork
shall be kept to a minimum length and shall not be used between rigid
sections of ductwork to change direction unless indicated on the Employer’s
Drawings or reviewed without objection by the Project Manager.

(f) Flexible ductwork shall be supported at a minimum of 900 mm intervals using

suitable supports connected to the soffit. Ductwork shall not rest on ceilings or
other services unless otherwise reviewed without objection by the Project
Manager.

(g) Unless otherwise reviewed without objection by the Project Manager, flexible
ductwork shall not exceed 2 m in length. Where longer runouts are necessary
to suit on Site conditions, solid circular ductwork shall used as necessary to
meet this requirement.

70.6.5 Flexible Connection

(a) Flexible joints shall be provided on all in-line fan inlet and outlet connections,
at expansion joints in the building and elsewhere on ductwork where indicated.
Flexible joints shall be of the same cross-sectional area as the mating fan
inlet/outlet or duct section. The centre lines of flexible joint connections shall
be coaxial.

(b) Connections shall incorporate flanges bonded and mechanically fastened to

the flexible material. The bonding material shall have 100% coverage.

General Materials & Workmanship Specification 11/13 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 70 – Ductwork & Fittings
70.6.6 Exposed Ductwork

(a) Exposed ductwork within areas accessible or visible to the public shall be
connected using slip joints, recessed flanges or similar and shall be supported
from above using an internal brace for circular ductwork or an angle fixed to
the top of rectangular ductwork.

70.6.7 External Ductwork

(a) Transverse joints on external ductwork shall have recessed flanges with hat
sections to provide a continuous surface. Ductwork joints shall be sealed with
a suitable caulking compound to provide an airtight, waterproof connection.

(b) Sheetmetal work shall be constructed and installed with adequate water
drainage from the top to avoid ponding of water. Access doors, equipment
connections and similar shall be sealed waterproof.

(c) Supply and return air ductwork shall be internally insulated.

(d) External ductwork shall be finish painted immediately after installation.

70.6.8 Round/Oval Ductwork

(a) Low-pressure circular duct shall have helical locked seams and shall be rigid
in construction. Where such ductwork is exposed to public view, joints shall
be neat and flush pop riveted. Bends shall be lobster back type.

70.6.9 Air Diffuser Connections

(a) Supply air diffusers mounted in suspended ceilings shall be separately

connected to the main duct by a maximum 1500 mm length of flexible
ductwork, or rigid duct connection.

70.6.10 Ductwork Cleaning Point

(a) Ductwork cleaning points shall generally be of a type consisting of a 50 mm

diameter metal flange with a 20 mm diameter hole closed with an airtight
screwed plug through which inspection, cleaning and disinfection of the
ductwork can be carried out. Clean out points shall be fitted at a maximum of
4 m centers in fully accessible locations and shall also be fitted before and
after bends, tees and other locations with difficulties in gaining access. For
fan coil units, at least one air duct cleaning point shall be provided in each
supply air duct, and any two points at 4 m maximum distance apart.

(b) Where the cleaning sleeve penetrates the air duct, the gap shall be sealed by
an expanded foam sealing ring held in position by secure flanges. Where the
sleeve penetrates the insulation, the vapour barrier shall be maintained.
Where the sleeve penetrates the false ceilings, the sleeve shall be secured by
matching flanges.

(c) The cleaning sleeve shall be kept straight and shall terminate at a readily
accessible position. The termination flange shall bear an instruction plate
indicating an air conditioning and ventilation access point in both Chinese and
English. It shall incorporate a threaded port and a screw cap which when
removed shall allow the coupling of air duct inspection and cleaning probes.

General Materials & Workmanship Specification 12/13 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 70 – Ductwork & Fittings
 (d) Ceiling access panels shall also be provided after the confirmation of service
panels and air duct cleaning points.

(e) All joints shall be air/water tight to prevent leakage.

(f) Interior of all ductwork shall be cleaned by rotary mechanical brush. All
contaminants shall then be removed by high efficiency vacuum pumps of
sufficient degree of vacuum to ensure removal of heavier particles.

(g) The ductwork cleaning point shall be of proprietary product, so constructed

and installed that no cold bridge that may cause condensation will occur.

70.6.11 Fire Rated Ductwork

(a) Cladding associated with access panels shall be fixed to the panel or secured
in a manner that allows ease of removal and refitting without the use of tools.

70.6.12 Access Panels and Doors

(a) Access panels for inspection and maintenance shall be installed adjacent to
each fire and motorized damper, duct mounted fan, electric heater and the
like.

(b) Access doors shall be supplied and fitted with retaining chain tied back to the
frame.

(c) Multiple screw fixings shall not be allowed.

(d) All fittings and screws shall be made of brass.

70.6.13 Flanges for Ductwork

(a) Proprietary ductwork flanges shall be fastened into the associated ductwork
be spot welding. Gaskets strip shall comply with BS 476 : Part 7, Class 1 and
ductwork sealant to BS 476 : Part 7, Class 2 shall be applied at the flange
joints and corner joints respectively to ensure maximum leakage-proof.

70.6.14 Test Holes

(a) Test holes shall be provided wherever necessary for effective balancing and
testing, except where air balancing and testing or air testing stations have
been called for else where in this General Materials and Workmanship
Specification. Test holes shall be 25 mm diameter and fitted with an effective
removable seal. Test points shall be provided to all dampers and items of
equipment to enable fan duties and items to be assessed and for
commissioning of the system.

General Materials & Workmanship Specification 13/13 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 70 – Ductwork & Fittings
[this page not used]
SECTION 71 WATER HANDLING EQUIPMENT

71.1 GENERAL

(a) The Contractor shall comply with other relevant sections of this General
Material & Workmanship Specification including but not limited to the sections
which specify:

(i) Section 72 “Pipework, Fittings and Valves”;

(ii) Section 76 “Electrical Equipment and Installation”; and

(iii) Section 79 “Testing, Inspection and commissioning – Mechanical

Services”.

(b) Water Pump Equipment

(i) The installation details should be in accordance with the instructions

prepared by the manufacturer.

(ii) Pumps shall be 'Type-tested' in accordance with the requirements of

BS 599 and BS EN ISO 9906 .

(iii) Pumps and their drives shall be segregated such that failure of pump
seals shall not result in damage to the drive motors.

(iv) The Contractor shall select all pumps suitable for the scheduled duties.
Pumps shall be capable of at least 5% head increase at rated
conditions by installing a new impeller.

(v) The pump heads given in the Employer’s Drawings and the
Specification are given for guidance only and the Contractor shall
select pumps to suit the actual total resistance of respective systems.
Pump motors shall be sized to cater for the most arduous operating
condition and with 10% spare capacity.

(vi) During testing and commissioning, each pump shall deliver the
specified water flow rate within the tolerance specified on the
Employer’s Drawings and the Specification. Any deviation shall be
rectified by adjusting pump impeller size but not by throttling on the
suction/ supply lines.

(vii) All pumps shall be constructed with materials compatible with the
chemical and physical properties of the liquid to be pumped.

(c) Water Treatment Equipment

(i) Water treatment for air conditioning water systems as follows shall be
carried out to maintain water in proper 'balance' condition (pH,
hardness, total dissolved solids, total alkalinity, etc.):-

- treatment of sea water for condenser cooling to kill or inhibit marine

growth and to inhibit the formation of scale, slime and foam in the
pumps, pipework and condenser tubes;

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 71 – Water Handling Equipment
 - treatment of water being circulated between condensers and
cooling towers including the water in the tower;

y to inhibit corrosion, scaling, slime and foam formation; and

y to sterilize the water to prevent biofouling and the growth of

pathological bacteria such as “Legionella Pneumophila”;
and

- treatment of chilled water in the circulation system to inhibit

corrosion, formation of foam, scale and slime in the pipework and
evaporator tubes.

(ii) The water system shall be capable of being completely drained as

rapidly as possible and the Contractor shall provide 50 mm valve drain
outlets on all points where the main pipework is 50 mm or over.

iii) The design, installation, commissioning, testing and operation of the

water treatment system shall be carried out by a water treatment
specialist who has at least five years relevant experience. The details of
the water treatment specialist shall be submitted to the Project Manager
for review without objection.

iv) The Contractor shall supply all the necessary labour, testing equipment
and chemicals for the pre-cleaning, commissioning and testing of the
water systems, including but not limited to the chilled water supply, make
up water supply, etc. The Contractor shall also allow for continuing the
treatment during the defects liability period.

(v) During the defects liability period, the Contractor shall employ the same
water treatment specialist to carry out, at a minimum of once per month,
on-site water treatment services and water analysis to demonstrate that
the performance of the treatment system is satisfactory and conforming
with the specified treatment strategy. Test reports, related treatment,
consumption of chemicals etc. shall be forwarded each month for to the
Project Manager for review without objection.

71.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, at the date of the Letter of Acceptance.

BS 599 Methods of testing pumps

BS 417 : Part 2 Specification for galvanized low carbon steel cisterns, cistern
lids, tanks and cylinders. Metric units
BS 970 : Part 1 Specification for wrought steels for mechanical and allied
engineering purposes. General inspection and testing
procedures and specific requirements for carbon, carbon
manganese, alloy and stainless steels
BS 1564 Specification for pressed steel sectional rectangular tanks

General Materials & Workmanship Specification 2/14 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 71 – Water Handling Equipment
 BS 4213 Specification for cold water storage and combined feed and
expansion cisterns (polyolefin or olefin copolymer) up to 500 L
capacity used for domestic purposes
BS EN 1092 Flanges and their joints. Circular flanges for pipes, valves,
fittings and accessories, PN designated.
BS EN 1561 Founding. Grey cast irons
BS EN 1982 Copper and copper alloys. Ingots and castings
BS EN 4504 : Part Circular flanges for pipes, valves and fittings (PN designated).
3.3 Specification for copper alloy and composite flanges
BS EN 13835 Founding. Austenitic cast irons
BS EN ISO 9906 Rotodynamic pumps. Hydraulic performance acceptance
tests. Grades 1 and 2

71.3 SELECTION

71.3.1 Water Pumping Equipment

(a) Fresh Water Pump

(i) Pumps for chilled water circulation or other fresh water pumping duties
unless otherwise specified, shall be of one of the following types:

- centrifugal type with volute casing split on the centreline of the

shaft with suction and delivery connections flanged and fitted to the
non-removable half of the casing; or

- end suction type, the pump set shall be installed with spacer type
coupling so that the pump impeller can be dismantled from the
motor side for servicing without disruption of the pipe-work nor
dismounting the motor; or

- vertical spindle type centrifugal pump with end suction at the

bottom.

(ii) Where large static heads have to be pumped against, centrifugal type,
end suction type or the vertical spindle type shall be used in multi-
stage configurations.

(b) Saline Water Pump

(i) These pumps shall be utilized for pumping seawater, brackish well
water, or treated effluent water wherever these applications apply.

(ii) Unless otherwise specified, the configuration of saline water pumps

inside a building plant rooms shall be of the split casing type as
specified in Section 71.3.1 (a) (i) above.

(c) Chilled water pumps shall be suitable for continuous 24 hour per day 7 day
per week operation when handling water having a temperature in the range of
3°C to 30°C.

General Materials & Workmanship Specification 3/14 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 71 – Water Handling Equipment
 (d) Variable speed pumps, motor, variable frequency drives, and associated
electrical equipment shall be selected so that the design performance is
achieved with 50 Hz supply to the motor. The pump set shall be capable of
being driven at 106% of design speed with consequent increases in flow and
head, by changes to the VFD speed maximum settings only.

(e) Pump motors shall be completely non-overloading at the specified design flow
with the maximum impeller diameter which the pump casing can
accommodate.

(f) At design conditions, pump efficiency shall not be less than 0.8. The
Contractor shall select the pump to provide, maximum available flow at break
off and the maximum available pressure at shut off exceed design flow and
pressure respectively by approximately 30%, for the proposed impeller.

(g) Pumps operating in parallel shall have continuously rising heads with
decrease in flow, and equal shut off heads.

(h) Pumps shall be selected for a casing pressure of not less than 1.6 MPa.

(i) Secondary chilled water pumps and associated motors shall be selected to
suit variable volume and variable frequency operation under all operating
conditions.

(j) Chilled water pumps shall be mounted either horizontal or vertical to suit the
chiller plant. Delivery flanges shall be cast on to the fixed half to allow full
accessibility to all internal parts without disturbing the alignment of the pump
set or breaking the pipe joints.

(k) Pumps shall be designed so that no thrust is transmitted to the driving motor.
The maximum pump speed shall not exceed 1,500 rpm. End suction type
shall not be used. The pump shall have external flush mechanical seals. The
pump bearings and mechanical seals shall be capable of being serviced
without disturbing the piping connections or electrical motor connections.

71.3.2 Water Treatment Equipment

(a) Basic Requirements

(i) Biocides shall be used to inhibit the growth of marine organisms

throughout the system. Biocides shall inhibit the formation of scale and
slime by acting as an efficient dispersant. Biocide treatments shall be
carried out at every 2 or 3 days and shall provide a 6-ppm concentration
of biocide solution for approximately 1 hour, sufficient to kill all
organisms. Continuous dosages shall not be applied at lower ppm levels
least they allow the organisms to build up immunity.

(ii) The specifications of the biocidal and dispersing agents for chilled water,
and fresh cooling water systems shall have the following properties:-

- pH value: approximate 6.8;

- turbidity (FTU scale): below 20 units;

- total dissolved solids (TDS): below 500 ppm;

General Materials & Workmanship Specification 4/14 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 71 – Water Handling Equipment
 - iron: below 1.0 ppm;

- copper: below 0.1 ppm;

- bacterial count: below 104 npml;

- strong biocidal properties;

- dispersing effect on deposits;

- filming properties providing a protective film to internal of pipework.

- RAT ORAL LD 50 mg/Kg not more than 3500;

- specific gravity approximates 0.98;

- non-flammable;

- easy application by chemical metering pump with or without dilution;

and

- sufficiently biodegradable not to cause environmental difficulties for

the marine life. A type acceptable and approved by the Hong Kong
Environmental Protection Department or relevant Government
Authorities.

(b) System Sizing and Design

(i) The advice of the manufacturer shall be sought on the dosages

required, together with calculation, for a specified systems water
volume.

(ii) Where variable pumping flows exist, the metering pump/pumps

concerned shall have the facility to automatically vary the amounts of
chemicals pumped in to correspond in proportion with the actual sea
water flow. This can be achieved by metering pumps that respond to
the reading of a flowrate sensor inserted into the main sea water pipe.

(iii) Variable pumping rates shall be required where a number of pumps

are 'stage' controlled or where individual pumps are being 'speed'
controlled.

(iv) Alternatively, sets of sea water pumps can be supplied with fixed
biocide input from one metering pump per main sea water pump with
inlet before the pump and as near as possible to the primary inlet sea
gate valve.

(v) Such metering pumps shall be controlled from the individual pump circuit
such that they only operate when their respective pump is operated.

(vi) Sets of pumps can also be supplied with a single source variable duty
metering pump controlled from a flow metering device placed after the
main header outlet. In such cases the chemical injection shall be
distributed to all pump inlets via solenoid valves with each controlled to
open when their respective main water pump is switched on.

General Materials & Workmanship Specification 5/14 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 71 – Water Handling Equipment
 (c) Flow Measurement and Control

(i) The flow measuring device shall be of a low flow interference inserted
velocity / static differential headed type.

(ii) The unit shall be inserted through and across the centre of the pipe in
which the fluid flow shall be measured. It shall be inserted with watertight
glands not less than length of 12 pipe diameters downstream from any
bend or other turbulence-creating feature.

(d) Biocide Storage

(i) Apart from the necessity to periodically replenish the biocide supply, the
installation shall otherwise be capable of catering for a minimum of 4
weeks unmanned automatic operation. Where the use of the biocide
manufacturer’s container is considered by the Project Manager as
inappropriate for the purpose, duplicate chemical tanks shall be provided
to the following specification.

71.3.3 Water Testing Equipment

(a) Unless otherwise specified, the water testing equipment used shall include
monitoring facilities to verify the performance of the water treatment system
offered. The monitoring facilities shall be handed over to the Project Manager
prior to the expiry of the Defects Liability Period.

(b) The equipment shall be suitable for operation with both fresh and seawater.
Plain DPD tablets and colour disc shall be provided for chlorine residual
concentration testing. A pH meter and phenol red solution and colour disc
shall be provided for pH value testing. Other relevant test kits shall include
total dissolved solid and corrosion inhibitor level tester.

71.4 MATERIALS

71.4.1 Water Pumping Equipment

(a) Fresh Water Pump for chilled water circulation

(i) Construction

Unless otherwise specified, the materials of construction of the pumps

shall be as follows:

- casing: cast iron with epoxy coating;

- impeller: gunmental (*cast iron or stainless steel);

- shaft: stainless steel;

- sleeves: stainless steel;

- casing rings: (*stainless or cast iron);

- shaft nuts: bronze;

General Materials & Workmanship Specification 6/14 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 71 – Water Handling Equipment
 - stuffing box housing: cast iron;

- glands: carbon steel; and

- lantern rings: bronze.

*final material selection subject to the review by the Project Manager

#Note 1: Stainless steel shall be used for water with temperature >28
°C.

(ii) Standards

- Casing Material
Unless otherwise specified for the above types of pumps, cast iron
shall comply with BS EN 1561.

- Impellers & Guide Rings

The impeller shall be of the enclosed type and be of leaded gunmetal
to BS EN 1982, keyed to the shaft. Renewable guide rings shall be
bronze and shall be provided in the casing, keyed to prevent rotation.

- Shaft, Sleeves and Glands

Stainless steel shall be to BS 970: Part 1 Grade 431S29, grade
316S31, ground and polished. Bronze sleeves shall comply with BS
EN 1982and shall be provided through the sealing glands to protect
the shaft from wear. The sleeves shall be keyed to prevent rotation
and secured against axial movement.

- Stuffing Boxes and Drain Piping

Cast iron stuffing boxes housing shall comply with BS EN 1561 and
shall be of ample length with bronze lined gland and neck bush, fitted
with packing reviewed by the Project Manager and lantern ring water
seal. Drain piping to remove gland leakage shall be provided.

- Mechanical Seal
Carbon rotary, ceramic stationing, Teflon packing, and stainless steel
spring and casing to BS 970 Grade SS 316.

(b) Saline Water Pump

(i) Construction

Unless otherwise specified, the materials of construction of the pumps

shall be as follows:

- casing: cast iron with epoxy coating;

- impeller: gunmetal (#see note 1);

- shaft: stainless steel;

- sleeves: stainless steel;

- casing rings: stainless steel;

General Materials & Workmanship Specification 7/14 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 71 – Water Handling Equipment
 - shaft nuts: bronze;

- stuffing box housing: cast iron;

- glands: carbon steel;

- lantern rings: bronze;

#Note 1 Stainless steel shall be used for water with temperature >28°C

(ii) Standards

- Casing
Unless otherwise indicated, the casing shall be of cast iron to BS EN
1561 or ISO 185 or better and approved.

- Impeller and Shaft Sleeve

Impeller and shaft sleeve of saline water pumps shall be of one of the
materials as below:

• zinc-free bronze to BS EN 1982 Grade PB1; or Grade CT1; or ISO

197-4;

• austenitic cast iron to BS EN 13835 Grade F1; or ISO 2892; or

• stainless steel to BS 970 Part 1, Grade 316S31.

- The shaft shall be of stainless steel to BS 970 Part 1 Grade 431S29

or Grade 316S31, ground and polished.

- Stuffing Boxes Drain Piping

Stuffing boxes shall be of ample length with bronze lined gland and
necks bush, fitted with approved packing and lantern ring water seal.
Drain piping to the nearest builder's drain for gland leakage shall be
provided. Alternatively, a mechanical seal may be offered.
Mechanical seals shall be of leak free operation. The mechanical seal
shall be the product of specialist proprietor and the materials used
shall be suitable for the pumped liquid.

(c) Pump Base-Plate

(i) The base plate shall be made of cast iron or fabricated mild steel.
Couplings shall be flexible of the steel pin and synthetic rubber bushing
type, and fitted with steel guards.

(ii) Inertia bases shall be provided where specified and equipment shall be
bolted directly to the integral concrete inertia blocks. All concrete
referred to in this section shall have a density of 2250 kg/m³.

(iii) The length and width of the inertia base shall be at least 20% greater
than the length and width of the supported equipment, and the weight of
the inertia base shall be at least twice the operating weight of the
equipment supported.

General Materials & Workmanship Specification 8/14 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 71 – Water Handling Equipment
 (d) Flanged Connections

(i) Pumps shall have flanged connections conforming to the Table of BS

EN 1092 and BS EN 4504 : Part 3.3 as appropriate to the maximum
working pressure. Taper pieces shall be provided where necessary for
connection to pipe-work.

(e) Water Filters

(i) The materials used in water filters shall not corrode or cause corrosion in
the water and shall generally be as specified for water-cooled
condensers and water chillers.

(f) Feed and Expansion Facility

(i) General

For the purpose of this General Material & Workmanship Specification,

the following definitions shall apply:

- cistern - an open top vessel; and

- water tank - a closed vessel.

(ii) Types of Cistern and Tank

- Cisterns and tanks shall be of one of the following types as below:

- Welded or riveted mild steel, to BS 417 : Part 2 Grade A and to be

heavily galvanized after manufacture.

- Pressed steel sectional to BS 1564, heavily galvanized after

manufacture.

- Fiberglass or plastics, for cisterns not exceeding 500-litre capacity

to BS 4213.

(iii) Pressed steel tanks shall be of the externally flanged type and complete
with all necessary tie rods. Galvanized mild steel cisterns and pressed
steel tanks shall be cleaned and painted internally with two coats of an
approved bituminous or epoxy solution or shall receive other such
internal treatment as indicated.

(iv) Covers to Cisterns

Each cistern shall be provided with a loose cover formed in sections not
exceeding 2 m long and 1 m wide. Covers for plastic or fibre-glass
cisterns shall be of the same material as the cistern body.

(v) Connections

Connections to mild steel cisterns and tanks shall be made by means of

bossed, screwed flanges or pads and studs. Connections on mild steel
cisterns shall be welded before galvanizing. Flanges shall comply with
BS EN 1092 and BS EN 4504 : Part 3.3 PN6 to PN40 as appropriate.

General Materials & Workmanship Specification 9/14 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 71 – Water Handling Equipment
71.4.2 Water Treatment Equipment

(a) Chemical Tanks

(i) The Contractor shall, provide two (number) chemical mixing tanks of
ultra violet resistant round moulded fibre glass or polyethylene. Each
tank shall not be less than 180 litres capacity.

(ii) The tanks shall be suitable for the mixing the chemicals specified and
though normally operated at ambient plantroom temperatures, they shall
nevertheless be suitable for solutions at temperatures of up to 400oC.

(iii) The tanks shall be complete with covers of high rigidity fibreglass or
polyethylene having suitable molded recesses to support mountings of
metering pump, agitator and liquid level controller switch.

(iv) The tanks shall be graduated in 10 litre steps.

(v) Each tank shall have a strong flat bottom providing adequate support
when full. The outer perimeter of the tank shall not be forced up by
water pressure causing the bottom to bulge.

(b) Chemical Tube Connection to the Circulation System

(i) Unless otherwise specified, the Contractor shall allow for drilling and
tapping into the delivery pipe at points near to the water intake and
installing a suitable sized PVC valve complete with connectors for
attachment of the chemical tubes from the metering pumps.

(c) Make Up Water Supply to Chemical Tanks

(i) Unless otherwise specified, the Contractor shall provide a 18 mm bib tap
situated over each chemical tank. The Contractor shall provide a
suitable supply to these bib taps with pipework securely fixed to the
walls. A 25 mm mains valved supply shall be provided within a 30 m
pipe run of the tanks. The Contractor shall supply suitable lengths of
chemical resistant flexible hose from bib taps to the tanks to facilitate the
filling operation.

(d) Chemical Metering Pump

(i) In conjunction with the chemical tanks, the Contractor shall provide
panel or tank-top mounted high efficiency metering pumps (one per
tank) capable of pumping from 2 litres to 90 litres of solution each in 1
hour. Chemical pumps shall have an on-off switch and a protection fuse.

(ii) The pumps shall be suitable for 100:1 output range facilitated by means
of independently variable stroke length and stroke frequency.

(iii) Pump housings shall be of corrosion resistant glass fibre reinforced

polypropylene and all electrical/ electronics components shall be
encapsulated. If necessary, anti-siphon/pressure release valve
mechanisms shall be provided to ensure anti-siphon protection plus
priming ease, even under pressure.

General Materials & Workmanship Specification 10/14 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 71 – Water Handling Equipment
 (iv) The pumps shall have an acrylic/polypropylene pump head,
PVC/polypropylene fittings, ceramic valve balls, metal reinforced Teflon
diaphragm, Teflon seal rings and liquiform face, anti-siphon mechanism.
The discharge tubes shall be 10 mm internal diameter and of suitable
PVC to transport the solutions involved.

(v) The pump suctions shall be mounted into the tank using a PVC suction
tube assembly that shall prevent the suction tube becoming wrapped
around the agitator shaft. The end of the pump suction tube shall not
extend beyond the bottom of the PVC tube shield.

(e) Chemical Tank Agitator

(i) The motor casing and screws shall be manufactured of non ferrous
metal.

(ii) The Contractor shall supply and install into the chemical mixing tank
cover one agitator assembly per mixing tank. This shall consist of a
fractional HP motor driving a stainless steel shaft and neoprene with
bronze hub impeller. The shaft shall be of suitable length to suit the
depth of the solution in the mixing tank.

(f) Chemical Tank Liquid Level Switch

(i) In order to prevent the metering pump and agitator from running if the
mixing tank is empty, the Contractor shall supply and install into each
tank cover a suitable liquid level switch and control system. A visual and
audio alarm shall also be provided at the control/indication panel.

(ii) The level switch shall be contained in a corrosion resistant assembly of

glass- reinforced polypropylene. It shall have a PVC float tube, foamed
polypropylene float and encapsulated reed switch.

(iii) In each case, there shall be a float protector to prevent false actuation
due to turbulence. An extra low voltage transformer shall be
incorporated to provide the supply to the reed switch for safety.

(iv) The liquid level switch casing shall be manufactured from corrosion
resistant material.

(v) In order to prevent the metering pump and agitator from running if the
mixing tank is empty, the Contractor shall supply and install into each
tank cover a suitable liquid level switch and control system. A visual and
audio alarm shall also be provided at the control/indication panel.

(g) Electricity Supply

(i) Unless otherwise specified, the electricity supply for the metering
pumps, agitators and level switch assemblies shall be operated with 220
V single phase 50 Hz supply.

General Materials & Workmanship Specification 11/14 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 71 – Water Handling Equipment
 (h) Automatic Operation

(i) The installation shall be capable of a minimum of 4 weeks unmanned

automatic operation. Where the use of the biocide manufacturer’s
container is in the opinion of the Project Manager inappropriate for the
purpose, duplicate chemical tanks shall be provided.

(i) Flow measuring device

(i) The flow measuring device shall be of the velocity/static differential

headed type, inserted into the water stream with low flow interference.

(ii) The unit shall be inserted through and across the centre of the pipe in
which the fluid flow is to be measured. It shall be inserted with water
tight glands not less than 12 diameters downstream from any bend or
other turbulence creating feature.

71.5 SUBMISSIONS

71.5.1 Particulars of Water Handling & Water Treatment Equipment

(a) The following particulars of the proposed equipment shall be submitted to the
Project Manager for review without objection:-

(i) Contractor’s Drawings showing the construction and assembly of all

water handling & water treatment components including accessories and
pump room arrangement;

(ii) test certificates with performance curves giving values of pump flow rate
and pump efficiency;

(iii) materials of chemical agents, chemical tanks, water filters and

associated accessories;

(iv) prior to ordering, calculations for the actual total resistance of each
system, based on the actual pipe runs and equipment offered; and

(v) details of the dosage required, together with calculations, for a given
system water volume, prior to installation.

General Materials & Workmanship Specification 12/14 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 71 – Water Handling Equipment
71.6 WORKMANSHIP

71.6.1 Water Pumping Equipment

(a) Driving Arrangement – The pump and motor shall be direct coupled and
mounted on a substantial machined bed plate of cast iron or of fabricated mild
steel. Couplings shall be flexible of steel pin and synthetic rubber bushing
type, accurately aligned, and fitted with guards. The whole assembly including
the bed plate shall be designed and supplied by the pump manufacturer.
Couplings with spacers shall be used for end suction pumps so that the
impeller can be dismantled from the motor side for servicing without disrupting
the pipework nor dismounting the motor.

(b) Valves – Each pump shall be provided with suction and delivery isolation
valves and where connected in parallel with other pumps, non-return check
valves.

(c) Vibration isolators in pipework – Unless otherwise specified, all pumps shall
be connected through neoprene vibration isolators at suction and delivery
such that pump vibration is not transferred to the remainder of the system.

Vibration isolators shall be of the same diameter as the pipes into which they
shall be fitted. Vibration isolators shall be as detailed in Section 75 of this
General Materials and Workmanship Specification.

(d) Stand-by Pumps – Where standby pumps are indicated with automatic
change-over, the change-over shall be initiated by means of flow sensing
devices of an approved pattern. The necessary non-return valves shall be
incorporated in the pipework which interconnects such pumps.

(e) Gauges – Each pump shall be provided with two pressure gauges, one
connected to the suction side and one to the discharge side.

71.6.2 Water Treatment Equipment

(a) The Contractor shall appoint a specialist firm to provide water treatment for
chilled water systems.

(b) The chilled water distribution system shall be completely flushed out, pre
cleaned and the water treatment systems fully commissioned prior to the initial
start-up of the chiller plant.

(c) Chemicals used for water conditioning, and the methods to store and feed the
chemicals into the system, shall comply with local by-laws and relevant
regulations.

(d) Storage tanks shall be fabricated from glass-reinforced plastics (grp) unless
otherwise shown on the Employer’s Drawings.

(e) Chemicals used for the water conditioning shall have no detrimental effect on
non-metallic materials, such as elastomeric or plastics products used in the
system.

(f) Dosing and metering pumps shall inject the chemicals into the system by
means of flexible plastics piping and an injector fitting.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 71 – Water Handling Equipment
 (g) The water treatment programme shall provide corrosion control for the water
circuit(s) by use of suitable corrosion inhibitors and pH control.

(h) Overall corrosion rate shall not exceed 5 micro-metres per year for steel
components of the circuit in continuous contact with the conditioned water.

(i) Provide suitable comparative corrosion test coupons representing the metals
in the treated circuit(s) for the purpose of measuring overall corrosion and
pitting rates.

(j) Formation of adherent mineral deposits in the form of scale which cannot be
flushed from heat transfer surfaces shall be prevented.

General Materials & Workmanship Specification 14/14 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 71 – Water Handling Equipment
SECTION 72 PIPEWORK, FITTINGS AND VALVES

72.1 GENERAL

(a) The Permanent Works and materials specified below shall comply with the
sections stated, unless otherwise stated in this section:

(i) Section 71 “Water Handling Equipment”;

(ii) Section 73 “Thermal Insulation”;

(iii) Section 78 “Instruments”; and

(iv) Section 79 “Testing, Inspection and Commissioning – Mechanical

Services”.

(b) Pipework, fittings, valves, vents, expansion devices and the like, associated
with all water services in this project shall be suitable for a minimum operating
pressure of 1.6 MPa.

72.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, at the date of the Letter of Acceptance.

ASME/ANSI B31 Piping Fabrication and Examination

ISO 7-1 Pipe threads where pressure-tight joints are made on the threads
- Part 1: Dimensions, tolerances and designation
ISO 65 Carbon steel tubes suitable for screwing in accordance with ISO
7-1
ISO 7005 Metallic flanges
ISO 9328 Steel plates and strips for pressure purposes - Technical delivery
conditions
ISO 9329 Seamless steel tubes for pressure purposes - Technical delivery
conditions
ISO 9330 Welded steel tubes for pressure purposes - Technical delivery
conditions
BS 476 Fire tests on building materials and structures.
BS 2779 Specification for pipe threads for tubes and fittings where
pressure-tight joints are not made on the threads
BS 2879 Specification for draining taps (screw-down pattern)
BS 3100 Specification for steel castings for general engineering purposes
BS 3974 Specification for pipe supports.

General Materials & Workmanship Specification 1/17 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
 BS 4504 Circular flanges for pipes, valves and fittings (PN designated).
Specification for copper alloy and composite flanges
BS 5150 Specification for cast iron gate valves
BS 5152 Specification for cast iron globe and globe stop and check valves
for general purposes
BS 5154 Specification for copper alloy globe, globe stop and check, check
and gate valves
BS 6129 Code of practice for the selection and application of bellows
expansion joints for use in pressure systems. Metallic bellows
expansion joints
BS 6755 Testing of valves
BS 5351 Specification for steel ball valves for the petroleum,
petrochemical and allied industries
BS 7350 Specification for double regulating globe valves and flow
measurement devices for heating and chilled water systems
BS EN 593 Industrial valves. Metallic butterfly valves
BS EN 970 Non-destructive examination of fusion welds. Visual examination
BS EN 1057 Copper and copper alloys. Seamless, round copper tubes for
water and gas in sanitary and heating applications
BS EN 1092-2 Flanges and their joints. Circular flanges for pipes, valves, fittings
and accessories, PN designated. Cast iron flanges
BS EN 1561 Founding. Grey cast irons
BS EN 1563 Founding. Spheroidal graphite cast iron
BS EN 1982 Copper and copper alloys. Ingots and castings
BS EN 10028 Specification for flat products made of steels for pressure
purposes.
BS EN 10029 Specification for tolerances on dimensions, shape and mass for
hot rolled steel plates 3 mm thick or above
BS EN 10051 Specification for continuously hot-rolled uncoated plate, sheet
and strip of non-alloy and alloy steels. Tolerances on dimensions
and shape
BS EN 10213 Technical delivery conditions for steel castings for pressure
purposes.
BS EN 10216 Seamless steel tubes for pressure purposes. Technical delivery
conditions.
BS EN 10217 Welded steel tubes for pressure purposes. Technical delivery
conditions.
BS EN 10259 Cold-rolled stainless and heat resisting steel wide strip and
plate/sheet. Tolerances on dimensions and shape
BS EN 12163 Copper and copper alloys. Rod for general purposes
BS EN 12164 Copper and copper alloys. Rod for free machining purposes

General Materials & Workmanship Specification 2/17 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
 BS EN 12165 Copper and copper alloys. Wrought and unwrought forging stock
BS EN 12167 Copper and copper alloys. Profiles and rectangular bar for
general purposes
BS EN 12334 Industrial valves. Cast iron check valves
BS EN 12420 Copper and copper alloys. Forgings
BS EN 12449 Copper and copper alloys. Seamless, round tubes for general
purposes

72.3 MATERIALS

72.3.1 Fabrication

(a) Valves, vents, unions, pipework accessories and the like shall comply with the
requirements of this General Materials and Workmanship Specification and
the Employer's Drawings and where otherwise required for the proper layout,
valving and operating of the entire installation.

(b) Chilled water pipework up to 125 mm diameter shall be black mild steel to ISO
65 “medium” grade.

(c) Chilled water pipework over 125 mm up to and including 300 mm diameter
shall be black mild steel to ISO 9328, ISO 9329 and ISO 9330 with wall
thickness not less than 6 mm.

(d) Chilled water pipework above 300mm diameter shall be black mild steel to BS
EN 10216 and BS EN 10217 ERW Grade 320.

(e) Refrigerant pipework shall be refrigeration grade copper tube material to BS

EN 1057 (R250 or R290). Pipework shall be fully annealed up to 18mm
diameter, and hard drawn from 22mm to 108mm diameter. Refrigeration grade
copper tube shall be to ASME/ANSI B31.5-1987.

(f) Chilled water pipework above 300mm diameter shall have the following
minimum wall thickness for the nominated pipework sizes:

(i) 350mm to 400 mm 8.0mm

(ii) 450mm to 500 mm 8.8mm

(iii) 600mm to 700 mm 10.0mm

(iv) 800mm to 900 mm 11.0mm

(v) 1000mm 12.5mm

(vi) 1200mm 14.0mm

(g) Flexible joints shall be designed to accommodate all anticipated building and
thermal movements. The Contractor shall be responsible for the design and
selection of appropriate flexible joint materials to ensure that the entire water-
side system operation will not be damaged by any anticipated movements.

General Materials & Workmanship Specification 3/17 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
72.3.2 Joints

(a) Flanged joints and connections shall comply with BS 4504, PN 16.

72.3.3 Bellow Expansion Joints

(a) Bellows type expansion joints shall be provided for all pipework passing
through building expansion joints.

(b) Joints shall comprise thin wall multi-plied omega formed convoluted bellows of
stainless steel material to BS EN 10029, 10051 and 10259 of appropriate
type.

(c) Bellow expansion joints shall be provided with a close fitting stainless steel
internal liner to reduce turbulent flow.

(d) End terminations shall be carbon steel threaded male to ISO 7-1 or carbon
steel flanges to ISO 7005 Standard to suit the line pressure.

(e) Expansion joints shall be of stainless steel multi-bellows type complete with
necessary guides as recommended by the manufacturer to give a working life
of not less than 20 years.

(f) Design working pressure shall not be less than 2,000 kPa unless otherwise
specified.

(g) Expansion joints shall be installed in strict accordance with the manufacturer’s
recommendations.

(h) The lateral and axial movements of the expansion joints shall not be less than
±6 mm, and shall be capable of accommodating the thermal expansion and
contraction of the system.

72.3.4 Hangers and Brackets

(a) Pipework supports shall comply with BS 3974 : Part 1, 2 and 3.

(b) Hangers for pipework up to and including 100 mm shall be split ring with
provision for vertical adjustment. Hangers for pipework sized 125 mm and
larger shall be of the clevis type.

72.3.5 Movement Facilities and Anchors

(a) Suitable provision shall be made for structural movement as well as thermal
expansion and contraction.

(b) Articulated couplings, bellows, loops or similar shall be provided on all

pipework that crosses any structural movement joint.

(c) Anchors & guides and metallic bellows shall comply with BS 3974 : Part 2 and
BS 6129 : Part 1 respectively.

(d) Anchors shall be constructed to withstand the higher thrust during piping
hydraulic pressure test.

General Materials & Workmanship Specification 4/17 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
72.3.6 Sleeve and Cover Plates

(a) Sleeves shall be of galvanised or copper pipe.

72.3.7 Drain Points and Vents

(a) All automatic air vents shall also act as automatic vacuum breakers during
drain down.

(b) Manual vents shall be of the plug cock type.

72.3.8 Strainers

(a) Strainers shall be fitted on the suction side of each pump and where specified
or shown on the Employer's Drawings. Strainers shall be of the basket or Y
type as shown on the Employer's Drawings having grade 316 stainless steel
body and cage with a perforation size of 1.5 mm woven mesh for chilled water
and a size of less than 1.5mm mesh for seawater. The straining cage area
shall be not less than 5 times the cross-sectional area of the pipe.

(b) A hose cock shall be provided at each strainer.

(c) Strainers for chilled water system up to 17 bar and size DN 15 to DN 25 shall
be pressed brass.

(d) Strainers for size DN 32 and DN 40 shall be bronze body, screwed ends, with
stainless steel screen, brass cap, neoprene based and suitably reinforced cap
gasket.

(e) Strainers DN 50 to DN 200 shall be cast iron flanged body to BS 4504, PN 16,
with stainless steel strainer screen, cast iron cap, neoprene based and
suitably reinforced cap gasket.

(f) Strainers DN 250 and above shall be cast steel flanged pot-type with scantling
as for DN 200.

72.3.9 Valves

(a) General

(i) The Contractor shall supply and install all control, drain, vent, check,
pressure relief, throttling, isolation, bypass and other valves to suit the
Works.

(ii) All chilled water valves shall be suitable for a minimum working pressure
of 1.2 MPa. Compressed air valves shall be suitable for a minimum
working pressure of 1.7 MPa.

General Materials & Workmanship Specification 5/17 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
 (iii) As a minimum, valves shall generally comply with the following
standards or suitable equivalent:

- gate valves : BS 5150, BS 5154;

- globe valves : BS 5152, BS 5154;

- butterfly valves : BS EN 593; and

- check valves &

silent check valve : BS EN 12334, BS 5154.

(iv) As a minimum, materials used in the construction of valves shall comply

with the following standards or suitable equivalent:

- copper alloy ingots and castings : BS EN 1982;

gunmetal BS EN 1982 LG2;

- copper alloy forging stock and : BS EN 12165,

forgings BS EN 12420;

- copper alloy rods and sections : BS EN 12163,

BS EN 12164,
BS EN 12167;

- flake graphite cast iron : BS EN 1561;

grey cast iron BS EN 1561 Grade 220;

- stainless steel : BS EN 970 SS316;

- spheroidal graphite (SG) : BS EN 1563;

cast iron (ductile iron)

- carbon and alloy steel : BS EN 10028, BS EN 10029

- steel castings :

- pressure purposes : BS EN 10213;

non-pressure purposes : BS 3100.

(v) Unless otherwise reviewed without objection by the Project Manager:

- flanged connections shall be a minimum PN 16 to BS EN 1092-2; and

- screwed connections shall comply with BS 21, BS 2779 or suitable

equivalent.

(vi) Valves shall be tested to BS 6755 or suitable equivalent.

(vii) Valves bodies shall incorporate cast in direction arrows.

(viii) Valves designed for manual operation shall be provided with hand
wheels or other suitable device. Ball valves may use levers. Drain cocks
and draining taps may use a diamond head or similar. Unless required to
suit Relevant Authority requirements, valve handles shall rotate in a
clockwise direction to close.
General Materials & Workmanship Specification 6/17 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
 (ix) Valve handles shall be cast iron, die cast aluminium alloy or suitable
equivalent except that valves up to ∅50 mm may be fitted with moulded
polymer handles. The finish of handles shall be smooth.

(x) Valve handles shall clearly marked with "open" and "close" direction
arrows and labelling.

(xi) Valves of identical size and type and of similar duty shall be
interchangeable.

(b) Chilled Water Valves

(i) Gate valves shall comply with the following:

- usage : isolation;

- minimum construction standard:

Construction Up to ∅50 mm ∅65 mm and

above
body Gunmetal grey cast iron
wedge gunmetal bronze trim
seat gunmetal bronze trim
stem brass brass

- configuration:

Configuration Up to ∅50 mm ∅65 mm and

above
ends screwed flanged
spindle inside inside
bonnet screwed bolted

- gate valves with roll grooved ends are acceptable.

(ii) Ball valves shall comply with the following:

- usage : isolation or throttling;

- minimum construction standard:

Construction Up to ∅50 mm
body bronze
ball chrome plated bronze
seat teflon
stem stainless steel

- configuration:

Configuration Up to ∅50 mm
ends screwed

General Materials & Workmanship Specification 7/17 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
 (iii) Globe valves, including oblique pattern globe valves, shall comply with
the following:

- usage : isolation or throttling:

- minimum construction standard:

Construction Up to ∅50 ∅65 - ∅100 ∅125 mm

mm mm and above
body gunmetal cast iron cast iron
disc gunmetal gunmetal cast iron
seat gunmetal gunmetal ring gunmetal ring
stem brass brass brass

- configuration:

Configuration Up to ∅50 ∅65 - ∅100 ∅125 mm

mm mm and above
ends screwed flanged flanged
spindle inside inside inside
bonnet screwed bolted bolted

- these requirements also apply to chilled water control valves and

globe valves used for balancing, flow measurement and similar
except that spindles shall be rising stem; and

- as a minimum, Works associated with double regulating globe valves

shall comply with the requirements of BS 7350.

(iv) Butterfly valves shall comply with the following:

- usage : isolation or throttling;

- minimum construction standard:

Construction ∅50 - ∅150 mm ∅200 -∅ 900 mm

body grey cast iron grey cast iron
disc stainless steel grey cast iron
seat EDPM/nitrile EDPM/Nitrile
shaft stainless steel stainless steel

- configuration:

Configuration Up to ∅50 mm ∅65 mm and

above
shaft stainless steel stainless steel
body wafer wafer
actuator 10 position lever worm gear

- butterfly valves with lugged, flanged and roll grooved ends are
acceptable except that butterfly valves used for dead end service
shall be double flanged.

General Materials & Workmanship Specification 8/17 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
 (v) Eccentric plug valves shall comply with the following:

- usage : isolation or throttling;

- minimum construction standard:

Construction ∅65 -∅ 300 ∅350 -∅ 500 ∅600 mm

mm mm and above
body grey cast iron grey cast iron grey cast iron
plug coating EDPM/nitrile EDPM/nitrile EDPM/nitrile
gasket epoxy nickel nickel
plug SG iron SG iron grey cast iron

- configuration:

Configuration ∅65 - ∅300 ∅350 - ∅500 ∅600 mm

mm mm and above
ends flanged flanged flanged
actuator worm gear worm gear worm gear
bonnet bolted bolted bolted

(vi) Swing check valves shall comply with the following:

- usage : non return;

- minimum construction standard:

Construction Up to ∅50 mm
body gunmetal
disc gunmetal
seat gunmetal
hinge gunmetal

- configuration:

Configuration Up to ∅50 mm
ends screwed
cap screwed

(vii) Silent check valves shall comply with the following:

- usage : non-return;
- minimum construction standard

Construction ∅65 mm and above

Body grey cast iron
Disc bronze
Seat bronze
spring stainless steel

General Materials & Workmanship Specification 9/17 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
 - configuration:

Configuration ∅65 mm and above

Ends flanged

(viii) Dual flap valves shall comply with the following:

- usage : non return;

- minimum construction standard:

Construction ∅65 mm and above

Body grey cast iron
Disc bronze
Seat EDPM/nitrile
pin/spring stainless steel
- configuration:

Configuration ∅65 mm and above

ends wafer

(c) Town Gas Valves

(i) Valves associated with the town gas installation shall comply with
Relevant Authority requirements.

(ii) As a minimum, town gas isolation valves shall be ball valves complying
with BS 5351.

(d) Miscellaneous Valves

(i) Ball float valves shall comply with the following:

- minimum construction standard:

Construction Up to ∅50 mm
body gunmetal
stem gunmetal
washer nitrile or similar
lever gunmetal
float copper

- configuration:

Configuration Up to ∅50 mm
ends screwed
bonnet screwed

General Materials & Workmanship Specification 10/17 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
 (ii) Automatic air vents shall comply with the following:

- minimum construction standard:

Construction Chilled Water Sea Water

body cast iron zinc free bronze
valve ball polyurethane or 316 stainless steel
similar
orifice stainless steel 316 stainless steel
springs stainless steel 316 stainless steel

- configuration:

Configuration Chilled Water Sea Water

end screwed (flanged screwed (flanged
above ∅50 mm) above ∅50 mm)
bonnet/cover bolted bolted

(iii) Drain cocks shall comply with the following:

- minimum construction standard:

Construction Chilled Water Sea Water

(∅32 mm and (∅32 mm and
above) above)
body gunmetal zinc free bronze
plug gunmetal zinc free bronze
gland packing graphite or similar (to suit application)

- configuration:

Configuration Chilled Water Sea Water

(∅32 mm and (∅32 mm and
above) above)
End screwed screwed
head diamond diamond
(no lockshield) (no lockshield)

- suitable UPVC valves may be used in lieu of zinc free bronze valves
for sea water subject to review without objection by the Project
Manager.

(iv) Draining taps shall comply with the following:

- draining taps up to ∅25 mm shall be constructed from bronze for

chilled water and zinc free bronze for sea water and shall comply with
BS 2879;

- draining taps shall be provided with diamond heads without a

lockshield arrangement; and

General Materials & Workmanship Specification 11/17 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
 - suitable UPVC valves may be used in lieu of zinc free bronze valves
for sea water subject to review without objection by the Project
Manager.

(v) Chilled water gauge cocks shall be of the bronze ground plug type with
lever handle. Sea water gauge cocks shall be similar except that they
shall be manufactured from zinc free bronze.

72.3.10 Flow Limiter

(a) Flow limiters shall incorporate stainless steel springs and piston cores with
calibrated openings to maintain constant flow ±5% within the pressure range
of the device.

(b) Cores shall be factory set but changeable on Site.

(c) Each flow limiter shall be fitted with pressure tapings for measuring flow rates.
Tapings shall extend beyond insulation as required.

(d) Flow limiters shall be selected so that the maximum expected pressure
differential across the device under minimum flow conditions at the
hydraulically most advantaged position in each SCHW circuit is within the
operating range of the flow limiter. It is the Contractor’s design responsibility to
select flow limiter spring ranges.

(e) A control valve shall be used for the chilled water tee-off for all retail areas,
CIP lounges and for the CRAC Units.

72.3.11 Automatic flow control valve with motorized modulating actuator

An integral means of automatic flow control valve, complete with motorized

modulating control actuator shall be provided for all connections to the AHUs and
PAUs.

(a) General

(i) The Contractor shall install control valves for AHU flow control.

(ii) Valves shall be electronic, modulating, 2-way, control devices.

(iii) Dynamic control valves shall be sized to provide the correct valve
authority to accurately control flow with +/-5% accuracy, independent of
system pressure fluctuation.

(b) Valve actuator

(i) Actuator housing shall be constructed to IP 44.

(ii) Actuator shall be driven by a 24V DC motor, and shall accept 2-10 VDC,
4-20mA, 3-point floating or pulse width modulation electric signal and
shall include resistors to facilitate any of these signals.

(iii) Actuator shall be capable of providing a 4-20mA or 2-10VDC feedback

signal to the control system.

General Materials & Workmanship Specification 12/17 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
 (iv) External LED read-out of the current valve position and the maximum
valve position setting shall be standard.

(c) Valve housing

(i) A housing for 15-40mm diameter shall be constructed of forged ASTM

(CuZn39Pb2) brass rated at no less than 25 Bar static pressure and
120ºC

(ii) A valve housing for 15-40mm diameter shall be double union

construction with a range of pipe connections available for the
appropriate pipe size.

(iii) A housing for 50-150mm diameter shall be constructed of Ductile Iron

ASTM A536-65T, Class 60-45-18 rated at no less than 4000kPa static
pressure and 120ºC

(d) Flow regulator

(i) Flow regulation unit shall be constructed in grade 316 Stainless steel
complete with hydrogenated acrylonitrile butadiene rubber. The flow
regulation unit shall be capable of controlling flow within +/-5% of each
rated flow.

(ii) Flow regulation unit shall be readily accessible, for maintenance.

(iii) Optional dual pressure/temperature test valves for verifying accuracy of

flow performance shall be available for all valve sizes.

72.3.12 Flexible Connector

Each AHU shall be connected to the chilled water pipework with flexible connectors
to prevent the transmission of vibration to the pipework. The flexible connectors
and connecting flanges shall be capable of withstanding at least 2 times the
operating pressure. Supports for piping between the AHU and the flexible
connectors shall be mounted on the base whilst supports for piping beyond the
flexible connectors shall be attached to structural members such as beams and
columns in preference to floor slabs or walls and shall be provided with rubber or
neoprene pads for vibration isolation.

72.4 SUBMISSIONS

(a) Notwithstanding the requirements of this General Materials and Workmanship

Specification, the Contractor shall fully calculate and design the requirements
for all pipework supports and hangers. Calculations shall be submitted to the
Project Manager for review without objection.

(b) Movement facilities and anchors shall be engineered to suit the particular
application. The Contractor shall submit calculations to the Project Manager
for review without objection to demonstrate the overall performance of the
pipework system including pipework expansion and contraction, anchor load
and pipework stresses.

(c) The Contractor shall submit flow limiter spring ranges for review without
objection by the Project Manager.
General Materials & Workmanship Specification 13/17 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
72.5 WORKMANSHIP

72.5.1 General

(a) Pipework shall be installed to prevent the generation or transmission of

vibration, noise, sagging, bowing, reverse pitching, liquid flashing, trapping,
deflection, hammer or strain on any connected equipment.

(b) Pipework shall be run generally parallel to the alignment of the adjacent
building surfaces and as close to the construction as practical. Pipework shall
be installed at least 40 mm away from insulation and free of unnecessary
traps and bends. Pipework shall be arranged to conform with the building
requirements and to clear all other works.

(c) Pipework over passages for plant operators and services shall be 2000 mm
minimum clear from the finished floor level wherever possible.

(d) Fixing generally shall be by metal expansion bolts for concrete and masonry.
Unless otherwise reviewed without objection by the Project Manager, power
fixings shall not be used. Applied loads shall not exceed 80% off the
manufacturer's recommended maximum applied load.

(e) Unless otherwise reviewed without objection by the Project Manager,

pipework shall be installed at a slope either towards a drain point or a vented
high point.

(f) Factory fabricated large radius elbows and bends shall be used. Mitred elbows
and bends shall not be used.

(g) Cut pipe ends shall be reamed and filed to remove burrs.

(h) Refrigeration pipes when stored or during installation whilst ends are open
shall have their ends covered with screwed metal caps, plastic caps, or
wooden plugs.

72.5.2 Joints

(a) Pipework connections under 65 mm to all pumps, valves, headers, coils,

chillers, tanks and the like shall be made up with screwed unions or rolled
grooved couplings. Pipework connections 65 mm and over shall be flanged, or
shall incorporate rolled grooved couplings. Flanges and unions shall be
located so that apparatus or equipment can be disconnected and removed
from the pipework system without having to dismantle the pipework system.
Solid final connections will not be accepted.

(b) Except where otherwise specified in this General Materials and Workmanship
Specification, joints and connections in steel pipes shall incorporate rolled
groove coupling or shall be welded and copper pipework shall incorporate
rolled groove couplings or shall be bronze welded or silver soldered.

(c) Branch connections shall be factory fabricated. Site fabricated fittings unless
of the same standard as factory fabricated fittings shall not be used.

General Materials & Workmanship Specification 14/17 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
 (d) Rolled groove couplings shall be self centering and of the flexible style
allowing up to 3° offset in pipework alignment.

(e) Rolled grooved couplings shall be used on chilled water pipework in the chiller
plant areas.

72.5.3 Hangers and Brackets

(a) The Contractor shall supply and install sufficient hangers, supports, spreaders,
beam clamps, clips, inserts and mounting devices to support all pipework
installed or modified as part of the Works, and shall be so located and
arranged as to permit free expansion and contraction of the pipework.
Supports shall be spaced in accordance with the following table:

Size of Pipe Intervals for Vertical Intervals for Horizontal Runs

(mm) Runs (Meters) (Meters)
6 1.2 0.9
9 1.2 0.9
12 1.2 0.9
15 1.8 1.2
22 1.8 1.2
28 2.4 1.5
35 .3.0 1.8
42 3.0 1.8

(b) All supports shall be connected to the building structure. No pipework shall be
supported from other services.

(c) Hangers shall be supported straight and true. Hangers shall not be located
near couplings, fittings or bends in pipework without provision for expansion.

(d) Where possible, vertical pipes shall be grouped on shaped galvanised steel
pipe racks which shall be firmly anchored and the pipework shall be bolted to
the rack.

(e) For risers and other vertical pipework not subject to expansion, the Contractor
shall use galvanised riser clamps at each floor.

(f) Hangers and brackets shall not contact other items of Plant.

(g) Insulated pipework shall be supported on the outside of the insulation, with
load spreading galvanized iron or corrosion treated steel metal plates of
suitable size and thickness between the insulation and supports to prevent the
insulation being crushed.

(h) Hanger rods and supports shall be of hot-dipped galvanized steel construction
to BS EN ISO 1461 with minimum coating thickness of 85 μm and 210 μm for
indoor and outdoor installation respectively with threaded vertical adjustment.

(i) All bolts, nuts and washers shall be electro-plated with zinc or cadium to
BS3382: Part 1 and 2 with minimum plating thickness of 25 μm.

General Materials & Workmanship Specification 15/17 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
 (j) Notwithstanding the requirements of this General Materials and Workmanship
Specification, the Contractor shall fully calculate and design the requirements
for all pipework supports and hangers. Calculations shall be submitted to the
Project Manager for review without objection.

(k) Unless otherwise reviewed without objection by the Project Manager, all
pipework throughout the Works shall be evenly supported at least twice
between each joint or connection.

72.5.4 Movement Facilities and Anchors

(a) Provision shall be made for structural movement and thermal expansion and
contraction.

(b) Articulated couplings, bellows, loops or similar shall be provided on all

pipework that crosses any structural movement joint.

(c) Movement facilities and anchors shall be engineered to suit the particular
application. The Contractor shall submit calculations to demonstrate the
overall performance of the pipework system including pipework expansion and
contraction, anchor load and pipework stresses for review without objection by
the Project Manager.

72.5.5 Sleeve and Cover Plates

(a) Unless otherwise reviewed without objection by the Project Manager, the
Contractor shall supply, install and caulk pipe sleeves for all pipework passing
through floors, walls, partitions, furring, roofs and ceilings. Where pipes pass
through walls and ceiling slabs, hot dipped G.I. sleeves shall be provided.

(b) Sleeves shall be large enough to accommodate pipework movement due to

expansion and also to accommodate insulation.

(c) The Contractor shall caulk with flexible caulking compound between pipe and
sleeve. Where sleeves are installed through fire-rated walls, infill material shall
provide the same FRP as the wall and shall be applied full length of the
sleeve. Caulking shall be retained by clamping rings and cover plates.

(d) Pipe insulation shall be sized to permit continuity of insulation through the
sleeves; pipe insulation through fire-rated walls and floor slabs shall be fire-
rated to BS 476.

72.5.6 Drain Points and Vents

(a) All drain points, manual and automatic vents, drip lines and the like shall be
piped by means of suitable copper tubing or similar to physically accessible
termination points in locations reviewed without objection by the Project
Manager.

(b) At each separate high point of the pipework and wherever air is likely to
become entrapped and adversely affect Plant performance, the Contractor
shall provide a manual valve with an automatic 6.5 mm minimum ball float
type air relief vent incorporating a stainless steel float and stainless steel seat.

(c) All vents on risers shall be fitted with a drain run to discharge 25 mm above
the nearest floor drain, funnel drain or drip pan as appropriate.
General Materials & Workmanship Specification 16/17 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
 (d) The Contractor shall supply and install manual vents at the flow and return of
each coil.

(e) Unless shown on the Employer's Drawings to be larger, the Contractor shall
provide at the low points of each circulating system minimum 25 mm diameter
screwed drains and quick fill valves complete with hose connections. The
open end of valves shall be plugged when not in use. Drain points on water
circulating systems shall be arranged to permit cleaning by means of a rod or
dismantling. Subject to review without objection by the Project Manager,
drains serving minor sections of pipework that can be drained and filled
without disruption to adjacent areas or indiscriminate discharge of water may
have screwed plugs fitted in lieu of valves.

(f) 25 mm diameter drip lines shall be provided from pump beds or pump bodies
expanded immediately after bedplates or pumps bodies if the drain holes are
less than 25 mm. At changes of direction, the Contractor shall install plugged
tees and unions for ease of cleaning and disconnection.

72.5.7 Strainers

(a) The strainers shall be easily accessible and designed to allow blowing out of
accumulated dirt without discontinuity of service and to permit removal of the
basket without the necessity to dismantle any pipework.

72.5.8 Valves

(a) Valves handles shall be installed at common centres and common heights.
Valves handles shall be clear of obstructions and shall not obstruct general
access, or access to other Plant. Valves handles shall be readily accessible.

(b) Open valves shall be plugged when not in use.

(c) Deadend service valves shall be double flanged to enable future extension
without disruption or without having to drain down.

General Materials & Workmanship Specification 17/17 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 72 – Pipework, Fittings & Valves
[this page not used]
SECTION 73 THERMAL INSULATION

73.1 GENERAL

73.1.1 General Requirement

(a) Thermal insulation and vapour barriers shall be applied to all Plant with an
external surface temperature less than the surrounding ambient air to ensure
that condensation does not occur.

(b) Insulation, adhesives and other associated materials shall be selected and
applied in accordance with the requirements of:

(i) FSD Circular Letter 4/96 and COP (2005); and

(ii) NFPA 90A.

(c) Thermal insulation shall be selected, evaluated and applied in accordance

with:

(i) BS 5422; and

(ii) BS 5970.

(d) In general, all ductwork and equipment shall be insulated if the air conveyed
within the ductwork and the air external to it have a temperature difference
which may cause an unwanted condensation either on the duct surface or
within the ductwork or result in unwanted thermal exchange between the
external and inside air of the ductwork.

(e) Thermal insulation shall be applied to chilled water pipework distribution

systems and to components within distribution systems such as valves,
storage vessels, strainer and accessories.

(f) All insulation shall fit tightly to surfaces to be covered, and all slabs and
sections shall be built up close, butting edges being mitred, chamfered or
shaped as necessary. Any minor interstices left in insulation shall be filled and
sealed with granules embedded in approved adhesive compound reviewed
without objection by the Project Manager.

(g) All materials delivered to Site shall be where appropriate, colour coded and
labelled at the factory to identify different grades, sizes and types. Insulation
shall be protected from damage after fixing.

(h) Immediately before applying insulation, clean all surfaces until these are free
of rust, scale and grease, and are thoroughly dry. Under no circumstances
should the insulation be applied to wet surfaces.

General Materials & Workmanship Specification 1/9 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 73 – Thermal Insulation
73.1.2 Standards

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as the date of the Letter of Acceptance.

BS 476 : Part 6 Fire tests on building materials and structures. Method of test
for fire propagation for products

BS 476 : Part 7 Fire tests on building materials and structures. Method of test
to determine the classification of the surface spread of flame
of products

BS 476 : Part 12 Fire tests on building materials and structures. Method of test
for ignitability of products by direct flame impingement

BS 1710 Specification for identification of pipelines and services

BS 4370 : Part 1 Methods of test for rigid cellular materials. Methods 1 to 5

BS 4370 : Part 2 Methods of test for rigid cellular materials. Methods 7 to 9

BS 5422 Method for specifying thermal insulating materials for pipes,

tanks, vessels, ductwork and equipment operating within the
temperature range -40°C to +700°C

BS 5970 Code of practice for thermal insulation of pipework and

equipment in the temperature range of -100°C to +870°C

DW/144 Specification for sheet metal ductwork

73.2 MATERIALS

73.2.1 General

(a) Each category of material being used throughout the installation shall be the
product of the same manufacturer and the same brand.

(b) As a minimum, materials shall be selected and applied in accordance with

manufacturer's recommendations.

(c) Unless otherwise indicated, all thermal insulating materials used within any
building shall, when tested in accordance with BS 476 comply with the
following:-

(i) BS 476 : Part 12 or equivalent: Ignitable T;

(ii) BS 476 : Part 6 or equivalent: Fire propagation I < 12, i1 < 6; and

(iii) BS 476 : Part 7 or equivalent: Surface spread of Flame Class 1.

General Materials & Workmanship Specification 2/9 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 73 – Thermal Insulation
 (d) Or comply with (c)(i) above and conform to Class 'O' to UK Building Regulation
1991 certified by the “Warrington Fire Test Laboratory” or approving
organizations and standards recognised by the Hong Kong Fire Services
Department.

(e) Material performance requirements for materials shall be as follows:

(i) CFC & HCFC Free Phenolic foam

temperature range: sub zero to 120°C

density:
compressive strength:
maximum conductivity:
maximum permeability:
external facing:
35 kg/m3 (unless otherwise required to
suit performance requirements including
hanger support and the like);
140 kN/m2 (BS 4370 : Part 1, method 3)
0.02 W/m.K at 20°C mean temperature
(BS 4370 : Part 2, method 7);
10μgm/Nh (independent of external facing
material); and
Aluminum foil bonded to reinforced kraft
paper with a maximum permeance of 1.2
ng/Ns.

Fire rating shall have class ‘O’ fire rating and test certificate from
independent laboratory.

(ii) Rigid fiberglass

minimum density range: not less than 48 kg/m³;

maximum conductivity: 0.033 W/mK;
external facing: Aluminum foil bonded to reinforced kraft
paper with a maximum permeance of 1.2
ng/Ns;
minimum length: not less than 0.9 m; and
minimum joint tape: not less than 100 mm wide

All fibreglass insulation shall be completely sealed at all joints. All holes,
tears, punctures, etc. made in the vapour barrier shall be completely
sealed with the same specified foil tape.

General Materials & Workmanship Specification 3/9 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 73 – Thermal Insulation
 (iii) Flexible (Semi-rigid) fiberglass

minimum density: 32 - 48 kg/m3;

minimum thickness:
maximum conductivity:
external facing:
not less than 38 mm
0.035 W/mK; and
Aluminum foil bonded to reinforced kraft
paper with a maximum permeance of 1.2
ng/Ns.

This form of insulation shall not be used on pipework.

The fiber diameter of the fibreglass shall be of 4 to 10 micron and fibre

length shall be of 3 to 6 cm.

(iv) Closed Nitrile Rubber

density: 65 kg/m3 ± 5 %
maximum conductivity: 0.035 W/mK;
maximum permeability: 0.28 μgm/Nh; and
(without additional vapour barrier foil)
maximum operating temperature: > 80°C

No putrefaction and mildew shall form on the insulation material. The

water absorption properties of the insulation shall be of not more than
1.5% after 28 days.

The Contractor shall provide a separate vapour barrier with a

permeance less than 3 ng/Ns to the surface of all insulation unless it can
be demonstrated that insulation itself provides an adequate barrier.
Vapour barriers shall be continuous over the entire surface being
protected.

Vapour barriers applied as a liquid shall be water based.

(v) Polystyrene Insulation

Preformed of slab polystyrene shall only be used where specified.

Polystyrene insulation shall be of the required thickness to meet with the

thermal insulation values stated in Table 73.4.

The material shall be of the type which is defined as ‘non-self

combustible’. Fire rating shall have Class ‘O’ fire rating and test
certificate from independent laboratory.

General Materials & Workmanship Specification 4/9 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 73 – Thermal Insulation
 (vi) Free CFC, HCFC and HCF Polyurethane Foam Insulation

minimum density range: 48 kg/m³;

temperature range:
compressive strength:
maximum conductivity:
close cell content:
Sub zero to 80°C
245kN/m2 (BS4370 : Part 1, method 3)
0.024 W/m.K at 20°C mean temperature;
and
95% minimum (BS 4370 : Part 2, method
10)

The insulation panel shall be laminated at factory with a minimum of 60-

micron thick aluminium foils on both sides. The aluminium foil shall be
embossed and coupled with a 2g/m2 layer of polyester paint. The
aluminium foil shall comply with the following requirement:

aluminum with pureness 98.8% (Aluminum Alloy 8079)

thickness 60µm
tensile strength (DIN 50154) > 60N/m2
elongation (DIN 50154) > 8%

The insulation panel together with the above-specified aluminium foils

shall achieve condensation control without any additional vapour barrier
foil.

73.3 SUBMISSIONS

73.3.1 General

(a) The Contractor shall submit samples of each type of insulation for review
without objection by the Project Manager, prior to placing any order for
insulation.

(b) Fire Certificate from FSD shall be submitted for Project Manager review
without objection.

(c) Sample shall be submitted for Project Manager approval in prior ordering.

73.4 WORKMANSHIP

73.4.1 General Requirement

(a) The Contractor shall allow sufficient clearance around Plant to enable the
installation of external thermal insulation.

(b) Insulation shall not be applied when the surface being lagged is wet or damp.

(c) An independent lining of insulation shall be applied to each adjacent or parallel

section of Plant.

General Materials & Workmanship Specification 5/9 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 73 – Thermal Insulation
 (d) Lap joints are preferred for joining sections of insulation together. Butt joints
may be provided if all joints are vapour sealed with a vapour barrier mastic
coating.

(e) Joints shall be wrapped with 150 mm wide adhesive tape or equivalent.

(f) Insulation joints shall not be located in sleeves or at hangers.

(g) Insulation of pipes and ducts passing through fire barriers shall be fire
resistant and all gaps around shall be caulked with fire resistant material.

(h) Where sheathing is applied to insulation, the seams shall be angled away from
view whenever practical.

(i) Immediately before applying insulation, clean all surfaces until these are free
of rust, scale and grease, and are thoroughly dry. Under no circumstances
should the insulation be applied to wet surfaces.

(j) A minimum of 10% of insulation installation workers shall have a certificate

from and have satisfactorily completed, relevant thermal insulation installation
courses organised by recognized organisations such as Hong Kong Institution
of Engineers (HKIE), and Air-conditioning & Refrigeration Association of Hong
Kong (ACRA) etc.

73.4.2 Ductwork

(a) Ductwork shall be externally lagged to meet thermal insulation requirements.

(b) In air conditioned areas, including sealed risers and concealed spaces within
such areas, external insulation shall be a minimum 25 mm thick 32 kg/m³ semi
rigid fiberglass. In non-airconditioned or partially air conditioned areas,
external insulation shall be a minimum 50 mm thick 48 kg/m³ semi rigid
fiberglass. External insulation shall be complete with a bonded facing of
aluminum backed reinforced kraft paper.

(c) In addition to the requirements for thermal insulation specified in the

Specification, internally lined ductwork shall comply with the requirements for
acoustically lined ductwork as specified in this General Materials and
Workmanship Specification.

(d) The Contractor shall provide thermal insulation on unlined ductwork adjacent
to or surrounding volume control dampers, fire dampers and similar
components to suit thermal insulation criteria specified in this General
Materials and Workmanship Specification.

(e) The Contractor shall ensure that cold bridging via fixings shall not occur.

(f) The Contractor shall secure insulation to ducts with adhesive applied with 150
mm brush widths at 300 mm intervals. Insulation shall be fixed with pins and
clips to prevent sagging. Perforations caused by fixing pins and clips or similar
shall be vapour sealed.

General Materials & Workmanship Specification 6/9 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 73 – Thermal Insulation
 (g) Insulation shall be cut so that longitudinal and circumferential seams are
covered with a minimum of 75 mm vapour barrier overlap. 150 mm wide
vapour proof adhesive tape strips may be used in lieu of vapour barrier
overlaps. Tying cord or bands at 900 mm centres shall be used until adhesive
sets. The Contractor shall ensure a vapour tight installation at all joints.

(h) Flexible connections shall be wrapped with insulation overlapped and secured
at both ends to solid ductwork using metal bands.

73.4.3 Fan Coil Units and Packaged Air Conditioning Units

(a) Where acoustic insulation is not required, the entire unit housing shall be
internally insulated with 25 mm of 32 kg/m³ density fiberglass blanket or 25
mm of 50 kg/m³ mineral wool blanket. Insulation shall be covered with
perforated aluminum foil bonded to reinforced kraft paper.

73.4.4 Pipework

(a) The Contractor shall insulate all supply and return mains, headers, branches,
risers, drips, runouts, pump suction and discharge, pipework fittings, flanges,
valves, expansion and movement devices, flexible connections and similar
Plant associated with the chilled water system.

(b) Hangers, supports, anchors, drains, vents and similar shall be insulated to suit
the thermal insulation criteria specified in this General Materials and
Workmanship Specification or as shown in the Employer's Drawings.

(c) The Contractor shall insulate all condensate drains.

(d) All refrigerant pipework shall be insulated.

(e) Insulated pipework shall have a continuous unbroken vapour barrier over the
entire outside surface of the insulation. The vapour barrier shall form a
durable, abrasion resistant coating in a dry state and shall have a minimum
film thickness of 5 mm. The vapour barrier shall comply with BS 476 : Part 7.

Insulation materials and minimum thickness shall be as follows:

Table 73.4

Type Insulation Thickness Sheathing Finish

Type material
CHW below Phenolic 25mm Aluminium Dull matt
50 dia. Foam foil and
vapour
barrier paint
CHW from Phenolic 40mm Aluminium Dull matt
50 – 250 dia. Foam foil and
vapour
barrier paint
CHW above Phenolic 50mm Aluminium Dull matt
250 dia. Foam foil and
vapour
barrier paint
Condensate Nitrile 19mm nil Dull matt
Rubber
General Materials & Workmanship Specification 7/9 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 73 – Thermal Insulation
 Type Insulation Thickness Sheathing Finish
Type material
Refrigerant Nitrile 32mm Nil, except Dull matt
pipe below 40 Rubber on chiller
dia.
Refrigerant Nitrile 50mm Nil, except Dull matt
pipe 40 dia. Rubber on chiller
and above

73.4.5 Valves, Flanges, Strainers, Fittings and Expansion Joints

(a) Insulation shall have an insulating value equal to that of the insulation on the
connected pipework. The Contractor shall vapour seal the Plant with two
brush coats of vapour barrier cement using 220 g canvas, or spiral wrap glass
fabric between coats.

(b) Valves, strainers, expansion and movement devices and other Plant requiring
inspection and/or maintenance shall have split sections of insulation complete
with 0.5 mm zinc anneal or aluminum split type boxes incorporating toggle
clips for ease of removal. Neoprene rubber gaskets shall be fitted at mating
surfaces of removable sections.

(c) All insulated flanges and fittings in plant rooms or exposed to weather shall be
finished with a 0.5 mm zinc anneal or aluminum sheathing jacket.

(d) Metal sheaths shall be designed and installed so that raw edges do not
impede or inconvenience access to or operation of valve handles or
instrument connection facilities.

(e) Unless otherwise specified, all expansion joints are to be insulated in

conformity with the pipework in which they are incorporated, and to the same
thickness. All such items where proper treatment on pipework connected to
the puddle flanges in tunnel and trenches is required shall be provided with
relevant insulation filled 0.8mm thick hammered aluminium split boxes,
arranged for easy removal, the box to enclose up to valve handle and to have
a lid for valve access. The insulation on the pipes immediately adjacent to
flanges, etc., shall be neatly swaged off to allow the insulated boxes to the
removed without damage to the pipe insulation.

73.4.6 Chilled Water Pump

(a) Surfaces shall be thoroughly cleaned and primed with asphalt paint.

(b) A minimum 50mm of phenolic foam with aluminium foil and vapour barrier
shall be provided and cut to fit contours of pumps.

(c) Insulation shall be split where pumps are split. Insulation shall be reinforced
with 15 kg/m2 copper sheets at the split.

(d) Pump shall be sheathed with a 0.5 mm zinc anneal or aluminium jacket, split
for ease of removal. Toggle clips shall be used for holding sections in position.
Neoprene rubber gaskets shall be fitted at mating surfaces of the removable
sections.

General Materials & Workmanship Specification 8/9 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 73 – Thermal Insulation
73.4.7 Painting and Identification

(a) Thermal insulation exposed to view (including that within plant rooms) shall be
painted the colour specified or directed by the Project Manager. Insulation
protected by aluminum foil or self coloured sheet, plastics film or a weather-
proof finish and is in concealed space, shall not require painting.

An undercoat and not less than two finishing coats shall be applied. Absorbent
surfaces shall also receive an initial coat of priming paint. All paints shall be
compatible with the surfaces to which they are applied.

(b) All distribution services shall be colour coded and provided with symbols for
identification purposes. Identification coding for ductwork, including thermal
insulation, shall be in accordance with HVAC Specification DW/144. For
pipework, including thermal insulation, the basic colour and colour coding shall
be in accordance with BS 1710.

General Materials & Workmanship Specification 9/9 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 73 – Thermal Insulation
[this page not used]
SECTION 74 SOUND ATTENUATORS

74.1 GENERAL

(a) The Permanent Works and materials specified below shall comply with the
sections stated, unless otherwise stated in this section:

(i) Section 70 “Ductwork and Fittings”;

(ii) Section 73 “Thermal Insulation”;

(iii) Section 75 “Noise and Vibration Control”; and

(iv) Section 79 “Testing, Inspection and Commissioning – Mechanical

Services”.

(b) Modifications to the fan acoustic performance, selection of acoustic lining,

ductwork layout, selection of registers or dampers and the like may result in
changes to attenuator requirements. Performance requirements scheduled in
the Employer's Drawings are shown as a guide only. The Contractor shall
confirm the values by calculation of the sound insertion loss required for each
system. A copy of these calculations shall be submitted to the Project
Manager for review without objection. The Contractor shall select appropriate
sound attenuators to suit the final equipment selection and system layout.

(c) The maximum pressure drop across attenuators at maximum design air
quantity shall be 75 Pa.

(d) Attenuators shall be designed with straight air channels formed by vertical
splitter elements mounted securely within the casing.

(e) Attenuators shall remain structurally sound when subjected to a differential

pressure of 2 kPa.

(f) Attenuators shall be delivered to Site with blocked ends.

(g) The direction of air flow, agreed reference number and supplier's type number
shall be clearly marked on each attenuator.

(h) Transitions between sound attenuators and connecting ductwork or equipment

shall be provided.

General Materials & Workmanship Specification 1/5 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 74 – Sound Attenuators
74.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as the date of the Letter of Acceptance.

BS 4718 Method of test for silencers for air distribution system

NFPA 90A Standards for the Installation of Air-Conditioning and
Ventilating System
NFPA Standard 255 Standard Method of Test of Surface Burning
Characteristics of Building Materials

COP Codes of Practice for Minimum Fire Service Installations

and Equipment and Inspection, Testing and Maintenance
of Installations and Equipment
ASTM E-84 Standard Test Method for Surface Burning Characteristics
of Building Materials
UL No. 723 Test for Surface Burning Characteristics of Building
Materials
FSD Circular Letter 96

74.3 MATERIALS

(a) Attenuator performance shall be measured in accordance with BS 4718.

(b) Outer casing of rectangular ductwork attenuators shall be fabricated from

galvanized steel not thinner than 0.8 mm in accordance with the
recommended practices in the ASHRAE Guide. Seams shall be 'lock-formed'
and mastic filled. Each silencer shall be provided with flanged inlet and outlet.
The internal baffles or splitters shall be of galvanized perforated steel not
thinner than 0.5 mm and having a nominal open area of 30%.

(c) Sound absorbent materials used within attenuators shall be inert, non-
hygroscopic, incombustible, rot and vermin proof, and shall be capable of
carrying passage velocities of at least 25 m/s without surface erosion or other
forms of material migration. The infill shall be of a density not less than 48
kg/m3 to obtain the specified performance and packed under not less than
10% compression to eliminate voids due to settling. Material shall be inert,
vermin and moisture proof.

(d) Attenuator materials including insulation and adhesives shall be selected and
applied in accordance with the requirements of:

(i) FSD Circular Letter No. 4/96 and COP (2005); and

(ii) NFPA 90A.

Unless otherwise reviewed without objection by the Project Manager, each

category of materials being used throughout the installation shall be the
product of the same manufacturer and the same brand.
General Materials & Workmanship Specification 2/5 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 74 – Sound Attenuators
 (e) Combustion rating for the attenuator acoustic in-fill shall not exceed the
following when tested in accordance with ASTM E-84, NFPA Standard 255 or
UL No. 723:

(i) Flame Spread 25

(ii) Smoke Developed 15

(iii) Fuel Contributed 20

The silencer shall be leak-proof at a differential air pressure of 2 kPa.

(f) Unless otherwise specified, ductwork attenuators shall have the following
minimum dynamic insertion loss under forward and reverse flow conditions of
10 m/s:

(i) insertion loss (dB) – for lowest pressure drop silencer

Silencer Length Octave Band Centre Freq. (Hz)

(mm) 125 250 500 1k 2k 4k
900 5 9 14 23 24 14
1500 7 13 21 29 39 20
2100 13 18 28 40 47 26

(ii) insertion loss (dB) – for low pressure drop silencer

Silencer Length Octave Band Centre Freq. (Hz)

(mm) 125 250 500 1k 2k 4k
900 5 10 17 17 13 10
1500 8 15 28 30 21 14
2100 12 20 36 38 28 18

(iii) insertion loss (dB) – for medium pressure drop silencer

Silencer Length Octave Band Centre Freq. (Hz)

(mm) 125 250 500 1k 2k 4k
900 7 12 19 23 23 18
1500 10 18 30 42 34 23
2100 14 24 36 48 44 31

(iv) insertion loss (dB) – for standard pressure drop silencer

Silencer Length Octave Band Centre Freq. (Hz)

(mm) 125 250 500 1k 2k 4k
900 10 15 25 34 35 28
1500 16 22 38 45 46 41
2100 17 34 44 49 49 45

General Materials & Workmanship Specification 3/5 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 74 – Sound Attenuators
 (v) Unless otherwise specified, ductwork attenuators shall have the
following maximum self-generated sound power level (dB re 10-12 Watt)
under the flow conditions of 10m/s:

Silencer Length Octave Band Centre Freq. (Hz)

(mm) 125 250 500 1k 2k
Lowest 51 51 49 47 50
Low 52 46 43 42 45
Medium 54 52 50 47 48
Standard 69 63 64 61 63

(g) Attenuators associated with hot smoke extraction systems shall incorporate
rockwool as the sound absorbing material.

(h) The sound absorbent materials in silencers used as part of exhaust systems
from food preparation areas shall be sealed in an imperforate material such as
polyethylene teraphthate or similar. The imperforate material shall not
degrade acoustic performance and shall be capable of being regularly steam
cleaned without damage.

(i) The Contractor shall select the final attenuation requirements for the individual
systems to achieve the minimum back ground noise levels. The Contractor
shall submit calculations for the required dynamic insertion losses to the
Project Manager, for review without objection.

(j) The geometry of selected attenuators shall not result in requirements for sharp
transformation in adjacent ductwork connecting to the attenuator and, shall not
interfere with adjacent services or with reasonable access to services and
shall not affect adversely the aerodynamic performance of the system or
encourage regeneration of noise.

(k) Evidence of performance of attenuators intended for use for the project shall
be submitted to the Project Manager for review without objection.
Submissions shall be based on test work carried out to BS4718: 1971 diffuse
field method or equivalent. Acoustic data shall include insertion loss and re-
generated noise levels at the relevant range of face velocities.

(l) Type testing on the pressure loss and insertion loss of the selected sound
attenuators shall be carried out by the Contractor to demonstrate that the
performance will comply with this Specification.

74.4 SUBMISSIONS

74.4.1 Particulars of sound attenuator

The following particulars of the proposed sound attenuators shall be submitted to

the Project Manager for review:

(a) contractor’s drawings detailing the position and installation details of the sound
attenuator;

(b) acoustical calculation for the sound insertion loss required for each system in
accordance with the as-built drawing; and

General Materials & Workmanship Specification 4/5 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 74 – Sound Attenuators
 (c) the proposed manufacturer’s certified test data (from an approved laboratory)
for pressure drop and insertion loss ratings in respect of:

(i) square and rectangular attenuators: 600 × 600 mm and circular

attenuators: 600 mm dia.;

(ii) certification data for pressure drop and net insertion loss; based on tests
of same attenuator; and

(iii) sample attenuators and tests subject to inspection upon request of

Project Manager.

74.4.2 Samples

The following samples of proposed materials shall be submitted to the Project

Manager together with the particulars referred to in 74.5.1 above:

(a) acoustic lining.

74.5 WORKMANSHIP

(a) All internal components shall be spot welded in place with welds on centres
not exceeding 100 mm. All spot welds shall be treated after with anti-
corrosive epoxy resin or other approved coating. Manifolded silencers shall be
provided with continuous metallic nosing crimped in place. Nosing pieces and
tails shall be as per the manufacturer's design.

(b) The attenuators shall be located at least three ductwork diameters from fans,
coils, elbows, branch takeoffs, or other ductwork elements.

General Materials & Workmanship Specification 5/5 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 74 – Sound Attenuators
[this page not used]
SECTION 75 NOISE AND VIBRATION CONTROL

75.1 GENERAL

The Contractor shall install sufficient noise and vibration control measures on the
plant/equipment, the interconnected piping, ductwork and conduit so that when the
installed plant/equipment are put into operation, the resulting noise and vibration
levels at locations within the building and at adjacent or nearby buildings shall not
exceed the acceptable limits.
All isolator selections shall be subject to review without objection by the Project
Manager; and isolating elements, bonding materials, casings and the like shall be
suitable for all expected ambient conditions and shall be resistant to oil, water and
chemicals likely to be present.

The manufacturers for the noise and vibration control equipment shall be ISO 9000
accredited.

75.2 MATERIALS

75.2.1 Vibration Isolators

(a) Ribbed or Waffle Pattern Neoprene Pads

(i) Vibration isolation pads of a cross ribbed or waffle pattern shall be 9.5
mm and 8 mm thick respectively and made from 40 durometer neoprene
unless specified otherwise in the Specification.

(b) Rubber in Shear Mounts

(i) Rubber in shear mountings shall have a minimum static deflection of 6

mm incorporating separate steel top and base plates completely
embedded in oil resistant neoprene, colour coded for identification of
load capacity and shall have non-skid mounting surfaces. The
equipment shall be bolted securely to the isolator.

(c) Spring Mounts

(i) Spring diameters shall be no less than 0.8 of the compressed height of
the spring at rated load. Horizontal spring stiffness shall be
approximately equal to vertical stiffness. When loaded, springs shall
have a minimum additional travel to solid equal to 50% of the rated
deflection, and in this condition shall not exceed the elastic limit of the
spring. Springs shall be mounted with adequate clearance from
brackets and base frames for ease of cleaning and shall be clearly in
view for close inspection.

(ii) Restrained spring mounts shall be used where a fluctuation of the spring
operating height of 12 mm or more may occur due to draining of the
equipment, wind loading and the like. Restrained spring mounts shall be
as specified above but shall be mounted in a housing which incorporates
vertical limit stops to prevent spring extension when the weight is
removed.

General Materials & Workmanship Specification 1/20 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 75 – Noise & Vibration Control
 (iii) Limit stops shall be designed to withstand the designed operating load
on the spring. Housings shall serve as blocking during erection.

(d) Hanger, Spring and Rubber in Shear

(i) Where required, hangers shall incorporate either spring, rubber in shear
or spring plus rubber in shear vibration isolating elements.

(e) Inertia Base

(i) Inertia bases shall be provided where specified and equipment shall be
bolted directly to the integral concrete inertia blocks. All concrete
referred to in this section shall have a density of 2,250 kg/m³.

(ii) The length and width of the inertia base shall be at least 20% greater
than the length and width of the supported equipment, and the weight of
the inertia base shall be at least twice the operating weight of the
equipment supported.

(f) Flexible Pipe Connections

(i) Flexible pipe connections shall be:

- made from corrugated metal, rubber, neoprene or other flexible liner

with braided metal or other similar internal or external reinforcing;

- intended for use without tie rods;

- installed without tie rods; and

- long enough to meet vibration isolation performance requirements.

(ii) The minimum internal bore shall not be less than the actual pipe internal
diameter.

(iii) The following minimum live lengths:

Pipe Nominal Bore Live Length

0-28mm 230mm
32-80mm 340mm
90-133mm 455mm
150-200mm 570mm
250-300mm 690mm

(g) Plant Room Acoustic Linings

(i) The wall linerboard shall be secured by 1.5 mm thick galvanized steel 'z'
or channel sections of 50 mm deep which shall be firmly fixed to the wall
surfaces at 600 mm intervals.

General Materials & Workmanship Specification 2/20 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 75 – Noise & Vibration Control
 (h) Vibration Isolation Equipment Performance

(i) The minimum static deflection requirements for the equipment types are
given in the table below

Requirements for vibration isolators:

Equipment Location Minimum Isolation Type
Deflectio
n
AHUs & PAUs Located above 50mm Springs, free
areas of NC35 internal standing
or below
2-3mm Neoprene
external
AHUs & PAUs Others 25mm Springs, free
internal standing

2-3mm Neoprene
external
Packaged air All 25mm Springs +
conditioning units neoprene pad
Axial fans All 25mm Springs, free
standing or
hung
Propeller fans Not wall 25mm Springs, free
mounted-any standing or
location hung

Pumps-base Any location 35-50mm Springs, free

mounted standing c/w
inertia base
Pipework Plant rooms 25mm Springs
CRACs All 25mm Springs
FCUs Shops, Office, 25mm Springs
retails
Centrifugal fans All 25-50mm Springs, free
standing or
hung
Transformer Any 25mm Spring
Generator Plant room 50mm Springs,
restrained
Air-cooled Chiller Chiller plant 65mm Springs,
restrained

75.2.2 Acoustic Louvres

(a) The Contractor shall select the final attenuation requirements for the individual
systems to achieve the minimum back ground noise levels. The Contractor
shall submit calculations for the required dynamic insertion losses to the
Project Manager, for review without objection.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 75 – Noise & Vibration Control
 (b) The geometry of selected louvres shall not result in requirements for sharp
transformation in adjacent ductwork connections and, shall not interfere with
adjacent services or with reasonable access to services and shall not affect
adversely the aerodynamic performance of the system or encourage
regeneration of noise.

(c) Evidence of performance of louvres intended for use for the project shall be
submitted to the Project Manager for review without objection.

75.2.3 Duct Acoustic Lagging

(a) External duct acoustic lagging shall be provided where necessary to avoid
break-out or break-back of noise through ductwork. The lagging shall take the
form of either:

(i) Construction using a minimum of 50mm (density 32 kg/m3) fibreglass

covered by a sound barrier material of adequate surface weight to resist
the level of break-through envisaged (using dry construction techniques
only); or

(ii) Construction of a separate enclosure whereby a support is taken from

the ductwork and the surface weight is adequate to resist the expected
break-through.

(b) The duct lagging shall be fixed to the duct wall using 100% coverage of fire
retardant adhesive. The lagging shall be fixed using GI steel bands at not
less than 600mm centres. No pin type fasteners linking the external layer of
the lagging to the duct wall shall be used. No fixings which pierce the duct
wall.

(c) The fire rating of the lagging shall comply with BS5588 and BS8313, or
equivalent. The lagging inside A/C plant rooms and that exposed indoors
shall have BS476 class 1 surface spread of flame rating or equivalent.

75.2.4 Pipe and Duct Hangers

(a) Hangers shall consist of a mild steel welded cage containing a helical spring,
or neoprene /rubber /glass fibre isolator, (or both) and be suitable for
suspension from drop rods. Where both types of isolating elements are used
together, the spring shall be at the pipe or duct end of the hanger. The spring
or active materials shall be used in compression.

(b) Steel springs shall be stable at all loadings up to full compression and full
compression shall not occur before 150% of the rated maximum loading. No
permanent deformation shall result from full compression. The load shall be
transmitted to the spring through a neoprene washer bushed into the moving
end to prevent metal to metal contact.

(c) Neoprene/rubber/glass fibre isolators shall be protected from overloading by

metal to metal restraints or lateral containment.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 75 – Noise & Vibration Control
 (d) The hanger cage shall be capable of carrying five times the maximum rated
normal service load without permanent distortion. The drop rod arrangement
shall allow 30 degrees movement without metal to metal contact.

(e) Stainless steel (minimum grade SS316) shall be used for external used spring
mounts, and for all isolators supporting condenser water pipe work.

75.3 SUBMISSIONS

75.3.1 Vibration isolators

(a) The Contractor shall submit calculations to the Project Manager for review
without objection taking into account the weight distribution of the Plant under
normal operating conditions, weight of unsupported pipework and ductwork
and any dynamic forces due to fluid movement, torque reaction and starting
and stopping. The calculations shall support his selection of vibration isolator.

(b) Contractor's Drawings shall be submitted to the Project Manager for review
without objection and shall indicate the make and model of isolators, the
number of the isolators to be used and their individual calculated loads.

(c) Contractor’s submissions shall be prepared by a corporate member of the

Institute of Acoustics, who has a minimum of 3 years experience in the
preparation of services noise control submissions. The submitted information
shall include:

(i) Ventilation fan and AHU schedules

(ii) Noise data of the plant

(iii) Silencer calculation sheets, one for each side of each fan or AHU

(iv) Details of louvres, lined ducts and lined plenums acoustic performance
prediction method.

(v) A description of the methodology employed

(c) Static deflection calculations for plant and equipment vibration isolation shall
be submitted. The submitted information shall include:

(i) Schedules for rotary plant (e.g. chillers, fans, pumps, generators etc)
and catalogues

(ii) Operating characteristics of plant (including weight, speed, dimensions)

(iii) Proposed vibration isolation efficiency

(iv) A summary schedule for vibration isolator selection including type, static
deflections, rated loading

(v) Catalogues of the proposed vibration isolators

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Section 75 – Noise & Vibration Control
 (d) Special noise control treatments for major plant such as chillers and generator
sets shall be submitted. The submission document should include:

(i) Contractors Drawings of the noise control treatments

(ii) Design calculations to demonstrate procedures in accordance with

Standard Acoustical Principles and Practices and compliance with the
noise and vibration criteria

(iii) Noise data of the plant manufacturers

75.4 WORKMANSHIP

75.4.1 Vibration Isolators

(a) Ribbed or Waffle Pattern Neoprene Pads

(i) For typical applications, the 40 durometer type neoprene pads shall be
loaded to a surface pressure of approximately 350 kPa. Where two or
more layers of neoprene pads are used, individual layers shall be
separated by 1.0 mm thick galvanised steel shims. The total deflection
shall be determined by multiplying the single layer by the number of
individual layers of neoprene pads. Unless otherwise specified in this
General Materials and Workmanship Specification or Employer's
Drawings, no holding down bolts nor adhesive shall be used with
neoprene pads.

(ii) Pads used as part of cast in situ machine and inertia bases shall be
protected to ensure that internal voids are kept free of concrete material.

(b) Rubber in Shear Mounts

(i) When holding-down bolts are used, they shall only be tightened a half
turn more than hand tight. If levelling is necessary this shall be done
with galvanised shims which, if placed on top, shall cover the full top
surface of the mounting.

(ii) Rubber in shear pads shall be protected from being overloaded by metal
to metal restraints and/or lateral containment.

(c) Spring Mounts

(i) Spring type isolators shall be free standing and laterally stable and in
series with two layers of ribbed or waffle pattern neoprene pads between
the base plate and the support. Ribbed or waffle pads shall be as
specified above.

(ii) Mountings shall be selected to support the actual loads with the
minimum spring deflections as specified in the Specification for the type
of equipment without being compressed solid or bridged out or
exceeding the manufacturer's maximum rated loads and rated
deflections under any operating condition.

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Section 75 – Noise & Vibration Control
 (iii) In the selection of the springs, the Contractor shall take into account the
weight distribution of the Plant under normal operating conditions, weight
of unsupported pipework and ductwork and any dynamic forces due to
fluid movement, torque reaction and starting and stopping.

(iv) Contractor's Drawings shall indicate the make and model of isolators,
the number of the isolators to be used and their individual calculated
loads.

(v) Mountings shall have leveling bolts that shall be rigidly bolted to inertia
bases or steel frames which in turn shall be rigidly attached to the Plant.

(vi) The clearance between spring mounted inertia bases or steel frames
and the floor shall be a minimum of 50 mm and a maximum of 100 mm.

(vii) A minimum clearance of 20 mm shall be maintained around isolators to

ensure that there is no contact between any isolator and any part of the
mounted assembly.

(viii) Spring isolators with static deflections greater than 50 mm or associated

with rotating machines which have a long run down time shall be fitted
with auxiliary dampening facilities.

(d) Hangers, Spring and Rubber in Shear

(i) The hanger casing shall have permanent structural integrity under the
design operating load.

(ii) Spring and rubber in shear vibration isolating elements shall be as

specified above. Springs shall have a resilient rubber insert to isolate
them from the hanger casing.

(iii) Spring diameters and cage lower hole size shall be large enough to
permit the hanger rod to swing through 30° of arc before contacting the
case and thus short circuiting the spring.

(e) Steel Frames

(i) Equipment shall be mounted on or be integral with structural bases with

perimeter members being rolled steel sections of a minimum depth
equal to one tenth of the longest dimension of the base.

(ii) Inertia bases or isolators as applicable shall be rigidly attached to the

underside of the steel frame or to brackets attached to the side thereof.

(f) Inertia Base

(i) Anchor bolts shall be fixed into position, and housed in steel bolt sleeves
to allow minor bolt locations adjustments or alternatively, pockets shall
be cast into the inertia block to permit the later insertion of anchor bolts.

(ii) A suitable base former of minimum 10 mm plywood or equivalent shall

be provided by the Contractor for forming the slab. Steel channel
isolator brackets shall be welded directly to channel frames., and
suitably located to accommodate the height of the deflected springs and
inertia base clearance with plinth.
General Materials & Workmanship Specification 7/20 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 75 – Noise & Vibration Control
 (iii) There shall be a minimum clearance of 20 mm all round the springs to
ensure that there is no contact between any spring and any part of the
mounted assembly for any possible alignment or position of the installed
inertia base. The clearance between inertia base and floor/plinth shall
be a minimum of 50 mm and a maximum of 100 mm.

(iv) All pumps shall be mounted on independent inertia bases of minimum

2.5 times the total pump weight.

(v) The design of the brackets and mountings shall allow the base to be
raised from (or lowered onto) the floor by adjustment of the levelling
bolts between mountings and brackets. The design shall also allow the
insertion (or removal) of the mountings when the base is resting on the
floor.
(g) Flexible Pipe Connections

(i) The axis of the connectors shall be perpendicular to the direction of

vibration. Alternatively, where the design allows, the connectors may be
formed into 90° bends.

(ii) Connectors with threaded ends shall be provided with flats or raised
bends for standard spanners or wrenches to allow fixing without
stressing the active elements.

(h) Pipework

(i) All pipework supports in plant rooms shall incorporate vibration isolating
elements with 5 mm deflection minimum. All pipework supports within
7.5 m of vibrating Plant shall incorporate both rubber in shear and spring
isolators with a combined minimum static deflection equal to that of the
equipment isolators. All pipework supports within 15 m of vibrating Plant
for pipework up to 300 mm in diameter, and within 20 m for larger
pipework, shall incorporate spring isolators with 20 mm minimum static
deflection or equal to the equipment isolator static deflection.

(ii) Alternatively pipework may be grouped and supported on a structural

rolled steel section and the whole assembly isolated from the building.
The isolator selection in this case shall be equal to the most stringent
requirement of any of the pipework supported.

(iii) The above pipework isolators shall be provided irrespective of the

installation of flexible pipe couplings.

(iv) The above isolators shall be provided for both hung and propped
pipework.

(i) Plant Room Acoustic Linings

(i) The wall liner boards shall be protected by 0.8 mm thick galvanized
perforated metal plates which shall be secured by self tapping screws to
the galvanized steel sections. The perforated metal plates shall be
removable to enable future maintenance.

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Section 75 – Noise & Vibration Control
 (j) The stiffness of vibration isolators shall be selected to suit the lateral isolation
efficiency required without causing instability. For rotating machines with
horizontal shafts, the horizontal stiffness perpendicular to the shaft shall not be
less than the vertical, if 'floor' mounted, and vice versa if 'side' mounted.

(k) Vibration isolators shall be provided with means of level adjustment to allow
for unevenness of the mounting surfaces. The amount of adjustment for floor
mounted isolators shall not be less than twice the permitted tolerance in the
levelling of the floor. Levelling bolts or studs shall be provided with lock nuts.

(l) The tie rod systems on expansion joints used for vibration isolation shall be
designed to achieve the isolation required across the joint. The tie rod fixings
shall use rubber or neoprene bushed washers to prevent metal to metal
contact throughout the normal range of movement of the joint.

(m) AHU Internal Vibration Isolation Devices

(i) The AHU shall have internal spring mounts fitted below the fan frame to
achieve an isolation efficiency of not less than 95%

(ii) The selection of vibration isolation systems shall allow for forces and
movement due to pressure differences at flexible connections.
Mountings shall be laid out and sized for their loadings at all operating
speeds.

(iii) Spring type vibration isolators shall be constructed from suitably treated
and finished steel or steel alloys. They shall be manufactured with
rubber, neoprene or fibreglass acoustic pads' to prevent transmission of
high frequencies. The material of the pad shall be selected to suit the
location. Holes shall be provided for fixing both to the supported
machine and the supporting structure.

(n) AHU External Vibration Isolation Devices

(i) The AHU casing shall be mounted on ribbed neoprene pad having a
static deflection of 2 to 3 mm.

(ii) The material used for 'pad' or 'mat' type mounting may be cellular,
ribbed, or studded. Pads and mats shall normally be bonded both to
supported and to supporting surfaces. Material and bonding agent shall
be resistant to lubricating oil and water.

(iii) The pad materials shall comply with all relevant local fire regulations.

(o) Commissioning Tests

(i) Balancing/commissioning of the services systems shall be carried out

such as to result in the specified noise criteria being achieved, but shall
be strictly in accordance with the non-acoustic performance
requirements of the systems.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 75 – Noise & Vibration Control
 (ii) The Contractor shall allow adequate time before occupation for
commissioning of noise/vibration levels and shall co-operate with, and
attend noise measurement in the presence of the representatives from
the Project Manager to confirm that acoustic criteria have been met.

(iii) Noise measurements shall be conducted with the system operating at

normal design conditions, and preferably with the internal finishes
installed.

(iv) Noise measurements shall be made using a meter complying with 'Type
1' requirements of IEC651 standard, or equivalent. The meter shall be
calibrated using an acoustic calibrator, before and after all sets of
measurements.

(v) The Contractor shall submit a noise report, 10 days after each noise
commissioning test, to the Project Manager for review without objection,
to record the measured noise levels and recommend any necessary
mitigation measures. The Contractor shall, at their own cost, implement
the recommended mitigation measures and ensure that the specified
noise limits are achieved.

(vi) The noise levels shall not be considered acceptable unless the relevant
Commissioning Test Reports have been reviewed by the Project
Manager without objection.

75.4.2 Fans

(a) General

(i) This section covers all fan installations in the supply air, the return air,
and the exhaust systems, including fans fitted in air handling units, fan
coil units, packaged air conditioning units and the like.

(ii) Fans with belt drives shall be mounted on a common fan/motor

structural steel support frame.

(iii) Where specified below, spring or rubber-in-shear isolators refers to

either floor or hanger mounts as applicable.

(iv) Fans shall be isolated from inlet and discharge ductwork with an
impregnated airtight and watertight flexible fabric connection. For low
temperature indoor applications the fabric shall be neoprene
impregnated. Outdoor applications shall utilize weather and solar
resistant fabric.

(v) Flexible duct connections shall be formed from resilient sound barrier
mat with a minimum 25 mm slack across a 100 mm gap designed and
installed to avoid impeding air flow.

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Section 75 – Noise & Vibration Control
 (vi) Flexible connections on axial fans shall generally be located remotely
from the fan inlet or discharge. In these cases the whole fan assembly
including inlet and discharge ductwork transitions shall be mounted on a
structural steel frame with vibration isolators as specified below.

(vii) External flexible connections shall be provided for all air handling units
irrespective of the provision of internal flexible connections.

(b) Axial Fans with Wheel Diameters up to 550 mm

(i) Units mounted on ground supported slabs shall be isolated using rubber-
in-shear isolators with minimum static deflection of 5 mm.

(ii) Units mounted on or hung from suspended slabs shall be isolated using
spring supports with 20 mm minimum static deflection.

(c) Axial Fans with Wheel Diameters over 550 mm

(i) All axial fans with wheel diameters over 550 mm shall be isolated using
spring isolators. The isolator minimum static deflection shall be 20 mm
for ground supported slabs and 40 mm for suspended slabs.

(d) Centrifugal Fans with Wheel Diameters up to 550 mm

(i) Units mounted on ground supported slabs shall be isolated using rubber-
in-shear isolators with minimum static deflection of 5 mm.

(ii) Units mounted on suspended slabs shall be isolated using spring

isolators with minimum static deflection of 25 mm.

(e) Centrifugal Fans with Wheel Diameters over 550 mm

(i) All centrifugal fans with wheel diameters over 550 mm shall be isolated
using spring isolators. The isolator minimum static deflection shall be 20
mm for ground supported slabs and 65 mm for suspended slabs. Fans
shall be mounted on concrete inertia bases for suspended slabs.

(f) Fans included in Packaged Equipment

(i) This section shall apply to air handling units, fan coil units, packaged air
conditioning units and the like.

(ii) Equipment mounted on ground supported slabs shall be isolated using

rubber-in-shear isolators with a minimum static deflection of 5 mm.

(iii) Equipment mounted on suspended slabs with fan motors up to 7.5 kW

shall be isolated using spring isolators with minimum static deflection of
20 mm. For units with a higher fan motor rating, spring isolators shall
have a minimum static deflection of 40 mm.

(iv) Wherever practical and unless otherwise reviewed without objection by

the Project Manager, fans shall be isolated from the equipment housing
with the housing rigidly supported. Subject to review without objection
by the Project Manager, where fans cannot be individually isolated, the
entire AHU or FCU housing shall be isolated.

General Materials & Workmanship Specification 11/20 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 75 – Noise & Vibration Control
 (g) Electrical Connections

(i) Electrical connections between vibration isolated equipment and the

structure shall be made through flexible conduit which changes direction
by at least 90° in a minimum length of 25 conduit diameters. MICC and
similar cables shall be taken through a 360° loop of 75 mm radius or
double the permissible minimum radius whichever is greater.

75.4.3 Noise Levels

(a) The Contractor shall ensure that in the selection of Plant, the lowest available
sound power levels are adopted. Sound power levels shall not exceed those
in the equipment schedule.

(b) The Contractor shall submit for review without objection by the Project
Manager certified octave band sound power levels for all noise emitting
equipment. Where octave data is not available, selections shall be based on
an NC level 5 dB lower than that required for the space.

(c) Maximum noise levels specified below do not include any allowance for the so
called "room effect". Any catalogue or certified data including "room effect"
allowances or the like shall be modified to show that the noise criteria has
been met.

(d) The Contractor shall comply with other relevant sections of the Specification
including but not limited to the sections which specify:
(i) "chilled water plant";

(ii) "insulation : acoustic";

(iii) "low voltage electric motors";

(iv) "sound attenuators"; and

(v) "testing and commissioning".

(e) Plant shall be selected and installed so that the total noise levels resulting
from the simultaneous operation of all Plant (including the effects of
regenerated, breakout and structure-borne noise) do not exceed the following:

Area Services Noise Criterion

(NC)
Administration Offices 40
Airline Ramp Accomodation 65
Offices
CIP Lounges and Lounges 45
Commercial/Restaurants etc 45
Concourse and Terminal Public 45
Areas
Kitchens 60
Plant room 75
Public Corridors 50

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Section 75 – Noise & Vibration Control
 Area Services Noise Criterion
(NC)
Public Toilets 50
Staff Areas 55
Staircases (normal use) 50
Staircases (escape only) 65
Transfer/Transit Lounges 50

(f) Sound pressure levels in external areas within 3 m of air intake and discharge
points on the perimeter of the building shall be limited to 75 dB(A) except that
85 dB(A) is acceptable when fans dedicated to smoke extraction are running.

(g) The above sound pressure levels shall not be exceeded when all Plant is
running on high speed as applicable, and when the background noise level is
at least 10 dB less than the above values. Acoustic treatment should be
provided to the plants to achieve the NC if the plants are installed at high level
of the occupied area.

75.4.4 Fan / AHU Casings and Duct Construction

(a) Noise breakout shall be controlled by selection of appropriate sound-insulating

enclosures and/or duct wall constructions to limit noise to the targets
specified. Such enclosures shall be, as a minimum requirement, of double
metal skin construction with the void containing an appropriate absorbent.
Access to such enclosures shall be via acoustically sealed hatches or covers.

(b) All flexible duct connections shall be formed from resilient sound barrier mat of
minimum of 25 mm slack and minimum 5 kg/m2 across a 100mm gap to
ensure effective isolation, installed in such a way to avoid impeding air flow.

(c) External flexible connections shall be provided for all AHUs irrespective of the
provision of internal flexible connectors.

(d) All air ductwork, associated fittings and components shall be well sealed to
avoid noise from air leakage and internally free from raw edges and
projections.

(e) Ceiling hangers and other support systems shall be kept clear of ductwork and
any ductwork insulation.

(f) All control dampers shall be selected to maintain smooth airflow and minimum
regenerated noise. The contractor shall, where required, provide secondary
attenuation to remove regenerated noise created by dampers and/or flow
regulators.

General Materials & Workmanship Specification 13/20 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 75 – Noise & Vibration Control
75.5 DESIGN AND TESTING REQUIREMENTS

75.5.1 Service Penetrations through Building Fabric

(a) Where services penetrate through the acoustic mineral fibre boards as
indicated on the Employer’s Drawings, the penetrations shall be detailed as
follows:

(i) Any gaps between the services and the boards and between board and
the surfaces of the aperture shall be filled with acrylic mastic

(ii) The sound insulation provided by the boards in the specified areas shall
not be less than the STC 35 when installed as shown on the Employer’s
Drawings.

(iii) The Contractor shall submit acoustic test certificates to demonstrate

compliance with the specified sound insulation class for the proposed
configurations of the penetration system. Where valid acoustic test
certificates are not available, the contractor shall, at their own cost,
conduct necessary acoustic tests to demonstrate compliance. All
acoustic tests shall be performed by an independent recognised acoustic
laboratory and shall be subject to review by the Project Manager without
objection.

(iv) The acoustic mineral boards shall comply with Hong Kong Fire
Regulations

(v) Trunking penetrating sound insulating structures shall be packed

internally and externally around the perimeter void with loose mineral
wool or fibreglass.

75.5.2 Variable Frequency Drives

(a) All Variable Frequency Drives (VFDs) shall be of an appropriate quality and
shall not result in audible high pitch noise from driving the motor. VFDs shall
have a built-in feature for adjustment to bypass the high pitch resonant
frequency.

75.5.3 Fan Coil Units

(a) Noise limits in terms of sound power levels are specified in this specification.
Noise levels testing of the FCU shall comply with BS 4196 : Part 3 -
Determination of Sound Power Levels in a Reverberant Chamber. The tested
sound power levels shall not exceed the following values:

Description Octave Band Centre Frequency (Hz)

125 250 500 1k 2k 4k

Radiated sound power levels of 67 60 55 51 49 48

FCUs at medium speed (NC40
areas)

Note: Sound power levels given in dB re 10-12W

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Section 75 – Noise & Vibration Control
 (b) All flexible duct connections to the FCUs shall be formed from resilient sound
barrier mat with a minimum of 25mm slack and minimum 5kg/m2 across a
100mm gap to ensure effective isolation, installed in such a way to avoid
impeding air flow.

(c) The Contractor shall allow additional noise control measures for casing
breakout when the above sound power levels cannot be achieved. Sound
power levels or alternative breakout noise control measures shall be
submitted for the Project Manager’s review without objection.

75.5.4 Air Handling Units

(a) The maximum sound power levels (SWLs) of the AHUs, when tested in
accordance with ISO 3746 : 1995E or equivalent, shall not be higher than the
specified noise limits below:

(b)
Octave Band Centre Frequency (Hz)
63 125 250 500 1k 2k 4k 8k
Supply 98 95 94 90 86 83 79 74
Inlet 88 83 79 76 74 72 71 70
Casing Breakout 83 78 74 71 69 67 66 65
Note: Sound power levels given in dB re 10-12W

(c) The Contractor shall, at their own cost, conduct any necessary acoustic tests
and submit test certificates to demonstrate compliance with the specified
noise limits for the acoustic air handling units. All acoustic tests shall be
conducted by an independent acoustic laboratory or a qualified acoustician
such as a member of the Institute of Acoustics or an equivalent, the details of
whom shall be submitted to the Project Manager for review without objection.

(d) The minimum length of the sound attenuators for PAUs/AHUs shall not be
less than 900 mm long.

75.5.5 Factory Acoustic Tests for AHU, PAU

(a) Factory acoustic tests for AHUs shall be conducted. The Contractor shall
submit a Method Statement to the Project Manager for review without
objection prior to the actual test. The test proposal shall include, but not be
limited to, the following

(i) Instrumentation to be used;

(ii) Measurement procedures;

(iii) Measurement locations;

(iv) Measurement personnel; and

(v) Ambient noise level for the tests.

(b) Noise measurements shall be made using a sound level meter complying with
'Type 1' requirements of IEC651 standard, or equivalent. The meter shall be
calibrated using an acoustic calibrator, before and after all sets of
measurements.

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Section 75 – Noise & Vibration Control
 (c) Measurement personnel shall be a qualified acoustician such as a member of
the Institute of Acoustics or equivalent who has experience in conducting
similar tests.

(d) Noise measurements shall be conducted with the system operating at normal
design conditions. All tests shall be witnessed by representatives from the
Project Manager.

(e) A type test certificates shall be submitted within 7 working days to the Project
Manager to certify that the factory test has complied with the specified sound
power levels.

75.5.6 Acoustic Panels For AHU and/or Fan Rooms & G/F Air Plenum Rooms

(a) Access panels shall be provided where indicated on the Employer’s Drawings
and/or elsewhere in the specification.

(b) The acoustic panels shall be minimum 100 mm thick and shall have an outer
skin of galvanised steel of minimum 1.5 mm thick appropriate reinforced and
internally lined with inert, non-hygroscopic, non-flammable glass or mineral
fibre (40 kg/m³ fibreglass or 120kg/m³ rockwool), stabilised by bonding with
resin or equivalent. The surface of the fibres shall be protected with a smooth
layer of woven or tissue faced fibreglass or mineral wool and a layer of
perforated galvanised mild steel having a thickness of not less than 1 mm,
and an open area of at least 23%.

(c) The acoustic panels shall have sound transmission losses of not less than the
following values when tested in accordance with ASTM E90-61T:

Min. Transmission Octave Band Centre Frequency (Hz)

Loss (dB) 63 125 250 500 1k 2k 4k 8k
Acoustic Panel 15 20 28 38 45 50 50 50

(d) The acoustic panels shall have no holes or other defects which would allow
noise leakage.

(e) The panel joining method shall be either tongue-and-groove construction, or

with panel H-joiners of sufficient strength and shape to prevent direct leakage
of sound, alternative methods may be proposed an shall be subject to review
without objection by the Project Manager. Acoustic infill shall be applied at
assembly joints.

(f) It is the Contractor’s responsibility to coordinate the arrangement of wall panel

layout and supporting brackets for piping and ducting. Contractor’s drawings
shall be submitted detailing the proposed arrangement for review. Such
arrangement shall be made in a tidy and neat manner and standardised for all
AHU/Fan rooms.

(g) All access panels shall be fitted with airtight seals and a latching mechanism
that ensures that the seals are correctly compressed when the access panels
are closed.

(h) The acoustic panels shall be demountable and capable of being used for
installation in other locations.

General Materials & Workmanship Specification 16/20 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 75 – Noise & Vibration Control
75.5.7 Acoustic Treatment for Generators

(a) The Contractor shall submit proposals to the Project Manager for review
without objection in treating the noise and vibration generated by generators.
During routine testing of the generators, the total noise level generated from
the exhaust pipes and intake and discharge louvres shall comply with the
requirements given in the relevant Technical Memorandum under Noise
Control Ordinance and the nearfield noise levels (i.e. at 1m) as specified in
other parts of this Specification.

(b) The Contractor shall provide all the necessary noise and vibration treatments
to comply with the requirements stipulated in the Contract Documents. These
treatments shall, include, but not be limited to, the following:

(i) Intake silencers (minimum 900 mm long)

(ii) Discharge silencers (minimum 900 mm long)

(iii) Acoustic wall lining (minimum 50 mm thick fibreglass or mineral wool

at 48 kg/m3, faced with perforated, expanded or mesh material)

(iv) Steel spring vibration isolators of minimum 50mm static deflection

(v) Industrial type exhaust silencers; and

(vi) Acoustic enclosures (as required).

(c) Submissions from the Contractor shall include the details of all the proposed
noise and vibration control measures, and supporting documentation
(including noise test certificates, catalogue and calculation sheets). All test
certificates shall be prepared by an independent acoustic laboratory to be
reviewed without objection by the Project Manager.

75.5.8 Vibration Isolation System Selection

(a) Vibration isolation systems shall reduce the vibration and structure borne
noise in all occupied areas, with the exception of plant rooms and services
areas, such that:

(i) resulting noise re-radiation will not exceed the Noise Criteria set out in
this specification.

(ii) vibration should not be perceptible to occupants, sitting, standing or

lying down. An rms surface vibration velocity of 0.1 mm/s shall be
taken as a reference limit of perception.

(b) The Contractor shall submit details of the vibration isolation system type and
performance to the Project Manager for review without objection prior to
installation.

(c) Where the vibration isolator type is not specified, the method of mounting
machinery and the size, type and active material of the mountings shall
comply with this vibration isolator specification.

(d) Services in any basement plant room shall be supported directly off the floor
wherever reasonably possible
General Materials & Workmanship Specification 17/20 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 75 – Noise & Vibration Control
75.5.9 Vibration Isolation Systems for Variable and Multi-speed Machinery

(a) Vibration isolation systems for variable or multi-speed machinery shall achieve
the degrees of isolation required by the specification at all the normal
operation speeds. The resonant frequency of the isolation system shall be
lower than any operating speed.

(b) The resonant frequency of vibration isolation systems for machinery and
electric motors with stepped speed starting arrangements (star delta, tapped
resistor and transformer etc.) shall not correspond to any of the speeds at the
step changes and shall allow for long 'run-up' and 'run-down' times.

75.5.10 Unsymmetrical Loading of Anti-vibration Mounts in a Vibration Isolation

System

(a) The vibration isolation system shall allow each mounting to be adjusted to the
design value at the operating condition of the supported equipment.

75.5.11 Static and Dynamic Forces due to Fluid Pressure at Flexible Connections to
Fans and Pumps

(a) The selection of vibration isolation systems for fans and pumps shall allow for
forces and movement due to pressure differences at flexible connections.
Mountings shall be laid out and sized for their loadings at all operating
speeds.

(b) Inertia blocks and counterweights may be used to reduce the percentage
variations in mounting loads at varying speeds.

(c) Isolated sway braces, buffers and similar devices may be used to limit
movement during start up and run down. Such devices shall be installed so
that they are not in contact with the vibrating device under normal conditions.
Sway braces and buffers shall not be used to control constant thrusts created
during normal operation.

75.5.12 Prevention of Overloading of Vibration Isolators or Equipment Connections

(a) Vibration isolation systems whose mountings can be overloaded by excessive

deflections, shall be provided with 'bottoming' or similar restraints. The
restraints may be part of the mountings, machinery or bases.

(b) These restraints may be omitted only from vibration isolation systems which
cannot be overloaded by pipe or ductwork during erection and are unlikely to
be used as hand or footholds subsequently.

(c) Vibration isolation systems fitted beneath boilers, cooling towers or other
equipment in which the weight of the liquid contents acts through the
mountings and forms a significant part of the load, shall be provided with
adjustable restraints which limit the movement of the equipment on draining
down such that it shall not cause any strain on the service connections and
the adjacent runs.

General Materials & Workmanship Specification 18/20 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 75 – Noise & Vibration Control
75.5.13 Pipe & Duct Supports Adjacent to Fans, Pumps and Other Equipment

(a) The weight of pipes, ducts, and their contents, or other services connected to
the equipment shall be supported independently of the equipment and shall
not impose any additional load on the equipment.

(b) All pipe work connected to vibration isolated equipment shall be mounted on
spring hangers or supports.

(c) The vibration isolators supporting the pipes shall provide the same static
deflection as the equipment supports for the length of service relating to the
first type of pipe support isolation specification.

(d) Flexible pipe work connections may be used in place of pipe work resilient
hangers only when the connectors comply with the requirements of the
section below.

(e) Flexible connections used for the vibration isolation of pipe work shall be
reviewed without objection by the Project Manager.

(f) Flexible connections not complying with the requirements may be used to
compensate for misalignment etc. provided that the connections comply with
the requirements of the following sections.

75.5.14 Pipe isolation inside plant rooms and adjacent to noise sensitive areas

(a) All pipes inside chiller plant rooms and chilled water pump rooms shall be
vibration isolated with minimum 25 mm static deflection springs in series with
neoprene vibration hangers.

(b) An additional 10m length of pipe from the plant room boundary walls shall be
vibration isolated with 25 mm static deflection spring in series with neoprene
vibration hangers.

(c) Where pipes are supported directly above, below or adjacent to a noise
sensitive area of NC45 or below, they shall be vibration isolated with 25 mm
static deflection spring in series with neoprene hangers or equivalent at the
supporting points up to a minimum of 10 m from the boundary of the noise
sensitive area.

(d) All pipes of diameter 100 mm or above shall be rested on correctly sized
neoprene inserts of minimum 8 mmm thick.

(e) Vibration isolation supporting points shall not interfere with any other services.
No support shall come into contact with any other service which may result in
vibration transmission.

General Materials & Workmanship Specification 19/20 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 75 – Noise & Vibration Control
75.5.15 Flexible Connections for Pipe work

(a) Where vibration isolated equipment is fitted with flexible connections, vibration
isolation shall be provided for the first three service supports form the
equipment. The vibration isolators shall provide a minimum 80% efficiency at
the fundamental forcing frequency of the equipment. The supports shall be
designed to prevent movement of the connected pipe or duct resulting from
static or dynamic forces exerted by the fluid weight or velocity.

(b) The vibration isolators shall provide an equivalent level of static deflection as
the main equipment supports.

75.5.16 Flexible Electrical Connections

(a) Electrical connections to all vibration isolated equipment and equipment fixed
to structure shall be made through flexible conduit which changes direction by
at least 90 degrees in a minimum length of 25 mm conduit diameters. Mineral
insulated cables shall be taken through at least 360 degrees at 75 mm radius
or double the permissible minimum radius, whichever is larger.

75.5.17 Air Gap Resonance

(a) The width of air gap between the underside of solid machine bases
(supported on vibration isolation mountings) and the floor shall be selected to
avoid resonance of the air gap.

75.5.18 Fan Acoustic Enclosures

(a) The acoustic panels shall be a minimum 100mm thick and shall have an outer
skin of galvanised steel of minimum 1.5mm thick. The panels shall be
reinforced and internally lined with inert, non-hygroscopic, non-flammable
glass or mineral fibre (40 kg/m³ fibreglass or 120kg/m³ Rockwool), stabilised
by bonding with resin. The surface of the fibres shall be protected with a
smooth layer of tissue faced mineral wool and a layer of perforated galvanised
mild steel having a thickness of not less than 1mm, and an open area of at
least 23%.

(b) The acoustic panels shall have sound transmission loss not less than the
following values when tested in accordance with ASTM E90-61T:

Min. Transmission Octave Band Centre Frequency (Hz)

Loss (dB) 63 125 250 500 1k 2k 4k 8k
Acoustic Panel 15 20 28 38 45 50 50 50

(c) The acoustic panels shall have no holes or other defects which would degrade
the acoustic performance

(d) Panels joining method shall be tongue-and-groove construction and of

sufficient strength and shaped to prevent direct sound transmission.

(e) All access panels shall be fitted with airtight seals complete with a latching
mechanism to ensure that the seals are fully compressed when the access
panels are closed.

(f) The acoustic panels shall be demountable and capable of being reused in
other locations.
General Materials & Workmanship Specification 20/20 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 75 – Noise & Vibration Control
SECTION 76 ELECTRICAL EQUIPMENT AND INSTALLATION

76.1 GENERAL

(a) This section covers the specific requirements for electrical equipment and
installation for mechanical services system. The general requirements for the
same shall be referred to Section 44.6.

(b) The Works and materials described herein shall comply with sections 46, 48,
49, 53, 57, and 59 of the General Materials and Workmanship Specification for
general requirements and details regarding the electrical installation including
the following:

(i) the Works and materials described herein shall comply with other
relevant sections of this General Materials and Workmanship
Specification including the sections which specify:

- Section 77 “Automatic Controls”;

- Section 78 “Instruments”; and

- Section 79 “Testing, Inspection and Commissioning – Mechanical

Services”.

76.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to that
edition of the document stated below, including all amendments issued by the
relevant authority.

IEC 529 Degree of protection of enclosures

IEC 60034 Rotating electrical machines
BS 88 : Part 2 Cartridge fuses for voltages up to and including 1,000V AC
and 1,500V DC. Specification for fuses for use by authorized
persons (mainly for industrial application)
BS 2757 Method for determining the thermal classification of electrical
insulation
BS 5486 Low-voltage switchgear and controlgear assemblies
BS EN 50081 Electromagnetic compatibility. Generic emission standard
BS EN 50082 Electromagnetic compatibility. Generic immunity standard.
Residential, commercial and light industry
BS EN 60529 Specification for degrees of protection provided by
enclosures (IP code)

General Materials & Workmanship Specification 1/12 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 76 – Electrical Equipment & Installation
76.3 MATERIALS

76.3.1 Motor Control Centres and Associated Enclosures

(a) General

(i) Motor Control centres, Control panels and similar enclosures shall be
designed, assembled and installed as a minimum to carry for at least 1
second the fault level scheduled on the Employer's Drawings within the
mechanical scope of work. The minimum fault rating shall be 16 kA.

(ii) The degree of protection for motor control centres (MCC's), control
panels and similar enclosures including variable frequency drive
cabinets shall be IP42 to IEC 529.

(iii) MCC's shall be Form 3 to BS 5486 except that:

- sections of a MCC housing plant associated with fans used for hot
smoke extraction shall be Form 4;

- motor control centres associated with fixed link fan coil units may be
Form 2; and

- unless otherwise specified in this General Materials and

Workmanship Specification or detailed on the Employer's Drawings,
motor control centres may be Form 2 where the MCC is rated at 30 A
or less and the MCC only serves fan coil units, general exhaust fans
and similar plant.

(iv) Unless otherwise shown on the Employer's Drawings as being back

access, MCC's shall be front access.

(v) All MCC's shall be fitted with volt, ampere and kilowatt hour meters on
the incoming supply.

(vi) Motor control centres and control panels shall have a momentary
contact “indicator test” pushbutton.

(vii) Where installed remote from motor control centres, isolators,

pushbuttons, indicating lights and other items shall be installed in
suitable enclosures with a degree of protection of no less than IP42 to
IEC 529.

(viii) Motor control centres, control panels and similar shall not be lockable.

(ix) Motor control centers for FSI plant, i.e. smoke extract fans etc., shall be
located within a separate 2 hours fire rated enclosure, in accordance
with FSD COP. All power supply and control cables for the hot smoke
extraction systems shall be rated to withstand 250°C for one hour.

(b) General Arrangement

(i) The general arrangement of motor control centres shall be subject to

review without objection by the Project Manager.

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Section 76 – Electrical Equipment & Installation
 (ii) Each circuit shall be complete with the following facilities mounted on the
compartment door:

- isolation switch;

- “remote-off-local”, "auto-off-manual" and other rotary control switches

specified in this General Materials and Workmanship Specification or
shown on the Employer's Drawings; and

- “on”, “off”, “fault”, “alarm”, “timer initiated”, “local-remote-manual-auto”

and other indicators specified in this General Materials and
Workmanship Specification or shown on the Employer's Drawings;

- “reset”, “lamp test” and other push button specified in this General
Materials and Workmanship Specification or shown on the
Employer’s Drawings.

(iii) Circuits shall be logically arranged.

(iv) Duty/Standby Plant shall have separate “Duty” and “Standby” indicators.

(v) Sequence indicators shall be provided for staged plant such as

secondary chilled water pumps and similar. Sequence indicators shall
illuminate the current configuration of plant staging.

(vi) Spare contacts for MBMS interface shall be provided for all plant under
MBMS monitoring and control.

(c) Construction

(i) MCC's shall be of modular construction, self supporting and designed to

allow maintenance, inspection and testing to be carried out safely and
easily. Facilities shall be provided to allow future extensions without
alterations to existing equipment.

(ii) Cubicles shall be constructed from minimum 2.0 mm mild steel using
folded and welded sections and angle iron bracing where necessary.
MCC's shall incorporate welded and/or bolded angle or channel iron
frames. All welds shall be ground flush.

(iii) MCC's shall be constructed with all matching and setting up done using
suitable jigs so that similar parts shall be readily interchangeable.
Where withdrawable switchgear is used, it shall be possible to fully draw
out a truck from the MCC without having to open the doors of adjacent
panels.

(iv) The following items as specified in the Specification or shown on the

Employer's Drawings, shall be mounted on the front panels or doors of
units:

- isolators;

- meters;

- transfer switches;

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Section 76 – Electrical Equipment & Installation
 - control switches;

- indicators;

- pushbuttons; and

- labels.

(v) Doors or lift-off panels as applicable shall be fitted to the front and rear
of cubicles.

(vi) Doors shall be hung on lift off hinges and shall open through a minimum
of 120°. Panels shall be complete with lifting handles and means of
support to retain the panels in place after the removal of fixing screws
and bolts.

(vii) Doors and panels shall be stiffened to prevent distortion and shall be
fitted with lockable chrome plated handles or other suitable means of
fastening. Doors shall be fitted all around with soft closed cell neoprene
compression gaskets.

(viii) A steel channel frame shall be incorporated in the base of the MCC to
provide rigidity and support for lifting. MCC's shall be fixed to the floor or
plinth using expansion bolts or equivalent. MCC's shall be fully closed off
at the bottom. The Contractor shall provide levelling rails as required.

(ix) MCC's shall be designed to ensure that they can be delivered to the final
locations with plant room doors and access ways into plant rooms built
and complete.

(x) MCC's shall be fitted with removable gland plates.

(xi) Spacing between equipment and wiring shall be arranged to ensure that
all equipment is accessible for adjustment or dismantling without
dismantling other equipment or removing wiring looms. Equipment
labelling shall not be obstructed by wiring looms.

(xii) Insulating panels, mounting brackets and associated connections shall

be provided in cubicles in such a way that future equipment can be
easily fitted without additional materials such as mounting screws,
terminals, panels, and the like.

(xiii) Wiring ducts shall be sized to allow for the future installation of 30%
more wiring including insulation.

(xiv) Cut-outs in the sheet metal through which wiring passes shall be suitably
bushed using PVC extruded channel section, having a return of not less
than 10 mm on each side. The bushing shall be neatly fitted to cover the
metal completely and shall be securely cemented into the panel. All
holes for wiring access shall be bushed with 2 piece 'screw up' PVC
bushes.

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Section 76 – Electrical Equipment & Installation
 (d) Busbars and Connections

(i) The minimum rating of busbars, supports and connections shall be as

scheduled on the Employer's Drawings or equivalent to that of the circuit
breaker feeding the MCC, whichever is the greater. Minimum rating shall
be 200 A.

(e) Cable Terminations

(i) Incoming and outgoing cables whether power or control, shall be

terminated in the fixed portions of units. Cable end boxes, gland plates,
cable glands, cable trays, cable lugs, and conduit entries as required
shall be provided between terminations and equipment. Cable entries
shall be equivalent to the corresponding IP rating of the MCC.

(ii) Provision for the entry of supply mains shall be made in the form of
suitable panel plates or cable entries.

(iii) Unless otherwise specified in the Specification or the Employer's

Drawings, all cables shall be top entry and exit.

(iv) The arrangement of cable terminations shall minimize the bending of

cores and allow for ease of termination.

(v) Cable terminations shall be clearly labelled.

(vi) Terminals for each MCC circuit shall be grouped together.

(vii) Terminal groups shall be segregated from each other by 25 mm, and a
minimum of 25% spare terminals for each group of control circuits shall
be provided.

(viii) Terminal blocks shall be provided in each cubicle between shipping

breaks of MCC's to facilitate ease of terminating control cabling when
the sections are installed on Site. The required interconnecting cabling
and terminal blocks shall be clearly marked to facilitate ease of
connection on Site.

(f) Control Wiring

(i) Control wiring shall be run separately from power wiring.

(ii) Wires shall not be jointed or tee'd between terminals.

(iii) Control wiring shall be laced and formed into looms supported on wiring
cleats.

(iv) Alternatively, wiring may be run in insulated ducts. Wire ties or

equivalent shall be used throughout.

(v) Fuses and links shall be provided to enable all circuits in a switchgear
unit to be isolated from the busbars or buswires. It shall be possible to
work on control wiring for test and maintenance purposes without
making an MCC "dead".

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Section 76 – Electrical Equipment & Installation
 (vi) Each wire shall be separately terminated with tinned (but not soldered)
crimped lugs suitable for the terminal and wire used.

(vii) Conductor terminations need not be provided where insertion or tunnel

type terminals are used. Terminal studs or blocks shall be adequately
rated for the duty. Terminals shall be identified using an appropriate
marking number system.

(viii) An allowance shall be made on the length of each wire at the point of
connection to a terminal for the remaking of the termination at least once
without the need to disturb the main run of the cable.

(ix) Wiring between hinged panels and fixed portions shall be secured by
insulating sleeves at both ends and shall hinge freely without undue
flexing of the cable and without fouling other parts of the MCC.

(x) Internal switchboard wiring must be kept to one side of the group of
terminals, leaving the other side clear for external cable terminations.

(g) Auxiliary Control Equipment

(i) Where control relays, timer relays, or control fuses common to more
than one circuit are specified, such relays and fuses shall be mounted in
a common panel. Each item of equipment shall be clearly identified.

(h) Metering Instruments

(i) Metering instruments shall be provided and mounted on fixed or hinged

panels near the top of the MCC and in such a manner that the
instruments are not affected by vibration or electrical fields.

(ii) Isolating links and fuses shall be provided in all instrument current and
potential circuits to enable testing and maintenance.

(i) Spare Fuse Cabinet

(i) A spare fuse rack shall be provided for each motor control centre
utilizing fuses. The rack shall accommodate in separate racks or clips a
total of 6 fuses for each rating used in the motor control centre and shall
be labelled with the corresponding rating and voltage. Sufficient spare
fuses to fill the rack shall be provided. Fuses used during testing and
commissioning and the Defects Liability Period shall be replaced.

76.3.2 Input and Output (I/O) Panel for Motor Control Centres

(a) The input and output (I/O) panels shall be used for direct interfaction with
equipment under the MBMS monitoring and control functions. These I/O
panels are located in the communication services drawings, along with an
equipment list and point schedule.

(b) The contractor shall comply with other relevant sections of this General
Materials and Workmanship Specification including but not limited to:

(i) automatic controls;

(ii) chilled water plant;

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Section 76 – Electrical Equipment & Installation
 (iii) instrument;

(iv) low voltage electrical installation; and

(v) Variable frequency drives

(c) The existing MBMS installation shall be extended to include the items of plant
and sensors included in the modification works. The extensions to the existing
system shall provide the same functions as required for the original system.
The standard quality and performance of the extended system shall be
equivalent to the original system already provided.

(d) Unless otherwise reviewed without objection by the Project Manager, remote
monitoring facilities and other miscellaneous items of Plant shall be assign to
I/O panels located located in adjacent mechanical services plant rooms. For
remote monitoring facilities that control or are associated with remote Plant,
appropriate labeling shall be provided on the I/O panel and the motor control
center from which it is fed to indicate:

(i) the type and function of the remote monitoring facilities; and

(ii) the effect of isolating the I/O panel and /or motor control center on
remote Plant performance

76.3.3 Pump Control Panels and Associated Enclosures

(a) General

(i) The degree of protection for pump control panels (PCPs), control panels
and similar enclosures shall be to IP 54 as specified in BS EN 60529.

(ii) Panel construction shall comply with Section 76.3.1 (c) of the General
Materials and Workmanship Specification.

76.3.4 Electrical Circuit Protection

(a) Cable shall comply with Section 48 of the General Materials and Workmanship
Specification.

(b) Electrical circuit protection devices including circuit breakers, isolators,

switches, fused switches and etc. shall comply with Section 46 of the General
Materials and Workmanship Specification

76.3.5 Cable Type and Installation

(a) Cable shall comply with Section 48 of the General Materials and Workmanship
Specification.

(b) Cables shall be sized for the rated current of the connected load.

(c) All main and sub-main armoured cables shall be Cu/XLPE/SWA/LSF type.

(d) Colour codes of the cables shall comply with the New Cable Colour Code for
Fixed Electrical Installations published by the EMSD and the amendments.

General Materials & Workmanship Specification 7/12 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 76 – Electrical Equipment & Installation
76.3.6 Low Voltage Electric Motors

(a) Maximum motor speed shall be 1,500 rpm.

(b) Smoke extraction fans, motors and associated Plant shall comply with
Relevant Authority requirements for dynamic smoke extraction systems
including the requirement that Plant shall be suitable for continuous operation
at 250°C for at least 1 hour. Motor insulation shall be Class H to BS 2757
minimum.

(c) Kitchen exhaust fans, motors and associated Plant whilst not part of the
dynamic smoke extraction system, shall also be suitable for continuous
operation at 250°C for at least 1 hour. Motor insulation shall be Class H to BS
2757 minimum.

(d) Details of motor specification shall comply with Section 53 of the General
Materials and Workmanship Specification.

76.3.7 Variable Frequency Drives

(a) When a variable frequency drives (VFD) is specified for a fan or a pump with
throughput power up to 150 kVA, it shall be a solid-state converter to convert
three phase mains supply to an adjustable voltage and frequency output at its
rated throughput power. VFD shall conform to BS EN 50081 and BS EN
50082 or other similar recognized international standards on Electromagnetic
Compatibility (EMC) compliance for industrial or commercial applications and
shall be manufactured to ISO 9001.

(b) The VFD shall incorporate a 6-pulse (as a minimum) full-wave uncontrolled
diode bridge, fixed voltage fed DC link with inductors and capacitors to form a
filter, a mains filter for EMC compliance, a pulse width modulation (PWM)
inverter bridge utilizing insulated gate bipolar transistors (IGBTS) and output
inductors in the motor lines. The inverter bridge shall be controlled by a
microprocessor to produce a pulse width modulation (PWM) waveform or
similar technique which would result in full motor voltage and sinusoidal
current mains supply in the motor circuit.

(c) The VFD shall be capable of continuously delivering rated output voltage even
when the mains supply voltage is down to 6% of its nominal value and shall be
able to control a standard IEC 60034 3-phase squirrel cage induction motor
over a speed range of 20% to 100% continuously and smoothly without the
need to de-rate the motor kW rating and to provide total power factor of not
less than 0.9 lagging, without external chokes or power factor correction
capacitors, at all loads within the speed range. The inrush current shall be
zero and during starting, the current shall start from zero and rise as the load
accelerates and shall not exceed the full load current.

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Section 76 – Electrical Equipment & Installation
 (d) The VFD shall allow unlimited switching of the motor circuit, at any load and
within the controlled speed range without damage and without the need of
auxiliary control switching. The VFD shall be capable of automatically
reconnecting to a spinning fan and running without tripping, following mains
interruption and on transfer from backup source. The VFD shall be capable of
running with no motor connected during functional testing. The VFD shall have
voltage/frequency (V/f) ratio suitable for centrifugal pumps and fans control.
Selectable V/f ratios shall be provided and it shall not be possible to set a
constant V/f ratio, to prevent damage to connected equipment and to optimize
energy usage.

(e) The complete VFD unit shall be housed in a single front-access enclosure
designed and built as an integral part of the VFD by the VFD manufacturer.
The VFD shall be protected to at least IP 44 for indoor and IP 55 for outdoor
application, without having to use a secondary enclosure. It shall be suitable
for continuous operation without de-rating under ambient temperature of up to
40°C and relative humidity of up to 99% unless otherwise specified.

(f) The VFD shall be fully rated to provide the performance as follows:

(i) minimum efficiency of 95% at 100% load and not less than 90%
efficiency at any other operating loads;

(ii) output torque shall be limited to 105% of full load torque;

(iii) no facility for reversing the motor rotation shall be incorporated;

(iv) the VFD shall have a maximum capacity of 150 kVA as recommended
by the "Limits for Harmonics in the United Kingdom Electricity Supply
System" published by the Electricity Council;

(v) the maximum allowable fifth harmonic current distortion expressed in

percent of the fundamental input current at the VFD input terminals
during operation within the variable speed range shall be less than 35%;
and

(vi) the electromagnetic compatibility shall comply with BS EN 50081 and

BS EN 50082.

(g) The following minimum features shall be incorporated in the VFD unit
complete with an integral control panel:

(i) acceptance of digital and analogue 0-10 V, 4-20 mA control signals;

(ii) integral measurement and selectable display of:

- output current;

- output voltage;

- output frequency;

- output speed;

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Section 76 – Electrical Equipment & Installation
 - output power; and

- motor temperature.

(iii) display of warning/fault/alarm status;

(iv) ability to transmit data on the output for remote interrogating and
reprogramming;

(v) programmable relay output (250V 2A) and programmable analogue

output of 4-20 mA or 0-10V DC suitable for the application;

(vi) 5 programmable preset speeds (including at least 2 skip frequencies of

adjustable bandwidth to overcome mechanical or air system resonance);

(vii) selectable local or remote control; and

(viii) provision of the following integral protection against:

- loss of mains and motor phase;

- motor short circuit;

- motor circuit earth fault;

- motor overheat;

- over voltage;

- VFD overheat;

- under voltage;

- input transients;

- VFD and motor overload; and

- mains input accidentally coupled to motor output terminals.

(h) An integral full 3-term PID control to provide close loop control direct from
signal transmitter without need for external signal conditioning;

(i) A facility for controlling motor anti-condensation heater for heater operation
when the motor is idle.

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Section 76 – Electrical Equipment & Installation
76.3.8 Local Motor Control Panel (LCP)

Separate motor controllers, where specified, shall be provided and shall include, but
not be limited to, the following :

(a) Construction
Each motor controller shall house the specified motor starter(s), control
switches and push-buttons, indications, alarms and accessories. The
enclosure for the motor controller shall be of standard mass produced product
by an approved manufacturer suitable for wall mounting and shall be of fine
coated sheet steel, not less than 2mm thick, with stoved enamel paint finish,
light grey in colour. For motor controller / LCP greater than 400A and/or with
more than six starters or feeder units, the panel/enclosure construction shall
be suitable for floor mounting.

(b) Door and Door Mounted Equipments

A gasketed front-access door with padlocking facilities for the isolator, in the
"OFF" position, shall be provided.
The door shall be hinged at the left hand side with car type chromium plated
handle and fitted with 6 x 6 mm neoprene gaskets.
Indication lamps and push buttons shall be flush mounted on the door of the
controller. They shall be chromium plated and shall be suitable for 22 mm
diameter single-hole mounting.

(c) Internal Components

Relevant controller components including contactors, starters, mains and
motor protective devices, main supply isolator, etc shall comply with GMWS
Section 76.3. Control relays and accessories shall be provided for the
specified controls, indications and alarms.

(d) Control and Indication Facilities

The controller shall have the following equipment fitted or as specified:

(i) Mains isolator complete with voltmeter and selector switch for the
controller supply.

(ii) Control and indications facilities in GMWS Section 76.3.

(iii) For a controller for more than one motor,

1. Duty selector switch.

2. Duty motor indication lamps.

76.4 SUBMISSIONS

76.4.1 General

The Contractor shall submit the following documents to the Project Manager for
review without objection:

(a) evidence of compatibility between thermistors and protection units; and

(b) details of control panels showing all indication signal, control, function and
component arrangement.

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Section 76 – Electrical Equipment & Installation
76.5 WORKMANSHIP

76.5.1 Cabling and Wiring

(a) Cabling and wiring shall comply with Section 48 of the General Materials and
Workmanship Specification.

(b) The minimum conductor size shall be 2.5 mm2 for phase, neutral conductors
and earth conductors. Control circuit cabling conductor size shall be 1.5 mm2
minimum subject to voltage drop limitations.

76.5.2 Conduits and Fittings

(a) Conduits and fittings shall comply with Section 49 of the General Materials
and Workmanship Specification.

76.5.3 Cable Trays, Cable Trunking and Fittings

(a) Cable trays, cable trunkings and fittings installations shall installed in
accordance with Section 49 of the General Materials and Workmanship
Specification.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 76 – Electrical Equipment & Installation
SECTION 77 AUTOMATIC CONTROLS

77.1 GENERAL

(a) The Contractor shall comply with other relevant sections of the Specification
including but not limited to the sections which specify:

(i) Section 72 “Pipework, Fittings and Valves”;

(ii) Section 76 “Electrical Equipment and Installation”;

(iii) Section 78 “Instruments”; and

(iv) Section 79 “Testing, Inspection and Commissioning – Mechanical

Services”

(b) Unless otherwise specified, control systems shall be microprocessor based

using digital control integrated into the Mechanical Building Management
System (MBMS).

(c) All sensors shall be arranged to give convenient access for servicing the
sensor.

(d) The power supply for all automatic control facilities including PLC’s, MBMS
panels controllers, field devices and similar shall be derived from the
associated motor control center (MCC).

(e) Unless other specified, individual items of plant shall be controlled through an
“Auto-Off-Manual” (AOM) rotary switch mounted on the relevant MCC, control
panel or the like, and shall operate as follows:
(i) “Auto” – item shall be operated as described;

(ii) “Off” – item shall be isolated regardless of any other control status
except fire mode control; and

(iii) “Manual” – item shall be operated independently of any other control

status except fire mode control, safety interlocks and circuits directly
associated with particular item.

(f) Smoke extraction fans shall be operated and shall be capable of being
controlled remotely by the FSD under fire mode regardless of the AOM switch
status of the relevant MCC.

(g) Motorized, solenoid and control valves shall be capable of being driven closed
by the associated actuator against a pressure drop across the valve
equivalent to that of at least the corresponding pump shut off head.

(h) Cooling coil control valves shall be interlocked with the air handling units and
fan coil units. When the air handling unit/fan coil unit control is de-energized,
the cooling coil control valve and motorized dampers shall close.

(i) Sensors, controllers, relays and the like shall be provided with identifying
nameplates or stencils. Labelling for devices in public areas shall be located
at the underside of the corresponding cover plate.
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Section 77 – Automatic Controls
 (j) Fans capable of starting up under fire mode control and the MCC cubicle door
of the circuit that feeds those fans shall be provided with a suitable warning
label indicating that the plant may start up under fire mode regardless of
control switch status.

(k) Air handling units and supply air fans shall be interlocked with the
corresponding exhaust air systems that serve the same area, adjacent toilets,
kitchens or the like. Interlocks shall be through the MBMS unless specified as
being hardwired through the MCC.

(l) As duty and standby operation of the system is used, the following function
shall be provided unless otherwise specified:

(i) standby plant shall start on receipt of a high temperature or fault alarms;

(ii) both duty and standby plant shall be capable of operating at the same
time; and

(iii) the MBMS shall be able to rotate plant from duty to standby status and
at the same time rotate the associated plant from standby to duty status.

(m) Unless otherwise specified, time delays to suit the safe operation of plant and
to suit Relevant Authority requirements including reduced voltage motor
starters, high speed/low speed motor changeovers and similar shall be
provided by integral electronic timer relays mounted in the relevant motor
control center or control panel. All such timer relays shall be individually
adjustable. Time delays associated with sequencing of plant including
confirmation of long term stability of control signals shall be through the
MBMS.

(n) Individual indicators on the front panel of MCC and control panels shall be
provided for each MCC or control panel mounted time relay except those
associated with a reduced voltage motor starter.

(o) Sensors monitored by MBMS may be used for fire mode monitoring. Their
contacts for fire mode status indication shall be separated from those for
MBMS status indication.

(p) All sensors used for the hot smoke extraction system shall be capable of being
operated at 250°C for one hour as per FSD requirement.

(q) All fire mode shutdown, fan initiation and damper control signals shall be
hardwired and shall be independent of the building management system.

(r) All cables associated with the smoke control fans shall be of fire resistant to
FSD requirements.

(s) The Specification for Motor Control Center (MCC) as described in this Section
shall be applicable for both Motor Control Center (MCC) and Local Motor
Control Panel (LCP) for Mechanical Services installations.

(t) The Mechanical Services Building Management System “MBMS” as described

in this Section shall be equivalent to Building Management System (BMS).

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Section 77 – Automatic Controls
77.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, at the date of the Letter of Acceptance.

IEC 529 Degree of protection of enclosures

Guidance Notes for Management of IAQ in Offices and Public Places
Guide for Participation in the IAQ Certification Scheme

77.3 DESIGN AND PERFORMANCE CRITERIA

77.3.1 Hard Wired Load Shedding Facilities

(a) Load Management

(i) Within MCCs, the Contractor shall provide at least two relays, the
supplies of which are fed through contacts that monitor the status of load
shed signals from the relevant low voltage main switchboard (MSB).
The relays shall have both NO and NC contacts so that MSB load shed
signals being monitored can be changed from NO to NC without
significant disruption.

(ii) The first stage of load shedding from the MSB shall de-energize all non-
essential plant; and

(iii) Load shedding initiated from the MSB shall be hard wired.

(b) Power Failure / Undervoltage Trip

(i) The Contractor shall provide phase failure/undervoltage relays in MCCs

which shall de-energize non-essential plant within the MCC in the event
of a phase failure or undervoltage fault; and

(ii) Phase failure/ undervoltage relays shall be capable of being reset either
at the MCC or through the MBMS.

77.3.2 Interface with Mechanical Services Building Management System

(a) Unless otherwise specified, the entire mechanical services controls

installation, associated components, equipment, fittings and the like for the
reconfigured and new mechanical services plant and equipment shall be
compatible and fully integrated with the existing MBMS to enable monitoring of
all temperature sensors, actuators, control valves and the like.

(b) The mechanical services control system shall be capable of being initiated and
operating independently when the MBMS central processor is in a fault
condition, or when the local area network cabling is disabled. To this end all
MBMS stop / start contacts shall be wired into the “Auto” control circuit and
shall not interfere with or override the “Manual”, “Test”, “Bypass” or “ Off”
facilities located on the motor control center or elsewhere.

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Section 77 – Automatic Controls
 (c) Start Up Sequences

(i) the MBMS shall incorporate a time switch and / or event initiated control
function as part of all mechanical services stop/start facilities; and

(ii) unless otherwise specified, each time switch programme services shall
be configured to include a sequence of at least 10 MBMS generated
time delays which initiate groups of plant at 20-30 second intervals to
reduce inrush current on startup.

(d) Plant Start Menu

(i) A special MBMS menu of at least 50 plant start options shall be provided
to enable an operator to select a pre-set combination of plant to stop and
start to suit particular circumstances.

(ii) These plant start options shall be capable of being initiated manually
through the MBMS or automatically in accordance with a pre-arranged
time schedule programmed into the system.

(iii) Plant start signals shall be capable of being programmed in parallel or

series with each other within the MBMS.

(e) Loading Shedding Menu

(i) A special MBMS menu of at least 50 separate load shedding options

shall be provided to enable an operator to select a pre-set combination
of plant and/or associated controls to be isolated or have limited
operation in the event of there being a fault associated with the electrical
supply or chilled water plant, for example:

- global reset of controller setpoints;

- global limiting of variable speed drives; and

- global limiting of control valve opening

(ii) These load shedding options shall be capable of being initiated

automatically or manually through the MBMS.

- The global signals shall be capable of being separately initiated on an

area by area basis

(f) Emergency shutdown

(i) In addition to hardwired fire mode shutdown facilities, a special MBMS

menu of at least 20 separate emergency shutdown options shall be
provided to enable an operator to select a pre-set combination of plant to
shutdown manually or automatically in an emergency.

(ii) The pre-set combination of plant is based on an area by area basis.

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Section 77 – Automatic Controls
 (g) MBMS Status Indication

(i) All digital input status indication for all MBMS stop / start facilities shall
be provided for status indication.

(ii) The status of the main contactor associated with the item of equipment
shall be monitored.

77.3.3 Fire Mode Control

(a) General

(i) Notwithstanding the requirements specified, FSD circular letter No. 96

and COP (98) shall be complied with.

(ii) In general, automatic fire mode control signal from the fire alarm control
system and manual fire mode signals from the “Smoke System Control
Panel” (SSCP) and the “Ventilation / Air Conditioning Manual Override
Control Panel” (VMOCP) shall be provided at terminal strips in relevant
MCCs. One type of signal to shutdown Plant not required for smoke
control such as air handling units and another type of signal to control
smoke extraction fans and associated Plant shall be provided.

(iii) When more than one automatic and/or manual fire mode signal is
received at a MCC, the following shall occur:

- motorized fire and smoke dampers (MSD’s) associated with those

smoke control zones for which a fire mode signal has been received
shall assume the relevant fire mode status. Under these
circumstances, a fire mode control signal to open a MSD shall take
precedence over a fire mode signal to close a MSD;

- a fire mode control signal to initiate high speed operation of a smoke

extraction fan shall take precedence over a fire mode control signal to
initiate a slow speed operation of the same smoke extraction fan; and

- the hot smoke extract fan shall run continuously until manually reset
at the hot smoke control panel or local MCC.

(iv) Fire mode indicators and momentary contact reset push button shall be
provided for each MCC, control panel and the like. The indicator shall
illuminate on receipt of any fire mode control signal and shall remain
illuminated until all signals have been cleared and MCCB and/or panel
has been reset.

(v) Separate indicators shall be provided for each separate fire mode signal
connected to the MCC.

(vi) Fire mode reset facilities shall be provided through the MBMS for each
control center, control panel and the like.

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Section 77 – Automatic Controls
 (b) Automatic Fire Mode Control

This type of fire mode control automatically initiated by the fire alarm system
shall be as follows:

(i) shutdown mode:

- on receipt of signal from the fire alarm system, the following plants
shall shut down irrespective of MBMS control status. Relevant
dampers shall assume corresponding fire mode positions; and

- following receipt of a shutdown fire mode control signal, the relevant

plant shall remain shutdown until manually reset at the MCC or
through the MBMS;

(ii) Type 1 : Initiation – Single Mode:

- on receipt of a signal from the fire alarm system, the relevant fan shall
start up and run irrespective of mechanical BMS (MBMS) control
status. Relevant dampers shall assume corresponding fire mode
position;

(iii) Type 2 : Initiation – Dual Mode:

- for two fans on high speed, on receipt of a signal from the fire alarm
system, the relevant fan shall run on high speed irrespective of
MBMS control status. Relevant dampers shall assume corresponding
fire mode position;

- for two fans on low speed, on receipt of a signal from the fire alarm
system, the relevant fan shall run on low speed irrespective of MBMS
control status. Relevant dampers shall assume corresponding fire
mode position;

(iv) Fire Interface:

- the status of the relevant equipment shall not be affected by the fire
alarm system.

The overall fire mode concept can be generally described as follows:

(i) areas requiring hot smoke extraction are designed as smoke control
zones; and

(ii) the following types of plant generally shutdown when a particular smoke
control zone goes into fire mode:

- air handling units serving the smoke control zone;

- air handling units serving adjacent areas whose return air inlets and/
or ductwork is required for extraction of the smoke zone control in fire
mode;

- plant that draws air from areas adjacent to smoke extraction intake
points; and

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 (iii) therefore an item of plant may be designed to serve more than one
smoke control zone depending upon the extent it affects or is affected by
adjacent smoke control zones.

(c) Manual Fire Mode Control

(i) The SSCP is designed to provide the FSD with facilities to manually
initiate and shutdown smoke control plant.

(ii) A signal from the SSCP to initiate smoke control plant in a particular
smoke control zone shall in the same control zone also cause all other
fire mode plant to shutdown under fire mode and remain shutdown until
reset manually at the MCC or through the MBMS.

(iii) The VMOCP is designed to provide the FSD with facilities to manually
shutdown fire mode plant.

(iv) A signal from the VMOCP to shutdown fire mode plant in a particular
smoke control zone shall have no effect on the status of other plant in
the same smoke control zone.

77.3.4 Control of Primary Air Handling Unit (PAU)

Micro-processor based electronic controller or DDC as specified shall be used for

the control of the PAU, its associated equipment and the interfacing and
communication with the MBMS and its associated zone AHUs and FCUs. The
following functions shall be provided unless otherwise specified:

(a) General

(i) each separate primary air handling unit shall be stopped and started
through the MBMS;

(ii) controls shall be interlocked with the corresponding air handling units;

(iii) AHU fans shall be hardwired interlocked using microswitches associated

with motorized AHU dampers so that the fan cannot start until the
dampers are sufficiently open to suit the performance of the plant; and

(iv) when the primary air handling unit controls are de-energized, the cooling
coil control valve shall close; and

(b) Temperature Control

(i) the supply air temperature shall be maintained within the range specified
by modulating valves in response to the corresponding supply air
temperature to regulate the chilled water flow through the cooling coil of
the PAU to maintain the pre-set supply air temperature; and

(c) Fire Mode

(i) on receipt of a fire mode signal, the corresponding air handling unit shall
shutdown and the associated outside air damper shall close; and

(ii) when probe type smoke detector located in the supply air duct senses
smoke the fan within the respective AHU will shut down.

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Section 77 – Automatic Controls
77.3.5 Control of Single Zone VAV Air Handling Unit (AHU) with Variable Outside Air

(a) General

(i) each separate air handling unit shall be stopped and started through the
MBMS.

(ii) controls shall be interlocked with the corresponding air handling unit.

(iii) AHU fans shall be hardwired interlocked using microswitches associated

with motorized AHU dampers so that the fan cannot start until the
dampers are sufficiently open to suit the performance of the plant.

(iv) when the air handling unit controls are de-energized, the cooling coil
control valve shall close.

(b) Temperature Control:

(i) Summer mode:

- the variable frequency drive output shall vary in response to the

corresponding space/return air temperature sensor; and

- the cooling control valve shall modulate in response to the

corresponding supply air temperature sensors.

(ii) Winter mode:

- the air flowrate shall be set at 50% of design flowrate and the space
temperature controlled by modulating the cooling coil control valve in
response to the return air temperature sensor.

(c) Outside Air Supply Control:

On receipt of a signal from MBMS CO2 control system, the outside air intake
damper shall be modulated in response to the outside air velocity sensor.
Sufficient amount of fresh air but not less than 50% of design fresh air flowrate
shall be provided to maintain the zone CO2 level at all zones within the range
specified;

(d) Fire Mode

(i) on receipt of a fire mode signal, the corresponding air handling unit shall
shutdown and the associated outside air damper shall close.

(ii) when probe type smoke detector located in the supply air duct senses
smoke the fan within the respective AHU will shut down.

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77.3.6 Control of Fan Coil Unit (FCU)

(a) General

(i) Control for fan coil units shall be similar to those provided for air
handling units. Non microprocessor based controls supplied by fan coil
unit manufacturers shall not be used.

(ii) Each separate fan coil unit shall be stopped and started through the
MBMS.

(iii) Controls shall be interlocked with the corresponding fan coil unit.

(iv) When the fan coil unit controls are de-energized, the cooling coil control
valve shall close.

(b) Temperature Control

(i) Fan coil units shall run continuously and the cooling coil control valve
shall be on-off in response to the corresponding space temperature
sensors.

(c) Fire Mode

(i) The plant shall stop or continue to run as scheduled on the Employer’s
Drawings.

77.3.7 Control of Single Speed Ventilation System

Unless otherwise specified, duty and standby fans shall be used for single speed
ventilation system and the following functions shall be provided:

(a) each separate fan including duty and standby fans shall be individually
stopped and started through the MBMS; and

(b) fans shall stop or continue to run as scheduled on the Employer’s Drawings.

77.3.8 Control of Single Speed Dual Function Ventilation System

Unless otherwise specified, duty and standby fans shall be used for single speed
dual function ventilation system and the following functions shall be provided:

(a) each separate fan including duty and standby fans shall be individually
stopped and started through the MBMS;

(b) fans shall be operated in fire mode as scheduled on receipt of fire mode signal
through MBMS;

(c) when the probe type smoke detector located in the exhaust duct senses
smoke, the fan shall shut down. The signal to operate in fire mode shall
override the signal from the probe type detector to shut down;

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Section 77 – Automatic Controls
 (d) maintenance testing of smoke extraction fans shall be initiated by simulating a
fire mode signal in an appropriate smoke control zone using a momentary
“break” contact energized through the MBMS. Smoke extraction fans shall be
stopped by resetting the simulated fire mode control system using a
momentary “make” contract energized through the MBMS; and

(e) during normal mode of operation, the MBMS system shall control the fans. In
fire mode, any fire control signals shall override the MBMS control and shall
remain so until such time as the fire control signals have been reset through
the “Fire Alarm System”.

77.3.9 Control of Constant Volume Ventilation System with VFD Drive

(a) Each separate fan shall be stopped and started through the MBMS.

(b) The variable frequency drive output shall be set manually through MBMS so
that the fan runs at constant speed.

(c) Fan operation shall be not affected by fire mode signals.

(d) Interlocks with town gas solenoid valves shall be provided for kitchen exhaust.

77.3.10 Control of Temperature Ventilation System

Unless otherwise specified, duty and standby fans shall be used for temperature
ventilation system and the following functions shall be provided:

(a) each separate fan including duty and standby fans shall be individually
stopped and started through the MBMS;

(b) fans shall cycle in response to corresponding temperature sensors; and

(c) all fans shall run for at least 15 minutes once initiated.

77.3.11 VFD Control System

Where microprocessor control facilities are specified for individual variable

frequency drives, the following performance requirements shall apply:

(a) Control panels shall be based on programmable logic controllers (PLC), or

similar industrial grade hardware, providing separate local data gathering and
processing capability. Each panel shall be a microprocessor based intelligent
unit complete with software and hardware, and operator’s panel for input and
output commands required for standalone operation.

(b) Panels and associated components shall be compatible with the MBMS and
shall meet MBMS performance requirements relating to the receipt,
processing and transmission of both analogue and digital data including all
protocols and other interfacing requirements.

(c) Each panel shall provide a local data interception point from various
monitoring sensors and control devices associated with the plant. The
connection to these devices shall not affect the safe operation of the plant.

(d) Each panel shall be complete with enclosure, termination strips and gland
points for cable entry. The degree of protection shall be IP42 to IEC 529.

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 (e) Line protection components shall be provided for protecting the
microprocessor hardware from electrical surge and other induced currents.

(f) An internal watchdog device shall be incorporated in the equipment for failure
detection. In the event of any software or hardware failure that affects the
normal function of the equipment, the watchdog device shall initiate a re-boot
procedure automatically and during this procedure ensure the safe operation
of the plant. The failure mode and the quantity count of such failure shall be
reported to the MBMS as part of the status change routine.

(g) All programme and configurable parameters shall be retained in long term
memory to enable immediate operation following long term power supply loss.
(h) The panel shall include a resident crystal controlled oscillator for critical timing
and real time clock maintenance functions, with a real time clock resolution of
100 milliseconds or better.

(i) Battery back-up for maintaining real time clock, buffers and point status shall
be capable of a minimum of 8 hours retention following a power failure. The
battery pack shall be automatically recharged when mains power is supplied.
A visual warning status shall be provided when battery is low, as well as
power supply status. This information shall be transmitted to the MBMS panel
as a status alarm.

(j) The panel shall ensure the integrity of the stored data and programs in the
event of a power failure. Hardware and software diagnostic routines shall be
automatically carried out during power on reset, manual reset and periodically
during device sequencing to identify faults. A self test pushbutton shall be
included in the panel to initialize manual testing. The tests shall also include
communications link checking. Detection of internal controller faults shall be
flagged to the MBMS panel, and displayed visually at the panel itself. The test
mode shall allow for the testing of all analogue digital points and sensors
within the plant.

77.3.12 Carbon Dioxide Control System

(a) The carbon dioxide control system shall be manually or automatically operated
through MBMS.

(b) Where an area has two CO2 sensors, each sensor shall be deemed to monitor
approximately 50% of the area.

(c) When a CO2 sensor records a CO2 level less than set point for longer than 30
minutes, the event shall be recorded by MBMS to alert the operator.

(d) If, at the same time, the ambient temperature external to the building is less
than 24°C then the operator shall be simultaneously alerted of this and a
message displayed advising against resetting to minimum outside air if there
is a demand for cooling and the intention is to save energy.

(e) The operator shall then decide, if any, AHU’s are to be reset to minimum
outside air.

(f) AHU’s that can be reset shall be grouped in a special menu based on the area
that CO2 sensor is deemed to monitor.

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 (g) If a CO2 sensor records a CO2 level greater than the set point for longer than
15 minutes then the operator shall be alerted. Any AHU’s serving the relevant
area that is on minimum outside air shall automatically reset to maximum
outside air.

(h) The operation as specified from (d) to (g) can be operated automatically by
switching the Carbon Dioxide Control System to “Auto” mode through the
MBMS by the operator.

77.3.13 Enthalpy control for free air cooling system

(a) The free air cooling control system shall be energized to monitor the system
conditions when the supply air fan of the air handling unit is turned on.

(b) Motorised control dampers shall be provided in the returned air path for
isolating the return air side and supply air side under the free air cooling
mode. This isolating damper shall be normally opened and fully closed under
the air cooling operation.

(c) Motorised fresh air supply dampers shall have a minimum setting to provide
the minimum fresh air supply to the system and shall be fully opened under
the free air cooling operation.

(d) Enthaply (Temperature and humidity) sensing devices shall be provided at the
fresh air supply intake to monitor the fresh air conditions. These sensing
devices shall provide all necessary information to the system controller which
shall determine and operate the free air mode when conditions meet with the
specified criteria.

(e) Enthaply (Temperature and humidity) sensing devices shall also be installed
downstream of the supply air fan to monitor the supply air conditions. The
control system shall allow top priority to these sensing devices to override the
signal of free air cooling when the conditions of the supply air fails to meet the
specified condition.

(f) The details and final configuration of free air cooling system shall comply with
the criteria specified under the Specification.

77.3.14 Control of CAV Single Zone Air Handling Unit (AHU) with Variable Outside Air

(a) General

(i) Each separate air handling unit shall be stopped and started through
the MBMS.

(ii) Controls shall be interlocked with the corresponding air handling unit.

(iii) AHU fans shall be hardwired interlocked using micro-switches

associated with motorized AHU dampers so that the fan cannot start
until the damper is sufficiently open to suit the performance of the
plant.

(iv) When the air handling unit controls are de-energized, the cooling coil
control valve shall close.

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 (b) Temperature Control

(i) The cooling control valve shall modulate in response to the

corresponding space/return air temperature sensor(s).

(c) Outside Air Supply Control

(i) On receipt of a signal from MBMS CO2 control system, the outside air
intake damper shall be modulated in response to the outside air velocity
sensor. Sufficient amount of outside air shall be achieved but not below
the minimum value stated in the Employers Drawings.

(d) Fire Mode

(i) On receipt of a fire mode signal, all non essential ventilation plant shall
automatically shutdown and the associated outside air dampers shall
close. The ventilation system shall be prevented from being restarted
until the fire alarm signal as been reset.

(ii) When probe type smoke detector, located in the intake air duct, senses
smoke the associated fan shall automatically shut down. The ventilation
system shall be prevented from being restarted until the fire alarm signal
as been reset.

77.3.15 Control of Chiller Plant

(a) An independent electronically/electrically operated control panel shall be

provided for each chiller and shall form an integral part of the unit. The control
panel shall incorporate the following safety control features :-

(i) Low refrigerant pressure or temperature for water cooler.

(ii) Low water temperature for water cooler.

(iii) High refrigerant pressure.

(iv) Low compressor oil pressure.

(v) Minimum chilled water flow.

(vi) Minimum condenser water flow.

(vii) High motor temperature.

(viii) High oil temperature.

(ix) Compressor motor current-limiting device to operate capacity-control

mechanism to limit load on compressor motor to safe maximum at all
times.

(x) High condenser temperature.

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 (b) Each chiller plant shall be equipped with the following control features:

(i) A control mode selector switch shall be located at each starter/motor

control panel of pumps or chiller. The switch shall have "Manual",
"Automatic" and "Off" positions.

(ii) In any mode the chilled water flow through each chiller shall be provided
by a relay responding to the running condition of the duty circulating
water pump and by its corresponding flow switch before the chiller's
control shall be energised. The evaporator of the chiller shall also be
protected by a low temperature cut-out. Delay timers and recycling
relays shall be provided where necessary to prevent chillers from
cycling.

(iii) A 2-position selecting system shall be provided for each group of chiller
for selecting the duty and standby pumps and sequencing the open or
close of the associated 2 way motorised valves.

(iv) One lead/lag/automatic selecting switch shall be provided for

determining the lead/lag/automatic operation for the chiller plant. The
automatic control shall include a cycling feature to select the duty units
from a group of chillers and pumps alternately to allow even wears of the
equipment.

(v) When the model selector switch is in the "Manual" position, the chiller
and the pumps shall be started and stopped manually at the MCC board.

(vi) When the mode selector switch is in the "Off" position, the system shall
be switch off automatically after a predetermined period (adjustable)
according to the recommendation of chiller manufacturer. All necessary
delay timers shall be provided to protect the chiller.

(vii) When the mode selector switch is in the "Automatic" position, the
following sequence shall be energized:

(viii) An automatic 24 hours time-switch shall first energized the lead chilled
water pump, in turn shall then energized a step controller, which shall
response to an immerse type thermostat at the common return water
header line, and a delay timer (0-30 second).

(ix) A Programmable Logic Controller (PLC), on increasing cooling demand,

by sensing the supply and return water temperature and the chilled
water flow rate shall determine the combination of chiller operation
required to cater for the cooling load demand.

(x) The PLC shall monitor the chilled water return temperature and control
the chiller plant to maintain the return water temperature not exceeding
12°C.

(xi) Time delay shall be allowed for chiller energisation after detection of
chilled water flow.

(xii) Time delay shall be allowed for chilled water pump such that the pump
shall continue to run for 15 minutes after stop operation of the
corresponding chiller.

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Section 77 – Automatic Controls
 (xiii) Chillers shall be designed to operate at maximum load, i.e. the
energization of the lag chiller shall happen only when the total demand
exceeds the capacity of the running chillers.

(xiv) Flow switches, flow meters and temperature sensors shall be provided
to indicate the chilled water demand and, according to the actual
demand, shall start/stop the chillers and pumps.

(xv) The chiller auto-sequencing programme shall be engineered to enable

the chiller plant operating in a flexible combination and adaptive to the
following step control criteria:-

- Pre-determined chiller supply temperatures. Set points and operating

differential to be adjustable.

- Pre-determined chiller return temperatures. Set points and operating

differential to be adjustable.

- Pre-determined chiller running current values. Set points and operating

differential to be adjustable.

- Pre-determined outdoor air temperature and enthalpy schedule. The

temperature set points and operating differentials to be adjustable.

- Dynamic calculated system enthalpy compared with the pre-calculated

cooling load inputs. Set points and operating differentials to be
adjustable.

- Adjustable time lag to cut in and cut out the next step equipment to
prevent hunting.

- Pre-determined maximum kW demand for the plant.

(c) Differential By-pass

(i) An electronic/electrical differential pressure transmitter/controller system

of industrial quality shall be connected to sense the water pressure of
the chilled water supply and return lines and shall provide proportional
plus integral control of an electrically operated two way control valve to
by-pass the chilled water from flow to return line as necessary to
maintain the desired differential pressure.

(ii) The local control shall be provided with gauges/meters flush mounted to
indicate the system differential pressure.

(d) The microprocessor shall control compressor anti-recycle function,

compressor lead-lag selection, low water temperature cut-out, loss of
refrigerant charge protection, leaving chilled water temperature control, load
limiting control, and timed periodic pumpdown.

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Section 77 – Automatic Controls
 (e) The chillers shall be provided with the following automatic control gears and
associated keypad for set point adjustment:

(i) Capacity control of microprocessor incorporating proportional integral

derivative (PID) control strategies to process the signal from the factory
assembled chilled water temperature sensor to reliably satisfy the load
requirements across the entire load range.

(ii) Demand limit control.

(iii) Pull down time period control.

(iv) Programmable 7-day time clock for auto start/stop including separate
schedules for holidays.

(v) A three- position key switch to provide a choice of local/

programme/remote modes of operation.

(vi) A keypad for digital programming of essential set points for:

- Leaving chilled water temperature;

- Percentage current limit;

- Pull down demand limiting;

- 7-day time clock for chillers and pump with holiday schedules; and

- Remote reset chilled water temperature range.

- Adjustment of chiller capacity.

- Humidity control of the control panel.

- Chilled water reset function

- Soft stop of compressor

77.3.16 Control of Make Up Water System

(a) Mechanical BMS interface facilities shall include:

(i) chilled water system pressure;

(ii) make up tank infill;

(iii) make up tank water level; and

(iv) alarm monitoring of make up water isolating valve adjacent to

connection point at the CHW return header.

77.3.17 Control of Chemical Dosing Pump

(a) The mechanical BMS shall monitor chemical pump operation.

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Section 77 – Automatic Controls
77.3.18 Control of Computer Room Air Conditioning (CRAC) Units

(a) General

(i) CRAC units shall have built-in micro-processor(s) for controlling the
desired indoor temperature and humidity. Each CRAC unit shall also be
interfaced with the MBMS. All digital and analogue input and output
signals shall be transmitted to/from CRACs to MBMS via high level
interface using RS422/232 ports, for CRAC system overall control and
monitoring. The MBMS shall provide relevant software and graphical
interfaces for CRAC systems at MBMS workstations.

(ii) The two CRAC units shall be in rotational operation to event out the
operation time.

(iii) The operational priority of the CRAC units shall be as follows : -

- Master CRAC, Chilled Water

- Master CRAC, Duty DX

- Slave CRAC, Chilled Water

- Slave CRAC, DX

(b) Temperature Control

(i) The cooling control valve shall modulate in response to the

corresponding space/return air temperature sensor(s).

(c) Fire Mode

(i) When probe type smoke detector located in the supply air duct senses
smoke the fan within the respective CRAC unit will shut down.

77.3.19 Normal Power Supply Failure

(a) When a normal power supply failure signal has been received from the
GBMS/MBMS, the controls of chiller plant shall automatically set to run a
maximum of 3 nos. chillers and associated chilled water pumps. Also, signal
will be sent from GBMS/MBMS to all related air handling field equipments
(AHUs, CRAC Units, FCUs, etc.) to limit the room temperature to 26 oC.

77.3.20 Control of Smoke Extraction Systems

(a) The control and actuation of smoke extraction systems shall be in compliance
with the FSD COP Section 5.23 and the Mode Tables shown in the
Employer’s Drawings.

77.3.21 Control of Sliding Doors

(a) Whenever any one or more smoke extraction system is activated, the smoke
extraction control panel shall send a signal (by means of dry contact) to the
designated sliding doors to allow air make-up from outside.

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Section 77 – Automatic Controls
77.3.22 Control of Miscellaneous Motorised Fire and Smoke Dampers

(a) Related fire signal (zoning based on smoke zones) will be transmitted from the
main Fire panel located at G/F FS Control Room to each miscellaneous
motorized fire and smoke damper to close it in order to seal any openings in
smoke reservoirs formed by ductwork passing through.

77.3.23 Control of Gas Purging and Periodic Ventilation Systems

(a) The following rooms shall be served by gas purge systems:

(i) Main communication rooms

(ii) Tenant Radio Room

(b) The gas purge system shall consist associated ductwork, silencers, and
motorised fire/smoke dampers connecting to the nearby toilet exhaust system.

(c) The gas purge system shall be capable of being operated locally (LOCAL
mode) and monitored by MBMS as dictated by a selector switch at the local
control panel (LCP) located in the FM200 Bottle Room. The 2 position selector
switch shall allow ‘On/Off’ modes.

(d) The system shall be provided with the following operation features in the
MBMS mode:

(i) Continuous monitoring of the status and fault reporting

(ii) Generation of warning alarm if any of the sensor input signal beyond its
operational limit

(iii) Software manual on/off switches to override the LOCAL mode of

individual plant

(iv) Alarm generation if feedback status deviates from normal

(v) Indication of the fans running hours and maintenance schedules, and
annunciation of ‘maintenance due’ for the fans

(e) The maintenance staff can operate the system in ‘On’ or ‘Off by a 2 position
switch at the LCP.

(f) The system shall be provided with the following operation features in the auto
mode:

(i) Continuous monitoring and by visual indication

(g) The gas purge control system shall be provided for maintenance staff to
start/stop each fan(s) and to open/close each fire and smoke damper.
Indicating lights showing the status of each item of equipment are provided to
facilitate the manual mode operation.

(h) For Communication Rooms, the LCP shall have 3 position selector switch
insists of two position to provide “Auto/off/Manual” selection. In auto mode, the
gas purging system is running as battery room ventilation system
automatically, and monitored and controlled by the MBMS.
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Section 77 – Automatic Controls
 (i) Operational requirements

(i) On occurrence of a fire in the served equipment room as detected by

smoke detector, a room fire signal shall be received from the
heptafluoropropane local panel to shut down all fans. All fire/smoke
dampers shall close and status close signal of each dampers shall be
displayed on the LCP and MBMS workstation. The motorised fire/smoke
dampers shall also be interlocked with the heptafluoropropane local
panel to ensure the dampers are closed when the gas system is
operated.

(ii) The exhaust gas purge fans shall be provided to purge the
heptafluoropropane gas after the gas has been released. To purge the
heptafluoropropane gas after the gas has been released, a manually
operated switch at the LCP shall release all electrical interlock, all
motorised fire/smoke dampers shall open and the status ‘open’ signal of
designated dampers shall be displaced on the LCP and MBMS
workstations. The gas purge fans shall be switched on for gas
extraction. The gas purge mode operation and the status of each fan
shall be displayed on the LCP and MBMS workstations. In addition, the
motorized control dampers shall be open/close to achieve low level
exhaust & high level intake.

(iii) In addition to the gas extraction function, for the gas extraction systems
serving communication rooms, the motorized control dampers shall be
open/close to achieve low level exhaust & high level intake. In addition,
the exhaust fans shall also be used periodically to ventilate the rooms
under the normal operating scenario with the motorized control dampers
shall be open/close to achieve high level exhaust and low level intake.
Timer(s) shall be provided within the local control panels such that the
fans will be switched on daily for 15 minutes (duration and frequency to
be adjustable) to periodically extract any possible hydrogen leakage. In
case of fire within the room served, the fan(s) & associated dampers
shall be shut off.

(j) Standby mechanical ventilation shall be also provided for minimum ventilation
rate only (5 ACH/hr) in the event of the duty air conditioning system fails. The
ventilation system also serves as periodically ventilation to dilute possible
hydrogen gas emitted from lead acid battery in normal operation.

77.3.24 Control of Periodic Ventilation Systems

(a) The following rooms shall be served by periodic ventilation systems:

(i) LV Switch Rooms

(b) The periodic ventilation system shall consist of exhaust fans, associated
ductwork, silencers, and motorised dampers.

(c) The periodic ventilation system shall be capable of being operated locally
(LOCAL mode) and monitored by MBMS as dictated by a selector switch at
the local control panel (LCP) located in the Room it serves. The 2 position
selector switch shall allow ‘On/Off’ modes.

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Section 77 – Automatic Controls
 (d) The system shall be provided with the following operation features in the
MBMS mode:

(i) Continuous monitoring of the status and fault reporting

(ii) Generation of warning alarm if any of the sensor input signal beyond its
operational limit

(iii) Software manual on/off switches to override the LOCAL mode of

individual plant

(iv) Alarm generation if feedback status deviates from normal

(v) Indication of the fans running hours and maintenance schedules, and
annunciation of ‘maintenance due’ for the fans

(e) The maintenance staff can operate the system in ‘On’ or ‘Off by a 2 position
switch at the LCP.

(f) The system shall be provided with the following operation features in the auto
mode:

(i) Continuous monitoring and by visual indication

(g) The periodic ventilation control system shall be provided for maintenance staff
to start/stop each fan(s) and to open/close each damper. Indicating lights
showing the status of each item of equipment are provided to facilitate the
manual mode operation.

(h) Operational requirements

(i) The exhaust fans shall be used periodically to ventilate the rooms under
the normal operating scenario with the motorized control dampers shall
be open/close to achieve high level exhaust and low level intake.
Timer(s) shall be provided within the local control panels such that the
fans will be switched on daily for 15 minutes (duration and frequency to
be adjustable) to periodically extract any possible hydrogen leakage. In
addition, a room type thermostat is provided inside for activate the
exhaust fan when the room temperature exceeds the preset limit (in
case of normal air-conditioning breakdown). In case of fire within the
room served, the fan(s) & associated dampers shall be shut off.

77.3.25 Fixed Link Bridge Relief Air Motorized Damper

(a) The fixed link bridge relief air motorized damper shall be opened and closed
through the MBMS.

(b) The damper shall be interlocked to open when either of the pre-conditioned air
(PCA) unit mounted on the underside of corresponding loading bridges is
initiated.

(c) When the PCA unit is not running, the damper shall close.

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Section 77 – Automatic Controls
77.4 MATERIALS

77.4.1 Chilled Water Control Valves

(a) Unless otherwise specified, control valves shall be 2-way normally closed with
single seating and linear characteristic ports. Rangeability shall be 30:1.

(b) All valves shall be sized in accordance with the recommendations of the
manufacturer to assure fully modulating operation.

(c) Control valves shall comply with the “Pipework” section of the General
Materials & Workmanship Specification. Modulating control valves shall be
oblique pattern globe valves.

(d) Control valves shall be designed and configured to close when any associated
item of plant is shutdown or de-energized.

(e) Control valves shall be designed and configured to fully open when their
pressure drop is equal to the pressure drop of the coil under 120% of design
flow.

(f) Unless other specified, fan coil units delivering an air quantity of 700 L/s or
less may use normally closed solenoid valves.

(g) Wherever electronic potentiometers are provided the MBMS shall monitor
valve position using this facility.

77.4.2 Control Valve Actuators

(a) Electric control valve actuators shall have reversible motor drives for 24V
power supply. They shall be of proper size to provide smooth modulating
control under design temperatures and pressure conditions. Actuators shall
be site interchangeable for direct or reverse action and be suitable for on/off
control or continuous operation.

(b) All control valve actuators for, air handling units (AHU) regardless of size, fan
coil units (FCU) and packaged chilled water units (PCW) of 50mm in diameter
or above, shall have the following features:

(i) labelled position indicator;

(ii) hand operated manual operation;

(iii) electronic potentiometer for MBMS monitoring of valve position; and

(iv) spring return for fail safe operation on power failure.

(c) All control valve actuators for fan coil units (FCU), below 50mm in diameter
and less shall have the following features:

(i) labelled position indicator; and

(ii) hand operated manual operation.

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Section 77 – Automatic Controls
 (d) Control valve actuators shall be mounted directly on the control valve without
the need for a separate linkage or the need for any adjustment of the actuator
stroke.

(e) End switches shall be furnished for all sequencing applications other than fan
coil units.

(f) Motor drives shall be supplied with a lever for manual operation.

(g) The actuator shall be power failure return version by spring return or by
incorporating a battery power D.C. motor to drive the actuator fully clockwise
or anti-clockwise on power failure.

77.4.3 Damper Actuators

(a) Damper actuators shall be designed to transmit 200% of the required torque.

(b) Damper actuators shall incorporate visual position indicators and inbuilt
potentiometers for MBMS monitoring of damper position.

77.4.4 Modulating Damper Actuator

(a) Modulating damper actuators shall have reversible motor drives and shall be
sized to provide smooth modulating control under design temperature and
pressure conditions. Actuators shall be site interchangeable for direct or
reverse action and be suitable for on/off or continuous operation.

(b) End switches shall be furnished for all sequencing applications.

77.4.5 Chilled Water Electromagnetic Flow Meter

(a) Electromagnetic flow measuring devices shall be of the direct reading type, i.e.
in l/s, and shall be suitable for the chemical and physical properties of the
fluids to be measured and suitable for both horizontal and vertical installations.

(b) Electromagnetic flow measuring devices shall consist of the flow sensor, an
integral signal converter/transmitter and a digital display unit. The measuring
devices shall incorporate a cast iron body and PTFE liner. The flow sensor
shall be installed in the water pipework without obstructing the flow. The
protection class of the sensor and converter/transmitter housing shall be at
least to IP 67 and IP 65 respectively. The installation of flowmeters shall be
as per the manufacturer’s recommendation with sufficient length of straight
pipe run both at the upstream and downstream piping.

(c) Scale range shall be 0.3 - 5.0 m/s and accuracy shall be ±1% of full scale at a
velocity of 0.3 m/s and sized to achieve a 3.0 - 3.5 m/s face velocity at design
conditions.

(d) Electromagnetic induced current meters shall incorporate electrodes capable

of being removed under pressure without system shut down.

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77.4.6 Carbon Dioxide (CO2) Sensors

(a) Carbon dioxide (CO2) sensors shall be suitable for room or ductwork
mounting.

(b) CO2 sensors shall have the following features:

(i) microprocessor based with 4 – 20 mA analogue output signal;

(ii) range : 0 – 2000 ppm;

(iii) accuracy : 0.5 % (0 – 1500 ppm); 5 % (above 1500 ppm)

(iv) repeatability : ± 100 ppm;

(v) drift : ± 100 ppm per annum; and

(vi) calibration frequency : 2/annum maximum.

(c) CO2 sensors shall incorporate a membrane filter or similar to protect the
sensing element.

77.4.7 Filter Differential Pressure Switch

(a) Filter differential pressure switches shall incorporate :

(i) inclined manometer or similar with a suitably graduated scale for local
indication;

(ii) switching contacts for MBMS monitoring; and

(iii) local set point adjustment.

(b) Differential pressure sensors shall have the differential pressure range of 0 –
400 Pa.

77.4.8 Temperature Sensors

(a) Temperature sensors shall be either of the thermister (NTC) type with a high
linear resistance change versus temperature change or “Platinum” (PT 1000)
to ensure good resolution and accuracy.

(b) Sensors shall be factory calibrated and shall be connected to remote

controllers by means of suitable cables without compensation for cable length.

(c) Immersion temperature sensors shall be provided with immersion pocket. The
sensing range shall be of 0°C to 120°C.

(d) Space temperature sensors and similar shall be non indicating and non
adjusting except through the MBMS control system.

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 (e) Space temperature sensors (room / wall mounted) shall have a connection
plate to permit easy removal of the sensor during decoration, etc. The
sensors shall have the following features:

(i) range : 0°C – 40°C; and

(ii) accuracy : 0.5 %.

(f) Ductwork type temperature sensors shall have a separate mounting flange
with snap-on connection to permit adjustment.

(g) Outdoor temperature sensors shall have the following features:

(i) range : -40°C to 40°C; and

(ii) accuracy : 0.5 %.

77.4.9 Humidity Sensors

(a) Humidity sensors shall have cast aluminium housing with a stainless steel
sensing tube and have the following features:

(i) range : 0 to 100% RH; and

(ii) accuracy : 2 % (0 to 90% RH) and 3% (above 90% RH).

(b) Sensors shall incorporate a membrane filter or similar to protect the sensing
element.

(c) Sensors shall be connected to the remote controller by means of suitable

cables, and sensors shall not require compensation for cable length, etc.

(d) Packaged air conditioning unit humidity sensors shall be similar to ambient
humidity sensors except that:

(i) range : 20 to 90% RH; and

(ii) accuracy : 5 %.

77.4.10 Pressure Sensors

(a) Pressure sensors monitored by MBMS may be used for fire mode monitoring,
however, contacts for fire mode status indication shall be separate from
contacts for MBMS status indication.

(b) All pressure sensors used for the hot smoke extraction system shall be able to
operate 250 °C for one hour as per FSD requirement.

77.4.11 Cabling

(a) The Contractor shall provide all control wiring from terminal strips within the
relevant MCC and between MCC and associated remote control panels.

(b) All cabling associated with the smoke control fans shall be fire resistant to
FSD requirement.

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77.4.12 Indicators and Reset Facilities

(a) Fire mode indicators and momentary contact reset pushbuttons shall be
provided on each MCC, control panel and the like. The indicator shall
illuminate on receipt of any fire mode control signal and shall remain
illuminated until all signals have been cleared and the MCC and/ or panel has
been reset.

(b) Separate indicators shall be provided for each separate fire mode signal
connected to the MCC. Type 0 fire mode indicators shall be provided in a
common area of the MCC. Type 1 and Type 2 fire mode indicators shall be
provided on the cubicle door of the circuit feeding the relevant smoke control
point.

(c) Fire mode reset facilities shall be provided through the MBMS for each MCC,
control panel and the like.

77.4.13 Direct Digital Controllers (DDC)

The DDC systems shall be operated at single phase mains voltage or at extra low
voltage such as 12V or 24V as specified. Unless otherwise specified, the direct
digital controllers shall have sufficient memory to support its own operating system
and databases, including:

(a) memory

RAM memory of the open processor shall be of 2 Mbytes RAM and each
controller shall have sufficient memory to support the followings:

(i) control processes;

(ii) energy management applications;

(iii) alarm management;

(iv) historical support applications;

(v) operator I/O; and

(vi) manual override monitoring;

The memory board shall be expandable to a larger size as needs grow;

(b) communication ports

(i) each controller shall be equipped with at least two communication ports
and one parallel port for simultaneous operation of multiple operator I/O
devices such as modems, printers, personal computers, and portable
operator’s terminals; and

(ii) the controller shall have provisions to allow temporary use of portable
devices without interrupting the normal operation of the permanently
connected modems, printers or network terminals;

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Section 77 – Automatic Controls
 (c) “Input / Output” (I/O)

(i) point terminal modules shall be available for analogue input or output
and digital input or output point types;

(ii) modules shall be quickly and easily snapped into place without tools,
and without having to re-terminate wires for fast servicing;

(iii) modules shall be snapped in and out without powering down the field
panel to minimize any system downtime; and

(iv) manual override shall be available on digital and analogue outputs to

allow the user to manually control the position of the end devices;

(d) expandability

(i) each outstation shall be factory pre-wired comprising a factory fabricated

metal enclosure, hinged door with master lock and name plate holder.
The outstation shall be of modular design with standard function
modules or similar to accept plug in printed circuit cards;

(ii) each outstation shall be loaded up to 85% capacity only; the remaining
15% shall be for future expansion; and

(iii) each outstation shall contain interface hardwire modules to accept a

plug-in portable operator terminal (POT) with visual display and
analogue facility to enable commissioning and fault finding;

(e) indicating lamps

(i) the direct digital controller shall provide local LED status indication for
each digital input and output; and

(ii) status indication shall be visible without opening the panel door;

(f) “Real Time Clock” (RTC)

(i) the real time clock shall display, year, month of the year, day of the
month, hour of the day, and minutes;

(g) automatic start after power failure

(i) the control station shall be provided with a power fail safe and restart
feature; and

(ii) an orderly restart controlled from the data processing controller shall
occur on resumption after a power failure without manual intervention.
There shall be no loss of system memory on power failure;

(h) battery backup

(i) battery shall be able to support the real time clock, programme, and all
volatile memory for a minimum of 60 days; and

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Section 77 – Automatic Controls
 (ii) when battery replacement is necessary, the open processor shall
illuminate a “battery low” status LED and shall send an alarm message
to the selected printer or terminals;

(i) time scheduling

(i) the following commands shall be able to time-scheduled for issue at a

later day and time:

- start and stop a point;

- change alarm limits, warning limits or set-point;

- lock / unlock point reporting or point control;

- demand limit target setting; and

- alarm summary;

(ii) separate schedules shall be stored for:

- regular weeks;

- special weeks; and

- holidays;

(iii) after recovery from a power failure, the system shall determine any time-
scheduled commands which should have been issued during the period
that the power was off. These commands shall automatically be issued;
and

(iv) the system shall allow holidays to be scheduled with a minimum of one
year in advance; and

(j) alarm management

(i) each analogue shall have the following defined:

- high alarm limit;

- high warning limit;

- low warning limit;

- low alarm limits; and

- differential;

(ii) when an analogue point goes outside the “High Warning” or “Low
Warning Limit” for more than one minute, a user defined warning
message shall be sent to the appropriate alarm printers;

(iii) when a binary point goes into alarm, a user defined alarm message shall
be sent to the appropriate alarm printers;

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 (iv) when a point returns to normal, the event shall be recorded in the printer
output;

(v) when a binary point goes into alarm, a user defined alarm message shall
be sent to the appropriate alarm printers; and

(vi) when the point module is placed in override, an alarm shall be sent to
the output of the printers.

77.4.14 Sulphur dioxide (SO2) and Nitrogen Dioxide (NO2) Sensors

(a) SO2 and NO2 sensors shall comprise a universal transmitter which can be
easily configured via solder-less shorting links for any of a wide variety of
plug-in electrochemical sensors.

(b) The sensor elements shall have a life expectancy of a minimum of 5 years,
shall be easily field replaceable, and shall not require electrolyte
replenishment.

(c) SO2 /NO2 sensors shall be prepared for use in ambient conditions of 40ºC air
temperature and up to 90% relative humidity.

(d) The re-productivity shall be +/- 10%. The zero and span drifts shall be +/- 10%
F.S. over 3 months. The effect of power voltage fluctuation shall be +/- 5%
F.S. (both zero and span sensibility) at rated voltage +/- 10%.

(e) The external concentration output signal is an insulation type 4-20 mA DC, 0-6
ppm proportional to the SO2 /NO2 concentration. The linearity error of output
signal to SO2 /NO2 shall be within +/- 10% F.S. after zero and span
adjustment. An alarm output in the form of SPDT no-voltage contact output
shall be sent when the SO2 /NO2 concentration is more than the set value.
The setting range shall be between 0 and 6 ppm with setting accuracy of +/-
5% F.S.

(f) Power supply shall be 24 VDC.

(g) The transmitter shall be factory configured and calibrated for the sensor
selected when ordered as a complete assembly. This transmitter shall accept
any of the listed sensors into a plug-in socket on the board, or an integrally
mounted sensor assembly on the industrial enclosure. Calibration shall be
achieved through a simple zero and span adjustment using the appropriate
calibration gases for the sensor installed.

77.4.15 Carbon monoxide (CO) sensors

(a) Power supply shall be 24 VDC.

(b) The performance of CO sensors shall be compatible with those mentioned in

the method IP-3 (Determination of Carbon monoxide or Carbon Dioxide in
Indoor Air) of the United States Environmental Protection Agency’s
Compendium of Methods for the Determination of Air Pollutants in Indoor Air
(EPA/600/4-90/010) and be in the range 0-250 ppm.

(c) The sensors shall have a minimum life expectancy of 10 years.

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 (d) CO sensors shall be prepared for use in ambient conditions of 40ºC air
temperature and up to 90% relative humidity.

(e) The re-productivity shall be +/- 10% at 50 ppm CO. The zero and span drifts
shall be +/- 10% F.S. over 3 months. The effect of power voltage fluctuation
shall be +/- 5% F.S. (both zero and span sensibility) at rated voltage +/- 10%.

(f) The external concentration output signal is an insulation type 4-20 mA DC, 0-
250 ppm proportional to the CO concentration. The linearity error of output
signal to CO shall be within +/- 10% F.S. after zero and span adjustment. An
alarm output in the form of SPDT no-voltage contact output shall be sent
when the CO concentration is more than the set value. The setting range shall
be between 0 and 250 ppm with a setting accuracy of +/- 5%.

77.4.16 Electric Actuators for Valves and Penstocks

(a) Electric actuator motor

(i) The electric motor shall be of totally enclosed squirrel cage induction
type, suitable for direct-on-line starting. The stator winding shall be of
Class F insulation with the design temperature rise not exceeding 80°C
under the most onerous operating conditions specified.

(ii) The electric motor shall be of high stalling torque low inertia design. Its
starting torque shall be not less than 185% of the unseating torque
required by the valve or penstock.

(iii) Electrical and mechanical disconnection of the motor shall be possible

without draining the lubricant from the electric actuator gear case.

(iv) Electric actuator sizing

- The electric actuator provided for the valve or penstock shall be

correctly sized for the duty taking into account the maximum differential
pressure across the valve or penstock and torque that may occur during
the opening or closure operation of that valve or penstock to which the
actuator is installed.

- A safety margin shall be allowed when sizing motors to ensure sufficient

power is available for opening and closing the valve so that the torque
switch will trip at the maximum valve torque with the supply voltage
10% below nominal.

- The operating speed of the electric actuator shall be selected to operate

a valve or penstock closing and opening at approximately 250-300 mm
per minute.

(b) Actuator and motor protection

(i) The following protection shall be provided for the actuator and the motor:

- over-travel of the valve or penstock in both direction as sensed by the

position and/or torque limit switches;

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 - de-energize the motor in case of a stall or an attempt to operate a
jammed valve or penstock as sensed by torque switches. The setting
range of the torque switches shall be less than 70% of the motor stalling
torque;

- overheating of the winding as sensed by an embedded winding

thermostat;

- single phasing of 3-phase mains supply; and

- phase rotation discrimination unless automatic motor rotation correction

is provided.

(c) Actuator enclosure

(i) The electric actuator shall have a double-sealed enclosure.

(ii) A Type Test certificate from an independent testing authority reviewed

without objection by the Project Manager shall be provided to certify the
actuator enclosure, including motor shown in the Employer’s Drawings,
with IP68 rating as specified.

(iii) The actuator enclosure shall have an inner watertight and dust-proof O-
ring seal between the terminal compartment and internal electrical
elements of the actuator, fully protecting the motor and all other internal
electrical elements of the actuators from ingress of moisture and dust
when the terminal cover is removed on site for cabling.

(iv) The actuator enclosure shall be suitable for temporary storage on- Site
without electrical supply connected.

(v) All external fasteners of the actuator shall be of 316 stainless steel.

(d) Gearing

(i) The actuator gearing shall be totally enclosed in an oil-filled gearcase

suitable for operation at any angle.

(ii) All main drive gear shall be of metal construction.

(iii) The actuator shall provide a lost-motion hammer-blow feature to

unseating valve or penstock.

(iv) Actuators for rising-stem penstocks or rising-stem valves shall have a

hollow output shaft to accept the rising stem and shall have thrust
bearings of the ball or roller type at the base of the actuator. The design
shall permit the gearcase to be opened for inspection or disassembled
without releasing the stem thrust or taking the valve or penstock out of
service.

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 (e) Drive bushing

(i) The electric actuator shall be furnished with a drive bushing easily
detachable for machining to suit the valve stem or gearbox input shaft.
The drive bush shall be positioned in a detachable base of the actuator.
Thrust bearings, when housed in a separate thrust base shall be of the
sealed for life type.

(f) Torque and turns limitation

(i) Torque and turns limitation shall be adjustable as follows:

- Position setting range: 0.5 to 100,000 turns, with resolution to 15 degree

of actuator output.

- Torque setting: 40% to 100% of rated torque

(ii) “Latching” shall be provided for the torque sensing system to inhibit
torque off during unseating or during starting in mid travel against high
inertia loads.

(iii) The electrical circuit diagram of the actuator shall not vary with the valve
or penstock type, and shall remain identical regardless of whether the
valve or penstock is to open or close on torque or position limit.

(g) Remote valve position/actuator status indication

(i) Six pairs of contacts shall be provided to indicate the following

status/positions of valve or penstock:

- valve opening or closing;

- valve moving (continuous or pulsing);

- motor tripped or torque in mid travel;

- motor stalled; and

- actuator being operated by handwheel.

- control available (remote)

The contacts shall be rated at 5A, 250VAC, 30VDC.

(h) Local position indication

(i) The actuator shall include a digital position indicator with a display from
fully open to fully closed in 1% increments.

(ii) Red, green and yellow lights correspond to open, closed and
intermediate positions respectively shall be included on the actuator.
The digital display shall be maintained even when the power to the
actuator is isolated.

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 (iii) Provision shall be made in the design for the addition of a contactless
transformer to give a 4-20 mA analogue signal corresponding to actuator
output torque for remote indication when required.

(i) Integral starter and transformer

(i) The reversing starter, control transformer and local controls shall be
integral with the actuator, suitably housed to prevent breathing and build
up of condensation.

(ii) The starter shall be suitable for 60 starts per hour, and of a rating
appropriate to motor size. The controls supply transformer shall be fed
from two of the incoming three phases. It shall have the necessary
tappings and be adequately rated to provide power for the following
functions:-

- 120V AC energization of the contractor coils;

- 24V DC output where required for remote controls;

- supply for all the integral electrical circuits; and

- the primary and secondary winding shall be protected by easily

replaceable fuses.

(j) Integral pushbuttons and selector

(i) The actuator shall be provided with integral local controls for open, close
and stop, and a local/remote selector switch padlockable in any one of
the following three positions:

- local control only;

- off (no electrical operation); and

- remote control plus local stop only. It shall be allowed to select

maintained or non-maintained local control.

(ii) The local controls shall be arranged so that the direction of valve and
penstock travel can be reversed without stopping the actuator.

(k) Control facilities

(i) The necessary wiring and terminals shall be provided in the actuator for
the following control functions:

- removable links for substitution by external interlocks to inhibit valve

and penstock opening and/or closing;

- connections for external remote controls fed from an internal 24V DC

supply and/or from an external supply (min. 12V, max. 120V) to be
suitable for any one or more of the following methods of control:

• open, close and stop;

• open, and close;

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 • overriding emergency shut-down to close (or open) valve or
penstock form a “make” contact; and

• two-wire control, energize to close (or open), de-energize to open

(or close).

- selection of maintained or push-to-run control for “open”, “close” and

“stop” modes above shall be provided and it shall be possible to reverse
the valve or penstock travel without stopping the actuator. The starter
contactors shall be protected from excessive current surges during
travel reversal by an automatic time delay on energization of
approximately 300 ms.

77.4.17 Velocity Sensor

(a) Velocity sensor shall have the following features:

(i) Range : 0 - 8m/s

(ii) Accuracy : ± 5%

(iii) Rise Time : 20 sec

(iv) Time Constant : 5 sec

(v) Ambient Temperature : -20ºC / +50ºC

(vi) Air Temperature : -10ºC / +60ºC

(vii) Microprocessor based with 4 - 20mA analogue output signal

(viii) Linear output signal

(b) The installation detail of velocity sensor should comply with the manufacturer’s
recommendation.

77.5 SUBMISSIONS

The Contractor shall submit the following documents to the Project Manager for
review without objection:

(a) system description

this shall demonstrate a clear understanding of the overall fire mode concept
including provisions for plant shutdown and plant control within the area
affected, and within adjacent areas;

(b) schedule of Plant operation under fire mode this shall list all smoke control
and shutdown zones and shall schedule:

(i) all plant that is required to shut down;

(ii) all plant that is required to startup and in what mode; and

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 (iii) all motorized fire and smoke dampers that are required to open or close;
and

(c) indicative control schematics

this shall clearly indicate the proposed method of shutting down, initiating,
controlling, and resetting plant and shall indicate operation when two or more
fire modes signals affect the same items of plant.

77.6 WORKMANSHIP

77.6.1 Carbon Dioxide (CO2) Sensors

(a) Carbon dioxide (CO2) sensors in a room shall be:

(i) positioned far away from the areas with low air exchange or close to
supply air outlets, windows, doors, etc.; and

(ii) mounted at minimum of 2 m AFFL.

(b) Carbon dioxide (CO2) sensors in ductwork shall be:

(i) positioned at the return air duct in a position far away from external heat
sources; and

(ii) the sensor stem shall be immersed in the controlled air stream.

77.6.2 Filter Differential Pressure Switch

(a) Filter differential pressure switches in a ductwork shall be positioned such that:

(i) sensor stem is fully immersed in the controlled air stream;

(ii) differential air switch shall be positioned where it will not be exposed to
corrosive or flammable atmosphere or vibration;

(iii) the pressure switch shall be mounted on a vertical surface and have two
air pressure tappings which are connected with tubing to the sensing
points in the duct;

(iv) the mounting method of the pressure transmitter shall be subject to the
manufacturer’s recommendation; and

(v) the sensor is not subject to thermal radiation.

77.6.3 Temperature Sensors

(a) Immersion temperature sensors shall be:

(i) provided with a means of withdrawal for calibration, servicing, etc.,

without the need for draining the system;

(ii) immersed (the whole active part of sensor) within the liquid;

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 (iii) located not less than 10 pipe diameters downstream from a point of
mixing, unless otherwise recommended by the manufacturer;

(iv) provided with a sufficient length of cable in flexible conduit to permit

complete withdrawal of the element; and

(v) located downstream from the valve, after the pump, for the control of
mixed flow temperature using mixing valves.

(b) Space temperature sensors shall be positioned:

(i) so the sensor is not subject to thermal radiation;

(ii) far away from doors, windows, and heat sources, etc; and

(iii) so that all conduit openings are sealed to avoid false temperature
measurement.

(c) Ductwork type temperature sensors shall be:

(i) positioned so that the sensor is not subject to thermal radiation;

(ii) immersed (the active part of sensor) in the controlled air stream;

(iii) fitted a few meters downstream from the heating coil at supply air duct;

(iv) fitted a few meters before the extract fan at extract air duct;

(v) positioned so that temperature stratification is accounted for, (i.e.

positioning for low temperature limit sensing, positioning for high
temperature limit sensing, positioning for average temperature sensing);
and

(vi) installed on a suitable framework and is suitably arranged for servicing if

of the capacity averaging type.

(d) Outdoor temperature sensors shall be positioned :

(i) away from the influence of direct solar radiation and local heat gains;

(ii) far away from the warm air outlets such as window or extract;

(iii) according to the sensor manufacturer’s recommendation unless

otherwise specified, such as determination of solar gain, wind influence
,etc.

(e) Temperature sensors and similar shall be non indicating and non adjusting
except through the MBMS control system.

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77.6.4 Humidity Sensors

(a) Humidity sensors shall be positioned:

(i) in a location which is representative of the space in which the humidity is

being measured;

(ii) such that the air velocity is within the range required by the sensors; and

(iii) in air free from airborne containments.

77.6.5 Carbon monoxide (CO sensors)

(a) All CO sensors shall be housed in a perforated faced stainless steel cabinet
complete with lockable access cover.

(b) CO sensors should be evenly distributed so that no part of the head of stand
road and APV parking bays are more than 25 metres horizontally from a
sampling point for monitoring. In addition, at least one sampling point should
be provided at each entrance and exit.

(c) The sampling points for CO monitoring should, whenever practicable, be:

(i) Between 0.9 metres and 1.8 metres above finished floor level which will
allow samples to be fully representative of the local atmosphere;

(ii) At least 0.1 metres clear of walls, columns and other vertical or near
vertical surfaces, and not in a position significantly influenced by either
supply air or car exhaust emissions.

77.6.6 Sulphur Dioxide (SO2) Nitrogen Dioxide (NO2) Sensors

(a) NO2 & SO2 sensors shall be housed in a perforated faced stainless steel
cabinet complete with lockable access cover.

(b) SO2 /NO2 sensors should be evenly distributed so that no part of the head of
stand road and APV parking bays are more than 25 metres horizontally from a
sampling point for monitoring. At least one sampling point should be provided
at each entrance and exit.

(c) The sampling points for SO2 /NO2 monitoring should, whenever practicable,
be:

(i) Between 0.9 metres and 1.5 metres above finished floor level which will
allow samples to be fully representative of the local atmosphere;

(ii) At least 0.1 metres clear of walls, columns and other vertical or near
vertical surfaces, and not in a position significantly influenced by either
supply air or car exhaust emissions.

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SECTION 78 INSTRUMENTS

78.1 GENERAL

(a) The Contractor shall comply with other relevant sections of this General
Materials and Workmanship Specification including but not limited to the
sections which specify:

(i) Section 72 “Pipework, Fittings and Valves”;

(ii) Section 76 “Electrical Equipment and Installation”;

(iii) Section 77 “Automatic Controls”; and

(iv) Section 79 “Testing, Inspection and Commissioning – Mechanical

Services”.

(b) Portable instrumentation shall be complete with purpose built carrying cases.

(c) Instrumentation including sensors, wells, probes, and the like shall be
compatible with the fluid with which it is in contact under all the operating and
standby conditions to a level at least equivalent to that of associated pipework
or ductwork.

(d) As a minimum, materials associated with pipework instrumentation shall

comply with the requirements for valves specified within the pipework section
of this General Materials and Workmanship Specification.

(e) Instrumentation including associated seals, tappings and the like shall be
rated for the corresponding pipework test pressure.

78.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, at the date of the Letter of Acceptance.

BS 21 Specification for pipe threads for tubes and fittings where

pressure-tight joints are made on the threads (metric
dimensions)
BS 6739 Code of practice for instrumentation in process control
systems: installation design and practice
BS 7350 Specification for double regulating globe valves and flow
measurement devices for heating and chilled water systems
BS 4504 : Part 3.3 Circular flanges for pipes, valves and fittings (PN designated).
Specification for copper alloy and composite flanges
BS EN 837-1 Pressure gauges. Bourdon tube pressure gauges.
Dimensions, metrology, requirements and testing

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 BS EN 50081 Electromagnetic compatibility. Generic emission standard.
Residential, commercial and light industry
BS EN 50082 Electromagnetic compatibility. Generic emission standard.
Industrial environment
IEC 529 Degree of protection of enclosures

ISO 1000 SI units and recommendations for the use of their multiples
and of certain other units
ISO 3966 Measurement of fluid flow in closed conduits -- Velocity area
method using Pitot static tubes
ISO 7194 Measurement of fluid flow in closed conduits -- Velocity-area
methods of flow measurement in swirling or asymmetric flow
conditions in circular ducts by means of current-meters or
Pitot static tubes

78.3 DESIGN AND PERFORMANCE CRITERIA

78.3.1 General

(a) Indicating instruments shall be appropriate and selected so that all normal
operating conditions are in the mid range of the scale. Scale ranges shall be
selected so that system conditions are shown when equipment is running and
when it is stopped. Graduation shall be appropriate for the operating range
and application to which the instrument is to be put. Graduation shall be at a
maximum of 10% intervals over the operating range of the instrument. The
design maximum operating condition shall be indicated at not less than 75% of
the total scale length.

(b) Power supplies required for instruments shall be fed from a separate circuit on
the MCC associated with the corresponding equipment being monitored or
controlled or if, compatible and appropriate, from the corresponding MBMS
panel into which instrument signals are fed.

(c) Fixed instruments incorporating microprocessors and/or electronic

components shall include facilities and protocols to enable connection into the
MBMS using 4 - 20 mA control signals.

(d) Electromagnetic flow measuring devices shall be interfaced with the MBMS
using 4 - 20 mA control signals.

78.3.2 Accuracy

(a) Minimum accuracy requirements for monitoring, control, testing and

commissioning facilities unless otherwise specified shall be as follows:

(i) Temperature
- air
• dry bulb : ±0.3 K;
• wet bulb : ±0.5 K;
- water : ±0.1 K;

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 (ii) Pressure
- air
• direct : ±2% of full scale;
• differential : ±2% of full scale;

(iii) Velocity
- air : ±2% of full scale;
- Rotational speed : ±1% of full scale;

(iv) Electrical
- voltage : ±1% of reading;
- current : ±1% of reading;
- power factor : ±1% of reading; and

(v) Flow : ±5% of actual flow.

(b) The above requirements relate to end to end accuracy including sensors,
transmission paths, analogue to digital converters, calculations and displays.

(c) Digital transmission shall be 10-bit minimum.

78.4 MATERIALS

78.4.1 General

(a) Instruments, gauges, sensors and the like shall be calibrated and shall
indicate in SI units in accordance with ISO 1000.

(b) As a minimum, works associated with flow measurement devices shall comply
with the requirements of BS 7350 or suitable equivalent.

(c) System-monitoring instruments shall comply with the latest Guidance Notes
for Management of IAQ in Offices & Public Places and the Guide for
Participation in the IAQ Certification Scheme published by the HKSAR
Government.

(d) Unless otherwise specified, the degree of protection for electrical and
electronic enclosures shall be IP 42 to IEC 529.

(e) Pressure gauges shall comply with BS EN 837-1.

(f) Electromagnetic flow measuring devices shall conform to BS EN 50081 and

BS EN 50082 or similar international standards on Electromagnetic
Compatibility (EMC) compliance for industrial and commercial applications.

(g) The flow sensing device shall be of the annubar type, or equal reviewed
without objection by the Project Manager, in compliance with ISO 3966 and
ISO 7194.

(h) Gauges shall have adjustable pointers that cannot be altered without the use
of tools.

(i) Sensing elements shall be positioned and of sufficient length and orientation in
accordance with manufacturer’s recommendation to give a stable
representative reading of the condition being measured.
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78.4.2 Temperature Gauges for Pipework

(a) Temperature gauges for pipework shall be 100 mm diameter and shall be of
the capillary, mercury-in-steel direct reading immersion type complete with
wells of chrome-plated steel, brass or bronze as appropriate. Stems shall be
at least 50 mm long and shall reach to the centreline of the pipe.

78.4.3 Thermometer for Ductwork

(a) Thermometers shall be of the mercury-in-glass type of at least 150 mm long.

78.4.4 Thermostat

(a) All thermostats shall be fully proportioning with a temperature range of

approximately 15°C to 36°C, and shall have adjustable set point. Thermostats
shall generally have concealed adjustment and shall be mounted
approximately l350 mm from FFL.

78.4.5 Pressure Gauges for Pipework

(a) Pressure gauges shall be 100 mm diameter with a Bourdon tube element and
chromium plated steel or durable plastic case and shall be fitted with 10 mm
bronze pet cocks or ball cocks with optical sight glass.

(b) Pressure gauges shall be calibrated in kPa from zero to not less than 1.3
times and not more than twice the operating pressure of the respective
equipment/system and shall be accurate to 1.5% of full scale reading, unless
otherwise specified.

(c) Pressure gauges used solely to indicate the head and pressure of water shall
be provided with an adjustable red pointer set to indicate the normal working
pressure or head of the system.

(d) Where a pressure reading may be negative, a compound vacuum pressure

gauge shall be used.

(e) Where pressure pulsation prevents a stable reading within the accuracy
requirements of the gauge, a pulsation snubber shall be used in conjunction
with the instrument.

78.4.6 Pressure Gauges for Ductwork

(a) System static pressure gauges shall be of the single limb inclined manometer
type.

78.4.7 Differential Pressure Sensors

(a) Differential pressure probes shall be suitable as flow measurement devices

including the provision of published performance characteristics calibrated to
suit the actual instrumentation and associated installation. The devices shall
incorporate probes to separately monitor the average total pressure of the
system across the full bore of the pipe into which it is inserted as well as the
system static pressure.

(b) Measurement accuracy shall be at least ±2% of actual flow.

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 (c) Accuracy shall be maintained for flows down to 10% of design.

(d) Probes shall be diamond shaped or similar to provide a fixed point of flow
separation to suit stability and accuracy requirements. Probes shall be
manufactured from stainless steel. Openings in the probes shall have
dimensions in any direction no less than 2 mm or the mesh size of the nearest
upstream strainer whichever is greater.

(e) Probes shall include suitable test points for connection to a differential
pressure sensor or similar instrument that can be used to indicate or calculate
fluid flow rate.

(f) Test points shall incorporate isolating valves including hand wheels and
screwed connections to suit supplementary instrumentation.

(g) Differential pressure sensor probes and test points shall be capable of being
removed as a single assembly without dismantling pipework or other Plant.

(h) For each of range of probe, the Contractor shall provide at least 2 sets of
portable square root extraction instrumentation including adaptors and
connections, which have been calibrated and supplied by the differential
pressure probe manufacturer. The instrumentation shall give a 4 – 20 mA
linear output proportional to flow rate.

78.4.8 Calibrated Balancing Valves

(a) Each calibrated balancing valve shall:

(i) be suitable for isolation purpose;

(ii) incorporate a double regulating control facility;

(iii) include a valve position indicator with a graduated scale; and

(iv) incorporate a calibrated orifice plate with integral flow measurement

tappings and test points.

(b) Calibrated balancing valves shall be installed on the "return" side of the
reticulation system so that the orifice plate can be removed with a minimum
amount of required pipework isolation.

(c) Calibrated balancing valves shall be provided for balancing and

commissioning purposes. For valves the following shall apply:

(i) Valves with diameter less than or equal to 200mm, shall be closed
coupled double regulating oblique globe type conforming to BS 5154 for
size DN 15 to DN 50 and to BS 5152 for sizes DN 65 to DN 200.

(ii) Double regulating valves with diameter greater than or equal to 250mm
shall be closed coupled butterfly type with stainless steel orifice plate
metering station and flanged connections. There shall be a minimum of
5 diameters straight length of the same diameter pipe between the
metering station and the double regulating valve, without intrusions and
upstream of the metering station.

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 (iii) The double regulating valves section shall be variable orifice type with
tappings for self sealing pressure test cock connections or built-in
double-seal pressure test valves.

(d) Flow measurement test points shall be capable of being rotated about a
longitudinal axis independent of the valve body.

(e) Test points with self sealing cores equivalent to that for universal test points
may be provided for orifice plates associated with calibrated balancing valves
on chilled water pipework up to a nominal bore of 200 mm. Test points for all
other orifice plates associated with calibrated balancing valves shall be valve
controlled incorporating lockshield diamond heads or suitable equivalent.

(f) Subject to review without objection by the Project Manager, differential

pressure probes may be used in lieu of orifice plates where:

(i) the installation of the probe is remote from any valves or similar fitting;
and

(ii) the installations in a straight section of pipework of sufficient length

which is approved by this differential pressure probe manufacturer as
being suitable for achieving an accuracy of ±5% as specified for
calibrated balancing valves.

(g) Valves shall be complete with locking device and indicator.

78.4.9 Pitot Static Tube

(a) The flow sensing device shall be of the annubar type, or equal reviewed
without objection by the Project Manager, in compliance with ISO 3966 and
ISO 7194, inserted through the wall of the pipe via suitable bush supplied by
the sensing device's manufacturer.

(b) The equipment shall be manufactured by a reputable and proven

manufacturer and shall receive the Project Manager’s notice of no objection
before installation.

(c) Each pitot static sensor shall be permanently marked externally with the
direction of flow.

78.4.10 Orifice Plates

(a) Orifice plates shall be as follows:

(i) For pipework up to 50 mm nominal bore:

- material : copper alloy; and

- ends : threaded to BS21 or suitable equivalent.

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 (ii) For pipework with a nominal bore above 50 mm:

- material : stainless steel; and

- ends : suitable for mounting within flanges to BS

4504 : Part 3.3, PN 16 or suitable equivalent.

(iii) “Material : stainless steel” is “Grade 316”

(b) Flow measurement tappings shall be integral with the orifice plate assembly.

(c) The resistance across the plant orifice shall not exceed 5 kPa (0.05 bar).

(d) The plate shall have two valved tappings for connection to manometer or
responder meter, etc.

78.4.11 Valve Monitoring Devices

(a) Valve monitoring devices for chilled water expansion tanks and similar
applications shall include the following features:

(i) injection molded enclosure or similar with a degree of protection of IP 54

to IEC 529;

(ii) suitable for non-rising stem applications; and

(iii) capable of being installed and replaced without having to drain the
chilled water system.

78.4.12 Energy Meters

(a) The calculator unit of an energy meter shall calculate and display digitally the
water enthalpy consumption in kWh with accuracy to a maximum error of
±1.5% throughout the range of measurement. The number of digits of
accumulated enthalpy consumption display shall not be less than six. The
housing protection for the microprocessor and calculator unit shall not be less
than IP 54. The requirement for the temperature sensors and the flowmeter
shall be as specified elsewhere in this General Materials and Workmanship
Specification.

(b) Fluid energy calculations including instantaneous and cumulative energy

usage shall be undertaken through the MBMS.

78.4.13 Universal Test Points for Pipework

(a) Universal test points shall be suitable for reading temperatures and pressures
using portable instrumentation.

(b) Universal test points shall be manufactured from a suitable copper alloy, shall
be self sealing and complete with bonded ethylene propylene cores or
equivalent designed to suit pipework test pressures and to enable insertion of
sensor probes under all operating conditions.

(c) Knurled dust caps shall be provided complete with suitable cap retainers.

(d) Universal test points shall not be used on sea water systems.
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Section 78 – Instruments
78.4.14 Test Points

(a) As a minimum, test points for flow measuring devices shall be manufactured
from a suitable copper alloy.

(b) Unless otherwise specified, test points shall be valve controlled and shall
incorporate a lockshield diamond head or suitable equivalent.

(c) Tests points shall be colour coded and shall be complete with knurled dust
caps and suitable cap retainers. Dust caps shall be capable of being removed
without the use of tools.

78.4.15 Thermometer Pockets for Pipework

(a) Thermometer pockets shall consist of 12.5 mm bore tube of the same material
as the pipework into which they are to be inserted.

(b) Pockets shall be brazed or welded into pipework, as appropriate.

78.4.16 Double regulating valve

(a) Double regulating valves up to DN 50 shall be screwed type to BS 21. Valves

DN 65 and above shall be flanged type to BS 4504, PN 16, outside screw,
non-rising stem. All sizes of valves shall be capable of full isolating action.

(b) Double regulating valves up to DN 50 shall have a non-dezincifiable metal

body, bonnet, disc, stem, gland, gland nut and pressure test valves; nylon
hand wheel; PTFE or non-asbestos packing; PTFE disc seal; composition
bonnet gasket and synthetic rubber ‘O’ ring drain cock gland. Valves DN 65
and above shall have cast iron body, bonnet, gland and hand wheel; steel
hand wheel nut, indicator stud bolt, gland stud and nuts, bonnet studs and
nuts; stainless steel stem; chrome steel disc, disc stem nut and body seat
ring; and stainless steel locking washer.

78.5 SUBMISSIONS

78.5.1 Particulars of instruments

The following particulars of the proposed instruments shall be submitted to the

Project Manager for review without objection:

(a) certified test data (from and approved laboratory) supporting the selection of
instrument; and

(b) details of each proposed instrument including manufacturer’s published

information and all manufacturer’s drawings.

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78.6 WORKMANSHIP

78.6.1 General

(a) Instruments shall be installed and commissioned in accordance with the

recommendations of BS 6739.

(b) Instruments shall be accessible for inspection, maintenance and connection to

supplementary devices.

(c) Gauges indicators, displays and similar devices for each component or
component system shall be locally mounted on the associated ductwork,
pipework or equipment except where visual observation from the floor or a
permanent maintenance platform is difficult, obscured or obstructed, in which
case the devices shall be remotely mounted. Remotely mounted devices shall
be grouped together in a logical manner. Associated capillary tubing and
wiring shall be run neatly and securely.

(d) Flow measuring instruments shall be installed in straight sections of pipework

in accordance with manufacturer's recommendations.

(e) Velocity sensors shall be installed in straight sections of ductwork in

accordance with manufacturer's recommendations.

(f) Differential pressure sensors shall be installed in accordance with the

manufacturer's recommendations for maximum accuracy.

(g) Subject to review without objection by the Project Manager, differential

pressure probes may be used in lieu of electromagnetic flow measuring
devices where:

(i) the installation of the probe is remote from any valves or similar fittings;

(ii) the installation of the probe is in a straight section of pipework of

sufficient length which is approved by the differential pressure probe
manufacturer as being suitable for achieving an accuracy of ±1% as
specified for the electromagnetic flow measuring devices; and

(iii) the installation shall include fixed instrumentation for square root
extraction calibration supplied by the differential probe manufacturer
including a linear 4 - 20 mA output signal proportional to the flow rate for
input into the mechanical BMS (MBMS).

78.6.2 Universal Test Points for Pipework

(a) Universal test points shall be installed in accordance with the associated
manufacturer's recommendations and orientated to suit the insertion of probes
during commissioning and after completion of the Works.

(b) For each operating temperature and pressure range, the Contractor shall
supply at least 3 sets of universal test point thermometers and pressure
gauges including adaptors, fittings and lubricant.

(c) On insulated pipework, universal test points shall incorporate extension pieces
as required.

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Section 78 – Instruments
78.6.3 Test Points

(a) Test points and associated valves shall be orientated to provide adequate
access for attaching and/or inserting sensors for flow measurement during
commissioning and after completion of the works.

(b) Test points and associated valves and shall extend beyond any insulation.

78.6.4 Thermometer Pockets for Pipework

(a) Pockets shall be installed, into a bend, or at an angle to the pipework so that a
minimum length of 100 mm is in contact with the pipework fluid.

(b) Pipework below 50 mm diameter shall be enlarged in section to at least 50

mm where pockets are to be installed.

(c) Pockets shall be extended clear of pipework insulation and shall be located to
allow easy insertion of thermometers. Pockets shall be vertical or sloping so
that heat transfer fluid can be used.

78.6.5 Ductwork Test Holes

(a) Plugged 10 mm test holes shall be provided to suit balancing, commissioning,

testing and inspections in the following areas:

(i) ductwork for air quantity, velocity and temperature readings as required;

(ii) "face and bypass" air handling units for air quantity and velocity readings
across coils and dampers; and

(iii) all air handling units for temperature readings of mixed air, "air on" and
"air off", and pressure reading across all filters, coils, electric heaters
and the like.

(b) Sealing plugs shall be provided and fitted to all test holes to prevent sweating
and condensation under all operating conditions. Test holes shall be
positioned so that thermometers are not affected by thermal radiation.

(c) Permanent thermometers shall be inserted in test holes for systems with air
volume slow rate of or greater than 5 m3/s.

(d) For systems with flow rate less than 5 m3/s, four numbers of thermometers or
in quantity equivalent to 10% of the total numbers of the test holes, whichever
is greater, shall be provided with each individual packed in protective casings
and to facilitate identification of correct location, and submitted to the Project
Manager. Each thermometer shall be complete with a pierced plug to fit the
test hole and each wet bulb thermometer shall be provided with a fabric
sleeve.

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Section 78 – Instruments
SECTION 79 TESTING, INSPECTION AND COMMISSIONING – MECHANICAL
SERVICES

79.1 GENERAL

(a) The Plant shall be inspected, tested and commissioned to confirm that Plant
performance complies with the requirements of the Contract.

(b) All such inspection, testing and commissioning shall, in particular but without
limitation, be planned, carried out and documented in accordance with:

(i) General Conditions of Contract;

(ii) volumes 1-4 of the General Materials and Workmanship Specifications,

General Specification, Particular Specification, Particular Technical
Specification and other contract documents (if any); and

(iii) the construction quality plans and inspection and test plans prepared by
the Contractor in accordance with the relevant ISO standard and
reviewed without objection by the Project Manager

79.2 TERMINOLOGY

(a) The following terms shall be used in all programmes, quality plans, reports
and other documents produced:

(i) Manufacturing Phase - the period during which the manufacture,

fabrication and assembly of the Plant, or a discrete element of the Plant,
is carried out off-Site;

(ii) Installation Phase - the period during which the fabrication, assembly
and installation of the Plant, or a discrete element of the Plant, is carried
out on-Site;

(iii) Pre-Commissioning Phase - the period when, in relation to the Plant or a

discrete element of the Plant, component tests and commissioning are
carried out in preparation for the plant commissioning phase;

(iv) Plant Commissioning Phase - the period when commissioning and

reliability tests are carried out to ensure that the Plant fully complies with
the design and operational requirements of the Contract;

(v) Plant Integration Phase - the period prior to issue of the Completion
Certificate when Plant integration tests and commissioning are
conducted to integrate the Plant with all work completed or being
undertaken by the Other Contractors, if any, in full compliance with the
design and operational requirements of the Contract;

(vi) Confidence Trial Phase - the period after issue of the Completion
Certificate when the Confidence Trials are carried out;

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 (vii) Phase - one or other of the phases identified in (i) - (iv) above;

(viii) Type Tests - tests undertaken on similar equipment or components in

lieu of individual unit tests;

(ix) Factory Tests - tests carried out on items of Plant at the manufacturer's
works or elsewhere before they are dispatched to Site;
(x) Site Tests - tests on static items of Plant and systems (e.g. inspection
and testing of welds and hydraulic testing of pipework) to ensure correct
and safe installation before setting to work;

(xi) Component Tests - tests on components to be incorporated in the Plant;

(xii) Commissioning - the advancement of the Plant or an element of the

Plant from the stage of static completion to full working conditions and to
meet the specified design requirements. This shall include setting to
work and regulation;

(xiii) Setting to Work - the process of setting a static system into motion;

(xiv) Plant Integration Tests - the measuring, recording and proving of correct
integration between the Plant and all other systems as detailed in the
Specification.

(xv) Regulation - the process of adjusting a system (eg the rates of fluid flow
and heat transfer in a distribution system) within specified tolerances;

(xvi) Reliability Tests - tests carried out over several trial periods and under
simulated operating conditions to prove reliability;

(xvii) Deferred Seasonal Tests - tests conducted at certain times of the year to
suit seasonal climatic conditions;

(xviii) Confidence Trials - tests undertaken after the issue of the Certificate of
Completion when the Plant is operational and being operated by the
Employer under the supervision of the Contractor;

(xix) Inspection, Testing and Commissioning Programme - the sub-network of

the Works Programme prepared by the Contractor and reviewed without
objection by the Project Manager, detailing the programme for the
inspection, testing and programme for the inspection, testing and
commissioning of the Plant;

(xx) Phase Notice - a notice prepared by the Contractor in accordance with

the requirements of the Specification;

(xxi) Phase Report - a report prepared in accordance with the requirements of

the Specification; and

(xxii) Test Results Form - a form prepared in accordance with the

requirements of the Specification

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 (b) The term "Tests on Completion" as defined and used in the General
Conditions of Contract refers to the Plant Integration Tests and such further
tests, if any, identified as such in the Specification.

(c) The term “Performance Tests” as defined and used in the General Conditions
of Contract refers to the Confidence Trials and such further tests, if any,
identified as such in the Specification.

79.3 TESTING AND COMMISSIONING PHASES

(a) In order to facilitate the orderly management of the testing and commissioning
of Plant and the Project Manager’s monitoring of progress of the Project as a
whole, the Contractor shall structure his construction quality plans (see section
14 of the General Specification), inspection and test plans (see section 15 of
the General Specification), the General Materials and Workmanship
Specification , and the Inspection, Testing and Commissioning Programme
(see section 10 of the General Specification) into the following Phases with
the tests to be carried out during each Phase identified under the following
categories:

(i) Manufacturing Phase:

- Factory Tests; and

- Type Tests.

(ii) Installation Phase:

- Site Tests.

(iii) Pre-Commissioning Phase:

- Component Tests; and

- Commissioning of elements of the Plant.

- Setting to work

(iv) Plant Commissioning Phase:

- integration of elements of the Plant;

- Commissioning; and

- Reliability Tests.

(v) Plant Integration Phase:

- Plant Integration Tests; and

(vi) Confidence Trails Phase.

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 (b) Any Deferred Seasonal Tests shall also be clearly identified in all plans and
programmes.

(c) For the duration of the Defects Liability Period, operational and safety controls
shall be sealed if adjustment beyond defined limits could result in malfunction
and give rise to a defect.

(d) The Contractor shall provide attendance and technical support during testing
and commissioning of any work with which the Contractor has an interface
during the confidence trails period in accordance with this General Materials
and Workmanship Specification .

79.4 QUALITY PLANS

(a) The Contractor shall identify in his construction quality plans any division of
the Plant into discrete elements to facilitate the preparation and service of
Phase Notices as called for in this General Materials and Workmanship
Specification .

(b) Refer to General Specification Section 14.

(c) The Project Manager, in reviewing any inspection and test plan, may require
further and better inspection, testing and Commissioning documentation as
may be considered reasonably necessary to record these processes.

79.5 PHASE NOTICES

(a) For each element of the Plant identified in the Contractor's construction quality
plans or, as the case may be, for the Plant as a whole:

(i) the Contractor shall prepare and submit to the Project Manager for
review a Phase Notice at the end of the Manufacturing Phase, the
Installation Phase and the Pre-commissioning Phase:

(ii) each Phase Notice shall contain a statement by the Contractor

confirming that all inspections and tests required during the relevant
Phase have been performed satisfactorily or identifying any non-
conformities or tests that have been failed and confirming that all reports
of such inspections and tests have been filed in his records office (in
accordance with Section 15 of the General Specification);

(iii) the Phase Notice relating to a Manufacturing Phase shall confirm that
the Contractor is satisfied that the relevant equipment or system or part
of a system is ready for release from the manufacturer's works;

(iv) the Phase Notice relating to an Installation Phase shall confirm that the
Contractor is satisfied that the equipment or system or part of a system
is ready for starting the pre-commissioning tests; and

(v) the Phase Notice relating to a Pre-Commissioning Phase shall confirm

that the Contractor is satisfied that the system or part of a system is
ready for Commissioning and Reliability Tests.

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79.6 TEST RESULTS FORMS

(a) In addition to the requirement in Section 15 of General Specification, each

report of an inspection or test shall indicate the following:

(i) the system or item being tested;

(ii) the identification reference for an item being performance tested;

(iii) the test acceptance criteria;

(iv) the tolerances;

(v) the test units of measurement;

(vi) the actual test results;

(vii) pass/fail;

(viii) whether a concession shall be requested under Section 14 of the

General Specification;

(ix) any concessions or variations made pursuant to Section 14 of the

General Specification; and

(x) whether a design review is requested.

(b) Test acceptance criteria shall be prepared by the Contractor in accordance

with the General Materials and Workmanship Specification and included as
part of each Test Results Form. Acceptance criteria may not be changed by
the Contractor except with the consent of the Project Manager in writing.

(c) The Contractor shall prepare and submit his proposed Test Results Forms as
part of his submission of the relevant Inspection, Testing and Commissioning
Plan.

79.7 PHASE REPORTS

(a) Without prejudice to the Contractor's obligations to produce summaries of test

data and other information in the General Conditions and the General
Specification, the Contractor shall upon completion of each Phase complete
and submit to the Project Manager for his information a phase report (the
“Phase Report”) setting out and detailing the test results including
performance figures obtained, graphs, charts, tabulated computer output, and
supporting narratives describing any special events, occurrences and other
discrepancies or deviations not expected in the original plan or programme.

(b) In particular, the Phase Report shall include a chronological diary of findings
and incidents including:

(i) workmanship;

(ii) Plant operating peculiarities and observations;

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 (iii) any measurement and checks which may be required by operating and
maintenance personnel; and

(iv) results of any statutory testing and inspection, e.g. earth grid
measurements.

(c) All hazardous conditions shall be corrected by the Contractor prior to or during
Commissioning. Comments shall be included on any observed deficiencies in
Plant design and performance.

(d) Any modifications to circuitry, instrumentation, etc. carried out a any time shall
be recorded in detail in the Phase Reports and shown on the Contractor’s
Drawings.

(e) Any conclusions that would be helpful to the Employer's operating and
maintenance staff shall be summarised at the end of the Phase Reports.

(f) The Phase Reports shall be prepared and submitted in the Employer’s
standard format as soon as practicable after the completion of each Phase.

79.8 STANDARDS AND REGULATIONS

(a) All testing and commissioning carried out by the Contractor shall be
undertaken using the International System of Units (SI) and shall comply, as
appropriate, with the latest and most up to date edition at the date of the Letter
of Acceptance, of the following standards, regulations and guides:

(i) the relevant "British Standard Codes of Practice" or "British Standard

Specifications" where applicable to the Works published by the British
Standards Institution;

(ii) the IEE Wiring Regulations issued by the Institution of Electrical

Engineers (U.K.);

(iii) "Code of Practice for inspections and testing of installations and

equipment" published by the HKSAR;

(iv) "Code of Practice for Electricity (Wiring) Regulations" published by the

HKSAR;

(v) "Codes of Practice for minimum fire service installations and equipment"
published by the HKSAR;

(vi) relevant circular letters issued by the Fire Services Department;

(vii) "Rules for automatic sprinkler installations" published by the Loss

Prevention Council;

(viii) “Ductwork leakage testing” published by Heating and Ventilation

Contractors’ Association;

(ix) the relevant codes and guides published by the American Society of
Heating, Refrigerating and Air Conditioning Engineers (ASHRAE-USA);

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 (x) the relevant codes and guides published by the Chartered Institute of
Building Services Engineers (CIBSE-UK);

(xi) the relevant codes and guides published by the National Environmental
Balancing Bureau (NEBB-USA); and

(xii) the relevant codes and guides published by the Building Services
Research and Information Association (BSRIA-UK).

79.9 CONTRACTOR'S TESTING AND COMMISSIONING STAFF

(a) All testing and Commissioning shall be undertaken by the Contractor's

appropriate testing and Commissioning specialist or by a competent
independent Commissioning specialist nominated by and acting for the
Contractor and reviewed without objection by the Project Manager.

(b) The Contractor shall provide all necessary skilled labour and assistance for
testing, operating, adjusting, Commissioning and verifying the performance of
all Plant.

(c) The Contractor's testing and Commissioning staff shall have had previous
experience with testing and Commissioning similar Plant of comparable duty.

(d) The Contractor's relevant specialist testing and Commissioning staff including
supervisors shall be available on Site at all times during testing and
Commissioning of the Plant.

79.10 TESTING AND COMMISSIONING EQUIPMENT AND INSTRUMENTS

(a) The Contractor shall provide all portable and supplementary instrumentation,
recording facilities, consumables and the like required for all Factory Tests
and testing and Commissioning on Site.

(b) Testing and Commissioning instrumentation shall be designed for field use
and to minimize field measurement errors through the use of electronic
sensors, digital displays and similar devices.

(c) The calibration of instruments shall be demonstrated immediately prior to, and
after completion of testing and Commissioning, and current calibration
certification submitted to the Project Manager for record purposes.

(d) At least one complete set of testing and Commissioning instrumentation,

including all accessories, fittings, attachments and purpose built carrying
cases, shall be made readily available in a calibrated and operation condition
for retesting by the Contractor for the duration of the Defects Liability Period.

(e) The end to end accuracy of instrumentation shall be verified in accordance

with the recommendations of ASHRAE 114.

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79.11 NOTIFICATIONS

(a) The Contractor shall, in accordance with section 15 of the General

Specification, give the Project Manager notice in writing, when tests or trials
shall be ready to commence provided that, notwithstanding section 15 of the
General Specification, not less than 48 hours' notice of all tests and trials
carried out on Site shall be given.

79.12 INSPECTIONS AND TESTING

(a) Prior to any inspection and testing by the Project Manager, the Contractor
shall inspect and test the Plant to ensure that equipment and facilities are
clean and complete and can reasonably be expected to meet successfully all
inspection and/or testing criteria.

(b) Prior to setting to Work, testing and Commissioning, the Contractor shall clean
all Plant and shall confirm in writing to the Project Manager that all the work is
complete and satisfactory for the purpose of testing and Commissioning.

(c) In the event that the Contractor considers that any testing is not appropriate or
required, the Contractor may submit alternative proposals to the Project
Manager for review.

79.13 FACTORY TESTING

79.13.1 General

(a) Wherever practical, Factory Tests shall cover subsystems rather than just
individual components.

(b) Unless otherwise reviewed without objection by the Project Manager, Factory
Testing of low voltage electrical Plant shall be undertaken at 380 V, or 220 V
as appropriate and 50 Hz.

79.13.2 Pumps

(a) Pumps shall be Factory Tested in accordance with BS 5316 : Part 2.

(b) Variable speed pumps shall be Factory Tested over the design operating
range.

(c) Performance results from Factory Tests shall be recorded at a minimum of 4

representative operating points across the range including both the maximum
and minimum flow rate conditions.

79.13.3 Air Handling Units

(a) Factory Testing shall include but shall not be limited to :

(i) calibration of controls and instruments;

(ii) fans and motors;

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 (iii) variable frequency drive; and

(iv) motorized dampers

(b) The Contractor shall provide temporary remote signals and devices,
temporary MCC facilities and cabling for Factory Testing.

79.13.4 Air Cooling Coils

(a) Cooling coils shall be Factory Tested at 2.6 MPa and leak tested at 1.7 MPa.

79.13.5 Automatic Controls

(a) The Contractor shall Factory Test microprocessor control functionality

including:

(i) measurement accuracy;

(ii) computer accuracy;

(iii) software programming;

(iv) cold and warm restart sequences; and

(v) downline loading sequences.

(b) The Contractor shall Factory Test all control algorithms. The Contractor shall
demonstrate functionality using actual Plant, electronic display panels,
computer simulation or similar.

79.13.6 Ductwork

(a) If insulation is applied to the pre-fabricated ductwork in the factory, leakage

test of the ductwork shall be carried out before the application of insulation.

(b) The leakage from any section of flexible ductwork shall not exceed 1% of the
local design air flow rate at the local maximum static pressure.

(c) All installed ductwork shall be tested to the latest edition of HVAC
standardDW/143 and as directed by the Project Manager as necessary to
prove the quality of the installation. Air leakage testing of ductwork on any
section of a completed installation shall be carried out and shall in accordance
with Appendices A of DW/144 and “Method of Testing” of DW/143. For those
items not covered in DW/144 and subject to the review without objection of the
Project Manager, the recommendations of the latest editions of “Low Pressure
Duct Construction Standards” and “High Pressure Duct Construction
Standards” issued by the SMACNA of U.S.A. shall be applied. Air ducts shall
be leakage tested as necessary.

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79.13.7 Chillers

(a) The Project Manager shall have authority to inspect the Manufacturers'
factory, during manufacture and after completion, all or any manufactured
material, apparatus or equipment ordered by the Contractor for incorporation
in the factory, and to require tests to be carried out in the presence of himself
or his representative in order to prove that the said material, apparatus or
equipment meets the requirements of the Specification. All costs incurred in
carrying out such tests and inspections, shall be included in the Contract and
shall be borne in full by the Contractor.

(b) The Contractor shall submit promptly to the Project Manager for review
without objection, at the time of issue, three copies of every order for bought
in material, apparatus and equipment intended for incorporation in the Works.
Each order shall clearly state that the item(s) which it covers is or are subject
to inspection and/or test by the Project Manager before despatch to site.

(c) Upon completion of manufacture, or before despatch in the case of stock

items, all materials, apparatus and equipment intended for incorporation in the
Works shall be offered for inspection by the Project Manager and shall be
subjected, in the presence of the Project Manager or his authorized
representative, to the tests specified in the relevant British Standard or
elsewhere in this Specification, together with such additional tests as may be
required by the Project Manager in order to prove compliance with the
Specification. When no relevant British Standard exists, or the appropriate
standard fails to specify tests, testing shall be carried out and be submitted to
review without objection by the Project Manager.

(d) The Project Manager and his authorized representative shall have right of
access, at all reasonable times during normal working hours, to the premises
of the Contractor for the purpose of inspection and/or testing material,
apparatus or equipment intended for incorporation in the Works. The
Contractor shall take all necessary steps to ensure that the right of access
extends to the premises of his suppliers and the manufacturers of bought-in
material, apparatus and equipment.

(e) No material, apparatus or equipment, from whatever source, shall be

despatched to site until the Project Manager has had the opportunity to
inspect it and either has formally waived his right to inspect or has reviewed
without objection prior to despatch following satisfactory test and/or
inspection.

(f) No inspection or testing by the Project Manager or his authorized

representative, nor the witnessing of satisfactory tests, nor the authorizing of
despatch to site shall in any way relieve the Contractor of any of his
obligations under this Contract, nor shall it in any way limit the right of the
Project Manager to reject such items after delivery to site if they subsequently
prove to be defective or unsatisfactory or unsuitable for their intended
purpose.

(g) No work shall be painted or otherwise prepared for despatch until it has been
inspected by the Project Manager and a notice and no objection issued.

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 (h) The factory test of the chillers shall include but not be limited to the following :

(i) The scope of factory tests or type tests for each major equipment or sub-
assembly shall be conducted in accordance with the test procedures
submitted by the Contractor and reviewed without objection by the
Project Manager.

(ii) Each chiller type of different capacity shall be individually factory tested
(or tested by an independent laboratory) to determine the capacity and
specific power consumption at 20%, 40%, 60% 80% and 100% of
specified load prior to shipment and be furnished with the full test report.

(iii) The following measurements shall be taken and used to calculate the
performance criteria noted above :

- Chilled water and condenser air flow leaving temperature.

- Chilled water and condenser air flow rates.

- Evaporator water pressure drops.

- Electrical power consumed at motor terminals.

(iv) Prior to carrying out the performance test, water tubes shall be cleaned.
Irrespective of this, all tubes shall be assumed to be fouled to give the
specified fouling factors. During the performance testing, the chilled
water temperature levels shall be adjusted to simulate the fouling
specified.

(v) For the part load performance test, condenser air temperatures should
be lowered in accordance with ARI 550/590 Standard.

(vi) For chillers to be acceptable, the performance tests shall demonstrate

that the specified capacity can be met at the specified conditions, whilst
the specific power consumption shall be no more than 5% above the
figures submitted with the tender by the Contractor at each level of load
operation.

(vii) The chillers shall be tested for balancing and leakage in the factory and
the test certificate shall include all test results for leakage, alignment,
vibration measurement and test records for balancing procedures.

(viii) The chillers shall be tested for safety control, automatic control. In
addition the microprocessor panel including wiring connection and
control operation shall be tested.

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79.14 TYPE TEST CERTIFICATES

The following type test certificates shall be submitted to the Project Manager for
review without objection.

(a) Fans

(i) type test certificates showing fan characteristic curves in accordance

with ISO 5801;

(ii) type test certificates for sound power levels in accordance with ISO
5136; and

(iii) fan dynamic balancing test certificates complete with a method of

statement from manufacture on testing to Grade 2.5, 4 & 6.3 on
appropriate fan types in accordance with ISO 1940.

(b) Pumps

(i) type test certificates for head, discharge, speed and power input in
accordance with ISO 2548, ISO 3555 and BS 599 as appropriate.

(c) Electric motors

(i) type test certificates in accordance with BS 4999 Part 143.

(d) Low voltage starter switchgear and control gear assembly

(i) type test certificates for starter and control panels assembly as a whole
in accordance with BS EN 60439-1.

(e) High voltage switchgear and motor control switchboard

(i) Type test certificates for high voltage switchgear and switchboard in
accordance with IEC 60056.

(f) Air Filters

(i) Type test certificates for air filters

79.15 SITE TESTING AND COMMISSIONING

79.15.1 Pipework

(a) All pipework shall be Site Tested for leaks before any pipework is enclosed,
insulated, or concealed in any way.

(b) Non-destructive Site Testing using 100% X-ray techniques or similar shall be
carried out on all welded joints associated with:

(i) pipework equal to or greater than 600 mm in diameter; and

(ii) all pipework associated with the town gas installation including sheaths
and vents.
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 (c) Chilled water pipework, pressure vessels and heat exchangers shall be Site
Tested hydraulically at 1.2 MPa pressure or one and a half times the total
working pressure whichever is higher after installation on Site. The test
pressure shall be maintained for not less than 24 hours. Pipework shall remain
completely watertight during this time. Pipework shall be filled with water
sufficiently in advance of the test to allow it to come to room temperature so
that any sweating can evaporate.

(d) The town gas installation including sheaths shall be pressure tested in
accordance with Relevant Authority requirements. Pipework and sheaths shall
be pressure tested in sections prior to filling risers with sand. On completion of
the overall installation, the entire town gas network shall be re-tested
pneumatically.

(e) All expansion and movement facilities, vibration isolators and similar shall be
restrained and/or temporarily removed during pipework pressure testing.

79.15.2 Sheetmetal and Ductwork

(a) Following installation but prior to concealment, enclosure, lagging or cladding,

all low pressure, medium pressure and high pressure sheetmetal and
ductwork including non-sheetmetal ductwork and fire rated ventilations
sheaths for town gas pipework shall be pressure tested in accordance with the
requirements and recommendations of:

(i) "DW 144 Specification for Sheetmetal Ductwork"; and

(ii) "DW 143 Ductwork Leakage Testing.

(b) Sheetmetal and ductwork pressure tests shall include all joints, dampers,
fittings, access panels and the like.

79.15.3 Noise and Vibration Levels

(a) Noise measurements shall be conducted with the system operating at design
conditions.

(b) Noise measurements shall be made using a meter complying with `Type 1'
requirements of IEC 651 standard. The meter shall be calibrated using an
acoustic calibrator, before and after all sets of measurements.

(c) Vibration shall not be perceptible to occupants sitting or standing. An RMS

surface vibration velocity of 0.1 m/s shall be taken as the reference limit of
perception.

(d) Noise levels shall be measured 1.5m above the finished floor level and at a
distance of 1.5m from a wall.

(e) Background noise level shall be measured with all plant off.

(f) All noise level readings are to be recorded and plotted on octave wave band
frequency chart.

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79.15.4 Regulation of Water Quantities

(a) Prior to water balancing, strainers shall be cleaned and flow limiter cores shall
be installed.

(b) Water quantities shall be balanced to within 0 to +5% of design.

(c) The Contractor shall confirm the flow rates using installed flow measuring
devices and pressure drops across components with known characteristics.
Results shall be cross-checked with pump performance readings.

(d) Flow limiters shall be tested to ensure that:

(i) under design conditions, the pressure drop across the flow limiter is in
the middle of the operating range of the device; and

(ii) under all SCHW pump operating conditions, the device is still within its
operating range.

79.15.5 Regulation of Air Quantities

(a) The Contractor shall balance all air diffusers and grilles by regulating the
dampers provided. Each system of ductwork shall be balanced so that every
branch duct, diffuser and grille shall carry the required quantity of air.

(b) Air quantities shall be balanced to within 0 to +10% of design.

(c) Air quantities shall be measured and recorded as recommended by the Sheet
Metal and Air Conditioning Contractors National Association Inc "Manual for
the Balancing and Adjustment of Air Distribution Systems". Air quantities shall
be measured at all supply, return, exhaust and outside air intake, registers,
diffusers, grilles, louvres, nozzles and the like, and these shall be
proportionally balanced.

(d) System and area air quantities shall be established by pitot tube readings
taken at locations determined in conjunction with the Project Manager and
shall be cross-checked with fan performance details.

(e) Air quantities associated with registers, diffusers, grilles, louvres, nozzles and
the like shall be established using microprocessor based, calibrated, back
pressure corrected, air flow measuring hoods. The Contractor shall provide
custom built hoods to suit air inlets and outlets as installed.

79.15.6 Automatic Controls

(a) All MBMS inputs and outputs shall be Site Tested and witnessed by field
observation of device operation and field confirmation of readings recorded by
the MBMS, including but not limited to:

(i) stop start commands and MBMS interlocks;

(ii) control valve response to controlling device;

(iii) damper response to controlling device;

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 (iv) VFD response to controlling device;

(v) safety interlocks; and

(vi) field instrumentation performance and calibration.

(b) All mechanical MBMS global commands shall be Site Tested including but not
limited to:

(i) global stop start commands;

(ii) load shedding sequences; and

(iii) global reset of controllers.

(c) The Contractor shall provide dedicated MBMS commands to globally control
Plant to suit Site Testing and Commissioning programmes including but not
limited to:

(i) global control of chilled water control valves on an area by area basis to
suit secondary chilled water Commissioning; and

(ii) temporary stop start programmes that do not require deletion or

modification of main control algorithms.

79.15.7 Secondary Chilled Water (SCHW) System

(a) Commissioning tests on each SCHW circuit shall include a minimum

continuous run of 12 hours. Readings shall be taken at least every 30 minutes
and compared to the design performance characteristics specified.

79.15.8 Pump and Water Treatment

(a) Flow limiter cores shall be removed until pre-commissioning cleaning is

complete.

(b) Prior to start up, testing and commissioning, the Contractor shall:

(i) thoroughly flush all chilled water systems with fresh water to remove any
dirt, dross and debris from pipework;

(ii) remove and clean all strainers and replace;

(iii) refill the system with fresh water to which has been added a suitable
detergent and circulate this cleaning agent for at least 24 hours;

(iv) drain the system, refill with fresh water and circulate for at least a further
24 hours. At regular intervals during this period, the Contractor shall
isolate and clean all strainers and open all drain points to remove any
debris arising from the cleaning agent;

(v) drain, fill and re-flush the system until all traces of the cleaning agent
and debris are removed and the pH of the water in the system is in the
range of 7 to 8. The water shall be tested to demonstrate compliance
with this requirement;
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Section 79 – Testing, Inspection & Commissioning –
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 (vi) drain the system, add sacrificial anodes and flow limiter cores; and

(vii) refill the system with fresh water and add chemical treatment.

(c) Sacrificial anodes shall be installed after cleaning.

(d) In addition to facilities shown on the Employer’s Drawings, the Contractor shall
install sufficient normally closed flushing bypass valves suitably sized to suit
pre-commissioning cleaning of pipework.

79.15.9 Pressure Testing for Refrigerant Systems

(a) Test Pressures

Refrigerant systems and circuits shall be pressure tested with nitrogen gas to
test pressures as indicated below:

Refrigerant High SideTest Pressure Low Side

kPa Test Pressure
KPa
R 22 (Air Cooled) 2950 1780
R 134a (Air Cooled) 2080 1190

In performing pressure tests for refrigerant systems and circuits containing

blend refrigerants (e.g. R407C and R410A), the individual manufacturer’s
recommended procedures and test pressures shall be followed.

After pressure testing, the nitrogen gas shall be evacuated to the satisfaction
of the Project Manager before final charging with refrigerant.

79.15.10 Fans

(a) Tests for fans associated with ventilation systems, air handling units, fan coil
units and similar shall include but shall not be limited to:

(i) instrument calibration Site Tests;

(ii) noise and vibration Commissioning tests; and

(iii) Commissioning tests of design flow rate.

(b) Commissioning tests for design flow rate under full load condition, flowrate
under specific part load condition and minimum flow rate under minimum load
conditions associated with variable volume fans shall be undertaken to confirm
stable operation of Plant.

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Section 79 – Testing, Inspection & Commissioning –
Mechanical Services
79.15.11 Variable Frequency Drives (VFD)

(a) Testing of variable frequency drives shall include but shall not be limited to:

(i) Commissioning tests to verify internal VFD functions, safety devices,

monitoring facilities and the like; and

(ii) Commissioning tests to verify MBMS interface facilities including

calibration of instrumentation.

79.15.12 Low Voltage Electrical Installation

(a) Testing and commissioning of the electrical installation shall be in accordance

with the requirements of BS 7671 and the EMSD Code of Practice for
Electricity (Wiring) Regulations.

(b) Current readings shall be determined in the field at starters, junction boxes or
similar.

(c) The Contractor shall undertake Commissioning tests to verify the operation of
bimetallic overloads by winding down the set point adjustment until the device
trips.

79.15.13 Chillers

Testing and start-up

(a) Testing and commissioning for the chiller system shall follow the CIBSE
Commissioning Code `R’ – Refrigerating Systems

(b) The following shall be supervised by the unit manufacturer’s representative:

(i) Charging.

(ii) Start-up.

(iii) Field testing

(c) Leak Test

(i) Units shall be site tested for leaks.

(ii) Leaks shall be checked with a halide testing device.

(iii) Units shall be dehydrated by producing a vacuum to 100 microns with

high vacuum pump. The vacuum shall then be maintained for 4 hours.
At the end of the 4 hour period, the pump shall be stopped. The vacuum
shall be maintained in the refrigeration unit for 24 hours without losing
more than 50 microns.

(iv) The tests shall be certified, and 6 copies of the certificates shall be
submitted before acceptance.

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Section 79 – Testing, Inspection & Commissioning –
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 (d) Field Refrigerant Piping Test

(i) Field tests shall be in accordance with the requirements of the relevant
local authorities Safety Code for Mechanical Refrigeration, ANS1 B-9.1.

(ii) The manufacturer shall submit certification to certify completion of

charging, start-up and field testing, and that the unit is ready for proper
operation.

(e) Safety devices

(i) All safety devices for all chillers shall be tested and certified during the
commissioning period.

(f) Site Test

(i) The Project Manager shall have the power to inspect all work in
progress and upon completion or substantial completion, and to require
the Contractor to carry out tests in his presence or in the presence of his
authorized representative in order to prove that all work carried out, and
all material, apparatus and equipment installed are wholly satisfactory
and fully meet the requirements of this Specification. All costs and
charges associated with or arising from such inspections and tests,
including costs incurred by the Contractor in carrying out the prescribed
tests and in attending upon the Project Manager whilst tests and
inspections are in progress, but excluding the Project Manager's costs
and expenses, and shall be borne in full by the Contractor.

(ii) Upon completion of the mechanical and/or electrical installation, or any

substantial section thereof, the installation or that section and all of the
associated equipment shall be subjected to the tests specified in the
relevant British Standards, IEE Regulations, CIBSE Standard, ASHRAE
Standard and HVCA Standards together with such other tests as may be
required by the Project Manager in order to prove compliance with this
Specification. When no relevant British Standard exists or the
appropriate British Standard fails to specify tests, tests shall be carried
out to the requirements of the Project Manager.

(iii) The Contractor shall carry out a visual inspection of all items of
equipment, as required by the IEE Wiring Regulations, before
conducting tests on the installation. The visual inspection shall be made
to verify that the installed electrical equipment is in compliance with this
Specification and applicable British Standards or other approved
Standard, correctly selected and erected in accordance with the IEE
Wiring Regulations and is not visibly damaged so as to impair safety.
Damaged or faulty items shall be replaced prior to testing.

(iv) Tests not carried out in the presence of the Project Manager shall not be
regarded as valid for the purpose of the Contract, unless the Project
Manager shall have previously signified his inability to attend, and shall
have authorized the Contractor to proceed with the testing process in his
absence.

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 (v) No materials, apparatus, equipment, or installation shall be covered or
otherwise permanently concealed from view until the Project Manager
has had the opportunity to inspect it, and either has formally waived his
right to inspect it or has given written notice of no objection prior to the
Contract proceeding.

(vi) Except for those items which are painted prior to despatch to site no
work shall be painted until it has been inspected by the Project Manager
a notice of no objection issued.

(vii) No inspection or testing by the Project Manager or his authorized

representative nor the witnessing of satisfactory tests shall in any way
relieve the Contractor of any of his obligations under this Contract, nor
shall it in any way limit the right of the Project Manager to reject such
items if they subsequently prove to be defective or unsatisfactory or
unsuitable for their intended purpose.

(viii) No apparatus, equipment, plant, or installations will be recognized as

complete and ready for taking over until all of the specified inspections
and tests have been satisfactorily carried out.

(ix) The site test shall include but not limited to the following items:

(reading taken at 25%, 50%, 75% and 100% of full load capacity)

- Ambient air temperature ºC

• Litres per second

• Entering and leaving temperature ºC

• Pressure drop – kPa

- Ambient air
• Cubic meter per second

• Entering and leaving temperature ºC

• Pressure drop, kPa

- Compressor
• Running kilowatts

• Refrigerant suction temperature ºC

• Refrigerant discharge temperature ºC

• Oil temperature ºC

• Oil pressure – kPa

• Thrust bearing temperature ºC

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 • Starting current and full load current

• Condenser fan, kW voltage and phase

- Chiller safety protection controls

• High pressure cutout

• Low pressure cutout

• Low oil pressure cutout

• Low water temperature cutout

• Low chilled water flow cutout

• High motor temperature

• High oil temperature cutout

• Compressor current limiting device

• Anti-freeze device

• Guide-vane controller (if provided)

(x) Three actual tests of the above described safety protection controls are
required to be carried out as per the specified procedure. The remaining
protection controls can be tested by simulation.

79.15.14 IAQ Equipment and System Testing

(a) General

(i) Before completion of Mechanical installation, the Contractor shall carry

out testing and commissioning of air-side equipment and systems
subject to review without objection by the Project Manager.

(ii) Testing and commissioning of IAQ installations shall be undertaken by

the Contractor’s own competent specialist staff or by a competent
Independent Commissioning Specialist nominated by and acting for the
Contractor the details of whom shall be reviewed without objection by
the Project Manager. The option chosen shall be declared by the
Contractor in the Tender Document.

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Section 79 – Testing, Inspection & Commissioning –
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 (b) Testing and Commissioning Requirements

(i) General Commissioning Requirements

Systems shall be properly adjusted and commissioned to ensure that the

equipment achieves the designed airflow rates. The following general
requirements shall be met before actual testing and commissioning of
IAQ installations are carried out.

- Plantrooms are free of construction waste and debris.

- Access doors to plantrooms are fitted and lockable.

- All builder’s works associated with the IAQ systems must be completed
and painted with dust preventing compound.

- All ceiling works are completed.

- All dust generating activities by other trades are completed and all
areas thoroughly cleaned to prevent ingress of building dust and debris
into the return air or fresh air intake systems

- Air intake screens and louvers are unobstructed and clean.

- Fan and other equipment chambers are clean and free of construction
debris.

- Fans are checked for proper operation.

- Floor gullies and drainage traps are clear and operational.

- All condensate drains and trays are clear and water can be drained
away satisfactorily.

- Dampers are clean.

- Ducting and other air passage ways are clean.

- All outside air, return air and spill air dampers are operative.

- All volume control dampers are fitted and are at appropriate opening
positions.

- Ductwork systems are cleaned by purging of the supply air fan, or by

robot duct cleaning recommended by the ductwork cleaning specialist.

- All VAV and CAV terminals are installed, together with grilles and
diffusers.

- All filter media are installed.

- Air conditioning systems and the building indoor area are purged to an
appropriate standard to be reviewed without objection by the Project
Manager.

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Section 79 – Testing, Inspection & Commissioning –
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 (ii) Particular Commissioning Requirements

After the general commissioning requirements have been verified by

inspection, testing and commissioning of the following IAQ equipment
and systems shall be undertaken:

- All air handling equipment: Fans, AHUs, FCUs, Electrostatic

Precipitator, Terminal Air Control devices, grilles and diffusers, etc..

- Air cleaning equipment: All pre-filters, main filters, high efficiency filters
and chemical filters.

- All ductwork and accessories: All ductwork, hoods and dampers.

Testing and commissioning procedures shall be carried out by licensed
personnel to adjust and regulate the system and equipment so as to
achieve the IAQ design criteria.

(c) IAQ Assessment and Methodologies

(i) Testing and commissioning of IAQ equipment and systems shall be

carried out to meet the IAQ design objective and to the satisfaction of
the Project Manager or to meet the requirements as stated in the
Specification.
(ii) IAQ assessments shall be performed as the last part of the testing and
commissioning process upon completion of the Mechanical installation.
Further assessments shall be done six months after the building has
been occupied and at two months before the expiry of the Defects
Liability Period, i.e.,

- First Assessment : After testing & commissioning

- Second Assessment : Six months after occupation of building or

substantial completion

- Third Assessment : Two months before the expiry of the Defects

Liability Period

(iii) IAQ compliance shall be proved by measurement results. In addition, an

end user satisfaction survey shall be conducted before the expiry of the
Defects Liability Period.

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Section 79 – Testing, Inspection & Commissioning –
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 (d) IAQ Measurement and Sampling

(i) The methods and procedures of the IAQ assessment, measurement and
sampling shall follow the guidelines provided by the EPD in particular for
the Indoor Air Quality Certification Scheme for Offices and Public Places
to achieve the Good Class. For measuring IAQ compliance,
assessments shall be carried out by either the real-time monitoring
method or the integrated sampling method. Real-time monitoring shall
be used for detection of pollutant sources and provide information on the
variation of pollutant levels throughout the day. The integrated sampling
method shall be carried out by taking samples of a particular pollutant
over an 8-hour period to obtain the total exposure level data. If it is not
practicable to have 8-hour samples, short-term sampling to cover the
worst scenarios shall be considered subject to review without objection
by the Project Manager. All measurements shall be conducted with the
use of calibrated instruments and equipment, standards and reference
materials with traceability to international or national standards.

79.15.15 Hot Smoke Test

(a) The hot smoke test shall be carried out in accordance with FSD circular letter
No. 2 of 2002 and Australian Standard AS4391-1999. Method statement,
prepared & endorsed by Fire Specialist, shall be submitted to FSD for
approval. Test fire location shall be agreed with FSD prior to commencement
of the test, and the intended test fire location is at ground floor, under centre
staircase void at grid 4/G-H. The size of test fire shall be at least 1MW or of
such size as agreed by FSD. The equipments for hot smoke test shall include,
but not limited to, the followings :

(i) Fire trays

(ii) Water bath

(iii) Heat sensors

(iv) Ceiling temperature sensors.

(v) Thermometer (Digital)

(vi) Thermometer (Conventional)

(vii) Tracer smoke

(viii) Smoke generator

(ix) Fuel

(x) Water

(xi) Video Cameras (minimum of two)

(xii) Cameras (minimum of two)

(xiii) Fire extinguishers

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Section 79 – Testing, Inspection & Commissioning –
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 (b) Prior to instigation of a hot smoke test, preliminary mock-up test shall be
carried out to ensure adequate operation of all installed systems.

79.16 REBALANCING AND RECOMMISSIONING TO SUIT COMPLETION

(a) In the event of sectioned completion, the Contractor shall rebalance all air,
water and control systems previously balanced, modified, adjusted, altered or
affected in any way of the Works. Sufficient confirmation shall be carried out,
recorded and witnessed to demonstrate that there has been either no effect or
that the required adjustments have been made.

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Section 79 – Testing, Inspection & Commissioning –
Mechanical Services
SECTION 80 AUTOMATIC SPRINKLER SYSTEM

80.1 GENERAL

(a) This section covers the general requirements for automatic sprinkler system.

(b) Automatic sprinkler system shall generally comply with the following:

(i) Cap 95 – Fire Services Ordinance;

(ii) Codes of Practice for Minimum Fire Service Installations and Equipment
and Inspection, Testing and Maintenance of Installations and Equipment
(FSDCOP) published by HKSAR;

(iii) relevant circular letters and requirements of Fire Services Department

(FSD);

(iv) The Loss Prevention Council (LPC) Rules for Automatic Sprinkler
Installations and Technical Bulletins;

(v) relevant circular letters and requirements of Water Supplies Department

(WSD); and

(vi) relevant British Standards.

(c) The classification of fire hazard shall be defined according to the LPC Rules
for sprinkler protection of various occupancy of the building or area.

(d) The complete sprinkler system shall comprise sprinkler heads, pipework and
fittings, flow switches, subsidiary monitored stop valve, sprinkler pumps and
tanks, pressure switches, pressure gauges, valves, alarm devices, sprinkler
control valve sets, sprinkler inlets, pump motors and starters, time delay relay,
electrical works and those shown on the Employer’s Drawings.

(e) All notices required by LPC Rules and/or FSD shall be in both the English and
Chinese languages.

80.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 5306 : Part 2 Fire extinguishing installations and equipment on

premises; Specification for sprinkler systems.

General Materials & Workmanship Specification 1/8 January 2011

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Section 80 – Automatic Sprinkler System
80.3 MATERIALS

80.3.1 Sprinkler Heads

(a) Sprinklers shall be of LPC approved makes and types and accepted by FSD.
They shall not be altered in any respect nor have any type of ornamentation or
coating applied after leaving the production factory, with the exception of anti-
corrosion treatment accepted by the LPC Rules.

(b) All sprinklers shall be suitable for ordinary hazard classification with a nominal
orifice size of 15 mm.

(c) Sprinklers shall be constructed with a heat sensitive quartzoid bulb of the
appropriate temperature rating in accordance with LPC Rules. In general area,
68°C sprinkler heads shall be used. Those for use inside kitchen shall be
93°C.

(d) Sprinklers heads of the same type shall be from the same manufacturer.

(e) The metal parts of the quartzoid bulb sprinkler heads shall be chromium plated
brass.

(f) A chrome-plated escutcheon plate shall be provided for all sprinklers installed
in area having suspended false ceiling.

(g) Unless otherwise specified on the Employer's Drawings, the types of

sprinklers head shall be as follows:

Type Orientation Location Accessories

Conventional Upright / Exposed,
/ Spray, fast pendent concrete ribbed
response soffit
Spray, fast Pendent Concealed, flat
response soffit
Conventional, Upright Ceiling with
fast response exposed
structural
steelwork
Spray, fast Pendent Under obstruction Complete with water
response deflection shields.
600mm dia. heat sink is
required if sprinkler is
installed at the periphery
of the obstruction.
Spray, fast Pendant Under false 600mm dia. heat sink is
response, ceiling required if sprinkler is
concealed installed at the
perforated false ceiling.

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Section 80 – Automatic Sprinkler System
80.3.2 Flow Switches

(a) Flow switches shall be of a type approved by LPC and FSD.

(b) Flow switches shall be of paddle type having the waterside completely
separated by a bulkhead from the electrical side. Contacts shall be suitable
for the working voltage and current of the circuits controlled, and shall be of
silver or approved alloy.

(c) Flow switches shall be capable of withstanding a test pressure of 1,600 kPa
for six hours without showing any sign of leakage.

80.3.3 Subsidiary Monitored Stop Valve

(a) Subsidiary monitored stop valve shall be provided for sprinkler system on
each zone.

(b) Factory built-in electrical micro-switch in the subsidiary monitored stop valve
shall give visual signals back to the fire alarm control and indication panel to
indicate the open/close state. Audible signal shall also be given when the
valve is not in fully open position.

(c) Leather strip padlock shall be provided for locking each valve at its open
position to prevent manual closing of the valve during normal operation.

(d) Warning sign shall be provided for each valve to prevent accidental closure of
valve after regular maintenance.

80.3.4 Pressure Switches

(a) Pressure switches shall have contact sets of silver or approved alloy rated to
suit the working voltage and current of the circuits controlled and shall have
independent adjustments for the cut-in and cut-out points and for the operating
differential. Electric alarm pressure switches shall be of the LPC approved
type.

(b) Scale ranges shall cover a band of at least two times the rated system
pressure. Pressure switches shall have differentials adjustable between 5%
and 30% of the set point scale ranges. The pressure sensing element of the
switch shall be capable of withstanding a momentary surge pressure of at
least 2 times the designed working pressure without losing its accuracy.
Suitable provision shall be made for relieving pressure to the pressure switch
through an orifice plate to allow testing of the operation.

80.3.5 Sprinkler Control Valve Sets

(a) All sprinkler control valve sets shall be listed and approved by Underwriter’s
Laboratories (UL), Factory Mutual Research Corporation (FM), LPC and FSD.

(b) Sprinkler control valves and all associated trimmings shall be form one
principal system manufacturer and form one mutually compatible system, all of
which shall be approved by the LPC and FSD.

(c) The minimum working pressure and factory hydrostatic test pressure of the
sprinkler control valve sets shall be 1,200 kPa and 2,400 kPa respectively.

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Section 80 – Automatic Sprinkler System
 (d) Each sprinkler control valve set shall be equipped with a sprinkler alarm valve
and the following trimmings:

(i) main stop valve and subsidiary stop valve;

(ii) angle valves;

(iii) ball valves;

(iv) orifice restriction;

(v) retarding chamber;

(vi) water motor alarm gong;

(vii) water pressure gauges to indicate upstream and down-stream system

pressure;

(viii) pressure switch;

(ix) test and drain valve;

(x) permanent direct reading flow meter; and

(xi) all required fittings

(e) Each stop valve in the sprinkler installation including the main stop valve shall
be secured open by a leather strap and brass lock under the master key
system.

(f) Sprinkler control valve set shall be of duplicate alarm valve arrangement or of
alarm valve with bypass arrangement, and with alarm monitoring facilities.

(g) Electric monitoring device shall be fitted at each valve to give signals back to
the fire alarm control and indicating panel to indicate the open/close state of
the valve.

(h) Audible signal shall also be given when the valve is not in fully open position.

(i) Drain connection to the system shall be led to conspicuous positions as

reviewed without objection by the Project Manager and comply with the
requirements of WSD.

(j) Sprinkler control valve set shall be of duplicate alarm valve arrangement or of
alarm valve with bypass arrangement, and with alarm monitoring facilities.

80.3.6 Sprinkler Inlets

(a) The sprinkler inlets shall be FSD approved type.

(b) Sprinkler inlets shall be made of gunmetal twin type comprising screw-down
globe type stop valve with male screwed outlet of suitable bore and two 65
mm instantaneous inlet connections.

(c) Outlet connection of the inlets shall not be less than 100 mm diameter.

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Section 80 – Automatic Sprinkler System
 (d) A separate check valve shall be provided for each inlet.

(e) A metal plate indicating the type of inlets in Chinese and English characters
using raised lettering shall be fixed to the wall immediately behind the inlets.
Labelling and lettering shall be in accordance with the FSDCOP.

80.3.7 Orifice Plates

(a) Orifice plates for system balancing, pump churning water circuits, where
applicable, shall be provided as required for proper commissioning of the
systems. Wherever necessary to suit the pump performance in respect of
system balance, orifice plates shall be provided even if they are not indicated
on the Employer's Drawings.

(b) Orifice plates shall be constructed and installed according to LPC Rules. They
shall be manufactured by factories producing LPC approved or UL listed
sprinkler equipment or equipment approved by similar widely recognized
independent regulatory body, and acceptable to the FSD.

80.4 SUBMISSIONS

(a) The Contractor shall submit the following for review without objection by the
Project Manager:

(i) pipe sizes and routings shown on the Employer’s Drawings are
indicative only. The Contractor shall produce detailed Contractor’s
Drawing to suit the Site conditions and characteristics of the equipment
offered and submit these to the FSD for approval prior to manufacture
and installation;

(ii) Contractor’s Drawings including detailed layout plans, elevation,

dimensions of pipework and equipment, electrical wiring diagrams,
operating weight, connection, mounting and fixing details, details of the
pipe supports, vibration eliminating provisions, construction details
through structural walls;

(iii) manufacturers’ literature for all equipment and materials of the

installation. Information shall include electrical characteristic, sound
power levels, performance specification, factory test reports, material list,
spare parts lists, wiring and control diagrams, piping connection
arrangement, maintenance clearance, mounting and fixing details;

(iv) detailed hydraulic calculations confirming the sizes of pipes, pumps,

orifices and all necessary accessories to achieve the design flow rate
and pressure, corresponding to the Site condition and relevant
Authorities' requirements; and

(v) testing and commissioning procedures in report format for the complete
system.

General Materials & Workmanship Specification 5/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 80 – Automatic Sprinkler System
 (b) The following catalogues with full technical data, characteristic curves and test
certificates issued by an independent and recognised testing authority shall be
submitted to the Project Manager for review without objection:

(i) sprinkler heads;

(ii) galvanized steel pipes / fittings;

(iii) flow switches;

(iv) subsidiary monitored stop valve;

(v) pressure switches;

(vi) sprinkler control valve set;

(vii) sprinkler inlets; and

(viii) orifice plates.

(c) The following samples shall be labelled and submitted to the Project Manager
for review without objection with detachable parts left loose so that they may
be taken apart for examination:

(i) sprinkler heads; and

(ii) protection guard.

80.5 WORKMANSHIP

80.5.1 Spacing and Location of Sprinklers

(a) Spacing and location of sprinklers shall be in accordance with the LPC Rules.

(b) Sprinkler heads at false ceiling level shall be installed at the exact center of
ceiling tiles. Positions shown on the Employer’s Drawings are for guidance
only. The Contractor shall be responsible for locating the sprinkler heads in
the exact levels/positions according to the suspended ceiling layout drawings.
The Contractor shall supply and install all necessary bends, tees, etc. to divert
the pipework to avoid structural beams and any other mechanical and
electrical services installations to reach the sprinkler heads in their locations
as shown on the Employer’s Drawings and as site conditions may dictate.

(c) All sprinklers heads in locations subjected be wetting by upper layer sprinkler
heads shall be fitted with water deflection shields of diameter not less than
100 mm.

(d) Metal baffles of the correct size shall be provided between sprinklers wherever
required by the LPC Rules.

General Materials & Workmanship Specification 6/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 80 – Automatic Sprinkler System
 (e) Sprinklers shall be protected by approved metal guards at location where the
sprinkler head is installed at a height less than 2m from ground level or In
situations where sprinklers are liable to accidental or mechanical damage or
where otherwise specified by the FSD. Guards shall not be used in
conjunction with sprinklers installed below false ceilings. Metal guards shall
be made from brass, wax coated or products having equivalent functions and
performance for corrosion resistance. It shall be of size not more than 65 mm
high.

(f) No sprinkler head shall be located directly above any luminaire, lamp holder,
loudspeaker, smoke/heat detector, fan coil unit and the like. No additional
cost can be claimed as a result of such coordination.

(g) LPC approved automatic flow switch testing system shall be supplied and
installed for sprinkler flow switches installed in a position difficult to be
accessed or checked in routine inspection such as those inside false ceiling,
at level higher than 2m above ground, etc. The automatic testing system for a
single flow switch shall include a solenoid valve. The controlling wiring and
accessories shall be wired and connected to the relevant fire main panel/fire
sub panel.

(h) Where automatic flow switch testing system is not provided, the Contractor
shall allow adequate drain points in the installation connected to the nearest
drain for routine testing of all flow switches when the sprinkler installation is in
operation.

80.5.2 Spare Sprinklers

(a) The Contractor shall supply and install a cabinet containing a minimum
number of spare sprinklers as recommended by the LPC Rules. Sprinkler
spanners as supplied by the manufacturers of the sprinklers shall also be
provided and kept in the cabinet.

80.5.3 Flow Switches

(a) Adequate space shall be allowed above the pipework for the installation of
flow switches. All flow switches and the associated accessories shall be
horizontally mounted.

80.6 PRE-ACTION SPRINKLER SYSTEM

(a) Pre-action sprinkler systems shall be provided for the specified area .

(b) Major components of each system shall include but not be limited to:

(i) flow release valve and check valve;

(ii) main stop valve;

(iii) air compressor and pneumatic control system for pressurization of

distribution pipework;

(iv) all ancillary equipment including but not necessarily limited to angle
valve, ball valves, orifice restriction, pipe fittings, retard chamber, water
pressure gauges, pressure switches, water motor and alarm gongs;

General Materials & Workmanship Specification 7/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 80 – Automatic Sprinkler System
 (v) manual release unit; and

(vi) smoke detectors and sprinkler network within the areas specified in (i)
above.

(c) The system shall operate as follows:

(i) the compressor pneumatic system shall automatically maintain system

air pressure downstream of the check valve continuously; and

(ii) the control system shall be ‘double interlocking’ i.e. arranged so that
water shall not enter the downstream pipework until both a sprinkler
head and a smoke detector within the protected space have been
activated. Activation of a smoke detector only shall not cause water to
enter the downstream pipeworks. Similarly activation of a sprinkler
head only shall not cause water to enter the down stream pipework.

(d) Air Compressors

(i) air compressors for the pre-action sprinkler systems shall be of air
cooled type complete with air receiver, regulators and associated valving;

(ii) the air compressor shall be driven from a 220 volt single phase motor;
and

(iii) the compressor shall operate by means of a pressure switch to maintain

a system pressure of 150 kPa in the pipework.

(e) Flow Release Valve

(i) the flow release valve shall be a quick opening, differential diaphragm
valve with a spring loaded floating clapper. The valve shall be used to
facilitate manual or automatic on/off control.

(f) Air compressor sets shall be fully automatic in operation and shall be self-
lubricating, with sealed compressor unit, designed for maintenance-free
operation. The duty rating of the compressor shall be such that it does not cut
in and out more than 4 times per hour, nor run continuously for more than 30
minutes in order to maintain the system pressure. Pump-up time shall not
exceed 5 hours.

General Materials & Workmanship Specification 8/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 80 – Automatic Sprinkler System
SECTION 81 HYDRANT AND HOSE REEL SYSTEM

81.1 GENERAL

(a) This section covers the general requirements for hydrant and hose reel
system.

(b) Hydrant and hose reel system shall generally comply with the following:

(i) Cap 95 – Fire Services Ordinance;

(ii) Codes of Practice for Minimum Fire Service Installations and Equipment
and Inspection, Testing and Maintenance of Installations and Equipment
(FSDCOP) published by HKSAR;

(iii) relevant circular letters and requirements of Fire Services Department

(FSD);

(iv) relevant circular letters and requirements of Water Supplies Department

(WSD); and

(v) relevant British Standards.

(c) The fire services inlets and hydrant outlets if not stamped with the British
Standard Mark shall be accompanied with a letter of approval issued by WSD.

81.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 336 Specification for fire hose couplings and ancillary

equipment;
BS 381C Specification for colours for identification, coding and
special purposes;
BS 1042 Measurement of fluid flow in closed conduits;
BS 3169 Specification for first aid reel hoses for fire-fighting
purposes;
BS 5041 : Part 1 Fire hydrant systems equipment. Specification for
landing valves for wet risers;
BS 5252 Framework for colour co-ordination for building
purposes;
BS 5306 : Part 1 Fire extinguishing installations and equipment on
premises. Hydrant systems, hose reels and foam
inlets;

General Materials & Workmanship Specification 1/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 81 – Hydrant & Hose Reel System
 BS EN 671 : Part 1 Fixed fire fighting systems. Hose systems. Hose reels
with semi-rigid hose; and
BS EN 1982 Copper and copper alloys. Ingots and castings.

81.3 MATERIALS

81.3.1 Fire Hydrant Outlets

(a) The hydrant outlet shall be of FSD approved type.

(b) The fire hydrant assembly shall conform to BS 5041 : Part 1 as appropriate.

(c) All hydrant outlets shall be installed not less than 800 mm and not more than
1,200 mm above finished floor level.

(d) The hydrant outlets shall be single or double type comprising screw-down
globe type stop valve for each outlet branch and with male screwed inlet of
suitable bore and 65 mm female instantaneous outlets to BS 336. Outlet
branches shall incline at 70° from the center line of the handwheel, and at 90°
to each other where applicable. The coupling control shall be located at the
side of each outlet branch. A bronze blanking cap held captive by a suitable
chain shall be fitted to each female outlet.

(e) The hydrant outlets shall be of all gunmetal construction to BS EN 1982

except for the handwheel which shall be of cast iron or hard aluminium alloy.

(f) The handwheel shall be of 137 mm diameter and shall be designed to open
the valve by counter-clockwise rotation. The direction of opening of the valve
shall be clearly engraved in both English and Chinese on the wheel of the
valve.

(g) The pressure at any fire hydrant outlet shall in no case exceed 850 kPa. The
running pressure at any hydrant outlet when delivering 450 L/min shall be not
less than 350 kPa.

(h) For those hydrant locations whose outlet pressure exceed 850 kPa, pressure
reducing valves or parity-drain shall be employed to maintain the outlet
pressure. The Contractor shall submit detailed hydraulic calculation for such
hydrant outlet selection to the Project Manager for review without objection.

(i) For self-contained pressure reducing hydrants, the pressure reduction shall be
achieved by means of hydraulic pressure balancing with metal diaphragm. All
pressure reducing mechanisms shall be located at the downstream side of the
valve seat.

(j) The pipes run as shown on the Employer’s Drawings are diagrammatic only
and the Contractor shall design the pipe runs to avoid structural beams and
other obstruction as Site conditions dictate.

General Materials & Workmanship Specification 2/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 81 – Hydrant & Hose Reel System
81.3.2 Hose Reels

(a) Hose reels shall be of fixed or swing type as shown on the Employer’s
Drawings and the construction, testing, performance and working pressure
shall be to FSD standard requirements. Hose reel shall be of FSD approved
type and shall comply with BS EN 671 : Part 1 and BS 5306 : Part 1.

(b) The hose shall be approved by FSD and shall be red reinforced rubber or PVC
tubing and comply with BS 3169 Type 2 with a design working pressure of not
less than 1,500 kPa. The length of hose shall be 30 m and internal bore shall
be 19 mm. There shall be no joint in the length of hose. The hose shall be
capable of being readily wound round a drum of 150 mm diameter without
kinking. The hose together with the connections, gland, etc. must be capable
of withstanding a bursting pressure of not less than 2,700 kPa and shall not be
porous or exhibit any sign of percolation under pressure up to 2,000 kPa.

(c) Drums shall be constructed of 2.5 mm thick pressed mild steel, hydraulically
balanced, free from denting and twisting, and finished in red enamel. The hub
and shaft shall be of brass, fitted with a device to prevent overrun of the hose,
having a glandless centre seal.

(d) Each hose shall be fitted with a jet nozzle having 4.5 mm orifice and simple
slow-closure type level-operated two way valve to open and shut off jet nozzle.
The valve shall not be spring loaded. The internal surface of the nozzle shall
be finished to provide a smooth surface. The nozzle shall give a plain jet only.
The nozzle shall be capable of projecting a jet of not less than 6m in length
with flow rate not less than 24 L/min as specified in BS EN 671 : Part 1.

(e) A 0.8 mm thick galvanized steel box with glass front panel complete with
lockable door shall be provided for locking the hose reel nozzle as per WSD
requirement. The front glass panel of the box shall not exceed 1.5mm in
thickness and shall be breakable to release the nozzle in emergency. A metal
striker about 300 mm long, shall be provided inside the hose reel cabinet for
the purpose of breaking the glass panel. The box shall have at least 3 coats
of painting, the top finish coat shall be red in colour. Padlock for the steel box
shall be provided.

(f) A sticker or plate carrying the following warning message shall be securely
fixed on or near every hose reel outlet and the message shall be easily visible.

消防用水
嚴禁作其他用途
USE OF WATER FROM FIRE SERVICES
FOR PURPOSES OTHER THAN FIRE
FIGHTING IS STRICTLY PROHIBITED

水務監督辦事處 Office of the Water Authority

(g) An instruction plate with engraved English and Chinese instructions and
illustrations for using of the hose reel shall be provided and fixed near the
hose reel or outside the hose reel cabinet. The size of character shall comply
with the requirement of FSD.

General Materials & Workmanship Specification 3/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 81 – Hydrant & Hose Reel System
 (h) The hose reels shall be installed such that the control valves, sited adjacent to
the nozzles are positioned above and not more than 1,350 mm from the
finished floor level. For recessed mounting type, the nozzles and control
valves shall be at a discernible and accessible position of not more than 500
mm from the surface of the wall.

(i) For hose reels, mounted within binnacles, hose reel drums shall be bare
finished in die cast light alloy with polished mins. All other hose reel drums
shall be finished in red, preferably no. 538, post office red; no. 537, signal red;
or no. 539, red, as given in BS 381C or BS 5252.

(j) A metal or plastic striker shall be provided in the vicinity of the cabinet for the
purpose of breaking the glass front panel in case of emergency.

81.3.3 Fire Service Inlets

(a) The fire service inlets shall be FSD approved type.

(b) Fire service inlets shall be made of gunmetal twin type comprising screw-down
globe type stop valve with male screwed outlet of suitable bore and two 65
mm horizontal male instantaneous inlet connections.

(c) A separate integral spring loaded resilient-seated check valve shall be

provided for each inlet.

(d) Outlet connection of the inlets shall not be less than 100 mm diameter.

(e) A metal plate indicating the type of inlets in Chinese and English characters
using raised lettering shall be fixed to the wall immediately behind the inlets.
Labelling and lettering shall be in accordance with the FSDCOP.

81.3.4 Venting and Draining

(a) All hydrant risers shall be supplied and installed with automatic air vents of
25mm size at the highest points and drain valves at the lowest points of the
system.

(b) Automatic air vents with suitable working pressure shall be fitted where
necessary or indicated on the Employer’s Drawings for the removal of air from
the fire hydrant and hose reel system.

(c) Drain valves shall be fitted on the lowest points of pipework as shown on the
Employer’s Drawings or where necessary for the water drainage of the system,
and drained water shall be discharged to a location agreed by the Project
Manager, and as acceptable to WSD.

General Materials & Workmanship Specification 4/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 81 – Hydrant & Hose Reel System
81.3.5 Controls

(a) Hydrant system controls, including control of booster pumps, shall be as

detailed in clause 5.14 of the FSDCOP.

(b) The Contractor shall provide pressure switches on the installation pipework for:

(i) automatic activation of jockey pump to maintain system pressure; and

(ii) automatic activation of the duty and standby pumps with changeover
facility upon activation of any hydrant or hose reel point.

81.4 SUBMISSIONS

(a) The Contractor shall submit the following for review without objection by the
Project Manager:

(i) pipe sizes and routings shown on the Employer’s Drawings are
indicative only. The Contractor shall produce detailed Contractor’s
Drawing to suit the Site conditions and characteristics of the equipment
offered and submit these to the FSD for approval prior to manufacture
and installation;

(ii) Contractor’s Drawings including detailed layout plans, elevation,

dimensions of pipework and equipment, electrical wiring diagrams,
operating weight, connection, mounting and fixing details, details of the
pipe supports, vibration eliminating provisions, construction details
through structural walls;

(iii) manufacturers’ literature for all equipment and materials of the

installation. Information shall include electrical characteristic, sound
power levels, performance specification, factory test reports, material list,
spare parts lists, wiring and control diagrams, piping connection
arrangement, maintenance clearance, mounting and fixing details;

(iv) detailed hydraulic calculations confirming the sizes of pipes, pumps,

orifices and all necessary accessories to achieve the design flow rate
and pressure, corresponding to the Site condition and relevant
Authorities' requirements; and

(v) testing and commissioning procedures in report format for the complete
system.

(b) The following catalogues with full technical data, characteristic curves and test
certificates issued by an independent and recognised testing authority shall be
submitted to the Project Manager for review without objection:

(i) hose reel;

(ii) fire hydrant outlet; and

(iii) fire service inlet.

General Materials & Workmanship Specification 5/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 81 – Hydrant & Hose Reel System
 (c) The following samples shall be labelled and submitted to the Project Manager
for review without objection with detachable parts left loose so that they may
be taken apart for examination:

(i) hose reel nozzle; and

(ii) rubber hose.

81.5 WORKMANSHIP

81.5.1 Pipework Installation

(a) The installation shall include all pipework and fittings fully installed as
indicated on the Employer’s Drawings, and as specified in Section 87 of this
General Materials and Workmanship Specification.

81.5.2 Fire Hydrant Outlets

(a) The hydrant outlets shall be installed not less than 800 mm and not more than
1,200mm above finished floor level. The hydrant outlet shall be of FSD
approved type.

81.5.3 Hose Reels

(a) Swinging type hose reels, where provided, shall be carried on a swinging
cradle recessed into the wall such that when not in use, the outer face of the
reel is flush with the wall and when required for use, the cradle may swing out
into the corridor or passage without due obstruction and without interference
with any exit point.

(b) If hose reels are located in recesses to which doors are fitted, such doors shall
be so fixed that when they are opened, they shall not cause obstruction to any
means of escape nor to the operation of the hose reels nor to the hose being
run out in either direction. Door locks shall not be fitted to such doors.

(c) For fixed type hose reels, a hose guide shall be provided so as to permit ease
of withdrawal of the hose. The guide shall be so designed that it will permit
the hose to be run off in any direction from left to right. Rollers used in the
guide shall be not less than 25 mm diameter and shall be constructed of nylon
or other non-metallic material.

81.5.4 Venting and Draining

(a) All hydrant risers both wet and dry types shall be provided with air relief valves
of 25 mm size at the highest points and drain valves at the lowest points of the
systems. Air relief valves on dry risers shall be of the automatic type.

General Materials & Workmanship Specification 6/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 81 – Hydrant & Hose Reel System
81.6 STREET HYDRANT SYSTEM

(a) Street hydrants shall be of pedestal type manufactured of cast iron.

(b) The system shall comply with the requirements of FSD and WSD.

(c) Spacing between fire hydrants shall be 100 m staggered on alternative sides
of the roadway wherever practicable.

(d) The hydrant shall be of FSD accepted standard pattern and, when tested in
accordance with provision of BS 1042 with one 65 mm outlet working, shall be
capable of delivering not less than 2,000 L/min (33.3 L/s) with a minimum
running pressure of 170 kPa at the outlet. The minimum output and pressure
as stated above shall be made available from two 65 mm outlets of the system
delivering at the same time, i.e. a total output of not less than 4,000 L/min
(66.7 L/s) at 170 kPa.

(e) Where the minimum standards are not possible from direct town mains, the
water supply shall be augmented by water tank and booster pumps. The
Contractor shall arrange to test the direct town mains water supply pressure
and flow at a nearby location reviewed without objection by the Project
Manager at early stage after the commencement of the Contract. The
Contractor shall submit to the Project Manager for review without objection
soonest after the test proposal for providing booster pumps and tanks for the
street hydrant system if the water supply pressure and flow from town mains
are not adequate to meet with the requirements of FSD.

(f) Valves shall be arranged such that clockwise rotation of the spindle closes the
valves.

(g) The stem of ground valve shall not deeper than 500 mm from ground level.

General Materials & Workmanship Specification 7/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 81 – Hydrant & Hose Reel System
[this page not used]
SECTION 82 GASEOUS FIRE EXTINGUISHING SYSTEM (FM200)

82.1 GENERAL

(a) This section covers the general requirements for gaseous fire extinguishing
system (FM200).

(b) Gaseous fire extinguishing system (FM200) shall generally comply with the
following:

(i) Cap 95 – Fire Services Ordinance;

(ii) Codes of Practice for Minimum Fire Service Installations and Equipment
and Inspection, Testing and Maintenance of Installations and Equipment
(FSDCOP) published by HKSAR;

(iii) relevant circular letters and requirements of Fire Services Department

(FSD); and

(iv) relevant British Standards.

(c) The Contractor shall provide proprietary FM200 gas extinguishing systems in
the locations as shown on the Employer's Drawings. Each FM200 gas
extinguishing system shall consist of the following major items of work:

(i) gas storage cylinders including cylinder valves and accessories;

(ii) control head with automatic and manual control facility;

(iii) manual release units;

(iv) all pipework;

(v) discharge nozzles;

(vi) gas control panels;

(vii) smoke detection including all detectors and associated wiring;

(viii) remote gas indicator panels;

(ix) audio visual advisory systems;

(x) all associated electrical wiring and controls;

(xi) interfaces with air-conditioning and ventilation equipment;

(xii) interfaces with computer system power supplies where required;

(xiii) complete computer calculations for each gas extinguishing system;

(xiv) testing and commissioning of the system; and

(xv) full initial charge of each system with FM200 gas.

General Materials & Workmanship Specification 1/12 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 82 – Gaseous Fire Extinguishing System(FM200)
 (d) The system shall be of the total flooding type with a high pressure open-ended
piping installation. The gas release mechanism shall be operated
automatically by means of the smoke detection system within the protected
space or manually by means of a manual release unit.

(e) The FM200 gas extinguishing system shall be designed and installed in
accordance with NFPA 2001 Standard on Clean Agent Fire Extinguishing
Systems.

82.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 21 Specification for pipe threads for tubes and fittings

where pressure-tight joints are made on the threads
(metric dimensions)
BS 381C Specification for colours for identification, coding and
special purposes
BS 5252 Framework for colour co-ordination for building
purposes
BS 5839 : Part 4 Fire detection and alarm systems for buildings.
Specification for control and indicating equipment
BS EN 10216 : Part 1 Seamless steel tubes for pressure purposes.
Technical delivery conditions. Non-alloy steel tubes
with specified room temperature properties
BS EN 10217 : Part 1 Welded steel tubes for pressure purposes. Technical
delivery conditions. Non-alloy steel tubes with
specified room temperature properties
NFPA 2001 Standard on Clean Agent Fire Extinguishing Systems

82.3 MATERIALS

82.3.1 Storage Cylinders

(a) FM200 extinguishing agent shall be stored in rechargeable steel cylinders to

hold the pressurized agent in liquid form at ambient temperature.

(b) Cylinders shall be securely mounted in the vertical position in a frame bolted
to the wall within each gas control room and arranged so that external parts
may be readily inspected. Each cylinder shall be fitted with an automatic
pressure release device for over pressure protection of the cylinder.

(c) Each cylinder shall be complete with gas valve, pressure gauge, pressure
switch, flexible hose, check valve and all other necessary accessories.

General Materials & Workmanship Specification 2/12 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 82 – Gaseous Fire Extinguishing System(FM200)
 (d) A device shall be provided for measuring the amount of liquid in the cylinder at
any time. The method of measurement shall not require the cylinder to be
detached from the remainder of the installation.

(e) The liquid shall be discharged from the cylinder through a syphon tube. The
pressure of the liquid stored in the cylinder shall be such that freezing cannot
take place at the lowest possible ambient temperature.

(f) Gas cylinders shall be painted signal red as specified in BS 381C in

accordance with the requirements of BS 5252. The type of extinguishing
agent, the tare weight, gross weight, liquid level at 25°C and also the degree
of superpressurization shall be clearly painted on each cylinder with white
paint.

(g) The gas valve assembly shall be equipped with a pressure gauge and safety
disc in accordance with NFPA 2001.

82.3.2 Control Head

(a) The control head shall be mounted directly on the cylinder valve and shall
provide both electrical and mechanical actuation of the cylinder valve for
release of gas.

(b) Electrical actuation shall be by means of the automatic smoke detection

system within the protected area.

(c) Mechanical actuation shall be by means of the remote cable operated manual
release unit.

82.3.3 Manual Release Units

(a) A manual release unit shall be provided in a suitable position outside each
entrance to the protected area. The manual release unit shall consist of a pull
handle or push button mounted in a box with "break glass" cover. The box
shall be so designed that its glass front may be readily replaced and its front
cover can be opened with a key for the purpose of operating the switch
without breaking the glass.

82.3.4 Emergency Release

(a) An emergency release handle with direct mechanism shall be provided in an

accessible position at the gas cylinders. The emergency release shall require
no power supply to operate and it shall be provided with a removable pin to
prevent accidental release of gas. Provision shall be made for operation of
the emergency release to simultaneously control the shutdown of ventilation,
air-conditioning, equipment, etc, and to sound the alarms.

82.3.5 Pipework

(a) Pipework shall be Grade 410 seamless schedule 40 steel pipe to BS EN

10216 : Part 1 and BS EN 10217 : Part 1.

General Materials & Workmanship Specification 3/12 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 82 – Gaseous Fire Extinguishing System(FM200)
 (b) Threaded steel pipework and fittings shall be free of burrs, spelter and rust
and shall be galvanized inside and out. Screwed threads shall conform to the
dimensions specified in BS 21. Screwed joints shall be made with PTFE tape
but chemically inert to the extinguishing agent used. Compressed fibre
gaskets free of asbestos shall be used for flange joints. Pipework shall be
painted signal red as specified in BS 381C in accordance with the
requirements of BS 5252. Brass fittings shall be left unpainted.

(c) Pipe work supports shall be located as near as possible to all joints and
changes of direction. Each support shall take its own share of the load. The
maximum space between supports shall take into consideration the total mass
of pipe and extinguishing agent. The minimum support requirements shall be
as follows:

Pipe size (mm) Span (m) Fixing steel angle size

(mm x mm x mm)
15 1.5 25 x 25 x 3
20 1.8 25 x 25 x 3
25 2.1 25 x 25 x 3
32 2.4 25 x 25 x 3
40 2.7 32 x 32 x 3
50 3.0 32 x 32 x 3
80 3.6 32 x 32 x 3
100 4.2 50 x 50 x 6
150 5.2 50 x 50 x 6

(d) Additional supports shall be provided where there are extra loads such as
valves.

(e) Flexible hose connections shall be designed for the working pressures and
temperatures to which they shall be subjected.

82.3.6 Discharge Nozzles

(a) Discharge nozzles shall be designed to provide the required flow rate and
distribution of FM200 gas to totally flood the protected area.

(b) Discharge orifices, and discharge orifice plates shall be of a material that is
corrosion resistant.

(c) Discharge nozzles shall be designed for use with the expected working
pressure and temperature without deformation.

82.3.7 Gas Control Panel

(a) A wall mounted gas control panel shall be provided for each gas extinguishing
system outside the protected area within each gas control room.

(b) The gas control panel shall be capable of operating independently from the
main fire alarm and detection system. The main fire alarm and detection
system shall monitor the status only of the gas control panel.

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Section 82 – Gaseous Fire Extinguishing System(FM200)
 (c) The gas control panel shall control and monitor the gas release system. The
manual release mechanism shall remain operative whether the automatic
system is on or off. A time delay unit shall be provided which shall be
adjustable and lockable in the range 15 to 30 sec. Relays shall be provided to
shut down ventilation and air-conditioning, to close openings and to switch off
power supply to equipment. These relays shall operate immediately when two
zones of the smoke detectors are activated or when the manual release is
operated. Release of the gas shall follow after the pre-set time delay.

(d) The gas control panel shall incorporate the following facilities and functions:

(i) monitoring of all smoke detection circuits for the protected space;

(ii) automatic electrical control of the control head upon activation of two
smoke detection circuits (second stage alarm) within the protected
space;

(iii) monitoring of gas storage cylinder pressure to raise alarm upon receipt
of low pressure signal from the pressure switch;

(iv) essential and back-up battery power supplies;

(v) activation of first stage alarm bells and second stage sirens;

(vi) interface with gas indicator panels located outside the protected area
adjacent to each entrance door;

(vii) voltage free alarm signals for activation panels located outside the
protected area adjacent to each entrance door;

(viii) voltage free signals for operation of motorised fire dampers or electro
thermal links via motor control centres;

(ix) voltage free signals for activation of computer power supplies shutdown;
and

(x) interface with the main addressable fire alarm and detection system to
provide gas system status information.

82.3.8 Gas Indicator Panel

(a) The Contractor shall provide a wall mounted gas indicator panel outside each
protected space immediately adjacent to each access door.

(b) Each gas indicator panel shall be provided with the following facilities:

(i) first stage alarm indicator;

(ii) second stage alarm indicator;

(iii) “gas released” indicator;

(iv) abort switch and indicator;

(v) “manual/auto” key switch; and

(vi) break glass alarm.

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Section 82 – Gaseous Fire Extinguishing System(FM200)
82.3.9 Smoke Detection

(a) Photo-optical smoke detectors shall be provided within the protected space,
within false ceilings and within raised floors as shown on the Employer's
Drawings.

(b) For each protected space detector shall be arranged in coincidence zones, i.e.
two smoke detection circuits per space.

82.3.10 Audio Advisory System

(a) The Contractor shall provide alarm bells and sirens within the protected space
and immediately outside the protected space.

(b) Activation of a detector in one zone shall cause alarm bells to sound.
Activation of detectors in two zones shall cause the siren to sound to warn that
if the system is in the automatic mode the extinguishing agent is about to be
released. These warnings shall also be activated by operation of the manual
release units.

82.3.11 Visual Advisory System

(a) All gas storage compartments and compartments protected by a gas

extinguishing system shall have a warning notice fixed on each entrance door
to the compartment. Configuration, lettering, colour and size of the notice
shall be in accordance with the requirement of the FSD. The notice shall be
made of sheet metal plate not less than 1.6 mm thick.

(b) The following warning lights shall be installed together with

explanatory/warning notices in English and Chinese. Such notices shall be
clearly legible and painted or engraved on substantial durable material.

(c) Inside the protected area:

(i) A flashing red light to indicate gas release imminent with a notice which
shall read:

“WARNING - FM200 gas release imminent.

Leave the room at once.”

(d) Outside each entrance to the protected area:

(i) A green light to show that the system is on manual control with
automatic control locked off, with a notice which shall read:

“Safe to enter. FM200 fire extinguishing system on manual control.

When room vacated switch to automatic control.”

(ii) An amber light to show that the system is on automatic control with a
notice which shall read:

“Not safe to enter. FM200 fire extinguishing system on automatic

control. Switch to manual control before entering.”

(iii) A red light to show that the system has operated, with a notice which
shall read:

"DANGER - Do not enter. FM200 gas discharged."

General Materials & Workmanship Specification 6/12 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 82 – Gaseous Fire Extinguishing System(FM200)
 (e) The manual/automatic lock off key switches, the manual release units and the
emergency release handle shall all be labeled in English and Chinese so that
it is clear what their purpose is and how to operate them.

82.4 SUBMISSIONS

82.4.1 General

(a) The Contractor shall submit the following for review without objection by the
Project Manager:

(i) pipe sizes and routings shown on the Employer’s Drawings are
indicative only. The Contractor shall produce detailed Contractor’s
Drawing to suit the Site conditions and characteristics of the equipment
offered and submit these to the FSD for approval prior to manufacture
and installation;

(ii) Contractor’s Drawings including detailed layout plans, elevation,

dimensions of pipework and equipment, electrical wiring diagrams,
operating weight, connection, mounting and fixing details, details of the
pipe supports, vibration eliminating provisions, construction details
through structural walls;

(iii) manufacturers’ literature for all equipment and materials of the

installation. Information shall include electrical characteristic, sound
power levels, performance specification, factory test reports, material
list, spare parts lists, wiring and control diagrams, piping connection
arrangement, maintenance clearance, mounting and fixing details;
(iv) detailed calculations confirming the sizes of pipes, equipment and all
necessary accessories to achieve the design flow rate and pressure,
corresponding to the Site condition and relevant Authorities'
requirements; and

(v) testing and commissioning procedures in report format for the complete
system.

(b) The following catalogues with full technical data, characteristic curves and test
certificates issued by an independent and recognised testing authority shall be
submitted to the Project Manager for review without objection:

(i) FM200 system;

(ii) control panel;

(iii) break glass;

(iv) alarm bell;

(v) smoke detector; and

(vi) pipework and fitting.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 82 – Gaseous Fire Extinguishing System(FM200)
 (c) The following samples shall be labelled and submitted to the Project Manager
for review without objection with detachable parts left loose so that they may
be taken apart for examination:

(i) break glass;

(ii) alarm bell;

(iii) smoke detector;

(iv) warning notices;

(v) mounting fitting; and

(vi) pipework and fitting.

82.4.2 Design Calculations

(a) The Contractor shall submit system flow calculations using a method
approved by the FSD.

(b) The actual size and location of pipes and nozzles and the number of nozzles
shall be designed on the basis of the calculated flow rates and terminal
pressures required to ensure successful operation. The calculations or
computer programme shall provide all the information necessary to complete
the installation including:

(i) quantity of gas required to flood the protected space to the required
concentration;

(ii) allowance for losses;

(iii) flow rates for each section of pipe;

(iv) start and end pressure for each section of pipe; and

(v) orifice size for each nozzle.

82.5 WORKMANSHIP

82.5.1 Design Performance

(a) FM200 total flooding systems shall be designed to achieve the required
concentration, rate of application and duration to maintain the extinguishing
concentration all as specified in NFPA 2001 in accordance with the volume,
hazard and environmental conditions of the protected rooms.

General Materials & Workmanship Specification 8/12 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 82 – Gaseous Fire Extinguishing System(FM200)
82.5.2 System Operation

Clean Agent total flooding gas extinguishing system shall be of high pressure open-
ended piping installation on the distribution side. The automatic gas release
mechanism shall be operated by means of fire detectors installed at the protected
compartment or manually by a pull handle.

(a) Automatic Release

A fire alarm shall be initiated automatically by means of the smoke detection

system. The fire signal from the smoke detectors in the protected
compartment shall be verified to ensure that gas discharge shall not occur
unless at least two smoke detectors (cross zone actuation) are activated in a
fire situation. The automatic operation of the Clean Agent system shall be as
follows:

(i) when either two detector operates, the coincidence unit shall initiate the
following functions:

- transmit a "Fire" alarm zone indication to the local Clean Agent

control and indication panel;

- operate the warning bells and flashing lights both inside and outside
the area; and

- close the pair of 5A 24V DC dry contact for the remote indication of
fire alarm of the protected area at the central fire detection and alarm
panel. The alarm signal for each Clean Agent system shall be
addressed as a single zone on the central fire detection and alarm
panel.

(ii) when any other detector(s) is actuated, the above functions shall be
retained. In addition, the coincidence unit shall initiate the following
operations:

- shut down all ventilation fans and computer equipment before Clean
Agent is discharged;

- close all fire dampers over openings through the fire compartments
and in ventilation air ducts before Clean Agent is discharged;

- at this time, activate the Pre-Discharge audio and visual circuit sound
the siren/sounder and activate the flashing light inside and outside the
protected area, and start the programmed time delay circuit; and
- release the Clean Agent after the 30 sec. adjustable preset time delay
and illuminate the discharge LED on the control panel.

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Section 82 – Gaseous Fire Extinguishing System(FM200)
 (b) Manual Release

The system shall also be operated manually by means of operating the

manual release pull station located outside the protected area as indicated on
plans. The manual operation of the system shall be as follows:

(i) actuate all visual and audio alarm devices both inside and outside the
protected area when the manual release pull station is being operated;

(ii) stop all ventilation and air-conditioning system and actuate the fire
dampers to seal up all openings through fire compartments; and

(iii) address the fire zones in question on the respective Clean Agent control
panel. Activate the discharge of Clean Agent and address the Gas
Discharged signal on the respective Clean Agent control panel and the
central fire detection and alarm panel.

82.5.3 Details of Installation Work

(a) The works for individual Clean Agent system shall include the supply,
installation, testing and commissioning of the following:

(i) Clean Agent storage cylinders, complete with low pressure switches,
liquid level indicators, discharge valve, check valve, agent release
module, manifolds, fittings and all necessary equipment;

(ii) Clean Agent discharge pipework and nozzles; and

(iii) smoke detectors, heat detectors, manual release pull station, lock
off/indication unit, Clean Agent control and indication panels c/w
batteries (and charger, alarm bells, sounder / siren units, flashing light,
warning signs, contactors, switches and all associated electrical wiring
and controls, etc.

(b) Supply and install the number of Clean Agent cylinders with an adequate
amount of Clean Agent to perform the function. The cylinders shall be
securely mounted in a frame bolted to the wall and arranged so that external
parts can be readily inspected and that corrosion cannot occur.

(c) Each cylinder shall be fitted with:

(i) a permanent nameplate specifying the agent, the gross weight of

cylinder plus agent, the net weight of the agent, the storage pressure at
the recorded temperature as well as other indications as required by the
Project Manager;

(ii) a tag recording the date of inspection, the gross weight of cylinder plus
agent, the net weight of the agent, the storage pressure at the recorded
temperature, the person performing the inspection as well as other
indications as required by the Project Manager;

(iii) an automatic pressure relief device for over pressure protection of the
cylinder;

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Section 82 – Gaseous Fire Extinguishing System(FM200)
 (iv) a mean to prevent gas discharge into the empty cylinders in a bank and
to prevent release of gas when any of the cylinders in bank is
disconnected;

(v) a low-pressure switch;

(vi) a liquid level indicator;

(vii) a gas release actuation device;

(viii) pressure gauge, manifold, and all other necessary accessories;

(ix) if chart is required to read out the weight of the Clean Agent inside the
cylinder, an ammoniated chart shall be tagged with the cylinders; and

(x) if the cylinder is not equipped with a liquid level indicator, a device which
is UL listed or FM approved shall be provided for measuring the amount
of liquid in the cylinder at any time. This shall be done by a method
which does not require the cylinder to be detached from the system. If a
weighing device of the type that requires suspension is proposed,
means shall be provided above each cylinder for the attachment of the
weighing device.

(d) Supply and install a high-pressure open-ended piping distribution system.

Locate all nozzles and pipework with particular regards to surrounding
obstructions; building features and other building services installations. The
nozzle shall be located at about 150 mm below ceiling soffit or below raised
floor. Provide deflector plates for those discharge nozzles install on ceiling
boards. Before installation of the discharge nozzle and valves, the pipework
and discharge nozzle shall be flushed with nitrogen or compressed air to
remove grease, dirt and dust.

(e) Supply and install a complete 24V DC fire alarm, detection and control system
comprising automatic fire detection system, local Clean Agent control and
indication panels, manual release pull station, controls, wirings and all
necessary accessories and materials comply with Chapter 2 of NFPA 2001,
BS 5839 : Part 4 and Rules for Automatic Fire Alarm Installation for Protection
of Property issued by Fire Offices' Committee.

(f) Supply and install the manual release pull station to act as a means to
manually discharge the Clean Agent when used in conjunction with the control
panel. Provide clear indication adjacent to each manual release pull station
notifying that the actuation shall cause Clean Agent discharge.

(g) Supply and install the lock-off / indication units outside the protected area.
The manual release pull station and lock off / indication units shall be
accommodated in well ventilated metal boxes positioned at about 1,350 mm
above the finished floor level at locations as shown on the Employer’s
Drawings. The metal box shall be constructed from 1.6mm thick stainless
steel and completed with a hinged front plate with glass window. The
functions of all switches, LED indicators, etc. shall be properly labeled with
engraved letters in English and the equivalent Chinese on the panels and
units subject to the review without objection of the Project Manager.

General Materials & Workmanship Specification 11/12 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 82 – Gaseous Fire Extinguishing System(FM200)
 (h) Provide the local Clean Agent control and indication panel to receive and
process all fire alarm from the smoke or heat detection system. The control
panel shall be positioned at about 1,350 mm above the finished floor level at
locations as shown on the Employer’s Drawings. The panel shall provide
pairs of dry contacts such as to shut down the air-conditioning and ventilation
systems, to activate the fire dampers, etc.

(i) Supply and install one battery and charger unit in the extinguishing agent
cylinder store room for the local Clean Agent control and indication panel to
provide 24V DC supply for the control, monitoring and operation of the Clean
Agent systems.

(j) Supply and install all F.S. control relays and signals to trigger the ventilation
control and the actuation of fire dampers.

General Materials & Workmanship Specification 12/12 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 82 – Gaseous Fire Extinguishing System(FM200)
SECTION 83 FIRE ALARM AND DETECTION SYSTEM

83.1 GENERAL

(a) This section covers the general requirements for fire alarm and detection
system.

(b) Fire alarm and detection system shall generally comply with the following:

(i) Cap 95 – Fire Services Ordinance;

(ii) Codes of Practice for Minimum Fire Service Installations and Equipment
and Inspection, Testing and Maintenance of Installations and Equipment
(FSDCOP) published by HKSAR;

(iii) relevant circular letters and requirements of Fire Services Department

(FSD);

(iv) The Fire Officers’ Committee (FOC) Rules for Automatic Fire Alarm
Installations for the Protection of Property;

(v) relevant circular letters and requirements of Water Supplies Department

(WSD);

(vi) Fire Zone Strategy of Passenger Terminal Building; and

(vii) relevant British Standards.

(c) The system shall raise alarm for open or short circuited condition of the
system. Where a residual current device is required to comply with the
statutory requirements for electrical installation, a fault on any other circuit or
equipment shall not be capable of resulting in isolation of the supply to the fire
alarm control system. The actuation of any detection device or any fault in the
loop shall not cause the loop to be disabled for any alarm and trouble signals
to be followed.

(d) Wiring system shall refer to Section 89 of this General Materials and
Workmanship Specification. All wiring in the panel shall be neatly arranged
and grouped together. Proper labels shall be supplied and installed.

(e) Surge arresters shall be supplied and installed for the fire alarm and detection
system to prevent false alarm and malfunctioning of the fire alarm control
system due to power surge.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
83.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 5839 : Part 1 Fire detection and alarm systems for buildings. Code
of practice for system design, installation and servicing
BS 5954 : Part 2 Dimensions of mechanical structures of the 482.6 mm
(19 in) series. Specification for cabinets and pitches of
rack structures
BS 5954 : Part 3 Dimensions of mechanical structures of the 482.6 mm
(19 in) series. Specification for subracks and
associated plug-in units
BS 7671 Requirements for electrical installations. IEE Wiring
Regulations. Sixteenth edition
BS EN 54-2 Fire detection and fire alarm systems. Control and
indicating equipment
BS EN 54-4 Fire detection and fire alarm systems. Power supply
equipment
BS EN 54-5 Fire detection and fire alarm systems. Heat detectors.
Point detectors
BS EN 54-7 Fire detection and fire alarm systems. Smoke
detectors. Point detectors using scattered light,
transmitted light or ionization
BS EN 54-11 Fire detection and fire alarm systems. Manual call
points
BS EN 60529 Specification for degrees of protection provided by
enclosures (IP code)
EIA Standard T568A Commercial Building Telecommunications Cabling
Standards
EIA Technical Technical Systems Bulletin Additional Cable
Systems Bulletin TSB- Specifications for Unshielded Twisted Pair Cables
36
EIA Technical Additional Transmission Specifications for Unshielded
Systems Bulletin TSB- Twisted-Pair Connecting Hardware
40
IEEE 802-3 Information Technology - Telecommunications And
Information Exchange Between Systems - Local And
Metropolitan Area Networks - Specific Requirements
Part 3: Carrier Sense Multiple Access With Collision
Detection (CSMA/CD) Access Method And Physical
Layer

General Materials & Workmanship Specification 2/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
83.3 MATERIALS

83.3.1 Intelligent and Addressable Fire Alarm Control System

(a) General

The fire alarm and detection system shall be of the analogue addressable type
consisting of the following components:

(i) Addressable field devices including:

- Analogue addressable optical point type smoke detector

- Analogue addressable point type heat detector

- Beam detectors

- Control modules for :

y Solenoid valves

y Activation of fire shutters

y Activation of fixed fire pump

y Activation of audio advisory system

y Activation of visual advisory system

y Activation of access control system

y Activation of electric alarm bells

y Activation of visual fire alarm

y Activation of smoke curtain

y Activation of lift homing

y Activation of fire and smoke motorised damper

y Activation of generator

- Monitor modules for:

y Flow switches

y Status of micro-switch for each sprinkler subsidiary valve

y Monitored isolating valve position

y Manual break glass unit

y Pressure switches

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 y “Closed status” of each fire shutters operated by smoke detector

y All FS pumps status (duty, standby and jockey) such as pump

running, pump fault and power supply failure (each phase)

y All FS tanks status such as overflow, low level and high level

y FM200 gaseous flooding system status such as zone 1 alarm,

zone 2 alarm, auto mode, manual mode, system fault, gas
discharge

y Status of automatic transfer switch (ATS) for dual feed power

supply

y “Closed status” of each motorised fire and smoke dampers

y “Closed status” of each smoke curtain

y Status of emergency generator such as power supply in normal,

essential power on, emergency generator manual mode,
emergency generator fail to start and fuel tank low level.

y Status of FS direct link such as line normal and line fault/isolated.

- Line isolator modules

(ii) Stand alone microprocessor based fire alarm control and indication main
panel and sub-panels, complete with associated battery and charger.

(iii) Fire alarm control and repeater panels, complete with associated battery
and charger at both the IAC and Terminal Duty Management Office
(TDMO).

(iv) Fire alarm delay control panel.

(v) Communication wiring between all panels.

(vi) Electric alarm bells and visual alarm including associated power wiring
from all fire main and sub panels.

(vii) Addressable loop wiring between all fire main/sub panels and
addressable field devices.

(viii) Portable personal computer (PC) connectable to fire main/sub panels for
maintenance, reconfiguration and diagnostic use.

(ix) All interfaces between the fire main/sub panels to MBMS / GBMS,
smoke extraction smoke control panel, VAC control panel, audio and
visual advisory system and repeater panels at the IAC and TDMO.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 (b) Automatic Fire Mode Control of Building Systems

Fire alarms within the building shall be arranged into “fire zones” as shown on
the Employer’s Drawings. Upon activation of a fire alarm within a fire zone,
building system shall be automatically controlled in accordance with the Fire
Safety Strategy (FSS) report. The following building systems shall be
controlled in the event of fire alarm:

(i) Smoke Control System

Upon activation of any two smoke detectors of the same smoke zone,
the fire alarm panel shall relay the corresponding fire zone signal to the
smoke control panel in fire control centre (via hard wire). Smoke
control system equipment shall be automatically activated by the
smoke control panel. All smoke curtains shall be activated via the fire
alarm panel.

(ii) VAC Control System

Upon activation of any fire signal a common fire alarm shall pass to the
VAC control panel in fire control centre for shut down of the VAC
equipment. The communications rooms shall be treated as a separate
VAC shutdown zone.

(iii) Audio and Visual Advisory System

Upon activation of a confirmed fire alarm, as described in the Fire

Safety Strategy, the public address system and flashing exit/directional
signs shall be activated. Control of the pre-recorded announcements
shall be in accordance with the Employer’s Drawings. Exit signs and
directional signs in public areas shall go into flashing mode.

(iv) Access Control System

Upon activation of a confirmed fire alarm, the fire alarm panel shall
send the common fire alarm signal to the respective escape doors
fitted with access control system to automatically release the door
locking mechanisms to allow free access to all fire escape routes.

(v) General Building Management System (GBMS)

Fire signals and status of major fire equipment shall be transmitted to

General Building Management System for monitoring.

(vi) Integrated Airport Centre (IAC) and TDMO

All control and monitoring signals including time delay function shall be
provided to both the IAC and TDMO for monitoring and control
purpose.

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Section 83 – Fire Alarm & Detection System
 (vii) Fire Shutter, Fire and Smoke Dampers

Upon activation of one smoke detector at either side of the fire shutter
and/or fire & smoke dampers (within 1.5m horizontal distance from the
fire shutter or fire and smoke dampers), the corresponding fire shutters,
fire & smoke dampers shall be activated.

(viii) Lift Homing

Upon activation of a confirmed fire alarm, the fire alarm shall be

relayed to firemen lift for lift homing.

(ix) Public Addressing System (PA)

Upon activation of a confirmed fire alarm, the fire alarm panel shall
send the corresponding fire zone alarm signal to PA system equipment
at communication rooms to activate the PA system to announce the
fire evacuation message for the fire zones. The signal interface shall
be dry contacts.

(c) Fire Alarm Control and Indication Main Panel

The fire alarm control and indication panel shall transmit and receive signals
from all other panels within the fire alarm and detection system.

(i) Hardware

- The fire main panel shall be microprocessor-based and use digital

system design techniques.

- The fire main panel shall be enclosed in a wall mounted metal

cabinet, constructed from not less than 1.2mm thick folded mild
steel to IP 54 protection with baked enamel finish. For floor
standing cabinet, the minimum thickness shall be 2mm. The panel
shall be fitted with hinged lockable glass front doors. Glass front
door shall be provided to cover up all indicators, display, keypad
and control switches. The cabinet shall be dust-proof, stiffened,
earthed and with gasket around all openings and door rims.

- The standby battery cabinet shall be separate from and below the
cabinet housing the fire main panel.

- All equipment not required for warning or indication shall be

concealed in the cabinet but shall be readily accessible for the
maintenance of relays and replacement of lamps.

- The fire main panel shall incorporate the following provisions on

the front face of the panel:

y A back-lit liquid crystal display (LCD) window capable of

displaying a minimum of 32-character messages for indication
of all alarm points, status and monitoring information.

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Section 83 – Fire Alarm & Detection System
 y Colour light emitting diode (LED) indicators for system on,
system fault, alarm on, input/output conditions and
communication conditions.

y Control switches for alarm acknowledge, alarm silence, system

reset, sound evacuate and message display.

- The fire main panel shall be of modular type design to facilitate

easy modification and maintenance. All printed circuit boards shall
be easily add-on as required for expansion without rewiring or
hardware change or any other major modification.
- Each loop controller board shall be capable of operating in
standalone mode. Failure of one shall not affect the operation of
others.

- The fire main panel shall have enough memory capacity to retain
at least 500 most recent events which can be recalled, displayed,
printed and downloaded on the portable computer.

- The fire main panel shall monitor any short circuit, open circuit,
earth fault conditions in all detection loops and alarm bell circuits.
Electrical isolation between loop controller/interface card and field
devices shall be designed to withstand continuous short
circuit/over voltage conditions and to provide noise/transient
filtering.

- Annunciater units/indicators shall be easily changeable and

expandable by the simple removal and addition of appropriate
circuit boards. To reduce current consumption, all indicators shall
be of LED type.

- The communication between the fire main panel and the repeaters
/ sub-panels shall be continuously monitored. Any communication
failure or wiring fault shall be acknowledged and registered at both
ends of the equipment.

- The fire main panel shall incorporate software that shall be

retained in Erasable Programmable Read Only Memory (EPROM).
The fire panel shall have monitoring control points, exclusive of
points dedicated to system supervision, and shall be equipped with
software routines such that any alarm point may be programmed to
operate any or all of the control points within the system.

- The fire main panel shall include appropriate modules to provide

the required programmable relay contact outputs for interfaces.
The panel outputs shall be field programmable and capable of
being randomly allocated to be activated by any zone, any detector,
any line device, any panel function, any panel operating
switch/button, or any combination of these inputs. The outputs
shall be volt-free dry contacts.

- The fire main panel shall include the fire alarm delay control
function with the following features:

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Section 83 – Fire Alarm & Detection System
 y The fire alarm delay control panel provides the means to
suspend the activation of audio / visual advisory system and
access control system for emergency evacuation.

y The fire alarm delay control panel includes the “Acknowledge

Alarm”, “Initiate”, “Mute”, “Lamp Test” push buttons.

y The “delay” function has a countdown setting of 60 seconds.

y When the fire alarm is activated, the red alarm LED lamp will
light up, the buzzer will sound and the countdown function will
set off progressively from 60 seconds to 0 seconds.

y After expiry of 60 seconds, all fire alarm outputs for audio /

visual advisory system and access control system shall be
activated.

y If the “Initiate” button is pressed, the “delay time” will be

overridden and relevant fire alarm output units will be activated
instantaneously.

y Upon expiry of the 20 minutes period, the fire alarm output

units will be automatically activated.

(d) Fire Alarm Control and Indication Sub Panel / Repeater

Fire alarm sub panels shall transmit and receive signals from addressable
field devices. All fire sub panels shall communicate with the fire alarm main
panel and shall include the following:

(i) Hardware

- The fire sub panel shall be microprocessor-based and use digital

system design techniques. It shall have built-in 2 way serial
communication board to enable peer-to-peer communication
between panels.

- The fire sub panel shall be enclosed in a wall mounted metal

cabinet, constructed from not less than 1.2mm thick folded mild
steel to IP 54 protection with baked enamel finish. For floor
standing cabinet, the minimum thickness shall be 2mm. The panel
shall be fitted with hinged lockable glass front doors. A glazed
panelled front door shall be provided to cover up all indicators,
display, keypad and control switches. The cabinet shall be dust-
proof, stiffened, earthed and with gasket around all openings and
door rims.

- The standby battery cabinet shall be separate from and below the
cabinet housing the fire main panel.

- All equipment not required for warning or indication shall be

concealed in the cabinet but shall be readily accessible for the
maintenance of relays and replacement of lamps.

General Materials & Workmanship Specification 8/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 - The fire sub panel shall incorporate the following provisions on the
front face of the panel:

y A back-lit liquid crystal display (LCD) window capable of

displaying a minimum of 32-character messages for indication
of all alarm points, status and monitoring information.

y Colour light emitting diode (LED) indicators for system on,

system fault, alarm on, input/output conditions and
communication conditions.

y Control switches for alarm acknowledge, alarm silence, system

reset, sound evacuate and message display.

- The fire sub panel shall be of modular type design to facilitate easy
modification and maintenance. All printed circuit boards shall be
easily add-on as required for expansion without rewiring or
hardware change or any other major modification.

- Each loop controller board shall be capable of operating in

standalone mode. Failure of one shall not affect the operation of
others.

- The fire sub panel shall have enough memory capacity to retain at
least 500 most recent events which can be recalled, displayed,
printed and downloaded on the portable computer.

- The fire sub panel shall monitor any short circuit, open circuit, earth
fault conditions in all detection loops and alarm bell circuits.
Electrical isolation between loop controller/interface card and field
devices shall be designed to withstand continuous short
circuit/overvoltage conditions and to provide noise/transient filtering.

- Annunicator units/indicators shall be easily changeable and

expandable by the simple removal and addition of appropriate
circuit boards. To reduce current consumption, all indicators shall
be of LED type.

- The fire sub panel shall have software which shall be retained in
erasable programmable read only memory (EPROM) to ensure
trouble free system and simplified start-up. The fire main panel
shall have monitoring control points, exclusive of trouble points
dedicated to system supervision and shall be equipped with
software routines whereby any alarm point may be programmed to
operate any or all of the control points within the system.

General Materials & Workmanship Specification 9/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 (e) Workstations

(i) A typical workstation shall include as a minimum, one colour graphics

monitor, associated processing hardware with adequate printing buffer,
keyboard, mouse or track ball, log printer, communication ports, and all
associated cabling. All the hardware and software shall be provided as
appropriate for compatible with the fire alarm control system. All
workstations shall be able to switch off without affecting the normal
operation of the system.

(ii) hardware:

- workstations shall be, as a minimum, desktop PCs or “Reduced

Instruction Set Computing” (RISC) workstations using processors,
clock speeds, cache and on-board memory capacities to perform, at
interactive speeds, the graphic windows applications operating on the
fire main panel. The workstation shall comprise at least:

y Pentium 4 processor 3.06 GHz with integrated 512 KB cache;

y integrated sound blaster compatible audio controller 16-bit;

y integrated Pro/1000MT (82545EM) gigabit Ethernet controller;

y 1.0 GB (2x512) PC1066 ECC RDRAM memory;

y 64 MB video memory card (dual monitor capable);

y 1.44 MB 3.5” floppy drive;

y extended keyboard with mouse (2-button with scroll);

y 20” Liquid Crystal Display (LCD) flat-screen, anti-static, non-

interlaced 1280x1024 0.26 mm monitor;

y hard drive with minimum capacity of 80 GB (7200 rpm and 2 MB

buffer) to support the software and/or data required for
operations from the workstation and spare capacity equal to the
used space;

y 48X CD-ROM drive;

y near silent power supply unit loaded to no more than 60 per cent
full load.

- portable user equipment shall be provided with appropriate user

interface application for maintenance, reconfiguration and diagnostic
purposes. These shall be connectable to fire main/sub panels, with
the appropriate connector supplied as part of the hardware;

- printers shall be mainly used for printing ad-hoc reports on requests

and for presentation material. A user printer shall be provided for
each workstation; and

General Materials & Workmanship Specification 10/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 - user printers shall be monochrome laser printers, which shall be
robust, heavy duty (duty cycles of better than 25,000 pages per
month), near silent, at least 600 dpi resolution, 15-A4 pages per
minute, 45 built-in scalable fonts, PostScript II, multiple tray input
capacity.

(iii) response times for workstation user commands

- priority shall be given to the execution of workstation user commands

and feedback information. The time from the initiation of any
execution command to receipt of field status feedback at the user
workstation shall be less than 3 seconds;

- the time from the initiation of any display requests to full display of all
requested graphical background and real-time field data at the user
workstation shall be less than 3 seconds; and

- a similar priority shall be given to real-time point information currently

graphically displayed on workstation displays, which shall provide an
accurate reflection of field conditions within 3 seconds of any changes
occurring.

(iv) workstation user interface

- all workstations shall employ interactive graphical user interfaces

(GUIs) and compliable to the existing system, which shall support
multiple graphic windows in multiple concurrent application sessions
operating through Local Area Network (LAN) connections to the fire
main panel;

- the menu hierarchy shall permit all functions to be logically grouped

within a maximum of 4 levels, and at the lower levels have direct
shortcut selection of related low level menus on other branches of the
hierarchy;

- the menu selections shall be 3-D sported buttons, with check boxes,
radio buttons, combo text/icon lists and other object controls to aid
more refined menu selections;

- the initial hierarchy and suite of menus shall be project specific and
shall be submitted to Project Manager for review without objection;

- the menu hierarchy and stylized menus shall be customisable by

maintenance staff;

- the application software shall support one set of graphic windows for
real-time events response management for each individual
workstation connected. These sets of windows include the following
list:

y date and time display to the nearest second;

General Materials & Workmanship Specification 11/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 y information display of the current number of genuine alarms that
are in the ‘unacknowledged’, ‘acknowledged but unactioned’,
‘acknowledged, actioned and not reset’ response status for each
priority blocks; ’auto-acknowledge on/off’ with its associated time
remaining; and window control for turning auto-acknowledge
facility on or off;

y display of current genuine alarms with window controls for

dynamically setting the alarms to be displayed, i.e. combinations
of alarm priorities, zones, alarm types, alarm response status.
Information on each alarm displayed shall show time of
occurrence to nearest 0.1 second alarm point identifier, alarm
message, response status;

y display of response management window which shall show either:

à a message stating that there are no current genuine alarms;

or

à details of the highest priority oldest alarm, its associated

listing of pre-prepared operator response instructions with
check boxes for response actions, a multi-line field for
entering additional response actions, and associated
window controls. (The window controls shall be ACCEPT,
ACKNOWLEDGE, NEXT, ACTIONED, RESET,
ASSOCIATED LOCATION MAPS); and

y display of a graphic location map of the alarm affected area with

real-time point status and alarm conditions and response status.

- real-time status, settings and genuine alarm status shall be shown on

graphical location (plan and/or elevation) maps and line diagrams in
views/pages. The real-time information shall be shown as dynamic,
multi-state, 3-D sported icons (in customisable visual graphic shapes,
colours and text);

- the icons shall imitate the actual physical operations of all field
devices and equipment. Each icon object shall have a
customisable ’right-mouse-click’ object command inspector, beside
the normal availability of such inspections on standard drop-down
menus or movable tearaway palettes;

- to ensure commonality of graphics presentation, all stylized graphic

background maps shall be supplied in standard scales of 1:1500,
1:500, 1:200, and 1:100;

- graphical displays shall be layered with independent display on/off

dynamic settings and each layer information independently
customisable;

- menubars, drop-down menus, toolbars, tearaway tool palettes shall

be provided and shall be customisable and assignable to
customisable macros; and

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 - an on-line context-sensitive hypertext help for all application driven
windows, menus, tables, maps, icons, text, settings, legends,
commands, navigation aids shall be provided.

(v) customization

- the system software shall support advanced customisation capability,

where the administrators shall be able to modularly and dynamically
customise all objects, and make and assign macro library modules to
objects;

- the user shall be able to employ easy-to-comprehend-and-use

customisation graphical windows, tools, macros, and controls to
configure, setup, run up and tune the whole system to suit the
particular structured control and response management of the site;

- the system shall employ graphical customisation methodologies in the

form of:

y windows, views, forms, tools, controls;

y database interfaces, functions, queries, reports, forms;

y simplified programmable logic controller programming tools, e.g.

ladder and process control logic functions for customising time,
and device event initiated programs; and

y with extensive use of pick, click, drag and drop 3-button mouse
techniques to minimise typing.

- provide on-line, interactive, dynamic point, feature and system

configuration and customisation, including visual programming aids,
tools and controls, and productivity functions for group copying,
entries, changes, settings, and commands;

- there shall be no need to compile any custom ’entries or programs’

off-line, nor take the system off-line to load and re-link code. New
connections to unoccupied spare inputs and outputs at the relevant
hardware, additions and removal of hardware and workstations shall
be carried out ’hot’ without any degradation and no risk to any part or
the overall system;

- it shall be the norm to configure and customise additions or changes

before any additional physical hardware and field devices are
installed, fitted, connected and made live. This customisation shall
cover hardware configuration, default and initial settings, response
instructions, database, graphical map and line diagrams, initiated
programs, queries and reports;

- for any expansion in hardware and field devices, provision shall be

made to configure and customise the unconnected hardware and
apply ’forced’ real-time states for simulated user checking. When the
hardware is connected, the fire alarm system shall be able to use the
customised information for downloading to them; and

General Materials & Workmanship Specification 13/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 - all database files shall be customisable and maintainable on-line by
the user administrators, without any degradation or loss of any other
system functions. The user administrators shall be able to prepare a
number of batch of modifications for any number of blocks of new or
existing records at any time, and instruct the system to execute any
one of the modification batches at a later date and time, either by
manual command or by a time schedule.

(f) Smoke System Control Panel (SSCP)

(i) The panel shall comply with Section 5.23 of the FSD COP and shall
include the following:

- One manual auto on/off control switch for each smoke zone within
the building;

- One LED indicator light for each smoke zone within the building.
This light shall indicate the status of the associated extract/purge
fan(s); and

- Audio visual alarm in the panel when activated.

(ii) The panel shall communicate directly with the fire main panel.

(iii) The smoke control equipment shall be controlled and monitored via
hard wire complied with FSD requirements.

(i) The panel shall be powered by a 220V, AC essential power supply and
backup by an independent charger and batteries.

(v) The panel shall have self diagnostic function to report to fire main
panel any circuit fault inside the panel.

(g) Ventilation/Air Conditioning (VAC) Manual Override Control Panel (VMOCP)

(i) The panel shall comply with Section 5.27 of the FSD COP and shall
include one manual override, switch for every mechanical ventilating
system (as defined in the FSD circular letter). Upon activation of the
switch the mechanical ventilating system shall shutdown.

(ii) The panel shall communicate directly with the fire main panel.

(iii) The VMOCP control equipment shall be controlled and monitored via
hard wire complied with FSD requirements.

(iv) The panel shall be powered by a 220V, AC essential power supply and
backup by an independent charger and batteries.

(v) The panel shall have self diagnostic function to report to fire main
panel any circuit fault inside the panel.

General Materials & Workmanship Specification 14/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 (h) Addressable Device Communication

(i) the fire main/sub panels shall communicate with addressable devices by
means of ring mains (loop) wiring;

(ii) all devices on the loops shall be periodically interrogated by the fire
main/sub panels to ensure its operation is satisfactory. A minimum scan
time of 1 per 2 seconds shall be required;

(iii) the wiring system shall consist of class “A” wiring loops, adaptable for
switching to two wire operation if one of the paths has failed;

(iv) addressable loops shall continue to communicate regardless of any

addressable field device failure. Any single physical break in the
addressable loop shall not result in communication failure;

(v) each addressable loop shall have the minimum capacity as follows:

- addressing capability:

y input analogue detectors: 99; and

y input / output modules: 99;

- addressing field device types:

y photo-optical detectors: analogue;

y heat-detectors;

y monitor module; and

y control module;

(vi) addressable loops connecting field devices shall be arranged such that
there is 30% spare address capacity for the future addition of analogue
addressable devices and 30% spare address capacity for the future
addition of digital devices.

(i) Control / Monitor Modules

(i) these devices shall be connected to the addressable loop to provide an

interface between dry contact type fire detection control devices and the
addressable loop communication system. They shall consist of either
control or monitor type devices and shall be capable of providing:

- individual addressable inputs for alarm devices;

- addressable control for indicating devices;

- integral LEDs to indicate operation;

- monitoring of detecting devices; and

- control of indicating devices.

General Materials & Workmanship Specification 15/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 (j) Analogue Addressable Fire Detectors

(i) smoke detectors

- automatic smoke detectors shall comply with BS EN 54-7 and the

FOC Rules and shall be of manufacture and type specifically
approved by FSD. They shall function correctly at ambient
temperature between –10°C to +80°C, relative humidity between 20
to 95% continuous without condensation. They shall also be suitable
for stable operation in the Hong Kong climate especially where high
humidity conditions may exist;

- smoke detectors shall be of the photo-optical type, designed to

operate in the presence of visible gases in the sampling chamber.
Detectors shall be suitable for inclusion in a supervised circuit and
failure of the light source or sensing amplifier shall activate a fault
signal but shall not initiate an alarm signal. The photo-optical detector
shall incorporate an external light which shall operate when the
detector is in a state of alarm. The detector shall not be initiated by
light from external sources. The internal light source shall have a
minimum service life of 8 years;

- the electronic circuitry may be of cold-cathode tube type, operating at

low voltage DC, or of solid-state type, operating at extra low voltage
DC. The quiescent current consumption of the unit shall be minimal
and shall not exceed 100 microampere. The printed circuit boards
shall be varnished, protected against moisture and dust;

- detectors shall be housed in a corrosion-proof plug-in unit designed to

be mounted pendent, surface or semi-recessed. Removal of the unit
from its base shall cause a fault alarm signal to be given. Sensitivity
shall be adjustable by means of a pre-set control only accessible by
use of a special tool. Built-in wind-shields shall be provided to ensure
that air currents of up to 10 m/s do not affect the proper operation of
the detector. Each unit shall be fitted with a flashing alarm condition
indicator lamp and shall also have an auxiliary facility for connecting
an extended alarm indicator lamp. A built-in wire mesh shall be
incorporated to prevent entry of insects into the interior;

- the internal electronic circuitry shall be of highest possible reliability

and protected against voltage spikes and surges. The detector shall
be capable of operating satisfactorily under minimum variation of
±25% in supply voltage. The circuitry shall also be protected against
electromagnetic interference;

- the detector base shall incorporate all communication circuitry and

detector address' facility such that all detector sensor units are inter
changeable without alarm system reconfiguration;

- the detector base shall be sealed with a plate during the installation
period. This plate shall facilitate electrical continuity through the base
such that the circuits can be tested or maintained;

General Materials & Workmanship Specification 16/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 - smoke detectors shall be of a neat and compact appearance and
shall provide a minimum area for the lodgement of dust. Detectors
shall be installed in such a way that each can be readily withdrawn
from service for testing and replacement without impairing the
effectiveness of the remaining detectors and installation;

- smoke detectors shall be fitted with air sampling probes and remote
lamp indicators when installed in above false ceilings;

- remote lamp indicators shall be installed at clearly visible positions.

They shall be 24V DC operated and shall be labelled with English and
Chinese characters. The remote lamp indicators shall be of the same
make as the detectors;

- all detectors shall be of the analogue addressable type and shall be

connected to the addressable loop. Each detector shall have a
unique address and, when polled by the fire main/sub panel shall
respond via a message code with:

y current analogue value;

y detector identification; and

y detector type.

- the Contractor shall submit to the Project Manager for review without
objection test results to demonstrate that the smoke detectors comply
with requirements of the FSD. All detectors shall be of a type
approved by the FSD;

- detectors mounted in exposed locations shall be colour matched to

the requirements of the Project Manager;

- where appropriate, detectors shall include a self-compensation

circuitry to provide maximum stability against ageing, dust and film
accumulation; and

- all detector alarms shall be latched after a preset number of scans

has verified smoke presence.

(ii) heat detectors

- automatic heat detectors shall be of point-type complying with BS EN

54-5, BS EN 54-2 and BS EN 54-4, and the FOC Rules for Automatic
Fire Alarm Installations for Protection of Property, 12th Edition and
shall be of manufacture and type approved by FSD;

- detectors shall be of combined fixed temperature and rate-of-rise type;

and

- detector units shall be of surface mounting type. Detector units in

suspended ceilings shall be flush mounted and shall, in the case of
modular constructed ceilings, be coordinated into the ceiling layout.

General Materials & Workmanship Specification 17/30 January 2011

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Section 83 – Fire Alarm & Detection System
 (k) General Building Management System (GBMS) Interface (For Projects in the
Passenger Terminal Building only)

(i) status signals shall be provided for the following:

- high and low water level for each sprinkler and hydrant tank within
each pump room;

- battery charge level for each battery/charger system;

- general fire alarms for all fire main and sub panels; and

- general fault signals for all fire main and sub panels.

(ii) signals for each of the above shall be provided at assigned terminal
strips within the motor control centres for each fire services tank and
pump room or at each fire panel; and

(iii) signals shall be in the form of voltage free contacts rated at 24V 2A
inductive. All digital outputs shall be provided with isolating facilities for
testing and maintenance purposes.

(l) Time-of-Day Clock (TODC) Interface Definition

(i) general

- the master TODC system provides a serial data signal to outlets

adjacent to each wall clock and each major computer-driven system
in the location as shown on the Employer’s Drawings. All other
associated fire alarm panels shall be synchronised internally with the
fire main panel master clock;

- the fire main and sub panels shall be capable of synchronising to

produce an accurate time signal immediately upon receipt of the
TODC signal under any system operating status;

- while this external synchronising clock signal shall be used to

synchronise the internal time clock of the fire main and sub panels,
the fire main and sub panels internal time clock shall be able to
operate independently of the external to TODC signal. The internal
time clock of the fire main and sub panels shall maintain an accuracy
of ±10 ms/day while unsynchronised; and

- the interface standard associated with these outlets is as defined

below.

General Materials & Workmanship Specification 18/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 (ii) electrical interface

- at an outlet located adjacent to the fire main and sub panels a type
RJ12 jack on a flush mounted escutcheon shall be provided by Other
Contractors. This shall be connected as follows:

y pin 1 : (not connected);

y pin 2 signal : more positive when marking / less

positive when spacing;

y pin 3 signal : less positive when marking / more

positive when spacing; and

y pin 4 : (not connected).

- the outlets shall present to the fire main and sub panels a balanced
interface circuit in compliance with EIA specification RS422-A; and

- the fire main and sub panels shall neither include specific line
terminating devices, nor provide a low impedance path between
circuit and protective grounds.

(iii) data content

- the reticulated serial data stream shall consist of the American

Standard Code for Information Interchange (ASCII) characters
“YYMMDDhhmmss*” followed by a carriage return character, where:

y YY indicates year tens and units (e.g. 93);

y MM indicates month (01 to 12);

y DD indicates day (01 to 31);

y hh indicates hours (00 to 23);

y mm indicates minutes (00 to 59); and

y ss indicates seconds (00 to 59).

- the ASCII character “*” shall denote either:

y “S” indicating that the given time is synchronised by global

positioning satellite to Hong Kong Standard Time; and

y “F” indicating that the TODC is unsynchronised and free-running.

The worst case drift under these circumstances shall not exceed
±10 ms per day.

- the complete group of fourteen characters shall be repeated

continuously at integer one second intervals.

General Materials & Workmanship Specification 19/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 (iv) data format

- data shall be transmitted asynchronously, with each character using

the format:

y one START bit;

y seven ASCII DATA bits;

y one bit restoring EVEN PARITY; and

y one STOP bit.

- the data signalling rate shall be 9,600 bits per second;

- when synchronised by global positioning system (GPS) satellite, the

leading edge of the START bit for the first Y-character shall occur
within ±1 ms of the Hong Kong Standard Time indicated by the data
group; and

- when free-running, the leading edge of the START bit for the first Y-
character shall occur within ±1 ms of the best-estimate Hong Kong
Standard Time derived from the TODC headend master oscillator,
and indicated by the data group.

(m) Line Isolator Module

(i) Line isolator module shall be installed to monitor the detection cable loop
condition and when detects a short circuit, isolate the affected section
whilst allowing the rest of the addressing circuit to function normally.

(ii) Line isolators shall be designed and installed for short-circuit protection
as required in BS5839:Part 1 to ensure that no short circuit fault can
disable more detection devices than would be lost on a conventional
non-addressable fire circuit.

(iii) A minimum of two line isolators shall be provided for each detection line
loop.

(iv) Location of line isolators shall be submitted to the Project Manager for
review without objection.

(n) Interface with Building Management System

(i) Status signals shall be provided for the following:

- High and low level for each sprinkler and FS tank

- FS pump status such as “Pump Run” and “Pump Fault”

- Battery and charger status for each battery and charger system

General Materials & Workmanship Specification 20/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 - General fire alarm for all fire main and sub-panels

- General fault signals for all fire main and sub-panels

(ii) Signals for each of the above shall be provided via the control modules
at the field devices.

83.3.2 Conventional Fire Alarm Control System

(a) General

(i) the conventional fire alarm control system shall be suitable for 24V DC
operation and the means of supplying power to the system is to be from
the public electricity mains and backed up by a standby supply
consisting of battery charging equipment and batteries;

(ii) all the devices, components and equipment used in the system shall be
fully compatible with one another throughout the whole system. Special
attention shall be drawn to the compatibility between fire detectors and
the fire alarm panel and the Contractor shall submit to the Project
Manager information of the fire detectors, the fire alarm panel, and other
associated equipment, and the required electrical interface with the fire
alarm panel, control panel(s) and repeater panel(s) as applicable.

(b) Fire Alarm Control and Indication Panel

(i) the panel shall be equipped to suit the fire alarm system of which it
forms a part. Conventional fire alarm control and indication panel shall
be supplied and installed to monitor centrally the manual fire alarm
system, fire hydrant and hose reel installation, VAC control system and
other fire service installations and equipment. Fire alarm signals may
originate from manual call points, flow switches, pressure switches and
gaseous flooding system alarm contacts as applicable. The connection
of these devices in zone (alarm circuits) shall be as specified;

(ii) the panel shall include the following minimum provisions:

- service features:

y relays, terminal strips, wiring and labels for the proper operation of
the whole system including alarm bells;

y auxiliary relay or additional relay contacts for automatic starting of

water pumps and other devices as specified; and

y test facilities for each alarm zone.

- user control switches:

y system isolation key switch;

y zone isolating key switch;

y alarm silencing switch with warning buzzer and indication;

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Section 83 – Fire Alarm & Detection System
 y buzzer mute;

y sound alarm switch for all indicator circuits and internal buzzer;

y system reset switch after clearance of an alarm or fault condition;

y lamp test switch;

y pump start switch;

y key switches for isolating signals to the VAC control system to the
fire shutters and to the lift controls with visual warning indication;
and

y other necessary controls for fire hydrant/hose reel system and

sprinkler system as required by the FSD.

- visual indicators:

y “supply on” visual indicator, green;

y “system on” visual indicator, green;

y “system or device isolated” visual indicator, amber with buzzer;

y “fire” alarm visual indicator for each zone, red;

y “zonal fault” visual indicator, amber;

y “system fault” visual indicator, amber;

y “battery” condition (full/charging/low) visual indicator,

green/amber/red respectively;

y “battery charger fault” visual indicator, red;

y “zone disable” visual indicator, amber;

y “tank low level” and “tank high level” visual indicators, amber;

y “pump running” visual indicator, green;

y “pump fault” visual indicator, red;

y “essential power on” and emergency generator running visual

indication, amber;

y subsidiary sprinkler stop valves status visual indication, red (light

up when valve closed);

y sprinkler control valve set status monitoring, amber;

y sprinkler flow switches activation visual indication, red;

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Section 83 – Fire Alarm & Detection System
 y fire alarm direct link fault/isolation indication, red;

y emergency generator manual mode visual indicator, amber;

y emergency generator fail to start visual indicator, red;

y emergency generator fuel tank low level visual indicator, red; and

y other necessary indications for fire hydrant/hose reel system and

sprinkler system as required by the FSD.

(iii) all visual indications shall be provided with twin indication lamps or twin
LED. All visual indications shall be easily seen at 2m away from the
panel;

(iv) upon operation of one or more triggering devices, the control equipment
shall give a fire alarm by:

- at least one internal alarm sounder in or near the indicating

equipment;

- at least one external alarm sounder;

- a visible indication for each zone in which a triggering device

operates; and

- where specified, a signal transmitted to the FSD through the fire

alarm direct link and the Computerized Fire Alarm Transmission
System.

(v) fire alarm control system shall be arranged for continuous monitoring of
all alarm circuits, including the wiring and the alarm signalling devices
connected thereto;

(vi) faults to be detected shall include open-circuits, short-circuits, and

removal of signalling devices;

(vii) indicator lamps shall be of a voltage rating 20% higher than the applied
voltage, and shall be of extra low voltage type. Where AC mains
operation is required, indicator lamps shall be operated at extra low
voltage via a step-down transformer and be suitably rated for long life
and reliability;

(viii) alarm bell circuits shall be interleaved and separately fused at the
control equipment;

(ix) relays shall be of the potted type or similarly protected against dust and
shall have solenoids with varnish-impregnated or plastic encapsulated
windings;

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Section 83 – Fire Alarm & Detection System
 (x) contacts shall be of silver and adequately rated. Additional contacts
shall be supplied and installed as required for the operation of auxiliary
controls; and

(xi) the control equipment shall incorporate battery charger set with
appropriate voltage regulators suitable for the rating of the
interconnected triggering devices and the equipment shall incorporate
overload cut-out or limiting devices to protect the external circuit against
excessive current.

(c) Repeater Panels

The repeater panels shall conform to BS EN 54-2 and BS EN 54-4 and shall
be factory made by the same manufacturer as the fire alarm panel. The
repeater panel shall be of construction identical to the fire alarm panel shall be
compete with all indication functions as specified for the fire alarm panel, and
the control functions as specified elsewhere in this Section.

(d) Conventional Type Fire Detectors

(i) general

- all fire detectors together with the fire alarm panel and all other
accessories, shall be from one principal system manufacturer and
form one mutually compatible system. All fire detectors shall be
approved by the Loss Prevention Council;

- the sensitivity of all fire detectors shall be calibrated and tested at the
manufacturer’s works before dispatch;

- each fire detector shall have a built-in flashing response indicator

lamp for visual identification upon activation. The indicator lamp shall
not be energized during the quiescent state of the detector. The
detector shall be capable to drive an additional remote alarm indicator;

- the detector bases shall be equipped with purpose made sealing

plates supplied by the detector manufacturer, to prevent penetration
of dirt, water and moisture during the installation period. The sealing
plates shall facilitate electrical continuity through the bases such that
the circuits can be tested or maintained before the detectors are fixed
into positions;

- the siting and orientation of the detectors and/or the response alarm
indicators shall be such that the indicator of an actuated detector can
readily be seen by a searcher in determining the position of fire alarm.
Fire detectors installed inside concealed spaces or at locations where
the built-in response indicators are difficult to be seen, shall be
equipped with remote alarm indicators fixed at conspicuous locations;

- fire detectors installed on the false ceiling shall be provided with

necessary decorative rings for base flush mounting to the underside
of the false ceiling. Unless otherwise reviewed without objection by
the Project Manager, detectors installed on the false ceiling shall be
fitted at the centre of the ceiling tiles;

General Materials & Workmanship Specification 24/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 - where called for elsewhere in this General Materials and
Workmanship Specification or as indicated on the Employer’s
Drawings, fire detectors to be installed in areas with critical
environmental conditions shall be equipped with detector heating
units for maintaining the temperature of the detectors by 2°C higher
than the ambient air so that performance of the detectors shall not be
adversely affected by moisture consideration the detector heating
units shall be suitable for working on 24V DC. The power
consumption for the detector heating units shall be included when
determining the capacity of the batteries and charging equipment;
and

- a set of detector gripping tool with an extendable rod shall be

provided by the Contractor, for mounting and for removing fire
detectors installed in high headroom areas. The tool shall be
compatible with all types of detectors used in the fire detection and
alarm system.

(ii) smoke detectors

- smoke detectors shall be of the photo-optical type and shall comply

with BS EN 54-7. They shall operate on the light scattering or light
obstruction principle and shall also be incorporated with rate-of-rise
temperature sensors (one exposed to the surrounding air and the
other insulated within the detector) for improving the smoke detection
performance of the detectors when a high rate-of-rise of temperature
is detected. The detectors shall respond adequately to T1 to T5 test
fires as specified in BS EN 54-7;

- optical smoke detectors shall function correctly at continuous relative

humidity up to 95%. They shall be designed to assume protection
rating of IP43. Each detector shall be housed in a corrosion-proof
plug-in unit designed to be mounted pendent, surface or semi-
recessed. Removal of the unit from its base shall cause a fault alarm
signal to be given in the fire alarm panel; and

- the internal electronic circuitry shall be of the highest possible

reliability and protected against voltage spikes and surges. The
detector shall be capable of operating satisfactorily under minimum
variation of ± 20% in supply voltage. The circuitry shall also be
protected against electromagnetic interference.

(iii) heat detectors

- heat detectors shall comply with BS EN 54-5. They shall have

combined fixed temperature (57°C to 65°C or other temperature
ratings as specified on the Employer’s Drawings) and rate-of-rise type
feature except in areas where because the risk of unwanted alarms
caused by rapidly rising temperature is high, detectors without a rate-
of-rise element shall be used; and

General Materials & Workmanship Specification 25/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 - heat detectors shall function correctly at relative humidity up to 95%.
The detectors and the bases shall be designed to assume protection
rating of IP54. All electronic circuits shall be virtually hermetically
sealed to prevent their operation from being impaired by dust, dirt or
humidity.

83.3.3 Direct Telephone Link Alarm Transmitters

(a) The alarm transmitters shall be provided, which shall be compatible with the
FSD Computerized Fire Alarm Transmission System. Alarm transmitters shall
be provided adjacent to or incorporated into the fire main panel.

(b) The Contractor shall coordinate and shall closely monitor the status of
completion of fire alarm direct link and the telephone line before fire service
inspection by FSD. The Contractor shall apply for and provide the required
telephone point for connection of the fire alarm direct link as required. The
Contractor shall coordinate with relevant parties and shall arrange the power
supply point for the fire alarm control and indication panel and for the fire
alarm direct link as necessary. The Contractor shall supply and install all
conduit works for the fire alarm direct link and associated telephone point.

83.3.4 Batteries and Chargers

(a) Batteries shall be of the sealed nickel-cadmium accumulator type and shall
require no maintenance throughout the normal life of the battery. The battery
and charger units shall be capable of maintaining the system in normal
operation for a period of at least 8 hours without recharging and thereafter
shall remain capable of operating in the maximum “alarm” condition for at least
30 minutes. The battery shall also have the capacity to provide the sprinkler
pump power supply failure alarm for at least 72 hours duration.

(b) Battery chargers shall be of the automatic trickle charge type, with facility for
manually-operated boost charge, capable of re-charging the battery to fully
charged condition in not more than eight hours. Battery overcurrent protection
shall be provided to safeguard the battery against short-circuit. Instruments
shall include voltmeter for battery voltage and ammeter for battery current,
“charge/discharge” type.

(c) The output of the rectifier shall be sufficient for the system to give visible and
audible fault warnings upon failure of the battery and shall be capable of
providing for additional alarm load arising from the operation of any alarm
device in two separate time zones.

(d) Batteries and chargers shall be mounted, either together or separately, in well
ventilated corrosion-proof lockable metal cabinets of similar construction to the
cabinet housing the control and indicating equipment. The Contractor shall
submit calculations for charger and battery capacities for review without
objection by the Project Manager.

(e) The battery charger shall be capable of completing the recharging of the
batteries from fully discharged to fully charged within 12 hours.

General Materials & Workmanship Specification 26/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
83.3.5 Flow Switches

(a) Flow switches shall comply with Section 80 of this General Materials and
Workmanship Specification.

(b) Flow switches shall be installed in the position as shown on the Employer's
Drawings and shall be supplied and installed to indicate through the fire
main/sub panels the level and area at which the sprinkler system has been
activated.

(c) Flow switch drains shall be supplied and installed for all flow switches.
Solenoid valves shall be provided for all flowswitch installations to facilitate
automatic testing of each flowswitch at the fire main/sub panel.

83.3.6 Monitored Isolating Valves

(a) Motorized isolating valves shall comply with Section 87 of this General
Materials and Workmanship Specification.

(b) FSD approved monitoring devices shall be supplied and installed on each of
the main isolating valves as shown on the Employer's Drawings. Individual
indication of the operation of any isolating valve shall be provided. The
movement of any valve from its normal position shall raise a fault alarm at the
fire main and sub panels.

(c) For intelligent and addressable fire alarm control system, each monitoring
device shall be interfaced to an addressable monitor module for converting the
signal to the addressable loop.

83.3.7 Alarm Bells

(a) FSD approved alarm bells shall be supplied and installed in positions as
shown on the Employer's Drawings.

(b) Alarm bells shall incorporate a gong of minimum ∅150 mm. Each alarm bell
shall be capable of producing a sound level of 80 dB(A) at 3m. The bell shall
consist of a micro motor as the driving unit offering high performance and
reliability together with low current consumption and low starting voltage
characteristic. Bells shall be painted red and labelled “FIRE ALARM” in both
English and Chinese. Bell circuits shall be “interleaved” and separately fused
at the control equipment.

(c) The alarm bells shall produce an alarm sound level complying with BS 5839 :
Part 1 in all accessible parts of the buildings and acceptable to FSD when the
doors of the rooms are closed. They shall produce an alarm sound level of
not less than 65 dB(A) and not less than 5 dB(A) above any background noise
likely to persist for a period longer than 30s when the building is in use at a
point anywhere in the building.

(d) The alarm bells shall be activated by a signal from a fire alarm.

(e) An audible warning device shall be provided on the fire main/sub panel to
indicate any fault conditions in the system.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 (f) Alarms bells shall be separately wired with 24V DC power wiring from the fire
main/sub panels.

(g) All electric alarm bells inside building shall be IP42 rating.

(h) Externally mounted bells shall be of weatherproof construction to IP55.

83.3.8 Breakglass Alarms (Manual Call Points)

(a) Manual call point shall be of “break-glass” type complying with BS EN 54-11.
Electrical contacts shall operate automatically upon breaking the frangible
element at the front of the unit. The cover shall be locked in position with a
special key and the frangible element (glass panel) shall be clipped firmly into
place. The unit shall be of pleasing appearance and styling, constructed of
non-combustible and non-corrodible materials, and finish enamelled red. The
words: “Fire : Break Glass” shall be suitably engraved or embossed in English
and Chinese on the front.

(b) Contacts shall be of silver or approved non-deteriorating alloy of the normally-

open or normally-closed type to suit the alarm system. A concealed “test”
device shall be included. The voltage and current ratings of the contracts shall
be marked in the unit.

(c) Call points shall be of flush mounting type suitable for direct connection to the
wiring system. Where special boxes are necessary for installation of the call
points in a conduit system, the boxes shall be provided by the Contractor.
Boxes, which are to be recessed in concrete or plaster, shall be of galvanised
steel.

(d) Generally, call points shall be fixed at a height of 1200 mm above the finished
floor unless otherwise indicated on the Employer's Drawings. They shall be
semi-recessed, presenting a side profile area of not less than 750 mm2. A
sample shall be submitted to the Project Manager for review without objection.

(e) A metal striker with chain shall be provided and attached to each call point.

83.3.9 Remote Alarm Indicators

Remote alarm indicators shall comply the following requirements:

(a) Each remote alarm indicators shall be equipped with LED indicator. The
colour of the LED shall be red when activated.

(b) The operation of the indicator shall not affect the brightness of the detector’s
built-in LED.

(c) Failure or disconnection of the remote indicator shall in no way impair the
operation of the detector connected.

(d) Label shall be provided on or near the indicator to identify address number of
the connected detector.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 (f) The indicator lamp shall protrude from the surface of the mounting plate for
visual identification from all directions.

(g) The indicator shall be of weatherproof construction when installed outdoor or

in open sided areas of the structure/building.

83.3.10 Electro-Thermal Links

Electro-thermal links shall be of the type listed by the Underwriters Laboratories Inc.
and shall be designed to react to an electrical impulse of 0.2 ampere over a short
period at a voltage of 6.3V DC.

83.3.11 Electro Magnetic Interference

(a) In addition to the requirements of Section 59 of this General Materials and

Workmanship Specification, the Contractor shall ensure that the completed
fire alarm and detection system shall be unaffected under all operating
conditions by all radio transmissions including those from portable telephones,
two way radios, trunked mobile radio systems and the like.

(b) The Contractor shall produce evidence that all fire alarm and detection system
components including smoke and heat detectors comply with the requirements
of this Section.

83.4 SUBMISSIONS

(a) The Contractor shall submit the following for review without objection by the
Project Manager:

(i) Contractor’s Drawings including detailed layout plans, elevation,

dimensions of equipment, electrical wiring diagrams, operating weight,
connection, mounting and fixing details;

(ii) manufacturers’ literature for all equipment and materials of the

installation. Information shall include electrical characteristic, sound
power levels, performance specification, factory test reports, material list,
spare parts lists, wiring and control diagrams, maintenance clearance,
mounting and fixing details;

(iii) detailed point schedule diagram to identify the fire zones and interface
with other services shall be submitted to the Project Manager for review
without objection.

(iv) testing and commissioning procedures in report format for the complete
system.

(b) The following catalogues with full technical data, characteristic curves and test
certificates issued by an independent and recognised testing authority shall be
submitted to the Project Manager for review without objection:

(i) alarm bell;

(ii) breakglass unit;

General Materials & Workmanship Specification 29/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
 (iii) smoke detector;

(iv) heat detector;

(v) fire control panel;

(vi) battery and charger; and

(vii) twisted pair detection loop cable.

(c) The following samples shall be labelled and submitted to the Project Manager
for review without objection with detachable parts left loose so that they may
be taken apart for examination:

(i) alarm bell;

(ii) breakglass unit;

(iii) smoke detector;

(iv) heat detector;

(v) electrical rigid/flexible conduit;

(vi) junction box; and

(vii) cables.

General Materials & Workmanship Specification 30/30 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 83 – Fire Alarm & Detection System
SECTION 84 PORTABLE HAND HELD EQUIPMENT

84.1 GENERAL

(a) This section covers the general requirements for portable hand held
equipment.

(b) All portable hand held equipment shall generally comply with the following:

(i) Cap 95 – Fire Services Ordinance;

(ii) Codes of Practice for Minimum Fire Service Installations and Equipment
and Inspection, Testing and Maintenance of Installations and Equipment
(FSDCOP) published by HKSAR;

(iii) relevant circular letters and requirements of Fire Services Department

(FSD); and

(iv) relevant British Standards.

84.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 7863 Recommendations for colour coding to indicate the

BS EN 3 : Part 1
BS EN 3 : Part 2
BS EN 3 : Part 3
BS EN 3 : Part 4
BS EN 3 : Part 5
BS EN 3 : Part 6
NFPA 10
ISO 7165
extinguishing media contained in portable fire
extinguishers
Portable fire extinguishers. Description, duration of
operation, class A and B fire test
Portable fire extinguishers. Tightness, dielectric test,
tamping test, special provisions
Portable fire extinguishers. Construction, resistance to
pressure, mechanical tests
Portable fire extinguishers. Charges, minimum
required fire
Portable fire extinguishers. Specification and
supplementary tests
Portable fire extinguishers. Provisions for the
attestation of conformity of portable fire extinguishers
in accordance with EN 3 Part 1 to Part 5
Standard for Portable Fire Extinguishers
Fire-fighting - Portable fire extinguishers - Performance
and construction

General Materials & Workmanship Specification 1/3 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 84 – Portable Hand Held Equipment
84.3 MATERIALS

84.3.1 Portable Fire Extinguishers

(a) Portable fire extinguishers shall be rechargeable hand operated extinguishers

of appropriate type to BS EN 3 : Part 1 to 6 , NFPA 10, ISO 7165 and BS 7863
for water, foam, dry powder, carbon dioxide, NAFS III, FM200 or other
approved agent type as indicated on the Employer’s Drawings, with a capacity
as specified.

(b) Potable appliances shall be in the list approved by FSD.

(c) The body of the portable fire extinguishers shall be made of high quality steel
sheet and provided with an anti-corrosion polyester-resin lining. The body
shall be coloured in accordance with BS 7863, and have the following
information marked or labeled:

(i) manufacturer’s label showing brand name, type, capacity and rating,
model, reference, approval and listing;

(ii) type of fire to be extinguished and operating instruction in both English

and Chinese characters;

(iii) gross weight and net weight;

(iv) date of last maintenance in accordance with requirements prescribed by

the Circular Letters of FSD; and

(v) other information by the manufacturer.

(d) Stored pressure type portable fire extinguishers shall be fitted with pressure
gauges.

84.3.2 Fire Blankets and Buckets

(a) Fire blankets, water buckets and sand buckets shall conform to the
requirements of FSD. Buckets shall be of 10L capacity and shall be
constructed of galvanized steel and painted red. Stands for floor mounting
buckets shall be provided. The materials of construction of the stands shall be
flame retardant type. The minimum size of fire blanket shall be 1,200 mm by
1,200 mm.

(b) Sand bucket shall be “Zinc Plated”.

84.3.3 CARBON DIOXIDE FIRE EXTINGUISHER

(a) CO2 fire extinguishers shall be 4.5 kg or 5 kg type, as shown on the

Employer’s Drawings. The body shall be slim shape with an external diameter
not greater than 170mm. The body shall be manufactured from aluminium
alloy, finished in gloss Black and complete with pictographic operating
instructions.

(b) Each cylinder shall have steel “squeeze-grip” handle together with a hose and
horn assembly for controlling the discharge of extinguishing agent. A “used”
indicator or seal shall be provided at the handle.

General Materials & Workmanship Specification 2/3 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 84 – Portable Hand Held Equipment
84.3.4 ABC DRY POWDER FIRE EXTINGUISHER

(a) The fire extinguisher shall be 2.0 kg stored pressure type with multi-purpose
dry powder suitable for classes A, B & C fire.

(b) The body shall be finished in stoved or powder coated epoxy paint to achieve
high degrees of corrosion resistant and finished in gloss French Blue,
complete with pictographic operating instructions.

(c) Each cylinder shall have pressure gauge and zinc die-cast “squeeze-grip”
handle together with a hose and nozzle assembly for controlling the discharge
of extinguishing agent.

84.4 SUBMISSIONS

(a) The Contractor shall submit the following for review without objection by the
Project Manager:

(i) Contractor’s Drawings including detailed location on layout plans,

dimensions of equipment, operating weight, mounting and fixing details;

(ii) manufacturers’ literature for all equipment of the installation. Information

shall include performance specification, factory test reports, material list,
mounting and fixing details; and

(iii) certificate approved by FSD.

(b) The following catalogues with full technical data, characteristic curves and test
certificates issued by an independent and recognised testing authority shall be
submitted to the Project Manager for review without objection:

(i) portable fire extinguishers; and

(ii) fire blankets and buckets.

84.5 WORKMANSHIP

(a) All portable fire extinguishers and fire blankets shall be fixed with wall
mounted brackets. Buckets shall be floor standing type. The mounting
method shall be such that free use of the extinguishers, blankets and buckets
can be achieved without any hindrance.

General Materials & Workmanship Specification 3/3 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 84 – Portable Hand Held Equipment
[this page not used]
SECTION 85 VISUAL FIRE ALARM

85.1 GENERAL

(a) This section covers the general requirements for visual fire alarm.

(b) All visual fire alarm shall generally comply with the following:

(i) Cap 95 – Fire Services Ordinance;

(ii) Codes of Practice for Minimum Fire Service Installations and Equipment
and Inspection, Testing and Maintenance of Installations and Equipment
(FSDCOP) published by HKSAR;

(iii) relevant circular letters and requirements of Fire Services Department

(FSD);

(iv) Barrier Free Access 1997 of the Building Department; and

(v) relevant British Standards.

85.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 5839 : Part 1 Fire detection and alarm systems for buildings. Code
of practice for system design, installation and servicing
NFPA 72 Section 6-4 National Fire Alarm Code

85.3 MATERIALS

(a) The visual fire alarm system shall be supplied and installed completed with the
red flashing light labeled “FIRE ALARM” signal and the corresponding wirings,
control equipment as well as all other necessary accessories as indicated on
the Employer’s drawings.

(b) Flashing lights shall produce signals which are distinctive from other similar
appliances used for other purposes in the same building. They shall have
pleasing appearance and styling, constructed of flame retardant high impact
housing with the exterior finishes to be gloss red. They shall give a clearly
visible light signals over a long distance which makes them ideal for noisy
environment.

General Materials & Workmanship Specification 1/2 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 85 – Visual Fire Alarm
 (c) Each flashing light unit shall consist of one tungsten bulb and shall be fitted
with all necessary flashing and control provisions. The unit shall be suitable
for 24V DC operation. The light output of each flashing light shall not be less
than 75 candela. The flash rate shall not be slower than 1 flash every 3
seconds and shall not exceed 3 flashes per second. The pulse duration (i.e.
the time interval between initial and final points of 10% maximum signal) shall
be not more than 0.2 seconds with a maximum duty cycle of 40%.

(d) The dimension, construction and design details of the unit shall be in
accordance with Section 6-4 of NFPA 72 or the standards acceptance to FSD.

(e) All flashing light units shall be surface mounted type. The unit installed
outdoor shall be of weather proof type and shall have degree of protection to
IP 55.

(f) Synchronized modules shall be provided in the flashing lights circuit and shall
be so arranged that the operation of all flashing lights will be synchronized.

85.4 SUBMISSIONS

(a) The Contractor shall submit complete catalogue information, approved

certificates and samples complete with full technical data, Contractor’s
Drawings for materials and equipment, and test certificates to the Project
Manager for review without objection.

85.5 WORKMANSHIP

(a) All testing provisions for the operation and functioning of the control and alarm
system should be provided. In addition, manual keyed by-pass switches shall
be incorporated so as not to send out fire signal to the air-conditioning system
and the lift installations when routine testing is carried out. The buzzer shall
be activated if the by-pass switches or other test switched back to their normal
operating status after the test.

(b) Flashing lights shall be so sited that the concentrated viewing path has to be
considered and that the operating effect of the appliance shall be capable to
be seen by the intended viewers and that the viewers shall be able to discern
when the appliance(s) have been illuminated regardless of the viewer’s
orientation.

(c) The flashing light units shall actuate upon fire alarm signals from any of the
breakglass units or detection system.

(d) Wall-mounted appliances shall be so located that the bottom of the appliances
are at a height of 2 meters to 2.4 meters above the finished floor level. The
appliances may also be mounted on the ceiling when the ceiling height is not
higher than 9 meters. The spacing between flashing lights shall not exceed 30
meters and its distance from the end of a corridor shall not exceed 4 meters.

General Materials & Workmanship Specification 2/2 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 85 – Visual Fire Alarm
SECTION 86 EXIT SIGN AND DIRECTIONAL SIGN

86.1 GENERAL

(a) This section covers the general requirements for exit sign and directional sign.

(b) All exit sign and directional sign shall generally comply with the following:

(i) Cap 95 – Fire Services Ordinance;

(ii) Codes of Practice for Minimum Fire Service Installations and Equipment
and Inspection, Testing and Maintenance of Installations and Equipment
(FSDCOP) published by HKSAR;

(iii) relevant circular letters and requirements of Fire Services Department

(FSD); and

(iv) relevant British Standards.

86.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 5266 : Part 1 Emergency lighting. Code of practice for the

BS 5499
BS 5499 : Part 1
BS 5499 : Part 2
emergency lighting of premises other than cinemas
and certain other specified premises used for
entertainment
Fire safety signs, notices and graphic symbols
Graphical symbols and signs. Safety signs, including
fire safety signs. Specification for geometric shapes,
colours and layout
Fire safety signs, notices and graphic symbols.
Specification for self-luminous fire safety signs

86.3 MATERIALS

86.3.1 General

(a) All components in connection with emergency illuminant such as batteries,

transistorised ballast, mains power failure detector, automatic changeover
relay, low voltage 'cut-out' battery protective device shall be contained inside
the exit sign and directional sign box.

General Materials & Workmanship Specification 1/4 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 86 – Exit Sign & Directional Sign
 (b) Fittings to exit sign and directional sign box:
The Contractor shall supply and install the following fittings and features on
the external surface of the sign box if emergency lighting modification unit
(conversion kit) is used.

(i) LED indication lamp to show that the main is "ON"

(ii) LED indication lamp to show that the battery is being charged;

(iii) A self-returning switch to be switched on to simulate failure of normal

supply to test the emergency operation of the emergency lighting fitting.

86.3.2 Exit Sign

(a) Exit signs shall conform to BS 5499. Exit signs shall include all related
directional signs in exit routes. Exit signs shall be internally illuminated
bearing the words “EXIT 出口”in block letters and characters of not less than
125 mm high with 15 mm wide strokes. For industrial Building or Baggage
sorting area inside Passenger Terminal Building, the characters shall not be
less than 180 mm high with 15 mm wide strokes. Colour contrast for
translucent surrounds to lettering shall be either one of the following
combinations or as specified:

Colour Contrasting Colour

Green White
White Green

(b) The colour combination selected shall be consistent throughout the same
building. The colour shall not deteriorate or become faint throughout the
service life and lasts for at lease ten years.

86.3.3 Directional Sign

(a) Where it is shown on the Employer’s Drawing that a sign cannot be installed
immediately above an exit or if an exit sign cannot be visible from normally
occupied parts of the premises, an internally illuminated directional sign
conforming to BS 5499 : Part 1 shall be supplied and installed. The graphic
design of directional sign shall conform to FSDCOP and FSD Circular Letters
and requirements.

(b) Directional signs shall be internally illuminated and in compliance with BS

5499 : Part 1 Table 10. The lamp elements shall be positioned to produce the
best illumination effect for the sign. A flashing light control gear shall be
integrated with each sign. An independent circuit including a separate set of
lamp-holder, wiring and protective gear shall be provided for each lamp
element. In normal situation, the lamp elements shall be in the “ON” condition.
Low level self-luminous directional signs not carrying radioactive substances
can be used at the approval of the Project Manager without objection when
illuminated signs are not specified. The low level self-luminous directional
signs shall be as approved by the FSD complying with BS 5499 : Part 2.

General Materials & Workmanship Specification 2/4 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 86 – Exit Sign & Directional Sign
86.3.4 Self-Luminous Sign

Self-luminous exit signs carrying radioactive substances shall not be used. All
illuminated exit signs shall be connected to the main supply. Self-contained exit
signs shall be provided with secondary battery. Central supplied exit sign shall be
connected to the central battery set of the emergency luminaire installation.
Centrally supplied exit signs or self-contained exit signs shall be supplied and
installed as specified. Where centrally supplied emergency luminaires are supplied
and installed, centrally supplied exit signs shall be used unless otherwise specified.
Where emergency power supply is available, the exit signs shall also be connected
to the emergency power supply. The design operating life of the batteries shall not
be less than four years. The battery, charger, wiring and testing facilities of the exit
signs shall comply with the relevant requirements of the centrally supplied
emergency luminaires or the self-contained emergency luminaires. The luminaires
for exit signs shall be of maintained type.

86.4 SUBMISSIONS

(a) The Contractor shall submit the following for review by the Project Manager
without objection:

(i) The Contractor shall submit complete catalogue information, approved

certificates and samples complete with full technical data, Contractor’s
Drawings for materials and equipment, and test certificates to the Project
Manager for review without objection; and

(ii) Contractor’s Drawings including detailed layout plans, elevation,

dimensions of equipment, electrical wiring diagrams, mounting and fixing
details.

(b) The following samples shall be labelled and submitted to the Project Manager
for review without objection with detachable parts left loose so that they may
be taken apart for examination:

(i) exit sign; and

(ii) directional sign.

86.5 WORKMANSHIP

86.5.1 General

(a) Exit signs and directional sign shall be connected to both mains and
emergency power supply. If the building is not equipped with an emergency
generator, the exit signs and directional sign shall be provided with secondary
battery in accordance with BS 5266 : Part 1.

(b) Where illuminated exit signs and directional sign are supplied and installed in
places with operation/performance mostly conducted in a dark environment,
the exit sign and directional sign shall be of such design that the illumination
shall be kept to the minimum level enough to satisfy the statutory
requirements but shall not be too bright as to cause discomfort to the public or
to affect the operation/performance taking place.
General Materials & Workmanship Specification 3/4 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 86 – Exit Sign & Directional Sign
 (c) The construction details, finishes and appearance of the exit signs and
directional sign shall be submitted to the Project Manager for approval without
objection before fabrication. The Contractor shall allow modifying the
appearance and details of the exit signs and directional sign to the satisfaction
of the Project Manager without objection.

(d) The construction of the illuminated signs shall be as specified and in

accordance with the requirements of the FSD. Each illuminated sign shall
consist of lamps, battery, charger, automatic changeover device,
inverter/ballast indications and switch.

(e) All wirings for the exit signs and directional sign commencing from the power
supply points as shown on the Employer’s Drawing shall be supplied and
installed by the Contractor.

(f) The exit signs and directional sign shall be internally illuminated by fluorescent
lighting fitting or incandescent 1amp, acceptable to the FSD and suitable to
use on 220V, 50 Hz, single phase AC supply.

(g) The battery shall be sealed, rechargeable and maintenance free nickel-metal
hydride type or a type of better functions and performance and approved by
the Project Manager without objection. The total battery capacity shall be
capable of maintaining light output of all lamp elements at not less than 50%
of the nominal light output under the maintained mode for at least two (2)
hours after mains failure. The charger shall be capable of recharging the
batteries to full capacity within twenty-four (24) hours after a total discharge.
Clear indications shall be provided on the sign box showing either the mains
supply is normal or the battery is discharging and an integrated toggle test
switch with “normal”, “battery-off” and “test” positions for testing the proper
functioning of the battery supply system.

(h) Under normal supply, the battery shall be charged to maintain in a fully
charged state and the lamps shall be operated by the mains supply. When
the mains supply fails, the automatic changeover switch shall instantaneously
switch to battery-powered operation until the restoration of the mains supply.
It shall then switch back to normal and the battery shall be re-charged again.

86.5.2 Operation

(a) Under normal conditions, the 220V AC mains shall power the fluorescent lamp
and charge a sealed nickel cadmium battery through a battery charger. On
failure of mains supply, the emergency lighting modification unit shall
instantaneously switch to battery power operation. Upon restoration of mains
supply, the unit shall switch back to normal power and the batteries shall be
re-charged again. The changeover operations shall be automatic.

(b) The duration of emergency operation shall be at least 2 hours after the mains
supply fails with a light output up to the end of the duration.

(c) The charging system shall be capable of recharging the battery to full capacity
in 24 hours after a total discharge of the battery.

(d) The battery shall be protected against over-discharge by a low voltage 'cut-
out' device which shall disconnect the battery from the load once the
discharging voltage of the nickel cadmium-cell drops below lV.
General Materials & Workmanship Specification 4/4 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 86 – Exit Sign & Directional Sign
SECTION 87 PIPEWORK, VALVES AND FITTINGS

87.1 GENERAL

(a) This section covers the general requirements for pipework, valves and fittings
for fire services system.

(b) All pipework, valves and fittings shall generally comply with the following:

(i) Cap 95 – Fire Services Ordinance;

(ii) Codes of Practice for Minimum Fire Service Installations and Equipment
and Inspection, Testing and Maintenance of Installations and Equipment
(FSDCOP) published by HKSAR;

(iii) relevant circular letters and requirements of Fire Services Department

(FSD);

(iv) relevant circular letters and requirements of Water Supplies Department

(WSD); and

(v) relevant British Standards.

(c) Design and construction of pipelines shall, unless otherwise specified, be in

accordance with BS 8010.

(d) Pipework shall include a complete piping system comprising all pipes, tubes,
valves, fittings, reducers, expanders, nipples, vents, bleed offs, drains,
expansion and contraction devices, hangers, brackets, anchors, saddles,
supports, sleeves, plates and all accessories and components connected
thereto as an integrated pipework installation.

(e) Pipework, fittings, valves, vents expansion devices and the like, associated
with all water services shall be suitable for a minimum operating pressure of
1,600 kPa.

(f) In the case of pipes passing through external walls and into water containing
chambers, adequate puddle flanges shall be provided by the Contractor.

(g) Where pipe sizes are stated in the following clauses, this is intended to relate
to nominal bore in the case of steel tubes and to nominal outside diameter in
the case of copper tubes.

General Materials & Workmanship Specification 1/15 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 87 – Pipework, Valves & Fittings
87.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 21 Specification for pipe threads for tubes and fittings

where pressure-tight joints are made on the threads
(metric dimensions)
BS 970 Specification for wrought steels for mechanical and
allied engineering purposes.
BS 1212 : Part 1 Float operated valves. Specification for piston type
float operated valves (copper alloy body) (excluding
floats)
BS 1387 Specification for screwed and socketed steel tubes
and tubulars and for plain end steel tubes suitable for
welding or for screwing to BS 21 pipe threads
BS 1968 Specification for floats for ballvalves (copper)
BS 3100 Specification for steel castings for general engineering
purposes
BS 3416 Specification for bitumen-based coatings for cold
application, suitable for use in contact with potable
water
BS 3974 Specification for pipe supports.
BS 3974 : Part 2 Specification for pipe supports. Pipe clamps, cages,
cantilevers and attachments to beams
BS 4504 Circular flanges for pipes, valves and fittings (PN
designated).
BS 4504 : Part 1 Circular flanges for pipes, valves and fittings (PN
designated). Ferrous
BS 5150 Specification for cast iron gate valves
BS 5152 Specification for cast iron globe and globe stop and
check valves for general purposes
BS 5154 Specification for copper alloy globe, globe stop and
check, check and gate valves
BS 6129 Code of practice for the selection and application of
bellows expansion joints for use in pressure systems.
BS 8010 Code of practice for pipelines.
BS EN 545 Ductile iron pipes, fittings, accessories and their joints
for water pipelines. Requirements and test methods
BS EN 593 Industrial valves. Metallic butterfly valves
BS EN 837 : Part 1 Pressure gauges. Bourdon tube pressure gauges.
Dimensions, metrology, requirements and testing

General Materials & Workmanship Specification 2/15 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 87 – Pipework, Valves & Fittings
 BS EN 1254 : Part 1 Copper and copper alloys. Plumbing fittings. Fittings
with ends for capillary soldering or capillary brazing to
copper tubes
BS EN 1254 : Part 2 Copper and copper alloys. Plumbing fittings. Fittings
with compression ends for use with copper tubes
BS EN 1561 Founding. Grey cast irons
BS EN 1563 Founding. Spheroidal graphite cast iron
BS EN 1982 Copper and copper alloys. Ingots and castings
BS EN 10028 Specification for flat products made of steels for
pressure purposes.

BS EN 10213 Technical delivery conditions for steel castings for

pressure purposes.
BS EN 12163 Copper and copper alloys. Rod for general purposes
BS EN 12164 Copper and copper alloys. Rod for free machining
purposes
BS EN 12165 Copper and copper alloys. Wrought and unwrought
forging stock
BS EN 12167 Copper and copper alloys. Profiles and rectangular bar
for general purposes
BS EN 12334 Industrial valves. Cast iron check valves
BS EN 12420 Copper and copper alloys. Forgings
BS EN 12449 Copper and copper alloys. Seamless, round tubes for
general purposes
ASTM A-47 Standard Specification for Ferritic Malleable Iron
Castings
ASTM A-183 Standard Specification for Carbon Steel Track Bolts
and Nuts
ASTM A-536 Standard Specification for Ductile Iron Castings
ASTM D-2000 Standard Classification System for Rubber Products in
Automotive Applications
ISO 7-1 Pipe threads where pressure-tight joints are made on
the threads - Part 1: Dimensions, tolerances and
designation
ISO 65 Carbon steel tubes suitable for screwing in accordance
with ISO 7-1

General Materials & Workmanship Specification 3/15 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 87 – Pipework, Valves & Fittings
87.3 PIPEWORK AND FITTINGS MATERIALS

87.3.1 Galvanized Mild Steel Pipework

(a) All pipework up to and including 150 mm diameter shall, unless otherwise
indicated, be galvanized mild steel of at least medium grade to BS 1387 / ISO
65 for steel tubes and tubulars for screwing to BS 21 / ISO 7-1 for pipe threads.

(b) For galvanized mild steel pipe laid underground shall be of heavy grade to BS
1387 / ISO 65 for steel tubes and tubular for screwing to BS 21 / ISO 7-1 pipe
threads.

87.3.2 Ductile Iron Pipework

(a) All tubes and fittings above 150 mm diameter shall be ductile iron to BS EN
545: Class K12, with cement mortar lining; and bitumen-based coatings
externally and internally to BS 3416 Type II.

(b) For ductile iron pipe laid underground shall conform to BS EN 545: Class K12
for ductile iron pipes and fittings, with cement mortar lining.

87.3.3 Steel Pipework Joints and Fittings

(a) Steel pipes up to and including 65 mm shall be jointed with screwed fitting,
screwed flanges, or screwed unions. Screwed joints shall have tapered
threads and shall be made with jointing material. Where the cutting of threads
removes galvanizing, the Contractor shall apply a cold galvanizing finish to
restore the integrity of the pipe protective finish. Fittings shall be galvanized.
Screwed fittings other than sockets shall be malleable iron. All pipes shall be
fitted with screwed flanges for jointing valves and other equipment having
flange connections.

(b) Flanges for mild steel pipework shall be wrought iron or annealed steel,
machined full face, suitable for the working pressures to which they will be
subjected.

87.3.4 Mechanical Grooved Couplings and Fittings

(a) For pipes of sizes from 80 mm upwards or lay underground shall be jointed
with proprietary mechanical grooved couplings and fittings unless otherwise
specified.

(b) Mechanical grooved couplings and fittings shall be approved by FSD for the
type and dimensions as used in the piping network of fire services installations.

(c) Suitable mechanical pipe coupling of approved type that can provide the
required allowance for angular deflection and contraction and expansion shall
be used.

(d) The use of mechanical grooved couplings and fittings shall be limited to
instances where ambient temperatures do not exceed 70°C. They shall be
installed in accordance with the manufacturer's installation instructions.

(e) Mechanical grooved couplings and fittings shall be of a bolted or mechanical

locking device type, with a pressure-responsive gasket.

General Materials & Workmanship Specification 4/15 January 2011

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Section 87 – Pipework, Valves & Fittings
 (f) Couplings shall consist of one or more pieces of ductile or malleable iron cast
housing, a synthetic rubber gasket, with nuts, bolts, locking pin, locking toggle
or lugs to secure units together.

(g) Gaskets shall be moulded or synthetic rubber in a central cavity pressure-

responsive configuration conforming to the pipe outside diameter and coupling
housing, of elastomers having properties as designed in ASTM D-2000.
Gasket shall be a Grade "E" EPDM compound. Bolts and nuts shall be heat-
treated carbon steel, track head, conforming to physical properties of ASTM A-
183 minimum tensile 780 MPa, cadmium plated or zinc electroplated.

(h) Fittings shall be cast of ductile iron conforming to ASTM A-536, Grade 65-45-
12, or galvanized malleable iron conforming to ASTM A-47, Grade 32510, with
grooves or shoulders designed to accept grooved end couplings.

(i) Mechanical grooved couplings and fittings including gaskets used on dry pipe
installations shall be suitable for dry pipe services.

(j) Mechanical pipe couplings shall not be used in fire-exposed areas unless the
system is automatically actuated.

(k) Mechanical pipe couplings shall consist of malleable cast iron or rolled steel
centre sleeve and end flanges, Nitrile (Grade T) wedge shape rubber sealing
rings, bolts and nuts and washers.

(l) Mechanical pipe couplings shall be designed for jointing plain-ended pipes of
the types and dimensions as used in the piping network of the fire services
installations.

87.3.5 Hanger Rod Pipework Supports

(a) All pipework shall be properly supported with substantial hangers, anchors,
brackets, saddles, guides, etc, to BS 3974 with adequate provision for
expansion and contraction.

(b) Hanger rod of steel threaded and furnished with two removable nuts at each
end for positioning rod and hanger and locking each in place shall be provided.

(c) Except as otherwise noted, hanger rods shall be of the following sizes:

Pipe size, mm Single rod diameter, mm Double rod diameter, mm

50 and below 10 10
65 and 80 13 10
100 and 125 15 13
150 20 15
200 and above 22 20

(d) Where pipework up to 50 mm is fixed to solid structure, brackets shall be of

the screw-on or long shank built-in type. Fixings to timber or to lightweight
structure shall be of screw-on pattern. Brackets for mild steel tube shall be
mild steel or malleable iron, galvanized; brackets for copper tubes shall be
brass or gunmetal. The pipe clip shall be detachable without disturbing the
fixing.

General Materials & Workmanship Specification 5/15 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 87 – Pipework, Valves & Fittings
 (e) Pipework of 65 mm size and larger subjected to expansion and contraction
shall be suspended on swivel hangers.

(f) Unless otherwise specified, hangers for horizontal pipework at high level shall
be supported from angle or channel irons, provided by the Contractor, suitable
for building-in or otherwise secured to the structure. Adjustable mild steel
hangers shall be used. Pipe rings shall be of malleable iron or fabricated steel,
made in halves and secured by bolts or machine screws.

Nominal pipe Spacing for Spacing for

size, mm vertical runs, m horizontal runs, m
Steel
15 2.5 2.0
20 and 25 3.0 2.5
32 3.0 3.0
40 and 50 3.5 3.0
65 and 80 4.5 3.5
100 4.5 4.0
125 5.0 4.5
150 5.0 5.0
200 6.5 6.5
Copper
15 1.5 1.0
22 and 28 2.0 1.5
35 and 42 2.5 2.0
54 3.0 2.5
76 and 108 3.5 3.0

87.3.6 Expansion Joints

(a) Movement of the pipework due to changes in temperature shall be

accommodated by the natural flexibility of the pipework run or by bellow
expansion joints, in either case allowable stress levels should be within PD
5500.

(b) Expansion joints shall be provided for all pipework passing across any building
expansion joints. They shall be of axial pattern bellows type and shall have
screwed or flanged ends as appropriate to facilitate replacement. They shall
incorporate internal liners if required and shall be manufactured from 18/8
stainless steel or other approved material appropriate to the system and shall
be designed to withstand the test pressure of the system. External protective
sleeves shall be fitted. Each joint shall be securely held by guides on both
sides.

(c) Movement facilities and anchors shall be designed to suit the particular
application. The Contractor shall submit to the Project Manager for review
without objection engineering calculations as Contractor's Drawings detailing
the overall performance of the pipework including pipework expansion and
contraction, anchor load and pipework stresses. Lateral movement of the
expansion joint shall match with the building movement. The lateral and axial
movements of the expansion joint shall not be less than ± 6 mm.

General Materials & Workmanship Specification 6/15 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 87 – Pipework, Valves & Fittings
 (d) Anchors and guides shall comply with BS 3974: Part 2.

(e) Stainless steel bellows shall comply with BS 6129.

(f) The expansion joints shall be the type of Water Authority approved and
accepted by FSD.

(g) Working pressure of the expansion joint shall be not less than twice of the
system pressure involved.

(h) Reference shall be made to the Structural Movement Report when selecting
flexible joints, anchors and mountings.

87.3.7 Pipe Sleeve and Cover Plate

(a) All pipework passing through floors, walls, partitions, furring, roofs and ceilings
shall be installed with pipe sleeves. Sleeves shall be the full thickness of the
construction finish to finish.

(b) Sleeves shall be large enough to accommodate pipework movement due to

expansion.

(c) Where pipework passes through walls, floors, ceilings or partitions in areas
exposed to public view, solid close fitting steel plates or escutcheons secured
with set screws shall be installed.

87.3.8 Puddle Flange

(a) Puddle flange shall be cast into the concrete water tanks. Connections to the
water tank shall be properly aligned in both the horizontal and vertical planes.
Additional compaction shall be provided around the puddle flange to ensure a
water tight joint.
(b) All puddle flanges shall be gunmetal.

87.4 VALVES AND FITTINGS MATERIALS

87.4.1 General

(a) All valves shall be of approved by the WSD and manufacture complying with
the appropriate British Standard bearing the BS kite mark, and approved for
the working pressure of 150% greater than the system pressure and of
minimum 1,000 kPa.

87.4.2 Stop Valves

(a) All stop valves on connections to water supplies, bypass stop valves and
sectional/subsidiary stop valves which may interrupt the flow of water to
sprinklers, shall be fitted with micro-switches for monitoring the status or mode
of the vales.

(b) Any partial or total closing of the valves other than the bypass stop valves, and
any partial or total opening of the bypass stop valves, shall activated visible
and audible alarms at the fire alarm panel.

General Materials & Workmanship Specification 7/15 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 87 – Pipework, Valves & Fittings
 (c) Test valve shall be provided at all locations shown on the drawings and the
following locations:

(i) 15 mm diameter bronze valve with hose bib attachment downstream of

each flow switch; and

(ii) 20 mm diameter cock downstream of pressure switch at discharge of all

fire pumps.

(d) All stop valves shall be right-handed i.e. turn clockwise to shut. Controlling
wheels shall be clearly marked showing in which direction the wheel is to be
turned to close the valve and an indicator which shall show whether the valve
is open or shut.

(e) All stop valves in the water supply main and the main stop valve shall be
secured open by a padlocked chain/leather strap.

(f) All valves in each instance shall be suitable in all respects for the class of
service and function. All valves shall be sized not less than the pipe size.
Valves installed more than 2 m above floor level shall be provided with chain
operators.

(g) As a minimum, valves shall generally comply with the following standards or
suitable equivalent:

(i) Gate valves - BS 5150, BS 5153, BS 5154;

(ii) Globe valves - BS 5152, BS 5154;

(iii) Butterfly valves - BS EN 593; and

(iv) Non-return valves - BS EN 12334, BS 5154.

(h) As a minimum, materials used in the construction of valves shall comply with
the following standards or suitable equivalent:

(i) Copper alloy ingots and castings - BS EN 1982;

- gunmetal - BS EN 1982 LG2;

(ii) Copper alloy forging stock and forgings- BS EN 12165,

- BS EN 12420;

(iii) Copper alloy rods and sections - BS EN 12163,

- BS EN 12164,
- BS EN 12167;

(iv) Flake graphite cast iron - BS EN 1561;

- grey cast iron - BS EN 1561 Grade 220;

(v) Stainless steel - BS 970 SS 316;

(vi) Spheroidal graphite (SG) - BS EN 1563;

General Materials & Workmanship Specification 8/15 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 87 – Pipework, Valves & Fittings
 (vii) Cast iron (ductile iron) - BS EN 1563;

(viii) Carbon and alloy steel - BS EN10028; and

(ix) Steel castings:

- pressure purposes - BS EN 10213;
- non-pressure purposes - BS 3100.

(i) Valve schedule:

Type of Valve Size (mm) Body Material Disc & Seat

Material
Gate & Globe 15 – 50 Bronze Bronze
65 and above Cast iron flange Bronze
Butterfly 50 and above Ductile iron steel / Stainless steel
PVC encapped
ductile iron
Swing Check 15 – 50 Bronze Bronze
65 and above Cast iron Bronze
Silent Seat Check 65 and above Cast iron Bronze / Stainless
Steel
Pressure 15 – 50 Bronze Bronze
Reducing
65 and above Cast iron Bronze
Ball Float 15 – 50 Bronze Bronze
65 and above Cast iron Bronze

(j) Valve Connections:

(i) Provide valves suitable for connection to adjoining piping as specified for
pipe joints. Use pipe size valves.

(ii) Valve sizes 50mm and smaller shall have taper screwed ends to BS 21.

(iii) Valves sizes 65mm nominal bore and larger shall have flanged
connection to BS 4504.

(iv) User grooved body valves with mechanical grooved jointed piping.

(v) Provide butterfly valve with tapped lug body when used for isolating
service.

87.4.3 Gate Valve

(a) Gate valves in nominal sizes up to and including 50 mm diameter shall be to

BS 5154 of heavy pattern rising stem type with cast iron wheel head with high
tensile brass or gunmetal stem. In bronze to BS EN 1982 with screwed joints.

(b) Gate valves in nominal sizes from 65 mm diameter and above shall be to BS
5150 or BS 5153 type B and in cast iron to BS EN 1561 with bronze trim and
high tensile brass stem. With flanged ends, flanges to BS 4504 : Part 1.

General Materials & Workmanship Specification 9/15 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 87 – Pipework, Valves & Fittings
87.4.4 Globe Valve

(a) Up to 50 mm with screwed bonnet, metal-to-metal seat. Threaded connection.

(b) 65 mm and larger with cast iron body, bronze mounted globe, regrinding,
replaceable seat and disc, bolted yoke bonnet. Flanged connection.

87.4.5 Check Valve

(a) Check valve shall comply with BS EN 12334 and BS 5154.

(b) Check valves shall be of the silent type and approved by the WSD. The
working pressure shall be 150% greater than the system pressure and of
minimum PN10.

(c) Silent check valves shall be of double guided disc sliding type and constructed
of cast iron body, bronze disc and seat, stainless steel spring with viton or
PTFE sealing material.

87.4.6 Butterfly Valve

(a) General: tight closing, water type or integral flanged type where indicated with
resilient seats. Provide seats that cover inside surface of body and extend
over body ends; or provide o-rings so that valve body may be bolted and
sealed between flat faced flanges with minimum bolt loading and without
additional gaskets; or provide integral pipe ends to suit piping used, with pipe
and faces concentrically grooved to seal against concentric protrusions in seat.

(b) Bodies: cast iron or ductile iron.

(c) Seats: suitable for the temperature rating of the system served.

(d) Discs: aluminium bronze or ductile iron for fresh water.

(e) Shaft stems: 316 stainless steel for fresh water.

(f) Control handles: Suitable for locking in any position or with 10 degree or 15
degree notched throttling plates to hold valve in selected position. Provide
gear operators for size over 80 mm. Provide position indicators and limit stops.

(g) All butterfly valves 450 mm or above shall be fitted with 20 mm by-pass globe
valve.

(h) All manual butterfly valves up to 80 mm shall be fitted with 10 position locked
levers. Valves over 80 mm shall be fitted with hand wheel screw type or worm
gear type actuators with position indicators and limit stops factory adjusted at
full open and full closure.

General Materials & Workmanship Specification 10/15 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 87 – Pipework, Valves & Fittings
87.4.7 Pressure Reducing Valve

Where shown on the Employer’s Drawings, pressure reducing valve sets shall be
installed in fire hydrant / hose reel system.

Each pressure reducing valve set shall be installed such that it is readily accessible
for maintenance purposes and shall comprise the following:

(a) Isolating and by-pass gate valves.

(b) Pressure reducing valve (fully functional for pressure reduction at “NO FLOW”
condition).

(c) Pressure switch to give signal when the PRV mal-functions.

(d) Taper pieces to reduce to the valve bore and enlarge afterwards to the bore of
the low pressure main.

(e) Pressure gauge installed on both high and low side of the reducing valve set,
registering in kPa and calibrated to twice the working pressure, fitted with a
hand set red pointer, in addition to the indicating block pointer. Each gauge is
to be fitted with a level handle, plug cock and gunmetal syphone and cock for
inspection gauge, and mounted on a hardboard panel fixed to the wall in an
easily readable position.

(f) The construction of pressure reducing valves shall be of bronze or cast iron
body, replaceable stainless steel/bronze body seat specially compounded
compositions seat, specially compounded compositions seat disc; nylon
reinforcement of Buna-N diaphragm or stainless steel. The valve for hose reel
pipes can be of the ratio reducing type or constant pressure type approved by
FSD or of the suitable type by means of adjusting spring and with maximum
pressure reduction ratio of 1/10.

(g) For normal sizes up to and including 50 mm valve shall be screw joints whilst
from 65 mm and upward valve shall be flanged joints to BS 4504 : Part 1
corresponding to system pressure.

(h) The valve shall maintain a constant reduced downstream pressure regardless
of changes in upstream pressure or below rate.

87.4.8 Ball Float Valve

(a) Ball float valves shall be of cast iron body with nickel alloy and stainless steel
working parts. They shall be of a slow closing type and of PN10 pressure
rating.

(b) Ball float valves in nominal sizes up to and including 50 mm diameter shall be
to BS 1212 : Part 1 and in brass with copper float to BS 1968.

(c) Ball float valves in nominal sizes from 65 mm diameter and above shall be to
BS 1212 : Part 1 and in cast iron with bronze trim and copper ball float to BS
1968. With flanged ends, flanges to BS 4504 : Part 1, rated at working
pressure involved but in no case less tan PN10.

General Materials & Workmanship Specification 11/15 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 87 – Pipework, Valves & Fittings
87.4.9 Vortex Inhibitor

(a) Vortex inhibitors shall be of LPC approved type with PN16 flanges to BS 4504 :
Part 1. They shall be used for operation under positive head conditions.

87.4.10 Drain Cock

(a) Drain valves shall be provided to ensure that every section of pipework can be
drained.

(b) Drain cocks of gland pattern shall be provided in such locations that all
sections of piping systems can be drained and shall be of 10 mm for pipes up
to 50 mm diameter and 25 mm on larger pipes. Drain cock shall be completed
with hose union.

87.4.11 Pipeline Strainer

(a) Water strainers shall be installed in all pipelines upstream of all pumps. For
pipelines of nominal bores between 15 mm and 50 mm diameter inclusive,
strainers shall be screwed gunmetal or bronze body “Y” type with brass or
stainless steel screen.

(b) For pipelines of nominal bores of 65 mm diameter and above, strainers shall
be flanged to BS 4504 : Part 1 to the appropriate table for the material with “Y”
type cast iron body, brass or stainless steel screen.

(c) Strainer screens shall have straining holes of 2 mm diameter.

87.4.12 Pressure Gauge

(a) Pressure gauges shall conform to BS EN 837:Part 1. They shall have brass
cases complete with dials not less than 100mm diameter.

(b) The maximum scale value of the pressure gauge shall be 150% of the
anticipated maximum operating pressure.

(c) Pressure gauges shall have the following scales:

Maximum Scale Value Scale with values not

exceeding
1 1,000 kPa 20 kPa
2 1,600 kPa 50 kPa
3 More than 1,600 kPa 100 kPa

(d) Pressure gauges shall be removable without causing interruption to the

installation. Gate valves shall be installed at the connection of the gauge for
isolation.

(e) Each pressure gauge shall have black pointer, red overrun indicators, and red
mark at normal working pressure.

(f) The pressure gauges at the suction and discharge side of the pumps shall be
damped type. Pressure gauges at the suction side of the pumps shall be with
measuring range showing the negative suction head.

General Materials & Workmanship Specification 12/15 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 87 – Pipework, Valves & Fittings
87.4.13 Automatic Air Vent

(a) Automatic air vent shall be of float operated type having cast iron bodies,
stainless steel floats and non-corrodible valve seats.

(b) Automatic air vent shall be mounted in the true vertical plane and shall be
equipped with an isolating valve.

87.4.14 Flexible Connector

(a) Flexible connectors shall be of stainless steel and the working pressure shall
be not less than twice that of the system pressure involved.

(b) All connectors shall have flanged connection to BS 4504 : Part 1 and shall be
suitable for connecting to the appropriate pipework and equipment.

87.4.15 Safety Relief Valve

(a) Pressure actuated type, spring return angle patter.

(b) Body, disc and base constructed of bronze.

(c) Trim, guides, adjusting screw with cap and threaded connections.

87.5 SUBMISSIONS

87.5.1 Pipework

(a) The Contractor shall submit the following for review without objection by the
Project Manager:

(i) Contractor’s Drawings and manufacturer's data. Contractor’s Drawings

shall show plans, elevations and sections of piping layout, and shall
show locations of valves, strainers, pipe hangers, pipe guides, pipe
anchors, and equipment to which the piping connects;

(ii) pipes, pipe joints, pipe support, hangers, guides and anchor details;

(iii) pipe testing and cleaning procedures;

(iv) complete testing report after testing and commissioning;

(v) complete hydraulic calculation and pressure drop calculation for the
pipework;

(vi) complete pipe material schedule, listing make, brand, origin and model;
and

(vii) operation pressure range of the equipment offered.

General Materials & Workmanship Specification 13/15 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 87 – Pipework, Valves & Fittings
87.5.2 Valves and Fittings

(a) The Contractor shall submit the following for review without objection by the
Project Manager:

(i) complete manufacturer's literature for material and equipment;

(ii) certification of compliance with the requirements specified;

(iii) support details for valves; and

(iv) operating and maintenance manuals.

87.6 WORKMANSHIP

Accessible pipes shall be in sections of convenient length for dismantling.

Embedded pipework shall be in straight lengths as far as possible. Pipes with
screwed joints shall be installed with hexagon unions at suitable intervals for easy
removal.

87.6.1 Cleaning and Draining

(a) All piping shall be thoroughly cleaned of loose scale, dirt, etc, before
installation. After installation and sealing of joints all piping shall be thoroughly
cleaned out with clean water under pressure. On completion of the installation
the system shall be opened for inspection by the Project Manager. Water
used for this purpose shall be discharged as directed by the Project Manager.

87.6.2 Venting and Draining

(a) Air vents and drain cocks shall be provided at high points and low points
respectively in all piping systems. Bottle type air vents terminating in an air
release cock shall be used where suitable.

87.6.3 Fabrication, Storage and Installation

(a) Valves, vents, unions, piping accessories and the like shall be supplied and
installed to the requirements of this specification and accompanying
Employer's Drawings and where otherwise required for the proper layout,
valving and operating of the entire installation.

(b) Pipework shall be installed to prevent the generation or transmission of

vibration and noise, sagging, bowing, reverse pitching, liquid flashing, trapping,
deflection, hammer and strain on any connected equipment.

(c) Pipework shall be run generally parallel to the alignment of the adjacent
building surfaces and as close to the ceiling or other construction as practical,
at least 40 mm away from insulation and free of unnecessary traps and bends.
Piping shall be arranged to conform to the building requirements and to clear
all other works including that of all other Contractors.

(d) Pipework over passages for plant operators and services shall be 2,000 mm
minimum clear from the finished floor level wherever possible.

General Materials & Workmanship Specification 14/15 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 87 – Pipework, Valves & Fittings
 (e) Fixing generally shall be by metal expansion bolts for concrete and masonry.
Power fixings shall not be used. Applied loads shall not exceed 80% the
manufacturer's recommended maximum applied load.

(f) Pipework shall be installed at a slope either towards a drain point or a vented
high point.

(g) Factory fabricated large radius elbows and bends shall be used. Mitred
elbows and bends shall not be used.

(h) Cut pipe ends shall be reamed and filed to remove burrs.

87.6.4 Dismantling Facilities

(a) All pipe runs shall be arranged for ease of dismantling and re-erection.
Disconnecting flanges, mechanical pipe coupling or screwed unions, as
applicable, shall be supplied and installed at suitable locations and at valves
and equipment. Unions shall be of ground-in spherical seated type. Unions for
steel pipes shall be of forged steel heavy-duty pattern and unions for copper
pipes shall be of gunmetal. Unions shall have hexagon bodies.

General Materials & Workmanship Specification 15/15 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 87 – Pipework, Valves & Fittings
[this page not used]
SECTION 88 PUMPS AND TANKS

88.1 GENERAL

(a) This section covers the general requirements for pumps and tanks.

(b) Pumps and tanks shall generally comply with the following:

(i) Cap 95 – Fire Services Ordinance;

(ii) Codes of Practice for Minimum Fire Service Installations and Equipment
and Inspection, Testing and Maintenance of Installations and Equipment
(FSDCOP) published by HKSAR;

(iii) relevant circular letters and requirements of Fire Services Department

(FSD);

(iv) The Loss Prevention Council (LPC) Rules for Automatic Sprinkler
Installations and Technical Bulletins;

(v) relevant circular letters and requirements of Water Supplies Department

(WSD); and

(vi) relevant British Standards.

(c) Water supplies for fire service installations and equipment shall be of types
approved by the Water Supplies Department and the FSD.

88.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 559 Specification for design, construction and installation of

signs
BS 970 Specification for wrought steels for mechanical and
allied engineering purposes
BS 4999 General requirements for rotating electrical machines
BS 5512 Method of calculating dynamic load ratings and rating
life of rolling bearings
BS EN 1561 Founding. Grey cast irons
BS EN 1982 Copper and copper alloys. Ingots and castings
BS EN 50347 General purpose three-phase induction motors having
standard dimensions and outputs. Frame numbers 56
to 315 and flange numbers 65 to 740
BS EN 60034-9 Rotating electrical machines. Noise limits

General Materials & Workmanship Specification 1/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 88 – Pumps & Tanks
88.3 MATERIALS

88.3.1 Tanks

(a) All tanks shall be constructed in compliance with the FSDCOP, LPC Rules for
Sprinkler Installations, FSD Requirements and Circular Letters, and the
requirements of Water Supplies Department, the HKSAR.

(b) All pipe work connections to the concrete water tanks shall be cast into the
tank with puddle flanges unless otherwise shown on the Employer’s Drawings.

88.3.2 Pumps

(a) General

(i) pumps and pump installations for sprinkler systems shall comply with the
LPC Rules. Pumps and pump installations for hydrant/hosereel systems
shall comply with FSDCOP and LPC Rules wherever applicable.

(b) Pump Construction

(i) pumps shall be of centrifugal, horizontal end suction type or horizontal

split casing type having casings of close-grained cast iron to BS EN
1561;

(ii) pumps and motors shall be mounted and located with dowel pins on
common rolled steel channel sections or cast iron baseplates. Pressed
steel baseplates will not be accepted;

(iii) pump feet and main piping connections shall be integrally cast with the
lower section of the casing;

(iv) casing shall be fitted with 10 mm minimum plugged vents and 25 mm

minimum drain holes;

(v) upper and lower sections of the pump shall be located using dowels;

(vi) lifting facilities shall be provided on the upper section of the pump casing;

(vii) bearings shall be accessible for inspection and replacement without the
need to remove the upper section of the pump casing;

(viii) impellers shall be of leaded gunmetal to BS EN 1982 and shaft shall be

of stainless steel to BS 970 grade 316S16 statically and dynamically
balanced after assembly. Impeller rings shall be of cast iron renewable
and secured from relative movement by stainless steel end rotation ring;

(ix) pump seals shall be of the mechanical seal type;

(x) bearings shall be of the ball or roller type dowelled into position. Each
bearing shall be provided with a capped grease nipple;

(xi) at design conditions, bearings shall have a minimum L 10 life of 100,000

hours. Rolling bearings shall be selected in accordance with BS 5512;

General Materials & Workmanship Specification 2/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 88 – Pumps & Tanks
 (xii) bearings shall be located in suitable housings with efficient shaft seals to
prevent the entry of impurities and the escape of grease. Housings shall
be fitted with accessible grease nipples and relief plugs to enable
bearings to be lubricated without the removal of end caps and without
the risk of pressure build up. Pumps shall be delivered to Site with
bearings lubricated using a lithium based grease suitable for minimum
bearing temperatures of 150°C; and

(xiii) inboard and outboard bearings shall be interchangeable.

(c) Motors for Pump Drives

(i) electric motors for pump drives shall be of the drip proof or totally-
enclosed fan-cooled squirrel cage induction type to BS 4999 and BS EN
50347. Totally enclosed fan-cooled motors shall be dust and moisture
protected to IP 54;

(ii) drip proof motors shall be fitted internally with an anti-condensation

heater of single phase pattern arranged so that the heater will be
switched off automatically when the motor is started and switched on
automatically after stopping;

(iii) motor terminal bodes shall be of weather-proof type;

(iv) the power factor of the motors shall not be less than 0.85 lagging under
all normal operating conditions;

(v) noise level of all motors shall be in accordance with or better than the
recommendations of BS EN 60034-9;

(vi) Class B insulation (90°C temperature rise over 40°C ambient) shall be
provided for general purpose motors. Minimum insulation resistance
shall be 1.5 M ohm;

(vii) approved ball bearings, guards at all motor shaft couplings, emergency
stop button mounted adjacent to the motor, and lift lugs for motors
heavier than 25 kg in weight shall be provided;

(viii) motors shall be statically and dynamically balanced, and mounted on

common bed with driven machine;

(ix) tachometer reading shall be provided for direct driven machine;

(x) cast iron terminal box suitable for connection of heavy duty flexible
conduit or armoured cables shall be provided. Box shall be rated at fault
level of 10 MVA at 415V assuming suitable back-up protection provided;

(xi) power supply for motors below 0.75 kW and above 0.75 kW shall be
single phase and three phase respectively;

(xii) motors shall be sealed at cable joints and have conduit fittings arranged
to prevent the entrance of water;

General Materials & Workmanship Specification 3/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 88 – Pumps & Tanks
 (xiii) current-carrying parts of electric motors shall be at least 310 mm above
the floor; and

(xiv) motors shall be provided with name plates, indicating brand name, frame
size, rating, voltage, power consumption, speed and serial number.

(d) Jockey Pumps

(i) jockey pumps complete with TEFC driven motor for maintaining
hydraulic pressure shall be of the multi-stage horizontal or vertical
centrifugal type having construction generally in compliance with this
Section.

88.4 SUBMISSIONS

88.4.1 Tank

(a) The Contractor shall submit the following for review without objection by the
Project Manager:

(i) Contractor’s Drawings and manufacturer's data for tanks, including

details of openings, means of access to openings, inlets and outlets and
all other access needed to routinely maintain the tanks;

(ii) Contractor’s Drawings showing the arrangement of the water tanks,

including coordination with building elements and other services;

(iii) calculation to justify the capacities of the tank;

(iv) structural calculation for tanks, supporting structures and means of

access; and

(v) where a BD submission is required, all other documentation necessary

to complete the submission.

88.4.2 Pump

(a) The Contractor shall submit the following for review without objection by the
Project Manager:

(i) Contractor’s Drawings showing plant room details, plans, elevations,

section, dimensions and operation weights of equipment, electrical
wiring and control diagram, pipework connections and flange details,
mounting and fixing details;

(ii) Contractor’s Drawings for mounting and fixing details shall include
details and dimensions of pump bases, fixing bolts, flexible connections,
vibration isolators and any other builder's work requirements;

(iii) certified characteristic curve to show total kW loading against pressure

head at specified operating speed;

(iv) calculation to indicate the exact pump head required according to the
pressure drops equipment being offered for approval;

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 88 – Pumps & Tanks
 (v) calculation to justify the capacity of pressure vessels. Only effective gas
volume will be considered for the calculation;

(vi) complete manufacturer's printed catalogue and complete material

specification;

(vii) manufacture's operation and maintenance manual;

(viii) factory test certificate in accordance with the requirement of BS 559; and

(ix) spare parts list as recommended by manufacturer.

(b) Pump characteristic submitted shall be plotted over the entire range from shut
off to free discharge as static pressure in kPa, total efficiency and operating
kW against water flow in L/s at the specified speed.

88.5 WORKSMANSHIP

88.5.1 Pumps

(a) Pump Operation

(i) Equipment schedules on the Employer's Drawings include initial

selection data relating to size, capacity, performance and the number of
pumps required for each system.

(ii) The scheduled performance details are based on the initial equipment
and material selections, piping layout and structural details. Pumps shall
be selected for duties compatible with the installed equipment, materials
used and the final piping layout.

(iii) Pumps for fire service installations shall be selected to suit the design
requirements for capacity (flow rate) as indicated on the Employer's
Drawings and shall discharge at a pressure which will produce running
pressures within the statutory requirements at the location concerned.
The figures given on the Employer's Drawings are for guidance only.

(iv) The Contractor shall carry out final accurate calculations of operating
heads based upon the characteristics of the pipework systems including
fittings, equipment and accessories as actually installed by him, and
select pumps to suit. Certified performance curves for the pumps with
the operating range clearly indicated, shall be submitted to the Project
Manager for review without objection.

(v) Pump drive motor output power shall be selected so as to exceed by

20% the full load input power requirements of the pump. Pump speed
shall not exceed 3,000 r/min.

(vi) Pumps shall be capable of running under conditions of zero or low

"draw-off" continuously without overheating. This may be achieved
either by pump design or by an automatic by-pass circuit arrangement.
Details of this shall be shown on the Contractor's Drawings. Overheat
alarm devices shall be provided if necessary but these shall not be
arranged to shut down the pump automatically.

General Materials & Workmanship Specification 5/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 88 – Pumps & Tanks
 (b) Maintenance

(i) Pump installations shall be complete with adequate facilities for

maintenance and future replacement of plant. Lifting eyes shall be
provided upon pumps and motors.

(c) Pump Installation

(i) The pump and motor shall be direct coupled and mounted on a
substantial machined base plate of cast iron or of fabricated mild steel.
Couplings shall be flexible of steel pin and synthetic rubber bushing type,
accurately aligned, and fitted with guards.

(ii) Pumps shall be complete with all necessary water seal connections,
vents, drains and priming plugs, and all installation materials including
foundation bolts and anti-vibration mountings. Drain pipework shall be in
copper and shall be run to a nearby drain gully or as directed on site.
Automatic priming equipment shall be included where necessary to
ensure that the pumps are primed at all times.

(iii) Pump alignment shall be factory checked. Alignment shall be verified,

and corrected as required on Site after the pumps have been placed in
position with pipework connections made, pipework filled with water and
tested at pressure.

(iv) The pipework assembly connected to pumps shall be separately

supported and anchored so that no load is imposed on the pump
assembly. Base elbows shall be fitted at each pump as required.

(v) Each pump shall be provided with suction and discharge isolating valves
and where connected in parallel with other pumps, non-return check
valves. Each pump shall be provided with two gauges, one connected to
the suction side, the other to the discharge.

(vi) Pipework vibration isolators shall be provided on the suction and

discharge side of each pump.

General Materials & Workmanship Specification 6/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 88 – Pumps & Tanks
SECTION 89 ELECTRICAL EQUIPMENT AND INSTALLATION

89.1 GENERAL

(a) This section covers the specific requirements for electrical equipment and
installation for fire services system. The general requirements for the same
shall be referred to Sections 45 to 50.

(b) The Works and materials described herein shall comply with Sections 46, 48,
49, 53, 57, and 59 of the General Materials and Workmanship Specification for
general requirements and details regarding the electrical installation including
the following:

(i) the Works and materials described herein shall comply with other
relevant sections of this General Materials and Workmanship
Specification including the sections which specify:

- Section 53 “Motors”; and

- Section 90 “Inspection, Testing and Commissioning – Fire Services”.

89.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 6207 : Part 1 Mineral insulated cables with a rated voltage not

exceeding 750 V. Cables
BS 6387 Specification for performance requirements for cables
required to maintain circuit integrity under fire
conditions
BS 6724 Specification for 600/1000 V and 1900/3300 V
armoured electric cables having thermosetting
insulation and low emission of smoke and corrosive
gases when affected by fire
BS 7211 Specification for thermosetting insulated cables (non-
armoured) for electric power and lighting with low
emission of smoke and corrosive gases when affected
by fire
BS EN 60529 Specification for degrees of protection provided by
enclosures (IP code)
IEC 60331 Tests for electric cables under fire conditions - Circuit
integrity
IEC 60702 Mineral insulated cables and their terminations with a
rated voltage not exceeding 750 V

General Materials & Workmanship Specification 1/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 89 – Electrical Equipment & Installation
 IEC 60754-1 Test on gases evolved during combustion of materials
from cables - Part 1: Determination of the amount of
halogen acid gas
IEC 60754-2 Test on gases evolved during combustion of electric
cables - Part 2: Determination of degree of acidity of
gases evolved during the combustion of materials
taken from electric cables by measuring pH and
conductivity
IEC 61034 Measurement of smoke density of cables burning
under defined conditions

89.3 MATERIALS

89.3.1 Pump Control Panels and Associated Enclosures

(a) General

(i) A pump control panel shall be provided for each set of pumps.

(ii) Control panels shall be constructed of pressed steel of 2mm thick and
have lockable front covers. The panel front shall have an indicator light
to show that power is available to the panel, run and trip indicators for all
rotating machinery.

(iii) Inside each control panel shall be mounted individual isolators, individual
starters with overload relays, line fuses, water level electrodes, pressure
switches, alternate operation relay and auxiliary relays for pump
operation. Fitted into the panel door shall be ammeter and voltmeter with
power phase selector switch(es), lead-lag selector for assigning duty
pump(s) and standby pump(s), two sets of ON and OFF buttons for
individual manual operation, indicating lights for water tank levels, pump
power on, pump running and pump failure indication.

(iv) An overall interior plate shall be provided with cut-outs to suit the fuse
carriers, operating face of contactors and switch dollies to present a neat
appearance within the enclosure and to ensure that all wiring, live
terminals etc., are contained behind the panel.

(v) The panel shall be fixed by knurled screws for easy removal. If the
panel is of metal construction adequate bonding with the main enclosure
body shall be provided; in addition it shall not be possible to make
contact with the panel to any live parts while removing the panel.

(vi) The degree of protection for PCP’s, control panels and similar
enclosures shall be to IP 54 as specified in BS EN 60529.

(b) Indicating Lights

(i) All indicating lights shall be duplicated or fitted with dual filaments.

(ii) Indicating lights shall be domed glass type with LED’s behind.

General Materials & Workmanship Specification 2/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 89 – Electrical Equipment & Installation
 (iii) Indicating lights shall have black bezels.

(iv) The bodies of indicating lights shall be ventilated to ensure efficient heat
dissipation. Connection to lights shall be screw or clamp terminals;
soldered terminations shall not be used.

(v) Color codes for pumps shall be:

- power on : white (for 1-phase) or
red, white and blue (for 3-phases);

- pump running : green; and

- pump failure : red.

(vi) Color codes for water tank levels shall be:

- normal : green;

- low level : amber; and

- empty : red.

89.3.2 Electrical Circuit Protection

(a) The electricity supply shall be fitted with high rupturing capacity fuses in
accordance with LPC Rules, Clause 17.4.12.4.

(b) Electrical circuit protection devices, including but not limited to, circuit
breakers, isolators, switches, fused switches etc, shall comply with Section 46
of the General Materials and Workmanship Specification.

89.3.3 Cabling and Wiring

(a) General

(i) Conduits, cable trays, ladders and ducts shall be run horizontally,
vertically or parallel to building members.

(ii) The minimum conductor size shall be 2.5 mm2 for phase, neutral
conductors and earth conductors. Control circuit cabling conductor size
shall be 1.5 mm2 minimum subject to voltage drop limitations.

(b) Type of Cable

(i) Type of cables shall be as follows:

Type A : Fire resistance cable complying with IEC 60331 / BS

6387 Category CWZ

Type B : Fire resistance cable same as Type A and can operate

continuously for at least one (1) hour at 250°C
temperature

Type C : Fire resistance cable same as Type A approved by FSD

and having low smoke zero halogen emission
General Materials & Workmanship Specification 3/8 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 89 – Electrical Equipment & Installation
 equivalent to BS 7211 or BS 6724 and tested to comply
with IEC 61034 for minimum value of light
transmittance; IEC 60754-1 for 0.5% maximum acid gas
emission and IEC 60754-2 for 4.3 minimum pH level of
gas evolved
Type D : Fire resistance cable same as type C and can withstand
815°C temperature for at least thirty (30) minutes

Type E : Mineral insulated copper sheathed cable complying with

BS 6207 : Part 1 / IEC 60702

(c) Use of Fire Resistant Cables

(i) Unless otherwise specified, the minimum grade of cable being used in
different parts of the fire service installation shall follow the table below:

Type of FS Use of cables / wirings in Type of cable

Installation different parts of the installation / wiring
Audio/visual The power supply / signaling C
advisory system cables to speakers and flashing
directional signs from control panel
/ console and AV equipment
Automatic fixed The power supply cable from main A
installations / sub-main switchboards to electric
using water motor of pumps including transfer
and intermediate pumps
Automatic fixed The power supply cable from main A
installations other control panels to fire extinguishing
than water agent actuating devices
Emergency All outgoing power supply cables A
generator / main from emergency generators and
backup power other main backup power sources
source to main switchboards and to main
essential power supply boards
General The power supply cable from main C or E
emergency switchboards, sub-main boards,
lighting central battery supply or other
power sources to emergency
lighting fittings except for self-
contained emergency lighting
fittings
Exit sign and Same as general emergency C or E
Directional sign lighting

Fire alarm The power supply / signaling C

system cables to alarm bells and visual
alarm signal units from fire alarm
control and indication panels

Fire detection The power supply/ signaling C

cables to audio/visual
General Materials & Workmanship Specification 4/8 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 89 – Electrical Equipment & Installation
 Type of FS Use of cables / wirings in Type of cable
Installation different parts of the installation / wiring
system alarm/detection devices from fire
alarm control and indication panels
(Remarks : twisted pair, shield
cable shall be used for
addressable system)
Fire hydrant / The power supply cable from main A
hose reel system / sub-main switchboards to electric
motor of fixed fire pumps and
intermediate booster pump
Fireman’s lift The power supply cable from main A
/ sub-main switchboards to traction
motors / car lighting / power circuit
of lift
Fixed foam The power supply cable form main A
system / sub-main switchboards to electric
motor of pumps
Pressurization of The power supply cable from main A
staircases / sub-main switchboards to electric
system motor of fans
Ring main The power supply cable form main A
system with fixed / sub-main switchboards to electric
pumps motor of pumps
Sprinkler system The power supply cable form main A
/ sub-main switchboards to electric
motor of pumps
Pre-action Heat detector circuit cables from D
recycling and to the control panel
sprinkler system

Smoke extraction The power supply cable from main B

system / sub-main switchboards to electric
motor of fans
Water spray The power supply cable form main A
system / sub-main switchboards to electric
motor of pumps
Street fire The power supply cable form main A
hydrant system / sub-main switchboards to electric
motor of pumps
Places of public Cables / wirings within the C or E
entertainment compartment
Power circuits Cables from main switchboards to A
not covered in control panels / consoles of
(unless
this table and various fire service installation
otherwise
installed by the
specified)
contractor
(ii) Except for hazardous areas, the following methods are acceptable
alternatives to the above table:
General Materials & Workmanship Specification 5/8 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 89 – Electrical Equipment & Installation
 - cables running in trunking or on cable trays inside fire resistant plant
rooms / enclosures of approved fire rating where termination of
cables at both ends are located;

- cables running inside concealed steel conduits embedded in concrete;

- cables running inside underground cable ducts and reinforced

concrete cable trenches of approved fire rating;

- cables embedded inside soil or concrete; and

- cables running within dedicated fire resistant cable ducts not mixing
with other services’ cable where the fire resisting period of the cable
ducts is not less than that of the corresponding building compartment;

(iii) The cables described in (ii) above shall comply with the following:

- where cables run within cable ducts / conduits, they shall not be
mixed with other services’ cable;

- for cables connecting centrally supplied emergency luminaries, the

cables shall be at least Category B cable to BS 6387 or IEC 60331;

- for cables for fireman’s lifts, for emergency generator and for smoke
extraction fan, the cables shall be at least Category CWZ to BS 6387
or IEC 60331;

- for cables to pre-action recycling sprinkler system, the cables shall

withstand 815°C for at least thirty (30) minutes;

- for control cables to the smoke extraction system and pressurization

of staircases system, the control cables shall be at least Category
AWX to BS 6387 or IEC 60331 and shall be suitable for continuous
operation at 250°C for at least one (1) hour;

- for cables supplying essential power to all pumps in fire service

installation including sprinkler pumps, fixed fire pumps, drencher
pumps, street hydrant pumps, jockey pumps, intermediate booster
pumps, foam pumps, ring main fixed pumps, transfer pumps, etc.,
shall be at least Category AWX to BS 6387 or IEC 60331; and

(iv) For cables other than the cases in ii), the cables shall be PVC insulated
cables complying with relevant section of this General Materials and
Workmanship Specification in concealed steel conduits or PVC insulated
and sheathed steel wire, with or without armour as required, complying
with relevant section of this General Materials and Workmanship
Specification in approved fire rated plant room, in approved fire rated
cable ducts, in underground cable ducts, or embedded inside soil, or
products having equivalent performance and function.

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Section 89 – Electrical Equipment & Installation
 (v) Cables and wires shall be installed using the loop-in loop-out system.
Cables shall be terminated only in terminals of equipment or accessories.

(vi) Cable and wire ends shall be prepared for termination without damaging
strands. Lugs or clips shall be fitted to prevent strands from spreading
when terminals are tightened.

(d) Cable Installations

(i) All cable installations shall comply with Section 48 of the General
Materials and Workmanship Specification.

(e) The colour coding of all cables shall comply with the New Cable Colour Code
for Fixed Electrical Installations, published by the EMSD.

89.3.4 Conduits and Fittings

(a) Conduits shall be completely separated from those for all other services.
Separate compartments shall be used for any wiring using duct systems.

(b) Conduits shall be sized to easily enable the insertion or removal of any one
cable with all other cables in place.

(c) Conduits shall be terminated at equipment or accessories by screwing and

locking in an approved manner. All conduits shall be cut square. All burrs and
rough edges shall be removed so that conduits are clean inside. All threaded
joints of steel conduits shall be treated with aluminum paint or other rust
preventative to ensure good electrical continuity.

(d) Conduits shall be packed out from walls and ceilings with spacers under
saddles and secured with a screw fixing.

(e) Conduits shall be installed complete with draw-wires.

89.3.5 Low Voltage Electric Motors

(a) Maximum motor speed shall be 3,000 r/min.

89.4 WORKMANSHIP

89.4.1 Cabling and Wiring

(a) The uniformity of phase colour shall be preserved throughout the installation.

(b) Cables and wires shall be installed using the loop-in loop-out system. Cables
shall be terminated only in terminals of equipment or accessories.

(c) Cable and wire ends shall be prepared for termination without damaging
strands. Lugs or clips shall be fitted to prevent strands from spreading when
terminals are tightened.

(d) Where ratings or sizes are not detailed, cables shall be rated to match circuit
breaker or fuse ratings. Stranded conductors shall be used throughout.

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 (e) Cabling in areas accessible or visible to the public including concourses,
check-in Hall, baggage reclaim, meters and greeters, gate lounges, catering
areas and similar shall be run in concealed spaces.

(f) Cabling and wiring shall comply with Section 48 of the General Materials and
Workmanship Specification.

89.4.2 Conduits and Fittings

(a) Conduits and fittings shall comply with Section 49 of the General Materials
and Workmanship Specification.

89.4.3 Cable Trays, Cable Trunking and Fittings

(a) All cable containments, including but not limited to conduits, cable trays, cable
trunkings and fittings installations shall comply with Section 49 of the General
Materials and Workmanship Specification.

89.5 SUBMISSIONS

The Contractor shall submit the following documents to the Project Manager for
review without objection:

(a) Details of pump control panels shall be submitted to the Project Manager for
review without objection. The Contractors Drawings of the pump control
panels shall include, but not be limited to, all necessary wiring, all indication
signals, visual/audio alarms, control, functions and component arrangements.
Labelling shall be in English and Chinese.

(b) Details of the pump control panels shall be submitted to the FSD for
endorsement.

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SECTION 90 INSPECTION, TESTING AND COMMISSIONING – FIRE SERVICES

90.1 GENERAL

(a) The Plant shall be inspected, tested and commissioned to confirm that Plant
performance complies with the requirements of the Contract.

(b) All such inspection, testing and commissioning shall, in particular but without
limitation, be planned, carried out and documented in accordance with:

(i) General Conditions of Contract;

(ii) volumes 1-4 of the General Materials and Workmanship Specifications,

General Specification, Particular Specification, Particular Technical
Specification and other contract documents (if any); and

(iii) the construction quality plans and inspection and test plans prepared by
the Contractor in accordance with the relevant ISO standard and
reviewed without objection by the Project Manager.

90.2 TERMINOLOGY

(a) The following terms shall be used in all programmes, quality plans, reports
and other documents produced:

(i) Manufacturing Phase - the period during which the manufacture,

fabrication and assembly of the Plant, or a discrete element of the Plant,
is carried out off-Site;

(ii) Installation Phase - the period during which the fabrication, assembly
and installation of the Plant, or a discrete element of the Plant, is carried
out on-Site;

(iii) Pre-Commissioning Phase - the period when, in relation to the Plant or a

discrete element of the Plant, component tests and commissioning are
carried out in preparation for the plant commissioning phase;

(iv) Plant Commissioning Phase - the period when commissioning and

reliability tests are carried out to ensure that the Plant fully complies with
the design and operational requirements of the Contract;

(v) Plant Integration Phase - the period prior to issue of the Completion
Certificate when Plant integration tests and commissioning are
conducted to integrate the Plant with all work completed or being
undertaken by the Other Contractor, if any, in full compliance with the
design and operational requirements of the Contract;

(vi) Confidence Trial Phase - the period after issue of the Completion
Certificate when the Confidence Trials are carried out;

(vii) Phase - one or other of the phases identified in (i) - (iv) above;

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 (viii) Type Tests - tests undertaken on similar equipment or components in
lieu of individual unit tests;

(ix) Factory Tests - tests carried out on items of Plant at the manufacturer's
works or elsewhere before they are dispatched to Site;

(x) Site Tests - tests on static items of Plant and systems (e.g. inspection
and testing of welds and hydraulic testing of pipework) to ensure correct
and safe installation before setting to work;

(xi) Component Tests - tests on components to be incorporated in the Plant;

(xii) Commissioning - the advancement of the Plant or an element of the

Plant from the stage of static completion to full working conditions and to
meet the specified design requirements. This shall include setting to
work and regulation;

(xiii) Setting to Work - the process of setting a static system into motion;

(xiv) Plant Integration Tests - the measuring, recording and proving of correct
integration between the Plant and all other systems as detailed in the
Specification.

(xv) Regulation - the process of adjusting a system (eg the rates of fluid flow
and heat transfer in a distribution system) within specified tolerances;

(xvi) Reliability Tests - tests carried out over ser trial periods and under
simulated operating conditions to prove reliability;

(xvii) Deferred Seasonal Tests - tests conducted at certain times of the year to
suit seasonal climatic conditions;

(xviii) Confidence Trials - tests undertaken after the issue of the Certificate of
Completion when the Plant is operational and being operated by the
Employer under the supervision of the Contractor

(xix) Inspection, Testing and Commissioning Programme - the sub-network of

the Works Programme prepared by the Contractor and reviewed without
objection by the Project Manager, detailing the programme for the
inspection, testing and programme for the inspection, testing and
commissioning of the Plant;

(xx) Phase Notice - a notice prepared by the Contractor in accordance with

the requirements of the Specification;

(xxi) Phase Report - a report prepared in accordance with the requirements of

the Specification; and

(xxii) Test Results Form - a form prepared in accordance with the

requirements of the Specification.

(b) The term "Tests on Completion" as defined and used in the General
Conditions of Contract refers to the Plant Integration Tests and such further
tests, if any, identified as such in the Specification.

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 (c) The term “Performance Tests” as defined and used in the General Conditions
of Contract refers to the Confidence Trials and such further tests, if any,
identified as such in the Specification.

90.3 TESTING AND COMMISSIONING PHASES

(a) In order to facilitate the orderly management of the testing and commissioning
of Plant and the Project Manager’s monitoring of progress of the Project as a
whole, the Contractor shall structure his construction quality plans (see section
14 of the General Specification), inspection and test plans (see section 15 of
the General Specification), the General Materials and Workmanship
Specification, and the Inspection, Testing and Commissioning Programme
(see section 10 of the General Specification) into the following Phases with
the tests to be carried out during each Phase identified under the following
categories:

(i) Manufacturing Phase:

- Factory Tests; and

- Type Tests.

(ii) Installation Phase:

- Site Tests.

(iii) Pre-Commissioning Phase:

- Component Tests; and

- Commissioning of elements of the Plant.

- Setting to work

(iv) Plant Commissioning Phase:

- integration of elements of the Plant;

- Commissioning; and

- Reliability Tests.

(v) Plant Integration Phase:

- Plant Integration Tests; and

(vi) Confidence Trails Phase.

(b) Any Deferred Seasonal Tests shall also be clearly identified in all plans and
programmes.

(c) For the duration of the Defects Liability Period, operational and safety controls
shall be sealed if adjustment beyond defined limits could result in malfunction
and give rise to a defect.
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 (d) The Contractor shall provide attendance and technical support during testing
and commissioning of any work with which the Contractor has an interface
during the confidence trails period in accordance with this General Materials
and Workmanship Specification.

90.4 QUALITY PLANS

(a) The Contractor shall identify in his construction quality plans any division of
the Plant into discrete elements to facilitate the preparation and service of
Phase Notices as called for in this General Materials and Workmanship
Specification.

(b) Refer to General Specification Section 14.

(c) The Project Manager, in reviewing any inspection and test plan, may require
further and better inspection, testing and Commissioning documentation as
may be considered reasonably necessary to record these processes.

90.5 PHASE NOTICES

(a) For each element of the Plant identified in the Contractor's construction quality
plans or, as the case may be, for the Plant as a whole:

(i) the Contractor shall prepare and submit to the Project Manager for
review without objection a Phase Notice at the end of the Manufacturing
Phase, the Installation Phase and the Pre-commissioning Phase;

(ii) each Phase Notice shall contain a statement by the Contractor

confirming that all inspections and tests required during the relevant
Phase have been performed satisfactorily or identifying any non-
conformities or tests that have been failed and confirming that all reports
of such inspections and tests have been filed in his records office (in
accordance with Section 15 of the General Specification);

(iii) the Phase Notice relating to a Manufacturing Phase shall confirming that
the Contractor is satisfied that the relevant equipment or system or part
of a system is ready for release from the manufacturer's works;

(iv) the Phase Notice relating to an installation Phase shall confirm that the
Contractor is satisfied that the equipment or system or part of a system
is ready for starting the pre-commissioning tests; and

(v) the Phase Notice relating to a Pre-Commissioning Phase shall confirm

that the Contractor is satisfied that the system or part of a system is
ready for Commissioning and Reliability Tests.

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90.6 TEST RESULTS FORMS

(a) In addition to the requirement in Section 15 of General Specification, each

report of an inspection or test shall indicate the following:

(i) the system or item being tested;

(ii) the identification reference for an item being performance tested;

(iii) the test acceptance criteria;

(iv) the tolerances;

(v) the test units of measurement;

(vi) the actual test results;

(vii) pass/fail;

(viii) whether a concession shall be requested under Section 14 of the

General Specification;

(ix) any concessions or variations made pursuant to Section 14 of the

General Specification; and

(x) whether a design review is requested.

(b) Test acceptance criteria shall be prepared by the Contractor in accordance

with the General Materials and Workmanship Specification and included as
part of each Test Results Form. Acceptance criteria may not be changed by
the Contractor except with the consent of the Project Manager in writing.

(c) The Contractor shall prepare and submit his proposed Test Results Forms as
part of his submission of the relevant Inspection, Testing and Commissioning
Plan.

90.7 PHASE REPORTS

(a) Without prejudice to the Contractor's obligations to produce summaries of test

data and other information in the General Conditions and the General
Specification, the Contractor shall upon completion of each Phase complete
and submit to the Project Manager for his information a phase report (the
“Phase Report”) setting out and detailing the test results including
performance figures obtained, graphs, charts, tabulated computer output, and
supporting narratives describing any special events, occurrences and other
discrepancies or deviations not expected in the original plan or programme.

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 (b) In particular, the Phase Report shall include a chronological diary of findings
and incidents including:

(i) workmanship;

(ii) Plant operating peculiarities and observations;

(iii) any measurement and checks which may be required by operating and
maintenance personnel; and

(iv) results of any statutory testing and inspection, e.g. earth grid
measurements.

(c) All hazardous conditions shall be corrected by the Contractor prior to or during
Commissioning. Comments shall be included on any observed deficiencies in
Plant design and performance.

(d) Any modifications to circuitry, instrumentation, etc. carried out a any time shall
be recorded in detail in the Phase Reports and shown on the Contractor’s
Drawings.

(e) Any conclusions that would be helpful to the Employer's operating and
maintenance staff shall be summarised at the end of the Phase Reports.

(f) The Phase Reports shall be prepared and submitted in the Employer’s
standard format as soon as practicable after the completion of each Phase.

90.8 STANDARDS AND REGULATIONS

(a) All testing and commissioning carried out by the Contractor shall be
undertaken using the International System of Units (S.I.) and shall comply, as
appropriate, with the latest and most up to date edition at the date of the Letter
of Acceptance, of the following standards, regulations and guides:

(i) the relevant "British Standard Codes of Practice" or "British Standard

Specifications" where applicable to the Works published by the British
Standards Institution;

(ii) the IEE Wiring Regulations issued by the Institution of Electrical

Engineers (U.K.);

(iii) "Code of Practice for Electricity (Wiring) Regulations" published by the

HKSAR;

(iv) "Codes of Practice for minimum fire service installations and equipment
and inspection, testing and maintenance of installations and equipment"
published by the HKSAR;

(v) the relevant circular letters issued by the Fire Services Department
(FSD);

(vi) "Rules for automatic sprinkler installations" published by the Loss

Prevention Council;

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 (vii) the relevant codes and guides published by the American Society of
Heating, Refrigerating and Air Conditioning Engineers (ASHRAE-USA);

(viii) the relevant codes and guides published by the National Environmental
Balancing Bureau (NEBB-USA); and

(ix) the relevant codes and guides published by the Building Services
Research and Information Association (BSRIA-UK).

x) the relevant circular letters and requirements of Water Supplies

Department.

90.9 CONTRACTOR’S TESTING AND COMMISSIONING STAFF

(a) All testing and Commissioning shall be undertaken by the Contractor's

appropriate testing and Commissioning specialist or by a competent
independent Commissioning specialist nominated by and acting for the
Contractor and reviewed without objection by the Project Manager.

(b) The Contractor shall provide all necessary skilled labour and assistance for
testing, operating, adjusting, Commissioning and verifying the performance of
all Plant.

(c) The Contractor's testing and Commissioning staff shall have had previous
experience with testing and Commissioning similar Plant of comparable duty.

(d) The Contractor's relevant specialist testing and Commissioning staff including
supervisors shall be available on Site at all times during testing and
Commissioning of the Plant.

90.10 TESTING AND COMMISSIONING EQUIPMENT AND INSTRUMENTS

(a) The Contractor shall provide all portable and supplementary instrumentation,
recording facilities, consumables and the like required for all Factory Tests
and testing and Commissioning on Site.

(b) Testing and Commissioning instrumentation shall be designed for field use
and to minimize field measurement errors through the use of electronic
sensors, digital displays and similar devices.

(c) The calibration of instruments shall be demonstrated immediately prior to, and
after completion of testing and Commissioning, and current calibration
certification submitted to the Project Manager for record purposes.

(d) At least one complete set of testing and Commissioning instrumentation,

including all accessories, fittings, attachments and purpose built carrying
cases, shall be made readily available in a calibrated and operation condition
for retesting by the Contractor for the duration of the Defects Liability Period.

(e) The end to end accuracy of instrumentation shall be verified in accordance

with the recommendations of ASHRAE 114.

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90.11 NOTIFICATIONS

(a) The Contractor shall, in accordance with section 15 of the General

Specification, give the Project Manager notice in writing, when tests or trials
shall be ready to commence provided that, notwithstanding section 15 of the
General Specification, not less than 48 hours' notice of all tests and trials
carried out on Site shall be given.

90.12 INSPECTIONS AND TESTING

(a) Prior to any inspection and testing by the Project Manager, the Contractor
shall inspect and test the Plant to ensure that equipment and facilities are
clean and complete and can reasonably be expected to meet successfully all
inspection and/or testing criteria.

(b) Prior to setting to Work, testing and Commissioning, the Contractor shall clean
all Plant and shall confirm in writing to the Project Manager that all the work is
complete and satisfactory for the purpose of testing and Commissioning.

(c) In the event that the Contractor considers that any testing is not appropriate or
required, the Contractor may submit alternative proposals to the Project
Manager for review without objection.

90.13 TYPE TEST CERTIFICATES

(a) Type test certificates shall be submitted for:

(i) pump control panel; and

(ii) electrical motors.

90.14 FACTORY TESTS

90.14.1 General

(a) Wherever practical, Factory Tests shall cover subsystems rather than just
individual components.

90.14.2 Pumps

(a) Factory Tests for pumps shall be in accordance with BS EN ISO 5198.

90.14.3 Control/Indicating Panels

(a) Factory acceptance tests on all components and sub-assemblies. Component

functional tests shall include fully assembled plug-in printed circuit boards and
plug-in assemblies (e.g. power supplies).

(b) Factory Tests shall include functional tests on all completed sub-assemblies
(e.g. fire services main panels and sub-panels).

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 (c) Software and hardware tests to prove the interfacing of the Works through
computer simulation of other systems.

(d) Any software that is required to be specifically designed, coded and

configured for the Works shall be fully tested in accordance with the software
development standards as reviewed without objection by the Project Manager.

90.15 MODEL TESTS

(a) Prior to the Installation Phase the Contractor shall assemble a working model
of the system to test the interworking of the complete system. This model
shall include the following:

(i) all necessary software required to test the complete system in the
simulated Chek Lap Kok operational environment; and

(ii) hardware shall be fitted and tested in completed equipment cabinets.

This shall include at least the fire services main panel and sub-panel’s
addressable loops and one type of each field device. The Contractor
shall ensure the hardware grouping is selected appropriately to
demonstrate the complete system is ready for Site installation after
completion of the model tests.

90.16 SITE TESTING AND COMMISSIONING

90.16.1 Water System Tests

(a) The following systems shall be fully Site Tested and Commissioned:

(i) sprinkler systems;

(ii) hydrant and hosereel systems; and

(iii) street hydrant system.

(b) All testing shall be carried out in accordance with the requirements of the
FSDCOP, LPC Rules for Automatic Sprinkler Installation and any relevant
Circular letters issued by the FSD.

(c) All water based systems shall be tested hydraulically to a minimum pressure
of 1,000 kPa or 1.5 times the working pressure whichever is the greater. The
test pressure shall be applied at the highest point of the system and held for a
period of not less than 6 hours without pressure drop. There shall be no visible
signs of leakage.

(d) After flushing out the pipework, a flow test shall be performed on the
hydrant/hosereel system in accordance with the FSDCOP.

(e) A water supply test with the drain and test valves fully opened shall be made
on the sprinkler system in accordance with the LPC Rules. An alarm test on
the water gong shall also be carried out by opening the test valve to ensure
that the alarm shall continuously sound for 30 seconds after the flow in the
system is detected.
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 (f) Current readings for the pumps shall be determined in the field at starters,
junction boxes or similar.

(g) The Contractor shall provide whatever hoses or drainage channels are
required to safely remove the test water discharged while carrying out these
tests in order to ensure that no damage to the building and property shall be
caused by the test water.

(h) For street hydrant system without pumps, the Contractor shall test the
incoming water supply pressure at a nearby supply point and at such time as
agreed with the Project Manager before the completion of the installation to
establish the adequacy of the water supply pressure. If the supply pressure is
inadequate, the Contractor shall propose remedial measures to the Project
Manager for review without objection. The Contractor shall find and select the
most appropriate nearby supply point for the test.

(i) Tests for fire pumps shall include, but not be limited to, the following:

(i) Insulation test and earth continuity test

(ii) Control / operational tests of the pumps.

(iii) The pump performance shall be tested at its duty point with the
pumped flowrate measured by water displacement in the tank.

(iv) The pump differential and delivery pressure shall be recorded and
together with the flowrate, matched against the pump curve,

(v) The pump motor current and supply voltage shall be measured at start
up and during operation.

(vi) The pump shall be run under closed delivery valve condition to
demonstrate the pump is capable of operating without any damage.

(vii) Start/stop control test of the fire pumps at various specified control
points.

(viii) Change-over test on duty and standby fire pumps.

(ix) Pump alignment test.

(j) Other tests to be carried out shall include, but not be limited to, the following:

(i) Hopper winding and kinking test for hose reels

(ii) Flow rate and flow pressure test through FS inlets and sprinkler inlets

(iii) Operations of all water tank level switches

(iv) Flow switch sensitivity test.

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90.16.2 Fire Alarm System Tests

(a) In addition to factory testing and commissioning requirements specified in this

General Materials and Workmanship Specification, the complete fire alarm
system shall be Site Tested and Commissioned including all field devices,
instrumentation and control algorithms.

(b) The Contractor shall confirm by field observation that all programme functions
and routines operate correctly and that all field devices respond accordingly.

(c) All fire alarm inputs and outputs shall be tested and witnessed by field
observation of device operation and field confirmation of readings recorded by
the fire alarm system:

(i) smoke detectors;

(ii) heat detectors;

(iii) break glass alarms;

(iv) flow switches;

(v) pressure switches;

(vi) isolating valve monitoring switches;

(vii) solenoid valve operation;

(viii) monitoring switches for hosereel doors, tunnel crossover doors,

extinguishers;

(ix) Beam Detectors;

(x) Fire services main panel and sub-panel, and all other mimic and control
panel operation interface with all other systems including:

System Interface Action

- Mechanical services system : Automatic and manual control
of smoke control and
ventilation fans
- Public address system : Automatic control of pre-
recorded evacuation
announcements
- Access control system : Automatic release of secured
fire escape doors
- Exit signs / directional signs : Automatic activation of
flashing mode
- Fire shutter : Automatic activation of fire
shutters
- Smoke curtains : Automatic activation of smoke
curtains
- Building management system : Monitoring of major fire alarms
- Lift homing : Automatic lift homing
- FS Repeater panels at IAC : Control and Monitoring of the
entire AFA system
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 System Interface Action
- Automatic Transfer Switch : Monitoring of status of ATS for
(ATS) in TX room dual feed power supply
- Motorised fire and smoke : Automatic activation of
dampers motorised fire and smoke
dampers
- Generator : Automatic activation of
emergency generator upon
receive of common fire alarm.

(xi) batteries and chargers;

(xii) direct links to Fire Service Communication Centre; and

(xiii) any other alarm and indicating devices.

(d) Electrical wiring systems shall be tested generally as required by this General
Materials and Workmanship Specification. Low-voltage wiring shall be
insulation tested to a DC voltage of twice the normal working voltage of the
system. Any tests that are liable to cause damage to the delicate components
such as those incorporating electronic circuits shall be carried out with the
components disconnected.

(e) Smoke detectors shall be checked for correct sensitivity settings by means of
manufacturer's test set and for operation by simulated smoke tests using freon.

(f) Rate-of-rise heat detectors shall be tested by gentle application of a heat

source such as hair dryer. Fixed temperature heat detectors must not be
tested other than using simulated tests.

(g) Battery capacity shall be tested by discharging through the alarm circuits and
being charged via the incorporated charger unit. The specific gravity of the
electrolyte shall be tested with a clean hydrometer.

(h) The input DC supply to the alarm supervisory circuitry shall be checked for
correct voltage and stability such as to match the signal and alarm triggering
devices.

90.16.3 Emergency Lighting and Exit Sign Tests

(a) Each self-contained luminaire and internally illuminated exit sign shall be
energized from its battery by simulation of a failure of the normal supply to the
lighting for a period of the rated duration of the battery. During this period all
luminaires and/or signs shall be examined and tested in accordance with BS
5266 to ensure that they are functioning correctly.

(b) Each central battery system shall be energized from its battery by simulation
of a failure of the supply to the normal lighting for a period of the rated duration
of the battery. During this period all luminaires and/or signs shall be examined
and tested in accordance with BS 5266 to ensure that they are functioning
correctly. All tests required in the FSDCOP shall be carried out and recorded.

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 (c) For those emergency lighting system with battery and backed up by
emergency generators, each emergency generator shall be started up and
allowed to energize the emergency lighting system for a continuous period of
at least one (1) hour. During this period all luminaires and/or signs shall be
examined visually to ensure that they are functioning correctly.

(d) For emergency lighting system and exit signs provided with central monitoring,
testing and logging system, the system shall be tested in accordance with the
manufacturer's specification and to meet the requirements in the FSDCOP.

(e) The Contractor shall co-ordinate with relevant parties, inspect and witness the
final tests on the emergency lighting installation and/or exit signs to comply
with FSDCOP, FSD requirements and Circular Letters. The Contractor shall to
notify the Project Manager before the tests take place.

(f) The Contractor shall coordinate with relevant parties to carry out the final
functional test and performance test.

90.16.4 Gaseous Extinguishing System (FM200)

(a) The complete gaseous extinguishing system shall be tested in accordance

with FSD requirements, FSD circular letters and standards and guidelines
issued by the NFPA

(b) The piping shall be pneumatically tested (in a closed circuit) for a period of
10 minutes at a pressure not less than 10 bars or 1.5 times of the operating
pressure of system whichever is greater. At the end of 10 minutes, the
pressure drop shall not exceed 10 percent of the test pressure.

(c) A “puff” test shall be carried out in accordance with NFPA 2001 and FSD
circular letter no.2/97.

(d) Gaseous nitrogen, or other inert gas submitted for review without objection
by the Project Manager, shall be used for the test.

(e) The Contractor shall undertake a full on-site discharge test after completion
of the installation, as and when required by FSD, to confirm the design
performance is achieved. The Contractor shall submit a method statement
describing how the test shall be carried out and shall submit this test to the
FSD and Project Manager for review without objection.

(f) After all site discharge tests, including the inspection by FSD, the gas
cylinders shall be recharged and the whole system shall be reinstated to a
functional operation status.

90.17 FSD INSPECTION AND WITNESS OF TESTS

(a) Additional tests, where not specified above, shall be carried out to meet the
requirements of the FSD and WSD. The Contractor shall prepare and submit
all necessary applications to FSD and WSD and thereafter provide attendance
with their representatives for the purpose of these tests and inspections at the
Contractor’s own expense.

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 (b) The Contractor shall note that completion of the statutory inspection and
acceptance of the fire service installation by FSD is one of the considerations
for certifying the completion of the Works.

90.18 PLANT INTEGRATION PHASE

(a) The Plant Integration Phase tests shall include integration with the building
systems integration head-end processor. These tests shall be detailed in the
Test Plan and shall include the following:

(i) functional test of communications and valid data transfers between each
and every interfacing works; and

(ii) a reliability test of no less than 4 weeks. During this test all equipment
shall be connected and operational and the relevant interfacing works
shall be fully operational simultaneously. The Contractor shall co-
ordinate to ensure that all necessary simulated on-line data is available.
Availability measurements shall be taken during the test and any failure
shall cause the complete test to be restarted. Testing shall continue
until the availability required is achieved.

(b) The Plant Integration Phase shall also be used to establish the actual system
sizing and traffic details to ensure the system can be operated within the
performance requirements as described in this General Materials and
Workmanship Specification.

90.19 TESTING AND COMMISSIONING REPORT AND CERTIFICATE OF

COMPLETION

(a) The Contractor shall submit a testing and commissioning report to the Project
Manager for review without objection within fourteen days after completion of
commissioning the installation. Together with this, a certificate of completion
signed by the Contractor shall be issued to the Project Manager with a copy
forwarded to the Director of Fire Services in conformity with Regulation 9 of
the Fire Service (Installations and Equipment) Regulations.

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SECTION 91 FOUL WATER DISPOSAL

91.1 GENERAL

This section of General Materials and Workmanship Specification covers the

general requirements for foul water disposal system.

(a) All foul water disposal materials and workmanship shall generally comply with
all regulations and requirements of the relevant government departments (e.g.
Drainage Services Department-DSD, Building Department-BD and the like).
The Works shall comply with the following:

(i) Cap 123 – Building (Standards of Sanitary Fitments, Plumbing, Drainage

Works and Latrines) Regulations; The Hong Kong Waterworks Standard
Requirements (February 2002); and

(ii) relevant British Standards as detailed below.

91.1.2 Above Ground Foul Water Drainage

(a) All above ground soil and ventilating pipes and fittings shall refer to Section 95
of this General Materials and Workmanship Specification.

(b) Balloon gratings shall be galvanized steel wire or copper wire balloons. Plastic
balloons shall be expressly reviewed without objection by the Project Manager.

(c) All floor drains inside toilets and public areas shall have stainless steel
gratings to match the floor finishes. Fixing screws shall be stainless steel flat
head counter-sunk type. Floor drains inside plant rooms shall have cast iron
grating fitted with stainless steel flat head counter-sunk screws.

91.1.3 Underground Foul Water Drainage

(a) Covers and frames shall comply with BS EN 124 with coating to BS 4164 of
the type and grade specified.

(b) Manholes steps shall comply with BS 1247 : Part 1 of malleable iron to BS EN
1562 hot dip galvanised in accordance with BS 729. Minimum zinc coating
shall be at least 610 µg/m2 thick.

(c) Subsoil drain pipes shall be:

(i) concrete porous drain pipes to BS 1194;

(ii) unglazed clayware field drain pipes and junctions to BS 1196;

(iii) perforated vitrified clayware to BS 65; and

(iv) perforated plastics pipes and fittings to BS 4962.

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91.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 970 : Part 1 Specification for Wrought Steels for Mechanical and

Allied Engineering Purposes. General Inspection and
Testing Procedures and Specific Requirements for
Carbon, Carbon Manganese, Alloy and Stainless
Steels.

BS EN 124 Gully tops and manhole tops for vehicular and

pedestrian areas. Design requirements, type testing,
marking, quality control.

BS 4164 Specification for coal-tar-based hot-applied coating

materials for protecting iron and steel, including a
suitable primer.

BS 1247 : Part 1 Manhole steps. Specification for galvanized ferrous or

stainless steel manhole steps.

BS EN 1562 Dental casting gold alloys Dental casting gold alloys.

BS 729 Quality requirements for welding. Fusion welding of

metallic materials. Guidelines for selection and use.

BS 1194 Specification for concrete porous pipes for under-

drainage.

BS 1196 Specification for clayware field drain pipes and

junctions.

BS 65 Specification for vitrified clay pipes, fittings and ducts,

also flexible mechanical joints for use solely with
surface water pipes and fittings.

BS 4962 Specification for plastics pipes and fittings for use as

subsoil field drains.

BS EN 887 Chemicals used for treatment of water intended for

human consumption. Aluminium iron (III) sulfate

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Section 91 – Foul Water Disposal
91.3 MATERIALS

91.3.1 Pipework

(a) Above ground foul water pipework shall comply with section 95 of this General
Materials and Workmanship Specification.

(b) Underground foul water pipework shall comply with section 95 of this General
Materials and Workmanship Specification.

91.3.2 Manholes, Sump Pits, Gully Sumps, Valve Pits and Interceptors

(a) All suspended manholes, manholes, sump pits, valve pits, and interceptors
shall be provided by the Contractor including covers, frames, step irons and all
necessary accessories.

(b) The Contractor shall make all connections to and between pipeworks, sump
pumps, controls, wiring/conduits, valves and fittings inside the manholes,
valve pits, sump pits and interceptors.

(c) All pipework and fittings requiring casting in concrete shall be correctly
positioned and properly fixed prior to concrete pouring.

(d) Where vertical drops are indicated in manholes, they shall be of ductile/cast
iron pipes, of the appropriate size, fixed to side of manholes and discharge by
means of ductile/cast iron berds into main channel. Connection from vertical
to horizontal shall be made by means of a junction with removable cleaning
eye to facilitate roding of horizontal drain.

(e) Cast covers, gratings, overflow weirs and frames clean shall be, free from air
holes, sand holes, cold shuts and chill, neatly dressed and carefully fettled.
Castings shall be free from voids, whether due to shrinkage, gas inclusions or
other causes.

(f) All excavation work, rock cutting and backfilling for manhole shall comply with
section 5 of this General Materials and Workmanship Specification.

91.3.3 Fresh Air Inlets

(a) Supply and install where shown on the Employer’s Drawings, fresh air inlets
consisting of a strong cast iron box approximately 150 mm x 100 mm
complete with fixing ears, cast brass front and mica flap. Inlets shall be fixed
with pipe nails and distance pieces and connected to manholes with ∅100 mm
cast iron ventilating pipe unless otherwise indicated on the drawings.

91.3.4 Floor Drains

(a) Floor drains shall include gratings having a net area not less than the cross
section area of the pipe to which they are connected and shall be completed
with clamping device, dome strainer, internal caulk outlet and installed with
reference to the Employer’s Drawings.

(b) Floor drains shall be proprietary product manufactured from brass or gunmetal
with stainless steel flat grating. Fixing screws shall be stainless steel flat head
countersunk type.
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Section 91 – Foul Water Disposal
 (c) Floor drains shall have a minimum of ∅100 mm grating for toilet drains and
∅180 mm grating for plant room.

91.3.5 Wall Gratings

(a) Wall gratings and screws inside toilets/pantries/kitchens shall be made of

stainless steel and wall gratings for all other areas shall be square chromium
plate brass type with chromium plated counter-sunk flathead screws.

91.3.6 Traps

(a) Traps shall be provided where shown and where required for all fittings, and
shall be suitable in all respects for their particular duty.

(b) All traps shall be provided with an accessible cleaning aperture, the size and
location of which has been reviewed without objection, and shall have a clear
internal cross section similar to the corresponding soil or waste branch pipe
section. Unless otherwise indicated elsewhere, trap sizes shall be: -

(i) wash basins - anti-syphonage type ∅32 mm inlet and outlet with 80 mm
deep seal;

(ii) sinks - anti-syphonage type ∅40 mm inlet and outlet with 80 mm deep
seal; and

(iii) urinals - anti-syphonage type ∅40 mm inlet and outlet P-trap with 80 mm
seal.

(c) The discharge outlet portion of anti-syphonage trap shall be suitable for the
connection with socketless epoxy coated cast iron pipe to BS EN 887.

(d) Cast iron/bronze resealing traps shall be used for floor drains and shall be
similarly coated to the cast iron pipework to which they are connected.

91.4 SUBMISSIONS

91.4.1 Particulars of Foul Water Disposal System

(a) The following particulars of the proposed foul water disposal systems shall be
submitted to the Project Manger for review:

(i) Contractor’s Drawings showing plans, elevations and sections of piping

layout and location of pipe support hangers, guides, anchors, and
equipment to which the piping connects;

(ii) details of the pipe joints, pipe support hangers, guides and anchors;

(iii) test certificates and complete catalogue information with full technical
data for pipe material and floor drains;

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 (iv) pipe testing and cleaning procedures; and

(v) complete testing report after testing and commissioning.

91.4.2 Samples

(a) The following samples of the proposed foul water disposal system shall be
submitted to the Project Manger together with the particulars referred to in
91.4.1 above.

(i) pipe material and fittings including flexible hose;

(ii) pipe jointing method; and

(iii) support hanger and accessories.

91.5 WORKMANSHIP

(a) The Contractor shall provide bolted access doors or inspection units to all
branches and bends (other than ventilating and anti-syphon pipes) and at the
foot of main soil stacks.
(b) Screw threads to UPVC pipes are not allowed. Plastic pipes shall be fixed
and jointed in accordance with the manufacturer’s recommendations. Joint
plastic pipes to pipes of other materials with proprietary adaptors.

(c) All gullies shall be set to levels such that sufficient depth is given to the
extension piece where back or side inlets are shown or required.

(d) The Contractor shall provide and install galvanized steel wire or copper
balloon which shall be positively fixed to the open end of each vent pipe above
roof at the level indicated on the Employer’s Drawings, or as required.

(e) All soil/waste vent pipes shall be terminated above roof level.

(f) The Contractor shall support the pipes under barrel with sockets overhanging.
Adequately chock bottom layer of pipes in stack to prevent stack collapse and
the stack shall not be higher than 2 m.

(g) Jointing rings couplings and adaptors shall be in accordance with the
manufacturer’s recommendations.

(h) The Contractor shall only use one type of pipe and bedding within any
individual drain length between any two drainage chambers.

(i) Lay pipes single straight to line and true to gradient with sockets facing
upstream starting at the downstream end of the trench.

(j) Compact granular bedding and trim to correct gradient and shape under barrel
and pipe sockets to ensure uniform support along whole barrel length. After
laying, jointing and testing pipeline, compact granular bedding material
concurrently on each side of the pipe to the specified level.

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 (k) Accurately trim natural bed to provide uniform and solid bearing for pipes
throughout the length of the barrels. Form short recesses in bed to clear
sockets by 50 mm minimum.

(l) During construction, plug open ends of pipes and maintain until completion, to
prevent entry of debris.

(m) Ductile iron pipes and fittings shall have flexible joints with gasket type.

(n) Plastic pipes shall be jointed and fitted in accordance with manutacturer’s
recommendations.

(o) Junction pipes if not to be connected up immediately shall be closed with a

temporary water tight plug. The position of all such junctions shall be clearly
marked and labelled.

(p) Generally all pipes shall be marked permanently in English or Chinese, with
the following:

(i) nominal size;

(ii) name of manufacturer (or Trade Mark); and

(iii) relevant standard to which pipes are manufactured.

(q) Markings shall be in colour and marked at intervals laid down in the particular
standard.

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Section 91 – Foul Water Disposal
SECTION 92 STORM WATER DISPOSAL

92.1 GENERAL

This section of General Materials and Workmanship Specification covers the

general requirements for storm water disposal system.

(a) All storm water disposal materials and workmanship shall generally comply
with all regulations and requirements including those of the government
departments (e.g. Drainage Services Department-DSD, Buildings Department-
BD and the like). The following are particularly standards:

(i) Cap 123 – Building (Standards of Sanitary Fitments, Plumbing, Drainage

Works and Latrines) Regulations; The Hong Kong Waterworks Standard
Requirements (February 2002); and

(ii) relevant British Standards as detailed below.

92.1.2 Above Ground Storm Water Drainage

(a) All above ground rainwater pipes and fittings shall refer to section 95 of this
General Materials and Workmanship Specification.

(b) Cast iron roof outlets shall be proprietary products complete with sealing
flanges and screws fixed flat or domical grating, reviewed without objection by
the Project Manager.

92.1.3 Underground Storm Water Drainage

(a) Covers and frames shall be to BS EN 124 with coating to BS 4164 of the type
and grade specified.

(b) Manholes steps shall be to BS 1247 : Part 1 of malleable iron to BS EN 1562

hot dip galvanised in accordance with BS 729. Minimum zinc coating
thickness to be 610 µg/m2.

(c) Planter drain pipes shall be perforated plastic pipes and fitting to BS 4962.

92.1.4 Syphonic Drainage System

(a) The Syphonic Drainage System shall be a proprietary system which shall
include, but shall not be limited to, gullies, gully pits, pits outlets, flexible
connections, coordinated down pipes, couplings, thrust block, fittings,
insulation, and fixings sized to efficiently collect rainwater from the roof and
discharge it to the underground surface water drainage system.

(b) The Syphonic Drainage System employs roof outlets which, under design
conditions exclude air so that the drainage pipes run at full bore, thus
generating water flow by syphonic action between the outlet level and
manhole level.

(c) All rain water down pipes shall be installed in stainless steel with satin finish.

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 (d) The Contractor shall be responsible for the complete design, coordination,
manufacture and installation of the Syphonic Drainage System including, but
not limited to, the final selection of materials, sizes, thicknesses, couplings,
fixings, and sealants all in accordance with the submission and review
requirements of the Contract.

(e) The Contractor shall be responsible for obtaining statutory approval for the
entire syphonic rainwater system to be installed.

(f) The Contractor shall design the Syphonic Drainage System such that it will
perform in accordance with the Specification for a minimum period of 25
years.

(g) Performance Criteria

(i) The Contractor shall carry out and supply actual test performance data
to the Project Manager, for review without objection, for roof outlets
showing:

- Maximum flow rate;

- Depth of water required around roof outlet to initiate syphonic action;

- Frictional losses through outlet at maximum flow;

- Acoustic date to confirm that the system, when operating at either

partial or full capacity, is within the acoustic performance criteria for
the space through which the down pipe runs, and

- Changes in pipe diameter required to ensure the system will continue

to operate syphonically under all conditions, before and after the
change in diameter.

(ii) The pipe work system shall be capable of withstanding both negative
and positive pressures. The pipework running through the open
departures concourse shall be unsupported and shall also be capable of
withstanding potential impact loads which could reasonably be expected
for the given location. Details of all the design loads shall be submitted
to the Project Manager for review without objection.

(iii) When installed, the outlet and associated roof coverings shall
adequately sealed to comply with the minimum sound insulation
requirements of the main roof so as to prevent break in noise.

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Section 92 – Storm Water Disposal
92.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 970 : Part 1 Specification for Wrought Steels for Mechanical and

Allied Engineering Purposes. General Inspection and
Testing Procedures and Specific Requirements for
Carbon, Carbon Manganese, Alloy and Stainless
Steels.

BS EN 124 Gully tops and manhole tops for vehicular and

pedestrian areas. Design requirements, type testing,
marking, quality control.

BS 4164 Specification for coal-tar-based hot-applied coating

materials for protecting iron and steel, including a
suitable primer.

BS 1247 : Part 1 Manhole steps. Specification for galvanized ferrous or

stainless steel manhole steps.

BS EN 1562 Dental casting gold alloys Dental casting gold alloys.

BS 729 Quality requirements for welding. Fusion welding of

metallic materials. Guidelines for selection and use.

BS 4962 Specification for plastics pipes and fittings for use as

subsoil field drains.

BS EN 887 Chemicals used for treatment of water intended for

human consumption. Aluminium iron (III) sulfate.

EN 1124-1 Stainless steel drainage pipes specifies requirements,

tests and quality controls applying to pipes and fittings.

EN 1124-2 Stainless steel drainage pipes specifies requirements

applying to pipe dimensions and dimensional
tolerances for various fitting and pipes.

92.3 MATERIALS

92.3.1 Pipework

(a) Above ground storm water pipework shall comply with section 95 of this
General Materials and Workmanship Specification.

(b) Underground storm water pipework shall comply with section 95 of this
General Materials and Workmanship Specification.

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Section 92 – Storm Water Disposal
92.3.2 Rainwater Outlets

(a) Rainwater outlets shall be used for new extension roof as specify on
Employer’s Drawings. The Contractor shall submit the details of rainwater
outlets for Project Manager review without objection prior to ordering.

(b) Rainwater outlets shall be proprietary made product in stainless steel grade
316 to BS 970 with dome grating and collar clamp suitable for fixing to flat
sheet metal made roof gutter.

(c) Apart from the main components as specified in (b), anti-vortex device shall be
provided for syphonage drain. All components shall be fixed by stainless steel
link rod.

(d) Connection spigot pipe of rainwater outlets shall be suitable for the connection
with socketless epoxy coated cast iron pipe to BS EN 877.

(e) Syphonic rainwater outlets shall be of a proprietary design and shall prevent
entry of air into the system during normal operation.

(f) Syphonic rainwater outlets shall be constructed of grade 316 stainless steel
,reviewed without objection by the Project Manager. The connection end shall
be suitable for connection to socket less cast iron pipe to EN877.

(g) The integral anti-vortex device shall be constructed of cast aluminium.

(h) Outlet gratings shall be of dome shape and constructed in cast aluminium.

92.3.3 Manholes, Sump Pits, Gully Sumps, Valve Pits and Interceptors

(a) Manholes, sump pits, gully sumps, valve pits and interceptors shall comply
with section 91 of this General Materials and Workmanship Specification.

92.3.4 Fresh Air Inlets

(a) Fresh air inlet shall comply with section 91 of this General Materials and
Workmanship Specification.

92.3.5 Wall Gratings

(a) Wall gratings shall comply with section 91 of this General Materials and
Workmanship Specification.

92.3.6 Flexible Hoses

(a) The Contractor shall provide flexible hoses between the rainwater outlet and
the vertical down pipe / horizontal main run inside the main ceiling void as
follows:

(i) material: corrugated stainless steel;

(ii) nominal diameter: dependent on final design solution and location;

(iii) joint to pipe: eight bolt flange to DIN or BS to suite outlet flange;
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Section 92 – Storm Water Disposal
 (iv) quantity: 1 no. per down pipe; and

(v) connection from flexible hoses to the cast-in pipework shall be of

sufficient strength and of a material that will not transfer any bending
moment into the cast-in pipework and shall allow the removal of the
flexible connection.

92.3.7 Roof Gutter Overflow Alarm

(a) The Contractor shall supply and install an overflow alarm sensor for each
gutter at roof to monitor possible blockage of roof rainwater outlets and
overflowing of roof drain system.

(b) An overflow alarm panel shall be provided for monitoring the overflow alarm.

(c) Alarm signal shall be repeated to existing Building Management System, in

form of digital I/O interface.

92.4 SUBMISSIONS

92.4.1 Particulars of Storm Water Disposal System

(a) The following particulars of the proposed storm water disposal systems shall
be submitted to the Project Manager for review without objection:

(i) Contractor’s Drawings showing plans, elevations and sections of piping

layout and location of pipe support hangers, guides, anchors, and
equipment to which the piping connects;

(ii) details of the pipe joints, pipe support hangers, guides and anchors;

(iii) test certificates and complete catalogue information with full technical
data for pipe material and floor drains;

(iv) pipe testing and cleaning procedures;

(v) complete testing report after testing and commissioning;

(vi) full hydraulic calculations for the roof syphonic drainage system shall be
submitted to the Project Manager for review without objection and further
submission to Drainage Services Department/ Buildings Department;
and

(vii) full acoustic calculations for the roof syphonic drainage system shall be
submitted to the Project Manager for review without objection to confirm
the system can operate within the specified acoustic performance
requirements and without any disturbing tonal characteristics.

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Section 92 – Storm Water Disposal
92.4.2 Samples

(a) The following samples of the proposed storm water disposal system shall be
submitted to the Project Manger together with the particulars referred to section
92.4.1 above.

(i) pipe material and fittings including flexible hose;

(ii) pipe jointing method;

(iii) roof outlet.

92.5 WORKMANSHIP

(a) Lay gutters generally to falls of 1 in 300 (minimum).

(b) Fix gutters with screwed brackets at 1m (maximum) centers.

(c) Joint gutters with jointing compound and bolt together.

(d) Joint pipe and gutters in accordance with the manufacturer’s

recommendations.

(e) Contractor shall also comply with section 91.5 of this General Materials and
Workmanship Specification.

(f) All excavation work, rock cutting, trenching and backfilling shall comply with
section 5 of this GMWS.

(g) The Contractor shall provide a neoprene mounting ring between the outlet and
supporting plate to cushion any load transferred from the outlet to the
membrane or vice versa.

(h) The Contractor shall supply the outlet with a suitable method of fixing the roof
waterproofing membrane to the outlet, which shall be fully warranted. The
Contractor shall provide a written guarantee from the membrane manufacturer
for the installation and attachment of the membrane to the rainwater outlet. The
outlet shall be supplied with a pre-attached membrane skirt.

92.6 INSTALLATION

(a) The Contractor shall install pipework to run in uniform gradients falling to the
outlets. Pipe work shall run straight in between changes of direction and shall
be adequately supported, with watertight joints aligned flush at internal
surfaces.

92.6.1 Structural requirements

(a) The Contractor’s design shall make provision for and take full account of the
structural frame to which the Syphonic Drainage System is fixed including ,
but not limited to, any compensation for expansion and construction joints;

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 (b) All hangers and supports shall be secured to take all potential shock loads
imposed on the pipe support system when the Syphonic Drainage System
operated in its maximum load condition;

(c) All pipework shall be supported from the primary support structure.

92.6.2 Dimensional co-ordination

(a) The Contractor shall submit to the Project Manager, for review without
objection, precise details of the proposed jointing and fixing system, methods
of adjustment and calculated tolerances to which the Syphonic Drainage
System can operate.

92.6.3 Neoprene flexible mounting ring

(a) The Contractor shall provide a neoprene mounting ring between the outlet and
supporting plate to cushion any load transferred from the outlet to the
membrane or vice versa.

92.6.4 Roof fixing

(a) The Contractor shall supply the outlet with a suitable method of fixing to the
roof waterproofing details at the outlet. The Contractor shall provide a
Manufacturer’s Warranty from the roof manufacturer for the installation and
attachment of the rainwater outlet.

92.6.5 Accessibility

(a) The Contractor shall locate all pipe fittings in accessible location, with
adequate clearance, to facilitate maintenance and/or servicing, including
inspection openings, cleaning points, joints designed to enable the easy
removal of pipes, and fittings.

(b) The Contractor shall, where practicable, conceal pipework so that it is

accessible within ducts or non-habitable enclosed spaces and does not
appear on external walls. The Contractor shall submit Contractors Drawings
indicating the location of exposed pipework, for the Project Manager’s review
without objection prior to installation.

92.6.6 Pipe supports

(a) The Contractor shall provide all necessary supports including anchors,
hangers, saddles, bolted clips to ensure the whole installation is securely
fixed. The selection of the supports shall allow adequate provision for
protecting the installation from potential building movements and controlling
expansion and contraction.

(b) The spacing of the fixings shall be sufficient to secure the pipework to
adjacent surfaces and to support it at joints, at changes of direction, and at
intervals as necessary to prevent sagging of pipework. The Contractor shall
make provision for adjustment of gradient as required.

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 (c) The pipe support material shall be the same material as the pipe, or
galvanised or non-ferrous metals fixed onto the steel reinforcement before
concreting.

(d) The Contractor shall note that the pipe thickness for the stainless syphonic
rainwater pipes running through the concourse shall be adjusted to ensure the
pipe can be run unsupported over the entire visible section.

92.6.7 Capping-off

(a) During construction, the Contractor shall temporarily seal open ends of pipes
to prevent the entry of foreign matter into pipe systems, and shall provide
purpose-made covers of pressed steel or rigid plastic.

92.7 TESTING

(a) The Contractor shall provide all necessary documentation including but not
limited to method statements, test reports, to demonstrate that the Syphonic
Drainage System satisfies the performance requirements of the Specification;

(b) The Contractor shall test all systems hydrostatically for a minimum of two
hours at a pressure not less than 1.5 times the maximum operating pressure
and/or not less 400 kPa at the lowest part of the system, whichever is the
greater. No leakage shall be recorded during the testing period;

(c) In the event of leakage, the Contractor shall carry out remedial works and
carry out further tests until it can be satisfactory shown that the complete
installation is leak free.

(d) The Contractor shall schedule all testing in accordance with the construction
programme, and agree the test schedule in advance with the Project
Manager.

(e) All final tests will be witnessed by the Project Manager’s representative and
where necessary the Buildings Department. Records of all testing shall be
retained and submitted to the Buildings Department for confirmation as
required.

(f) Tests shall not be carried out without prior notice of at least 28 days being
given to the Project Manager; and

(g) On completion of the installation, the Contractor shall carry out functional tests
for individual components and on the system as a whole to the satisfaction of
the Project Manager. Such testing shall include timed discharge tests of
selected individual systems.

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Section 92 – Storm Water Disposal
SECTION 93 WATER SUPPLY

93.1 GENERAL

(a) This section covers the general requirements for potable water system,
flushing water system and cleansing water system.

(b) All water supply systems shall generally comply with the following standards
or suitable equivalent:

(i) Cap 123 – Building (Standards of Sanitary Fitments, Plumbing, Drainage

Works and Latrines) Regulations; Cap 102 – Waterworks Regulations;

(ii) Hong Kong Waterworks Standard Requirements;

(iii) The Institute of Plumbing – Plumbing Engineering Services Design

Guide; and

(iv) relevant British Standards as detailed below.

(c) All plumbing works shall be carried out by a licensed plumber.

93.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 970 : Part 1 Specification for Wrought Steels for Mechanical

and Allied Engineering Purposes. General
Inspection and Testing Procedures and Specific
Requirements for Carbon, Carbon Manganese,
Alloy and Stainless Steels

BS 1010 : Part 2 Specification for Draw-Off Taps and Stop valves

for Water Services (Screw-Down Pattern).
Draw-Off Taps and Above-Ground Stop valves

BS 6700 Specification for Design, Installation, Testing

and Maintenance of Services Supplying Water
for Domestic use within Buildings and their
Curtilages

BS EN 1982 Copper and Copper Alloys. Ingots and Castings

BS EN 13280 Specification for Glass Fibre Reinforced Cisterns

of One-Piece and Sectional Construction, for the
Storage, Above Ground, of Cold Water

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Section 93 – Water Supply
93.3 WATER SUPPLY REQUIREMENTS

93.3.1 Potable Water Supply Requirements

(a) Design Data:

(i) minimum head at any outlet shall be 150 kPa;

(ii) maximum head at any outlet shall be 550 kPa;

(iii) maximum water velocity in distribution pipework shall be 1.85 m/s; and

(iv) water temperature shall be 3°C – 30°C.

(b) The potable water supply system shall be connected from Water Supplies
Department / Employer ’s main potable water supply pipe.

(c) Sizing of the potable water lines shall be based on maintaining uniform
pressure and minimum head at each draw off point.

(d) The potable water supply system shall be sized for simultaneous demand from
fixtures with a minimum pipe size of ∅20 mm when serving more than a single
fixture.

(e) Requirements of water storage tanks shall refer to Section 97 of this General
Materials and Workmanship Specification.

93.3.2 Flushing Water Supply Requirements

(a) Design Data:

(i) minimum head at any outlet shall be 100 kPa;

(ii) maximum head at any outlet shall be 550 kPa;

(iii) maximum water velocity in distribution pipework shall be 1.85 m/s; and

(iv) water temperature shall be 3°C – 30°C.

(b) The flushing water supply system shall be connected from Employer ‘s main
seawater supply pipe.

(c) The capacity of water storage tanks for flushing shall be 45 litres for each
flushing point. The tanks shall be provided with close-fitting but not airtight lids
to ensure that the water will not be polluted. Easy access shall be available for
maintenance inspection and cleaning. Suitable overflow pipes shall be
provided and pipe to nearest drain.

(d) Requirements of water storage tanks shall refer to Section 97 of this General
Materials and Workmanship Specification.

General Materials & Workmanship Specification 2/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 93 – Water Supply
93.3.3 Cleansing Water Supply Requirements

(a) Cleansing water shall be supplied to all cleansing water points.

(b) The cleansing water system shall be connected from the Water Supplies
Department / Employer’s main potable water supply pipe.

(c) Separate water storage tank shall be provided for cleansing water system.

(d) Indirect supply shall be used for cleansing water supply system.

(e) All cleansing water points shall be housed in lockable box with padlock.

(f) The cleansing water system shall be maintained a minimum head of 100 kPa
at each cleansing water point, pneumatic booster pump units shall be provided
if necessary. Details of pneumatic booster pump shall refer to Section 97 of
this General Materials and Workmanship Specification.

(g) Requirements of water storage tanks shall refer to Section 97 of this General
Materials and Workmanship Specification.

93.4 MATERIALS

93.4.1 Pipework and Fittings

(a) All pipework and fittings for potable water supply system, flushing water supply
system and cleansing water supply system shall refer to Section 95 of this
General Materials and Workmanship Specification.

93.4.2 Pipe Supports

(a) All pipe supports for potable water supply system, flushing water supply
system and cleansing water supply system shall refer to Section 95 of this
General Materials and Workmanship Specification.

93.4.3 Valves and Cocks

(a) All the valves and cocks for potable water supply system, flushing water
supply system and cleansing water supply system shall refer to Section 95 of
this General Materials and Workmanship Specification.

93.4.4 Cover Plates

(a) Potable water pipes and flushing water pipes emerging from walls, floors or
ceiling surfaces, shall be covered by cover plates manufactured from either
non-ferrous metal finished to match the pipe, or stainless steel with
dimensions as follows:

Pipe diameter Cover plate diameter (nominal)

Up to 20 mm 65 mm
Up to 50 mm 100 mm
Larger than 50 mm 50 mm larger than pipe

General Materials & Workmanship Specification 3/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 93 – Water Supply
93.4.5 Water Chiller for Drinking Fountain

The water chiller for drinking fountain shall be constructed as follows:

(a) Chilled Water Reservoir

(i) cooling tank of welded stainless steel in grade 304 to BS 970 : Part 1
tested for 800 kPa working pressure. Evaporator mounted within the
storage tank and constructed of copper pipe with a minimum wall
thickness of 1.5 mm.

(b) Refrigeration Unit

(i) high efficiency hermetic compressor with an air or water-cooled

condenser and full controls for automatic operation including adjustable
thermostat high / low pressure status, dehydrator sight glass and
head/suction gauges. Refrigerant shall be ozone safe.

(c) Recirculating Pump

(i) centrifugal pump installed on rubber pads over stainless steel drip pan.
Piping shall be fully insulated and include dial thermometer on discharge
line, manual by-pass valve, and drain.

(d) Controls

(i) programmable microprocessor controller to provide digital display of

cooling values and diagnostic functions. Standard alarms of: (1) high
and low water temperature, (2) high and low refrigerant pressure, (3) low
refrigerant oil pressure, (4) compressor thermal overload, (5) high filter
differential pressure and (6) low UV intensity shall be provided to protect
water chiller.

(e) Make-up Water Treatment

(i) dual element type stainless steel construction consisting of: (1)
particulate filter with replaceable element for removal of suspended
matter down to 5 microns and (2) absorbing filter with minimum 0.05 m3
activated carbon for removal of taste, odour, organic chemicals, chlorine
and other waste chemicals. A differential switch shall also be included
to indicate when filter needs servicing.

(f) In-Loop Sterilizer

(i) to control bacteria or other micro-organisms in the circulating loop, the

chiller shall include on ultraviolet sterilizer inside the cabinet with a UV
intensity alarm incorporated into the microprocessor controller.

General Materials & Workmanship Specification 4/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 93 – Water Supply
93.5 SUBMISSIONS

93.5.1 Particulars of Water Supply Systems

(a) The following particulars of the proposed water supply systems shall be
submitted to the Project Manager for review without objection:

(i) Contractor’s Drawings showing plans, elevations and sections of piping

layout and location of valves, pipe support hangers, guides, anchors,
and equipment to which the piping connects;

(ii) details of the pipe joints, pipe support hangers, guides and anchors;

(iii) test certificates and complete catalogue information with full technical
data for pipe material, valves, pumps and water tanks;

(iv) approval letter of fibreglass water tanks from Water Supplies

Department;

(v) pipe testing and cleaning procedures;

(vi) complete testing report after testing and commissioning; and

(vii) The Contractor shall submit to the Project Manager, for review without
objection, a complete set of hydraulic calculations showing the pipe
frictional loss of all the water supply systems.

93.5.2 Samples

(a) The following samples of the proposed water supply systems shall be
submitted to the Project Manger together with the particulars referred to in
93.5.1 above.

(i) pipe material and fittings;

(ii) valves; and

(iii) pipe joints, pipe support hangers, guides and anchors.

93.6 WORKMANSHIP

93.6.1 Water Supply Pipes

(a) Water supply installation shall comply with BS 6700.

(b) Taps, valves and fittings shall be a proprietary type approved by Water
Supplies Department. Red lead jointing materials shall not be used.

(c) All water supply pipes shall be installed in straight lines and uniform grades
without sags.

(d) All water supply pipes shall have sufficient unions, flanges and isolating valves
for satisfactory removal of piping and fittings for maintenance.

General Materials & Workmanship Specification 5/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 93 – Water Supply
 (e) The number of joints for pipework shall be kept in minimum.

(f) Valves shall be arranged together where practicable in operational grouping,

in convenient and readily accessible positions.

(g) All water supply pipes shall have adequate spacing of at least 25 mm between
pipes or pipe insulation, 50 mm between pipes or pipe insulation and electrical
cables.

(h) All the pipe fittings (e.g. control valves and design joints to enable removal of
pipes) shall be located in accessible positions with adequate clearance for
maintenance.

(i) All potable water pipework, water storage tanks and associated pumps and
equipment shall be cleaned internally and sterilized.

(j) The other general requirements of pipework installation shall refer to Section
95 of this General Materials and Workmanship Specification.

93.6.2 Pipe Supports

(a) Installation of pipe supports for potable water supply system, flushing water
supply system and cleansing water supply system shall refer to Section 95 of
this General Materials and Workmanship Specification.

General Materials & Workmanship Specification 6/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 93 – Water Supply
SECTION 94 HOT WATER SUPPLY SYSTEM

94.1 GENERAL

This section covers the general requirements for hot water supply system.

(a) All hot water supply systems shall generally comply with the following
standards or suitable equivalent:

(i) Cap 102 – Waterworks Regulations;

(ii) Hong Kong Waterworks Standard Requirements;

(iii) The Institute of Plumbing – Plumbing Engineering Services Design

Guide;

(iv) Code of Practice for the Electricity (Wiring) Regulations; and

(v) relevant British Standards as detailed below.

(b) The hot water supply system shall comprise electric mains heater and all
necessary pipework and safety features.

(c) All electrical water heaters shall comprise a heating element, corrosion
resistant inner vessel, encased in sheet steel insulated casing, in a single
proprietary package.

(d) All electrical water heaters shall be installed by grade R registered electrical
workers whom are specifically permitted by Relevant Authority to carry out
such works.

(e) The water heaters shall be of Water Authority approved type.

(f) Test pressure of the water heaters shall be minimum 1.5 times to the
maximum working pressure.

(g) All plumbing works shall be carried out by a licensed plumber.

94.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 476 : Part 7 Fire Tests on Building Materials and Structures.

Method of Test to Determine the Classification
of the Surface Spread of Flame of Products

BS 3955 Specification for Electrical Controls for

Household and Similar General Purposes

General Materials & Workmanship Specification 1/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 94 – Hot Water Supply System
 BS 5422 Method for specifying thermal insulating
materials for pipes, tanks, vessels, ductwork and
equipment operating within the temperature
range –40°C to +700°C

BS 6282 Devices with Moving Parts for the Prevention of

Contamination of Water by Backflow

BS 6283 Safety and Control devices for Use in Hot Water

Systems

BS EN 1111 Sanitary Tapware. Thermostatic Mixing Valves

(PN 10). General Technical Specification

BS EN 1286 Sanitary Tapware. Low Pressure Mechanical

Mixing Valves. General Technical Specification

BS EN 60335-2-21 Specification for Safety of Household and

Similar Electrical Appliances. Particular
Requirements. Particular Requirements for
Storage Water Heaters

BS EN 60335-2-35 Specification for Safety of Household and

Similar Electrical Appliances. Particular
Requirements. Instantaneous Water Heaters

BS EN 60730-2-1 Specification for Automatic Electrical Controls

for Household and Similar use. Particular
Requirements. Electrical Controls for Electrical
Household Appliances

BS EN 60730-2-9 Specification for Automatic Electrical Controls

for Household and Similar use. Particular
Requirements. Temperature Sensing Controls

94.3 MATERIALS

94.3.1 Pipework and Fittings

(a) All pipework and fittings for the hot water supply system shall comply with
Section 95 of this General Materials and Workmanship Specification.

94.3.2 Pipe Supports

(a) All pipe supports for the hot water supply system shall comply with Section 95
of this General Materials and Workmanship Specification.

94.3.3 Valves, Cocks

(a) Valves and cocks (except thermostatic mixing valves) for the hot water supply
system shall comply with Section 95 of this General Materials and
Workmanship Specification.

General Materials & Workmanship Specification 2/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 94 – Hot Water Supply System
 (b) Thermostatic Mixing Valves

(i) thermostatic mixing valves shall be corrosion resistant copper alloys and
stainless steel, all valves shall comply with the performance
requirements of BS EN 1286 and BS EN 1111;

(ii) the thermostatic mixing valves shall supply blended water between 35°C
and 45°C with supplies of 15°C cold and 65°C hot with normally
balanced pressures;

(iii) the blended water temperature shall be maintained within 1°C with a
10°C change in the hot or cold water supply; and

(iv) the minimum flow rate of valves shall be 0.3 L/s.

94.3.4 Thermal Insulation

(a) All hot water pipework, mixed water pipework (downstream of thermostatic
mixing valve) and other direct hot water services shall be insulated with
fibreglass insulation or suitable alternative preformed sections or mats to BS
5422 and shall be:

(i) of minimum density 24 kg/m3;

(ii) of minimum thickness 25 mm;

(iii) of thermal conductivity 0.04 W/m °C;

(iv) of maximum moisture absorption 0.2% by volume; and

(v) graded as class 1 when tested in accordance with BS 476 : Part 7.

94.3.5 Water Heaters

(a) Thermal Storage Type Electric Water Heater

(i) the electric thermal storage type water heater shall be unvented type
with storage capacity not exceeding 200 litres and comply with BS EN
60335-2-21;

(ii) the heater shall be equipped with:

- thermostat with maximum setting temperature of 80°C;

- thermal cut-out device which shall comply with BS 3955, BS EN

60730-2-1 & 9 and set at 80°C. The thermal cut-out shall be wired
with the thermostat in series and require manual re-setting that is only
possible when the enclosure of the water heater is dismantled;

- non-resettable temperature relief valve shall comply with BS 6283

and have a set temperature of 90°C. A manual test easing gear shall
be provided;

General Materials & Workmanship Specification 3/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 94 – Hot Water Supply System
 - pressure relief valve shall comply with BS 6283 and have a set
pressure not greater that the maximum designed pressure of the
water heater or 1000 kPa. A manual test easing gear shall be
provided; and

- a combined temperature and pressure relief valve as an alternative to

the temperature relief valve and the pressure relief valve may be
employed in the heater.

(iii) every system incorporating an unvented electric thermal storage type

water heater shall be provided with:

- a supply pipe that branches off from the feed pipe at a point above
the top of the water heater, or some other device to prevent the water
from draining down from the water heater of there is a failure at the
source of the water supply; and

- an anti-vacuum valve complying with BS 6282 or other device to

prevent heated water from being siphoned back to supply pipe.

(iv) the drain pipe shall be provided for the relief valves to discharge the
water released from the valves to a safe and visible location;

(v) a vessel shall be provided to accommodate the expansion of heated

water where that expansion is constrained by a non-return valve,
incorporated at the inlet of the water heater, or, outlet of the water heater
shall not be valved so that the outlet can be served as expansion pipe;

(vi) electrical supply to the electric water heater shall be 220V, single phase
or 380V, 3 phases; and

(vii) the water heater power supply shall be cut-off automatically when the
water outlet temperature reaches to 60°C.

(b) Instantaneous Type Electric Water Heater

(i) instantaneous type electric water heater shall comply with BS EN 60335-
2-35;

(ii) the water heater shall be suitable for low flow pressure and conductive
water;

(iii) each water heater shall be served up to draw off points within 3 m.
Heating elements shall be well insulated;

(iv) spur units will be provided at the vicinity of the heater;

(v) the water heater shall be electrically operated on a 3 phases 380V

power supply. Each heater shall have a heating element rated up to 18
kW maximum;

General Materials & Workmanship Specification 4/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 94 – Hot Water Supply System
 (vi) the water heater shall be operated by a pressure differential switch
integral to the heater mechanism and totally enclosure inside the heater;

(vii) partial load switch shall be provided to enable selection to 2/3 of the full
load. A pilot light shall be provided in the heater casing to indicate the
ON / OFF status of the heaters;

(viii) as overheat protection switch and safety valve shall be provided in the
heater. All switches and valves shall be factory tested and each heater
shall be accompanied by a test certificate;

(ix) quick coupling sockets shall be provided in water inlet and outlet of the
water heater for ease of removal / maintenance. Each connection shall
be provided with factory cut gasket suitable for hot water;

(x) the water heater shall be supplied with at least 1 meter of supply cable
for necessary adjustment when required. Cable shall be installed inside
flexible metallic conduits;

(xi) each unit shall be included mounting bracket and no drilling and
punching to any part of the water heater will be permitted;

(xii) material of the water contacting part shall be in copper and the external
finishes shall in white enamelled paint or equivalent; and

(xiii) no part of the pipework shall be used as the support of the water heater.

94.4 SUBMISSIONS

94.4.1 Particulars of Hot Water Supply System

(a) The following particulars of the proposed hot water supply system shall be
submitted to the Project Manger for review:

(i) Contractor’s Drawings showing plans, elevations and sections of piping

layout and location of valves, pipe support hangers, guides, anchors,
and equipment to which the piping connects;

(ii) details of the pipe joints, pipe support hangers, guides and anchors;

(iii) test certificates and complete catalogue information with full technical
data for pipe material, valves, and water heaters;

(iv) pipe testing and cleaning procedures; and

(v) complete testing report after testing and commissioning.

General Materials & Workmanship Specification 5/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 94 – Hot Water Supply System
94.4.2 Samples

(a) The following samples of the proposed hot water supply system shall be
submitted to the Project Manger together with the particulars referred to in
94.4.1 above.

(i) pipe material and fittings;

(ii) valves; and

(iii) pipe joints, pipe support hangers, guides and anchors.

94.5 WORKMANSHIP

94.5.1 Pipework

(a) Installation of pipework for the hot water supply system shall comply with
section 95 of this General Materials and Workmanship Specification.

94.5.2 Pipe Supports

(a) Installation of pipe supports for the hot water supply system shall comply with
section 95 of this General Materials and Workmanship Specification.

94.5.3 Water Heaters

(a) All water heaters shall be firmly fixed in position with the factory supplied
supporting brackets.

(b) All water heaters shall be installed so as not to allow the weight of the water
heater transmitted to its water connection pipes.

(c) All water heaters shall be installed in the position to allow easy access and
enable future maintenance / replacement of heaters.

General Materials & Workmanship Specification 6/6 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 94 – Hot Water Supply System
SECTION 95 PIPEWORK, FITTINGS & VALVES

95.1 GENERAL

95.1.1 Pipework

(a) Pipework shall include all pipes, tubes, valves, fittings, reducers, nipples,
vents, bleed offs, drains, expansion and contraction devices, hangers,
brackets, anchors, saddles, supports, sleeves, plates and all accessories and
components connected thereto as an integrated pipework installation.

(b) All pipework delivered to Site shall be colour banded to identify different
grades.

(c) All pipe runs shall be installed in accordance with Contractor’s Drawings,
previously reviewed without objection by the Project Manager.

(d) All pipes shall be marked permanently, in English or Chinese, to show the
following:

(i) nominal size;

(ii) name of manufacturer (or Trade mark);

(iii) standard to which pipes are manufactured; and

(iv) other requirement laid down in the particular standards.

(e) Pipework shall be installed with correct falls to ensure adequate venting and
draining.

(f) Pipework installed in ducts, trenches, voids and inaccessible places shall have
joints for connecting to valves or where a particular type of joint is specifically
called for.

(g) No pipe joints shall be permitted within the thickness of walls or floors.

(h) The Contractor shall provide pipe sleeves where pipe pass through wall, floors
or ceilings. Sleeves for cast iron and steel pipes shall be steel. Sleeves for
galvanized pipe shall be galvanized steel. For plastic pipes the sleeves shall
be galvanized steel . The Contractor shall provide puddle flanges where pipes
pass through water tanks, rooves, diaphragm walls or screen walls rendered
liquid-tight.

(i) No welding is permitted on galvanized steel pipe under any circumstances

whatsoever.

(j) Pipes passing through the building expansion joints shall be fixed with pipe
expansion joints.

(k) The Contractor shall be responsible for the selection of all necessary
provisions to accommodate building, operational and thermally induced
movements. The Contractor shall make reference to the Appendix G of the
Particular Specification, Volume 2, Appendix A16.1 Structural Movement
Report.
General Materials & Workmanship Specification 1/26 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
95.1.2 Fitting and Valves

(a) All valves and cocks shall require approval by the Water Supplies Department
and review without objection by the Project Manager.

(b) All valves supplied shall be suitable for the working pressure and testing
pressure of the system as specified elsewhere in this General Materials and
Workmanship Specification and shall be non-asbestos type.

(c) All valves delivered to Site shall provide adequate identification for different
grades and sizes.

(d) Provide pressure gauges, air vents, drain valves and gunmetal test cocks for
all equipment.

(e) Provide isolating valves for all equipment.

(f) Provide regulating valves of globe type shall be fitted on branch lines and
bypass where regulation of flow is required for balancing.

(g) Brand name and standards of the valves shall be cast on the body and cast or
stamped on the bonnet. Provide valves of a given type from same
manufacturer expect for special application.

(h) Provide valves suitable for the working hydraulic pressure specified for the
services and as specified in the Section 99 of this General Materials and
Workmanship Specification. Provide gate and globe valve suitable for
repacking under pressure. Regardless of service, do not furnish valves rated
for less than 1,035 kPa working pressure.

(i) Valve Connections:

(i) provide valves suitable to connect to adjoining piping as specified for

pipe joints;

(ii) thread pipe sizes ∅50 mm or smaller;

(iii) sizes ∅65 mm and large shall be flanged connections to BS EN : 1092

Part 1 PN 16; and

(iv) solder or screw to solder adaptors for copper tubing.

(j) Unless otherwise specified, all valves shall be of full line size.

(k) All valves used in flushing water system shall be suitable for use with
seawater.

(l) All valves shall be arranged so that clockwise rotation of the spindle closes the
valve. Where installed at a change in direction of the pipework, angle valves
are preferred to straight valves and bends.

(m) All valves shall be provided with an indicator to show the open and shut
position.

General Materials & Workmanship Specification 2/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 (n) Bodies of valves and cocks up to ∅50 mm shall be of cast gunmetal or
bronze; valves having heavy pattern hot-pressed bodies may be used subject
to review without objection by the Project Manager. Valves over ∅50 mm
shall have ductile iron bodies.

(o) Valves and cocks for installation in screwed jointed pipework shall have taper
screwed ends. Flanges of flanged valves shall be to BS EN 1092-2 for PN 16
rating or otherwise specified.

(p) Operating hand wheels shall be of malleable iron, or of composition having

metal insert for securing positively to the stem.

95.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

ISO 7-1 Pipe Threads Where Pressure-Tight Joints are

Made on the Threads - Part 1: Dimensions,
Tolerances and Designation

ISO 7005 Metallic Flanges

BS 416 Discharge and Ventilating Pipes and Fittings,

Sand-Cast or Spun in Cast Iron. Specification for
Spigot and Socket Systems

BS 970 : Part 1 Specification for Wrought Steels for Mechanical

and Allied Engineering Purposes. General
Inspection and Testing Procedures and Specific
Requirements for Carbon, Carbon Manganese,
Alloy and Stainless Steels

BS 1010 : Part 2 Specification for Draw-Off Taps and Stopvalves

for Water Services (Screw-Down Pattern). Draw-
Off Taps and Above-Ground Stopvalves

BS 1188 Specification for Ceramic Wash Basins and

Pedestals

BS 1212 : Part 1 Float Operated Valves. Specification for Piston

Type Float Operated Valves (Copper Alloy
Body) (Excluding Floats)

BS 1212 : Part 3 Float Operated Valves. Specification for

Diaphragm Type Float Operated Valves
(Plastics Bodied) for Cold Water Services Only
(Excluding Floats)

BS 1244 : Part 2 Metal Sinks for Domestic Purposes.

Specification for Sit-On and Inset Sinks

General Materials & Workmanship Specification 3/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 BS 1254 Specification for WC Seats (Plastics)

BS 1256 Threaded Pipe Fittings in Malleable Cast Iron

and Cast Copper Alloy

BS 1387 Specification for Screwed and Socketed Steel

Tubes and Tubulars and for Plain End Steel
Tubes Suitable for Welding or for Screwing to
BS 21 Pipe Threads

BS 1876 Specification for Automatic Flushing Cisterns for

Urinals

BS 1965 : Part 1 Specification for Butt-Welding Pipe Fittings for

Pressure Purposes. Carbon Steel

BS 1968 Specification for Floats for Ballvalves (Copper)

BS 2456 Specification for Floats (Plastics) for Float

Operated Valves for Cold Water Services

BS 3100 Specification for Steel Castings for General

Engineering Purposes

BS 3505 Specification for Unplasticized Polyvinyl Chloride

(PVC-U) Pressure Pipes for Cold Potable Water

BS 3974 : Part 2 Specification for Pipe Supports. Pipe Clamps,

Cages, Cantilevers and Attachments to Beams

BS 4346 : Part 1 Joints and Fittings for Use with Unplasticized

PVC Pressure Pipes. Injection Moulded
Unplasticized PVC Fittings for Solvent Welding
for Use with Pressure Pipes, including Potable
Water Supply

BS 4772 Specification for Ductile Iron Pipes and Fittings

BS 5150 Specification for Cast Iron Gate Valves

BS 5152 Specification for Cast Iron Globe and Globe

Stop and Check Valves for General Purposes

BS 5154 Specification for Copper Alloy Globe, Globe

Stop and Check, Check and Gate Valves

BS 5163 Specification for Predominantly Key-Operated

Cast Iron Gate Valves for Waterworks Purposes

BS 5422 Method for Specifying Thermal Insulating

Materials for Pipes, Tanks, Vessels, Ductwork
and Equipment Operating within the
Temperature Range –40°C to +700°C

General Materials & Workmanship Specification 4/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 BS 5503 : Part 3 Vitreous China Washdown WC Pans with
Horizontal Outlet. Specification for WC Pans
with Horizontal Outlet for Use with 7.5 L
Maximum Flush Capacity Cisterns

BS 5520 Specification for Vitreous China Bowl Urinals

(Rimless Type)

BS 5627 Specification for Plastics Connectors for Use

with Horizontal Outlet Vitreous China WC Pans

BS 6129 : Part 1 Code of Practice for the Selection and

Application of Bellows Expansion Joints for Use
in Pressure Systems. Metallic Bellows
Expansion Joints

BS 6340 : Part 8 Shower units. Specification for Prefabricated

Shower Trays Made from Glazed Ceramic

BS 7357 Specification for 7.5 L WC Flushing Cisterns

BS EN 545 Ductile Iron Pipes, Fittings, Accessories and

their Joints for Water Pipelines. Requirements
and Test Methods

BS EN 593 Industrial Valves. Metallic Butterfly Valves

BS EN 598 Ductile Iron Pipes, Fittings, Accessories and

Their Joints for Sewerage Applications.
Requirements and Test Methods

BS EN 877 Cast Iron Pipes and Fittings, Their Joints and

Accessories for the Evacuation of Water from
Buildings. Requirements, Test Methods and
Quality Assurance

BS EN 1044 Brazing. Filler Metals

BS EN 1057 Copper and Copper Alloys. Seamless, Round

Copper Tubes for Water and Gas in Sanitary
and Heating Applications

BS EN 1092-1 Flanges and their Joints. Circular Flanges for

Pipes, Valves, Fittings and Accessories, PN
Designated. Steel Flanges

BS EN 1092-2 Flanges and Their Joints. Circular Flanges for

Pipes, Valves, Fittings and Accessories, PN
Designated. Cast Iron Flanges

BS EN 1124 Pipes and fittings of longitudinally welded

stainless steel pipes with spigot and socket for
waste water systems.

General Materials & Workmanship Specification 5/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 BS EN 1254-1 Copper and Copper Alloys. Plumbing Fittings.
Fittings with Ends for Capillary Soldering or
Capillary Brazing to Copper Tubes

BS EN 1254-2 Copper and Copper Alloys. Plumbing Fittings.

Fittings with Compression Ends for Use with
Copper Tubes

BS EN 1254-4 Copper and Copper alloys. Plumbing Fittings.

Fittings Combining other End Connections with
Capillary or Compression Ends

BS EN 1329-1 Plastics Piping Systems for Soil and Waste

Discharge (Low and High Temperature) within
the Building Structure. Unplasticized Poly(vinyl
chloride) (PVC-U). Specifications for Pipes,
Fittings and the System

BS EN 1452 -1 Plastics Piping Systems for Water Supply.

Unplasticized Poly(vinyl chloride) (PVC-U).
General

BS EN 1452 -2 Plastics Piping Systems for Water Supply.

Unplasticized Poly(vinyl chloride) (PVC-U).
Pipes

BS EN 1452 -3 Plastics Piping Systems for Water Supply.

Unplasticized Poly(vinyl chloride) (PVC-U).
Fittings

BS EN 1452 -4 Plastics Piping Systems for Water Supply.

Unplasticized Poly(vinyl chloride) (PVC-U).
Valves and Ancillary Equipment

BS EN 1452 -5 Plastics Piping Systems for Water Supply.

Unplasticized Poly(vinyl chloride) (PVC-U).
Fitness for Purpose of the System

BS EN 1515-1 Flanges and Their Joints. Bolting. Selection of

Bolting

BS EN 1561 Founding. Grey Cast Irons

BS EN 1563 Founding. Spheroidal Graphite Cast Iron

Bs EN 1982 Copper and Copper Alloys. Ingots and Castings

BS EN 10028-1 Specification for Flat Products Made of Steels

for Pressure Purposes. General Requirements

BS EN 10028-2 Specification for Flat Products Made of Steels

for Pressure Purposes. Non-Alloy and Alloy
Steels with Specified Elevated Temperature
Properties

General Materials & Workmanship Specification 6/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 BS EN 10029 Specification for Tolerances on Dimensions,
Shape and Mass for Hot Rolled Steel Plates 3
mm Thick or Above

BS EN 10051 Specification for Continuously Hot-Rolled

Uncoated Plate, Sheet and Strip of Non-Alloy
and Alloy Steels. Tolerances on Dimensions and
Shape

BS EN 10213-1 Technical Delivery Conditions for Steel Castings

for Pressure Purposes. General

BS EN 10213-2 Technical Delivery Conditions for Steel Castings

for Pressure Purposes. Steel Grades for Use at
Room Temperature and at Elevated
Temperature

BS EN 10216-1 Seamless Steel Tubes for Pressure Purposes.

Technical Delivery Conditions. Non-Alloy Steel
Tubes with Specified Room Temperature
Properties

BS EN 10217-1 Welded Steel Tubes for Pressure Purposes.

Technical Delivery Conditions. Non-Alloy Steel
Tubes with Specified Room Temperature
Properties

BS EN 10253-1 Butt-welding Pipe Fittings. Wrought Carbon steel

for General Use and Without Specific Inspection
Requirements

BS EN 10259 Cold-Rolled Stainless and Heat Resisting Steel

Wide Strip and Plate / Sheet. Tolerances on
Dimensions and Shape.BS EN 12163 Copper
and Copper Alloys. Rod for General Purposes

BS EN 12106 Plastics piping systems. Polyethylene (PE)

pipes.

BS EN 12164 Copper and Copper Alloys. Rod for Free

Machining purposes

BS EN 12165 Copper and Copper Alloys. Wrought and

Unwrought Forging Stock

BS EN 12167 Copper and Copper Alloys. Profiles and

Rectangular Bar for General Purposes

BS EN 12334 Industrial Valves. Cast Iron Check Valves

BS EN 12420 Copper and Copper Alloys. Forgings

BS EN 13709 Industrial valve, Steel globe and globe stop and

check valves

General Materials & Workmanship Specification 7/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
95.3 MATERIALS

95.3.1 Above Ground Waste, Soil, Combined Soil and Waste and Vent Pipes

(a) Pipework from ∅32 mm to ∅40 mm shall be of UPVC. Pipes and fitting shall
comply with BS EN 1329-1. Both pipe and fitting shall be of the same
manufacturer and solvent welded with solvent cement recommended by the
pipe manufacturer. The Contractor shall confirm that pipes and fittings are
suitable for their intended use, particularly where non-domestic effluents or hot
liquids in kitchens, laboratories etc. may be discharged into the system.

(b) Pipework from ∅50 mm to ∅150 mm shall be socketless cast iron pipes and
fittings and shall comply with BS EN 877 with internal epoxy coating and
external anti-oxidant protective primer. Pipes shall be joined using stainless
steel coupling joints with passivated stainless steel captive bolts and an EPDM
elastometic gaskets. Stainless steel coupling joints, passivated stainless steel
captive bolts and EPDM elastometic gaskets shall comply with BS 5422.

(c) Pipework above ∅150 mm shall be of ductile iron pipes and fittings to BS EN
598 Class K9 with flexible joint.

(d) Cast iron pipes and fittings with epoxy paint. The epoxy paint shall be applied
to provide a thickness of not be less than 130 μm.

(e) Hubless cast iron pipes shall be jointed by flexible couplings conforming to BS
6087. All joints shall be complete with a EPDM seal to BS 2494.

(f) The flexible couplings shall be made of stainless steel grade 316 tightened
multiple high grade stainless steel bolts of adequate strength to hold the pipe
works in their correct alignment throughout the maximum imposed loads plus
20%

(g) The entire hubless drainage system shall be assembled and supported in
accordance with the manufacturer's recommendation. The system shall be
capable of withstanding all likely surge pressures, especially at the bottom of
stacks. Detail of anchor and fixings shall be submitted to the Project Manager
for review without objection.

(h) Provisions for electrical continuity shall be included.

(i) Access points shall be provided in pipe and fittings to comply with the
Buildings Department's requirements.

95.3.2 Underground Rainwater, Waste, Soil, Combined Soil and Waste and Vent
Pipes

(a) Pipework ∅100 mm to ∅150 mm shall be cast iron pipes and fittings to BS
437, and be pipes and fittings of longitudinally welded stainless steel pipes
with spigot and socket for waste water systems to BS EN 1124.

(b) Pipework above ∅150 mm shall be cement-lined ductile iron complete with
fittings to BS EN 598 Class K9 with flexible joint.

General Materials & Workmanship Specification 8/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
95.3.3 Pump Discharge Pipes (For Drainage System)

(a) Pipework shall be of ductile iron pipes and fittings to BS EN 598 Class K9 with
flexible joint.

95.3.4 Above Ground Rainwater Water Pipe

(a) Unless otherwise shown on the Employer’s Drawings, all visibly concealed
pipe work ∅65 mm and above shall be socket less cast iron pipes and fittings
to BS EN 877 with internal epoxy coating and external anti-oxidant protective
primer. Stainless steel coupling joint with passivated stainless steel captive
bolt and an EPDM elastometic gasket to BS 5422.

(b) Cast iron pipes shall be jointed by flexible couplings conforming to BS 6087
with a EPDM seal to BS 2494.

(c) The flexible couplings shall be made of stainless steel grade 316 tightened by
one or more high grade stainless steel bolts of adequate strength to held the
pipe works in their correct alignment.

(d) The entire hubless drainage system shall be assembled and supported in
accordance with the manufacturer's recommendation & shall be capable to
withstand any surge pressure especially at the bottom of stacks. Detail of
anchor and fixings shall be submitted to the Project Manager for review
without objection.

(e) Provisions for electrical continuity shall be included & installed in strict
accordance with the manufacturer's recommendations.

(f) Adequate access doors shall be provided in pipe and fittings to meet Buildings
Department's requirements.

(g) Unless otherwise shown, all visible pipe work shall be constructed in Stainless
Steel to Grade 316 with Satin Finish.

(h) The stainless steel pipes shall be jointed by stainless steel flexible couplings.
The coupling housing is to be manufactured in 316 stainless steel conforming
to ASTM A 351, A 743 & A 744. Bolts/Nuts shall be of the round-head,
square-neck, type 316 stainless steel bolts and heavy hex nuts conform to
ASTM F-593. The seals shall be EPDM to B.S. 2494.

(i) No joints shall be allowed in any portion of the pipework within the visible
length of the RWP passing through the public areas.

(j) The Contractor shall submit calculations to confirm the couplings selected
shall be capable of withstanding an operational pressure of 1.5 times the
maximum expected working pressure of the syphonic drainage system.

(k) The Contractor shall select the pipe diameter and pipe thickness to allow the
pipe to run unsupported through the entire exposed length of the concourse
taking into account all expected operational forces and potential impact loads
of passengers and baggage

General Materials & Workmanship Specification 9/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 (l) The pipework shall not contain any joints within the visible length of the RWP
passing through the public areas.

(m) The Contractor shall be responsible for all necessary submissions to the
BD/DSD.

95.3.5 Potable Water Pipes and Cleansing Water Pipes

(a) For Town Main to Sump Tank and Upfeed Pump Pipe

(i) Pipework shall be of cement-lined ductile iron pipes and fittings to BS

4772 and BS EN 545, metallic zinc coated.

(b) For Distribution to All Draw Off Points and Cleansing Water Pipe

(i) Pipework shall be of copper pipes to BS EN 1057 R250 in half hard

condition. Fittings for use with copper pipes shall comply with BS EN
1254-1 & 2, capillary joint and shall be non-dezincifiable. Silver brazing
filler material to BS EN 1044 shall be used on all capillary joints on
potable water supply.

95.3.6 Flushing Water Pipes

(a) For Upfeed Pump Pipe and Main Distribution

(i) Pipework shall be of cement-lined ductile iron pipes and fittings to BS

4772 and BS EN 545, metallic zinc coated.

(b) For Downfeed Pipes, Floor Distribution and Final Connection

(i) Pipework shall be of MDPE pipes PE80 to BS 6730 in sizes ∅20 mm to

∅63 mm and PE pipes PE100 to WIS4-32-13 in sizes ∅90 mm to
∅1,000 mm and automatic electofusion fittings to WIS4-32-14. All sizes
as indicated on the Employer’s Drawings are the minimum internal bore
size required.

95.3.7 Hot Water Pipes

(a) Pipework for hot water supply shall be copper in half hard condition with
thermal insulation and shall comply with BS EN 1057 R250. Fittings for use
with copper pipes shall comply with BS EN 1254 Part 1 & 4, capillary joint and
shall be non-dezincifiable. Silver brazing filler material shall comply with BS
EN 1044 and shall be used on all capillary joints on hot water supply system.

95.3.8 Town Gas Pipes

(a) Pipework shall be carbon steel and shall comply with BS EN 10216-1 and BS
EN 10217 Part1 with minimum pipe thickness of 5.6 mm. Carbon steel butt
weld fittings shall comply with BS 1965 : Part 1 and BS EN 10253-1 jointed by
welding. All pipes and fittings shall be coated with minimum one layer of
external epoxy primer.

General Materials & Workmanship Specification 10/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
95.3.9 Above / Underground Irrigation Water Pipes

(a) Above ground irrigation water pipework shall comply with Section 95.3.5 (a).

(b) Underground irrigation water pipework shall comply with BS EN 1452 for
unplasticized polyvinyl chloride (uPVC) plastics piping systems for water
supply, or BS EN 12106 for plastics piping systems for polyethylene (PE)
pipes, reviewed without objection from the Project Manager.

95.3.10 Valves, Taps and Cocks

(a) General

(i) valves shall comply with the following Standards or suitable equivalent:

- gate valves : BS 5150, BS 5154;

- globe valves : BS 5152, BS 5154;
- butterfly valves : BS EN 593; and
- non-return valves : BS EN12334, BS 5154;

(ii) materials used in the construction of valves shall comply with the
following Standards or suitable equivalent:

- copper alloy ingots and castings : BS EN 1982;

- gunmetal : BS EN 1982 LG2;
- copper alloy forging stock and forgings : BS EN 12165,
: BS EN 12420;
- copper alloy rods and sections : BS EN 12163,
: BS EN 12164,
: BS EN 12167;
- flake graphite cast iron : BS EN 1561;
- grey cast iron : BS EN 1561 Grade 220;
- stainless steel : BS 970 in grade 316;
- spheroidal graphite cast iron : BS EN 1563;
- carbon and alloy steel : BS EN10028 : Part 1 & 2;
- steel castings:
y pressure purposes : BS EN 10213-1 & 2; and
y non-pressure purposes : BS 3100.

General Materials & Workmanship Specification 11/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 (b) Gate Valves

(i) isolating valves shall be of fullway gate type and regulating valves shall
be of globe type, unless otherwise specified;

(ii) all working parts shall be of gunmetal or bronze. Spindles shall be high
tensile bronze, forged brass or stainless steel with Teflon packing to the
manufacturer's standard. Gate valves shall have split or solid wedge
gates of bronze with bronze seats. Disc valves shall have renewable
discs free to rotate on the spindle;

(iii) gate valves in potable water system not exceeding ∅50 mm shall be of
bronze construction to BS 5154 PN 25;

(iv) gate valves in potable water system / flushing water system exceeding
∅50 mm shall be double-flanged ductile iron resilient seated gate valves
with zinc free bronze spindle and inside screw and non-rising stainless
steel stem in grade 316 to BS 970 : Part 1 and complying with BS 5163
Type B. The valve body shall be epoxy-coated internally and externally.
Pipe connections shall be flanged and shall comply to BS EN 1092-2;

(v) gate valves in flushing water system not exceeding ∅50 mm shall be
UPVC diaphragm or ball type valves and shall be constructed with
material suitable for sea water use;

(vi) stop valves of ∅20 mm, used at inlet to flushing cisterns, shall be PVC
ball valve; and

(vii) gates valves for the hot water system shall be copper alloy and shall
comply with BS 5154 PN 25. Gates shall be double disc or split wedge
type, all gunmetal. Pipe connections shall be screwed BSP or flanged
and shall comply with BS EN 1092-1 & 2 and BS EN 1515-1.

(c) Globe Valves

(i) globe valves shall be:

- in compliance with BS 5152 and BS 5154;

- heavy pattern outside screw rising stem type with cast iron hand
wheel;

- cast iron with bronze trim for use in the potable water supply
system;

- cast iron with zinc free bronze trim or stainless steel trim grade 316
to BS 970 : Part 1 and suitable for sea water duty for use in the
flushing water supply system;

- screwed or compression joints for sizes up to ∅50 mm appropriate

to the duty required;

- flanged joints for sizes from ∅65 mm and upwards;

General Materials & Workmanship Specification 12/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 - flanged joints for use in pump discharge pipe; and

- flanges to BS EN 1092-2. Rated at the specified working pressure

but in no case less than PN 16.

(d) Non-Return Valves

(i) Non-return valves for use in the potable water system not exceeding
∅50 mm shall be of bronze construction to BS 5154 PN 25, of the silent
type with screwed plug cover and shall be suitable for installation in a
horizontal or vertical pipe line. Pipe connections shall be screwed BSP
or flanged to BS EN 1092-1 & 2 and BS EN 1515-1;

(ii) non-return valves in potable water system exceeding ∅50 mm shall be

stainless steel body in grade 316 to BS 970 Part :1 and complied with
BS EN 13709 of the silent swing check pattern with bolted cover and
shall be suitable for installation in a horizontal or vertical pipe line. When
the valve is installed vertically, the flow shall be in an upward direction.
For valves installed at the discharge side of the booster pump shall be of
silent swing check pattern;

(iii) non-return valves in flushing water system not exceeding ∅50 mm shall
be PVC diaphragm valves of quick closing type to eliminate the sudden
surge in the pipe line on closing;

(iv) non-return valves in flushing water systems exceeding ∅50 mm shall be

of stainless steel body in grade 316 to BS 970 : Part 1, double door non
return valves with stainless steel grade 316 to BS 970 : Part 1 disc, pin,
hinges and the likes valve to BS EN 13709. For valves installed at the
discharge side of the booster pump shall be of silent swing check
pattern; and

(v) non-return valves in flushing water systems shall be of construction

suitable for seawater application.

(e) Loose Jumper Stop Cocks Valves

(i) loose jumper stop cocks and valves in nominal sizes up to and including
∅50 mm shall be:

- gunmetal with crutch head to BS 1010 : Part 2 for use in potable

water supply; and

- unplasticized polyvinyl chloride (UPVC), with wheel head suitable

for operating temperature up to 40°C for use in flushing water
supply system.

(f) Ball Float Valves

(i) ball float valves shall be of the slow closing type with tinned copper float,
unless otherwise specified elsewhere. The valve body shall be robust
shaped to give a good flow pattern;

General Materials & Workmanship Specification 13/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 (ii) the valve piston shall close in the direction of flow such that the pressure
from the mains supply acts to keep the valve closed and the piston seal
is afforded protection from the flow by the piston;

(iii) lever arms shall be of stainless steel for flush water application;

(iv) ball float valves shall be of bronze or cast iron valves body with nickel
alloy and stainless steel working parts;

(v) ball float valves up to ∅50 mm for water tank shall be bronze to BS 1212
: Part 1, suitable for high pressure. For salt water systems the bronze
shall be zinc free bronze piston, seat and guide;

(vi) ball float valves over ∅50 mm for water tank shall be cast iron body with
gunmetal piston, seat and guide, suitable for high pressure. For salt
water systems ball float valves shall have a cast iron body with zinc free
bronze piston, seat and guide;

(vii) where ball float valves are installed inside sump tanks, extended guide
pipes with submerged discharge ends shall be provided after ball valves.
Guide pipes shall be of diameters not less than the incoming pipes and
shall be holed as appropriate to avoid back siphoning;

(viii) all internal parts shall be easily removable for maintenance with the face
and piston seals easily replaceable;

(ix) ball floats selected for valves shall be sized in accordance with the
pressure zone of the valve, and shall comply with BS 1968 or BS 2456;

(x) ball float valves for flushing cisterns shall be diaphragm type float
operated valves to BS 1212 : Part 3 with rubber or plastic diaphragms
suitable for high, medium or low pressure. Metal parts of valves shall be
suitably coated to prevent corrosion;

(xi) for fresh water applications ball floats may be of copper, tinned copper,
or plastic. For salt water applications ball floats shall be either neoprene
coated copper or plastic. All ball floats shall be spherical unless
otherwise specified; and

(xii) the use of jointing material based on red lead will not be permitted.
Solder used for jointing copper or copper alloy potable water pipes shall
be lead free and comply with BS EN 1254-1 and 2.

(g) Pressure Reducing Valves

(i) pressure reducing valve sets shall be of pilot-operated type and installed
to provide ready access for maintenance purposes and shall comprise
the following:

- isolating gate valves and by-pass valve;

- pressure reducing valve;

- taper pieces to reduce to the valve bore and enlarge afterwards to

the bore of the low pressure main;

General Materials & Workmanship Specification 14/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 - pressure gauges shall be installed on both the inlet side and the
outlet side of the reducing valve set. Each pressure gauge shall,
register kPa and be calibrated to twice the working pressure, fitted
with a hand set red pointer and an indicating block pointer. Each
gauge shall be fitted with a lever handle, plug cock and gunmetal
syphon and cock for inspection gauge, and mounted on a
hardboard panel fixed to the wall in an easily readable position;

- pressure reducing valves shall be stainless steel in grade 316 to

BS 970 : Part 1 body, body seat, specially compounded
compositions seat disc, nylon reinforcement of Buna-N diaphragm
on stainless steel. The valve shall be of the ratio reducing type or
of the suitable type by means of adjusting spring; and

- for normal sizes up to and including ∅50 mm, valve shall be screw
jointed whilst from ∅65 mm and upward valve shall be flanged
joints to BS 1092 : Part 2 corresponding to system pressure.

(ii) The performance curve of pressure reduction against flow rate shall be
submitted to the Project Manager for review without objection.

(h) Water Hammer Arrestor

(i) the water hammer arrestor shall be stainless steel grade 316 to BS 970 :
Part 1 construction suitable for seawater application;

(ii) the unit shall have welded nesting type bellows surrounded by non-toxic
mineral oil in a factory sealed pressurised compression chamber
capable of absorbing the hydrostatic shock occurring in water-lines; and

(iii) the unit shall be suitable for 1,600 kPa working pressure and shall be
installed in an upright position or as recommended by the manufacturer.

(iv) The water hammer arrestor installed inside tank rooms shall be of hydro-
pneumatic accumulator bladder type whilst those installed for toilet
blocks shall be piston type.

(i) Draw Off Taps shall be

(i) to BS 1010 : Part 2;

(ii) in forged brass for use in potable water supply system;

(iii) in seawater corrosion resisting zinc free bronze for use in flushing water
supply system;

(iv) heavy pattern bib or pillar taps or screw-down or non-concussive spring

type appropriates to the duty required;

(v) chromium plated;

(vi) capable of withstanding a working pressure of at least 1,000 kPa; and

(vii) Water Authority’s approved type.

General Materials & Workmanship Specification 15/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 (j) Automatic Water Taps for Basins shall be

(i) automatically operated by infrared sensors with adjustable sensing

distance of 200 to 300 mm. Power supply to sensors shall be 6V DC
battery;

(ii) suitable for the water supply pressure of 70 kPa to 700 kPa with
minimum flow rate of 0.15 L/s;

(iii) supplied with built-in filters and aerators;

(iv) fabricated with chrome - plated brass; and

(v) Water Authority’s approved type.

(k) Flushing Valves

(i) flushing valves shall be constructed with material suitable for seawater
use;

(ii) the cartridge and other valve components shall be easily replaceable;

(iii) filters shall be installed before flushing valve;

(iv) valve body and all water contacting parts shall be made of either/or the
combination of gunmetal to BS EN 1982 and stainless steel in grade 316
to BS 970 : Part 1;

(v) all flushing valves shall pass the 200,000 cycles endurance test as
required by Water Authority;

(vi) flushing valves for urinals shall be automatically operated by infrared

sensor; and

- valves shall be suitable for the water supply pressure of 70 kPa to

700 kPa and with adjustable flushing volume from 2.5 litres to 5
litres; and

- power supply to infrared sensors and solenoid valves shall be

220V AC.

(vii) flushing valves for water closets shall be manually operated by lever.

- valves shall be suitable for the water supply pressure of 70 kPa to

700 kPa and with flushing volume adjustable from 7.5 litres to 13
litres.

General Materials & Workmanship Specification 16/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
95.3.11 Sanitary Fixtures

(a) Shower

(i) shower trays shall be to BS 6340 : Part 8 and shall be made from
vitreous china; and

(ii) shower fittings shall be Water Supplies Department approved chromium

plated brass easy clean valve or combination valve fitted with an
exposed swan neck riser and one of the following:

- 90 mm fixed rose;

- swivel-jointed rose; and

- self cleansing swivel-jointed rose with an adjustable spray.

(b) Wash Basins

(i) wash basins shall be to BS 1188 and shall be made from vitreous china
of the following types:

- type A (1) with back skirting up to 76 mm high, size 635 x 455 mm;

- type A (2) ditto, but 560 x 405 mm;

- type B (1) without back skirting 635 x 455 mm; or

- type B (2) ditto, but 560 x 405 mm.

(ii) cold water tap shall be connected to wash basins and shall be spring
loaded type for the wash basins in public areas;

(iii) wash basins shall be supported on one of the following as specified:

- pair of concealed painted steel brackets;

- pair of porcelain enamelled towel rail brackets;

- set of porcelain enamelled or chromium plated legs and brackets;

or

- proprietary brackets to suit the basins reviewed without objection

by the Project Manger; and

(iv) water tight seal between the walls and the basins shall be made by
using silicone sealant.

(c) Sinks

(i) sinks shall be to BS 1244 : Part 2, stainless steel (18/8) 0.9 mm

minimum thick, with satin finish to the size and configuration shown on
the Employer’s Drawings with overflow and sound deadening pads
under the sink and drainers; and

General Materials & Workmanship Specification 17/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 (ii) sinks shall be provided with an effective means of attaching a bonding
conductor which shall be accessible to the electrician after the sink has
been installed.

(d) Water Closets (W.C.)

(i) W. C. pans shall be vitreous china washdown with horizontal outlet to

BS 5503 : Part 3, white plastic single ring seat and cover with plastic
fixing bolts all to BS 1254 and flushing cistern to BS 7357, complete with
valveless symphonic flushing apparatus, discharge pipe, ball valve and
overflow. The flushing cistern shall be of one of the following types:

- low level plastic;

- high level plastic;

- low level vitreous china; or

- close coupled vitreous china.

(e) Urinals

(i) urinals shall be vitreous china bowl type to BS 5520 complete with
vitreous china automatic flushing cistern to BS 1876, plastic flush pipes
and spreaders to suit the number of appliances in the range as follows:

- 4.5 litres to serve single bowl;

- 7.5 litres to serve 2 bowls; or

- 13.5 litres to serve 3 bowls.

95.4 SUBMISSIONS

95.4.1 Particulars of Pipework, Fittings and Valves

(a) The following particulars of the proposed pipework, fittings and valves shall be
submitted to the Project Manger for review without objection:

(i) Contractor’s Drawings showing plans, elevations and sections of piping

layout and location of valves, pipe support hangers, guides, anchors,
and equipment to which the piping connects;

(ii) details of the pipe joints, pipe support hangers, guides and anchors;

(iii) test certificates and complete catalogue information with full technical
data for pipe material, fittings and valves;

(iv) approval letter from Water Supplies Department for pipework, fittings
and valves;

(v) pipe testing and cleaning procedures; and

(vi) complete testing report after testing and commissioning.

General Materials & Workmanship Specification 18/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
95.4.2 Samples

(a) The following samples of the proposed pipework, fittings and valves shall be
submitted to the Project Manger together with the particulars referred to in
Section 95.4.1 above.

(i) pipe material and fittings;

(ii) valves; and

(iii) pipe joints, pipe support hangers, guides and anchors.

95.5 WORKMANSHIP

95.5.1 Pipework

(a) Valves and similar items shall be located in accessible positions.

(b) Pipework shall not generate or transmit vibration or noise, nor shall it sag,
bow, reverse pitch, liquid flushing, trap, deflect, hammer or strain any
connected plant.

(c) Pipes shall be installed with correct falls for venting and draining and attention
must be paid to neatness of installation, i.e. groups of pipes shall be
accurately spaced, valves and joints symmetrically arranged. Where
practicable, when two or more pipes are visible and change direction together
bends shall be formed from a common radius point. All vent pipes shall have
a minimum gradient of 1:80 unless otherwise noted on the Employer’s
Drawings.

(d) In particular for drainage pipes, cleaning eyes shall be provided at bends and
tees, etc. and access doors shall be provided at the lowest accessible point of
the pipes. The access doors shall be sealed with a rubber or synthetic washer
and secured by bolts.

(e) The Contractor shall bond all metal water pipes to the electrical installation
main earth terminal as near as possible to their point of entry into the building.

(f) Contact between certain dissimilar metals shall be avoided in particular the
direct contact of copper with galvanized iron or steel pipes. If contact between
dissimilar metal is permitted gunmetal joints shall be provided between
dissimilar metals.

(g) Provide solar protection or insulation for pipes running at roof top by shelter or
by painting them white.

(h) Pipes shall not run through lift motor rooms, switch rooms, transformer rooms,
PABX rooms, telephone rooms, or computer rooms.

(i) In other areas, pipes shall not be located within 1.5 m of any electrical
apparatus.

(j) Pipework over passages for plant operators and services shall have a
minimum clearance of 2100 mm from the finished floor level.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 (k) Sufficient elbows and offsets shall be provided to permit free expansion and
contraction of pipe runs.

(l) Large radius elbows and bends shall be factory fabricated for drainage pipes.

(m) Reducers shall be used where changing pipe sizes.

(n) All hydraulic installations passing through fire/protected compartments shall be

enclosed by fire rated material with the same fire resisting period of the
compartments.

95.5.2 Pipe Penetrations

(a) Pipes shall be sleeved when passing through walls, floors and ceilings.

(b) The sleeves shall be short lengths of galvanized mild steel pipe and where
fitted in floors, they shall extend 100 mm above the finished floor level unless
otherwise indicated on the Employer’s Drawings. For copper pipe, sleeves
shall be either copper or brass.

(c) There shall be 20 mm clearance between sleeves and pipes contained in

them.

(d) Pipe sleeves fitted in fire rated walls or floors shall be caulked for the full depth
with fire resistant material providing the same fire resisting period as the
element through which the pipe breaches.

(e) Masking plates shall be provided on both sides of walls and ceilings and shall
be sealed by the weather proof material.

(f) Where UPCV / PE pipes pass through any fire / protected compartment floor
or wall, fire collars acceptable to FSD shall be installed to pipework with
installation method recommended by the manufacturer of the fire collar and
approved by FSD.

95.5.3 Pipe Supports

(a) Furnish hangers, supports, guides, saddles and anchors to BS 3974 with
adequate provision to allow expansion and contraction. Pipework supports
shall be installed as near as possible to joints at all points and change of
direction and each support shall take its share of load.

(b) All pipe supports shall be steel, adjustable for height and prime coated and
finish coated with rustoleum. Pipe support materials shall be:

(i) ferrous pipes shall have ferrous bracket;

(ii) copper pipes shall have brass brackets; and

(iii) UPVC / PE pipes shall have ferrous brackets coated with PVC.

General Materials & Workmanship Specification 20/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 (c) Additional supports shall be provided adjacent to valves and pumps.

(d) Pipe hangers shall be designed and constructed to be capable of withstanding

the loading of pipework without failure when the loads are applied steadily in a
non-shock manner.

(e) All fasteners and bolts shall be furnished with lock washers and nuts.

(f) Gaskets shall be provided between clamps and pipes or dissimilar materials.

(g) Pipe supports shall provide for the removal of any pipe section without the
necessity of disconnecting other adjacent pipes.

(h) For pipework up to ∅50 mm fixed to solid structures: brackets shall be screw-
on or long shank built-in type. Fixings to timber or to light-weight structures
shall be screwed.

(i) Pipework of ∅65 mm and larger subject to expansion and contraction, shall be
suspended on swivel hangers.

(j) The discharge pipework from pumps and all pipework where vibration could
be transmitted to the building structure shall be supported with brackets
through neoprene-in-shear hangers or with spring mounted brackets though
neoprene/rubber washers at contact of bracket to pipe shall be provided.

(k) UPVC / PE pipework shall be adequately supported such that no deflection of

pipe occurs and supports shall be provided at all joints.

(l) Pipe anchors at the ends or turning points of UPVC / PE pipes subject to
water hammer shall be fixed to directly transmit forces to the anchors.

(m) Spacing of supports shall not exceed the intervals given below unless
otherwise indicated.

Table for Maximum Support Spacing

Material of Nominal Support Centre(m)

Pipework Bore(mm) Vertical Horizontal
Ductile Iron All 3.0 1.75
Cast Iron All 3.0 1.75
Galvanized Up to 15 2.4 1.8
Steel 20and 25 3.0 2.4
32 3.0 2.7
40 and 50 3.6 3.0
65 and 80 4.5 3.6
100 and 150 5.4 4.5

General Materials & Workmanship Specification 21/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 Material of Nominal Support Centre(m)
Pipework Bore(mm) Vertical Horizontal
Copper 15 to 22 1.8 1.2
28 2.4 1.8
35 and 42 3.0 2.4
54 3.0 2.7
76 and 108 3.6 3.0
UPVC 15-20 0.9 0.6
25-32 1.1 0.9
40-80 1.4 1.2
100 1.9 1.9
150 2.1 2.1

95.5.4 Pipe Joints

(a) All pipe joints shall be in accordance with the manufacturer’s

recommendations.

(b) Ductile iron pipes shall be jointed with flanges or flanged fittings. Flanges
shall comply with BS EN 1092: Part 2 PN 16.

(c) Galvanized mild steel pipes up to and including ∅100 mm nominal bore shall
be jointed with screwed fittings. Screwed flanges shall only be used for
galvanized steel pipes ∅150 mm and above.

(d) Joints for the copper pipework shall be as follows:

(i) size up to and including 65mm shall be of the capillary or compression

type to be BS EN 1254-1 & 2. Size of the 76mm and 108mm shall be
the flanged compression. Size for pipework above 108mm shall be
flanged or welded;

(ii) pipework shall be arranged with adequate connection points to allow

easy dismantling. Connection points in copper pipework size up to and
including 65mm size shall be unions and for pipework of size 76mm and
above shall be flanged; and

(iii) the outside of the tubing and inside of the fittings at the point of contact
shall be cleaned before commencing jointing.

(e) UPVC / PE pipe shall not be joined by screw threads. Fixing and jointing
UPVC / PE pipes shall follow the manufacturer’s recommendations. Jointing
UPVC / PE pipes to pipes of other material shall be connected by proprietary
adaptors.

(f) Fittings for carbon steel pipes shall comply with BS 1965 : Part 1 and BS EN
10253-1 jointed by welding. All pipes and fittings shall be coated with minimum
one layer of external epoxy primer.

General Materials & Workmanship Specification 22/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
95.5.5 Valves and Strainers

(a) Every Section of branch supply piping and water supply risers shall be
controlled by a stop valve.

(b) Every major item of equipment shall be independently controlled for cold
water, and selected items of equipment for hot and cold water, by means of
globe valves and gate valves. Branch piping to every group of fixtures shall
also be valved.

(c) Valves shall be in accordance with the regulations of the Relevant Authority.

95.5.6 Fire Collars

(a) All UPVC / PE drain pipes and flushing pipes passing through floor slabs or
walls separating fire compartment shall be equipped with FSD approved fire
collars to maintain the compartmentation.

95.5.7 Access Pipes

(a) Access pipes shall be provided at the lowest accessible point of each rain
water, soil and waste pipe, at each junction and change in direction of piping,
or elsewhere indicated on the Employer’s Drawings.

(b) Access pipes shall be sealed with a rubber or synthetic washer and secured
by two bolts.

95.5.8 Movement Facilities and Anchors

(a) Suitable provision shall be made for structural movement as well as thermal
expansion and contraction.

(b) Articulated couplings, bellows, loops or similar shall be provided on all

pipework that crosses any structural movement joint.

(c) Anchors & guides and metallic bellows shall comply with BS 3974 : Part 2 and
BS 6129 : Part 1 respectively.

(d) Anchors shall be constructed to withstand the higher thrust during piping
hydraulic pressure test.

95.5.9 Bellows Expansion Joints

(a) Bellows type expansion joints shall be provided for all pipework passing
through building expansion joints.

(b) Joints shall comprise thin wall multi-plied omega formed convoluted bellows of
stainless steel material to BS EN 10029, 10051 and 10259 of appropriate
type.

(c) The bellow expansion joint shall be provided with a close fitting stainless steel
internal liner to reduce turbulent flow.

(d) End termination to be carbon steel threaded male to ISO 7-1 or carbon steel
flanges to ISO 7005 Standard to suit the line pressure.

General Materials & Workmanship Specification 23/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 (e) Expansion joints shall be of stainless steel multi-bellows type complete with
necessary guides as recommended by the manufacturer to give a working life
of not less than 20 years.

(f) Design working pressure shall not be less than 2,000 kPa unless otherwise
specified.

(g) Expansion joint shall be installed in strict accordance with the manufacturer’s
recommendations.

(h) The lateral and axial movements of the expansion joint shall not be less than
±6 mm.

(i) Reference shall be made to the Structural Movement Report.

95.5.10 Sanitary Fixtures

(a) Cast-in type brackets shall have at least 75 mm cover.

(b) Waste outlets to wash basins, sinks, and showers shall be bedded using
proprietary jointing compounds. The Contractor shall provide and install
compression couplings or soldered capillary jointed couplings to connect water
tubing to taps and valves, to connect wastes and overflows.

(c) Taps shall be fixed to make a watertight seal with the sanitary appliance. Hot
taps shall be fitted on the left and cold taps on the right as viewed by the user
of the appliance.

(d) All accessories shall be fixed using brass or stainless steel screws set into
plastic plugs as required.

(e) Antisyphonage traps provided with sanitary fixtures shall have a 80 mm seal.

(f) Water tight seal between the walls and the basins shall be made by using
silicone sealant.

(g) The Contractor shall follow the manufacturer’s recommendations regarding

materials and fittings to be used and method of jointing.

(h) Stainless steel sinks shall be properly built into cabinets with the sink back set
into the tile work as shown on the Employer’s Drawings. The Contractor shall
ensure that no crevices remain anywhere around the edge surfaces which will
harbour dirt and shall point joints between counter tops and sink sides with
silicone sealant as detailed

(i) Pedestal type W. C. pans shall be fixed as follows:

(i) bed W. C. pans on concrete floors in white lead putty or other non-
hardening compound. If cement mortar is used for bedding, it shall be
not richer than 1:6 ratio of cement to sand, and a thin layer should be
applied only to that part of the pedestal which is in contact with the floor.
Fix with No.14 SG round-headed brass screws 70 mm long with domed
plastic inserts in colour to match to fixture; and

General Materials & Workmanship Specification 24/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 (ii) jointing W.C. pans to soil pipes with PVC W.C. pan connectors to BS
5627 or other type shall be reviewed without objection by the Project
Manger;

(j) Asiatic type W. C. pans shall be bedded on concrete floors in cement and
sand mortar 1:3 and joint to soil pipes in similar mortar.

(k) Wall hung type W.C. pans shall be fixed to load bearing walls or support the
walls and the edge of the W.C. pans shall be made by appropriate sealant.

(l) Fixing urinals (slab type) as follows: -

(i) bed channel outlet to waste connector in proprietary jointing compound;

(ii) bed treads in cement and sand mortar 1:3 with fall towards channel;

(iii) completely fill space behind slabs with cement and sand mortar 1:5; and

(iv) joints to be 3 mm (maximum) wide. Rake out joints to a depth of 5 mm

and point flush with an approved proprietary white grout.

(m) Fixing urinals (stall type) as follows: -

(i) bed outlet to waste connector in proprietary jointing compound; and

(ii) bed base and overlap facing in cement and sand mortar 1:3.

(n) Fixing urinals (wall type) as follows: -

(i) fix bowl and division to wall with brackets, concealed hangers or screw,
as required.

(o) Samples: -

(i) After finalization of all details, the Contractor shall produce samples of
sanitary fixtures and accessories and obtain a notice of no objection
from the Project Manager, before proceeding with manufacture.

(ii) Samples shall comprise materials in their final form as proposed for
inclusion in the Permanent Works.

(p) Prototypes: -

(i) The Contractor shall construct off-site (or on-site if specifically required
by the Project Manger), a working model of the sanitary fixture to test the
performance and show the workmanship and finishes, prior to
manufacturing.

(ii) The prototypes shall be tested and examined in terms of quality,

materials, interfacing details for accessibility by other trades, and
workmanship by the Project Manger.

(iii) The arrangements shall be as shown on the Employer’s Drawings, and

shall include all visible components of the various constructions.

General Materials & Workmanship Specification 25/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
 (iv) Certain prototypes may, upon acceptance, and if so agreed by the
Project Manager, be stored on Site in an area designated by the Project
Manager for subsequent use in the Permanent Works. Following the
fixing of the first elements of such prototypes, they shall be reviewed
without objection by the Project Manager and shall, if to the satisfaction
of the Project Manager, be used as a comparative measure, to monitor
the quality of subsequent installation.

(v) The Contractor shall provide, maintain and/or clear away all prototypes.

(q) Benchmarks: -

(i) The Contractor shall ensure that a benchmark is completed for the first
public toilet block including all fixing seals in order that the quality of the
Contractor’s work can be assessed prior to commencement of the
Permanent Works.

(ii) These benchmarks shall be used to set the standards of quality,

materials and workmanship of the Permanent Works, or where
specifically stated, for the purposes of testing. These benchmarks shall
after review without objection by the Project Manager form part of the
permanent Works, and the Contractor shall ensure that it is maintained
in a good condition for comparison with the remainder of the Works.

General Materials & Workmanship Specification 26/26 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 95 – Pipework, Fittings & Valves
SECTION 96 TOWN GAS RETICULATION

96.1 GENERAL

(a) This section covers the general requirements for town gas reticulation and
installation works.

(b) Town gas reticulation and installation works shall generally comply with all
regulations and requirements including those of the government departments
(e.g. FSD, BD and EMSD) and Gas Supply Company. The Works shall
comply with the following:

(i) Gas Safety Ordinance and its Regulations;

(ii) Fire Services Ordinance and its Regulations; and

(iii) relevant British Standards as detailed below.

96.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 5501 : Part 1 Electrical Apparatus for Potentially Explosive

Atmospheres. General Requirements;

BS 5501 : Part 5 Electrical Apparatus for Potentially Explosive

Atmospheres. Flameproof Enclosure 'd';

BS 5501 : Part 7 Electrical Apparatus for Potentially Explosive

Atmospheres. Intrinsic Safety 'i'; and

DW/144 Specification for Sheet Metal Ductwork.

96.3 MATERIALS

96.3.1 Pipework and Fittings

(a) All pipework and fittings for town gas reticulation and installation works shall
refer to Section 95 of this General Materials and Workmanship Specification.

96.3.2 Pipe Support

(a) All pipe support for town gas reticulation and installation works shall refer to
Section 95 of this General Materials and Workmanship Specification.

General Materials & Workmanship Specification 1/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 96 – Town Gas Reticulation
96.3.3 Enclosure for Town Gas Pipes

(a) Enclosure for town gas pipes shall be provided at the non ventilated area and
had individual continuous pipe enclosure (2 HRS F.R.P.) with ventilation
opening at both high level and low level to open air.

(b) Enclosure shall have free opening area equal to 1/150 of cross section area of
the duct or 0.05m2 whichever is the greater.

(c) Enclosure shall have access panel for ease of maintenance.

(d) Enclosure elements in any basement and the separation between the
basement and any adjoining storey shall have F.R.P. not less than 4HRS.

(e) The table of minimum internal size of enclosure for gas pipe are as follows:

Gas Pipe Diameter (mm) Internal Size of Enclosure L x L (mm)

15 100
20 100
25 150
32 150
40 150
50 200
80 300
100 300
150 350
200 450
250 500
300 550

96.4 GAS DETECTION SYSTEM

96.4.1 General

Gas detection systems shall be installed to continuously monitor methane and

hydrogen gas concentrations in the sheaths. Details of the gas detection system
are as follows:

(a) System Description

(i) The gas detection system shall consist of three major components: (1)
the microprocessor-controlled gas alarm control unit, (2) the explosion-
proof pellistor (electrocatalytic principle of heat reaction) sensor gas
detector and (3) a printer which records the time and LEL status of
individual gas detector.

General Materials & Workmanship Specification 2/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 96 – Town Gas Reticulation
 (ii) Each sheath shall be monitored by at least two independent gas
detection systems. In the event of one system malfunctioning,
monitoring activities shall be maintained, but the number of functional
gas detectors will be reduced.

(iii) Upon the detection of concentration of either methane or hydrogen gas

equivalent to 20% of the LEL, an audible alarm shall be actuated in each
Gas Detection System Panel and through the MBMS. In the event that
the concentration of either gas rises to 40% of the LEL, the Gas
Detection Systems shall also actuate an alarm in the FSD via direct
telephone links provided by the Contractor.

(b) Equipment Specification

(i) The equipment proposed and planned for use must be formally
approved by at least one of the following testing laboratories:

- BASEEFA (Britain); or
- FM (USA).

(c) Automatic Gas Detectors

(i) The gas detectors shall be able to detect either of the following gases at
20% and 40% of the LEL (lower explosive limit):

- methane; or
- hydrogen.

(ii) The gas sensor for combustible gases and vapours shall work on an
electrocatalytic principle of heat of reaction (Pellistor).

(iii) The gas detector shall be of modular design (e.g. contained within a
single unit).

(iv) The gas detector shall be usable in explosion hazardous areas.

(v) The gas detector shall be conform to protection category EEX II as well
as to the BS 5501 : Part 1, 5 and 7.

(vi) The capsule of the sensor shall be made of aluminium, stainless steel or
plastic.

(vii) The gas detector shall be of addressable type.

(viii) The data bus topology shall be selectable as stub or as loop type or any
combinations of those topologies.

(ix) The wiring of the detector data bus shall be with unshielded 3 or 4 wires
twisted pair in conduits.

(x) The calibration of the detectors shall be possible in explosion-hazard

areas.

(xi) The calibration of the addressable detectors shall be processor

controlled.
General Materials & Workmanship Specification 3/7 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 96 – Town Gas Reticulation
 (xii) The gas detector shall comply with the following conditions:-

- Ambient Temperature -25°C to +64°C;

- Relative Humidity 10% to 95%;
- IEC Protection Category > IP 65;
- Supply Voltage 19V to 27V; and
- Gas Concentration 20% LEL to 100% LEL
selectable.

(xiii) Each detector data bus shall be designed to connect at least 10

addressable gas detectors.

(xiv) All detector data bus shall be monitored against open/short circuits and
ground fault.

(xv) For each detector 3 alarm levels shall be free programmable: warning,
pre-alarm and alarm.

(xvi) Calibration of the detectors shall not have an effect on the normal
operation of the rest of the system not involved in the calibration
procedure.

(xvii) The display of the momentary concentration values of each detector

shall be displayed in numerical (digital) and analogue value.

(xviii) It shall be possible to program the values of the upper and lower level of
the analogical display for each detector or for several groups of
detectors individually; the alarm levels of each detector shall be
displayed on the analogue scale for control purposes.

(d) Gas Alarm Control Units

(i) The gas control unit shall consist of modular, unit-type assemblies to
facilitate removal, maintenance and system expansion.

(ii) The gas control unit shall be a self contained unit, capable of operating
in a stand-alone mode, with or without connection to a higher
hierarchical system level.

(iii) The gas control unit shall be capable of connection to gas detectors. If
detectors of one type have to be replaced by detector of another type,
no changes to the control unit hardware shall be necessary.

(iv) The gas control unit shall be microprocessor based and shall be
designed to ensure the high reliability and availability which is necessary
for life safety systems.

(v) The gas control unit shall process and evaluate a minimum of 40 gas
detectors via data bus loop or stub lines.

(vi) The gas control unit shall have common potential free contacts for
failure, warning, pre-alarm, alarm and remote transmission to the MBMS
and FSD.

General Materials & Workmanship Specification 4/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 96 – Town Gas Reticulation
 (vii) The potential free contacts shall be free programmable in "and/or" mode.

(viii) It shall be possible to integrate a protocol printer into the local gas
control unit.

(ix) The gas control unit shall contain the power supply for the entire gas
detection system.

(x) The power supply unit shall contain suitable over-voltage protection to
prevent any malfunction or damage which might occur from line power
surges (lightning).

(xi) The gas control unit shall be equipped with a built-in standby battery and
charger rated to maintain operation for 6 hours after mains power failure.
An alarm condition shall be maintained for at least 30 minutes after the
expiry of the 6 hours time period.

(xii) Upon loss of mains power, the power supply unit shall automatically
revert to battery power, and the system shall remain fully operational.
Automatic re-start after power surge is required.

(xiii) When battery voltage drops below 20V of nominal 24V DC, a fault
indication shall be provided to indicate a battery fault condition.

(xiv) The entire power supply and charger circuits including all fuses shall be
monitored by MBMS. Any malfunction, blown or missing fuse shall
result in a fault indication on the local gas control unit, and transmission
of the fault to the MBMS.

(xv) The gas control unit shall comply with the following ambient conditions:

- Operating temperature -5°C to +50°C;

- Relative humidity (non- Maximum 95%; and
condensing)
- IEC protection category Minimum IP 20.

(xvi) Automatic gas detector signals from gas detection panel shall be
repeated to the existing MBMS and gas detection system. Digital I/O
shall be provided in each detection panel for connection to the existing
MBMS and gas detection system.

(e) Protocol Printer

(i) The printer shall be protocol type and record all detector status. It shall
be integral with the gas control unit.

General Materials & Workmanship Specification 5/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 96 – Town Gas Reticulation
96.5 SUBMISSIONS

96.5.1 Particulars of Town Gas Reticulation and Installation Works

(a) The following particulars of the proposed town gas reticulation and installation
works shall be submitted to the Project Manger for review:

(i) Contractor’s Drawings showing plans, elevations and sections of piping

layout and location of valves, pipe support hangers, guides, anchors,
and equipment to which the piping connects;

(ii) details of the pipe joints, pipe support hangers, guides and anchor;

(iii) test certificates and complete catalogue information with full technical
data for pipe material, valves, components of gas detection system (e.g.
automatic gas detector and gas alarm control unit) and accessories;

(iv) pipe testing and cleaning procedures;

(v) complete testing report after testing and commissioning; and

(vi) fixing detail of the gas detectors in the fire rated enclosure.

96.5.2 Samples

(a) The following samples of the proposed town gas reticulation and installation
works shall be submitted to the Project Manger together with the particulars
referred to in Section 96.5.1 above.

(i) pipe material and fitting;

(ii) valves;

(iii) pipe joints, pipe support hangers, guides and anchor; and

(iv) components of gas detection system (e.g. automatic gas detector).

96.6 WORKMANSHIP AND INSTALLATION

96.6.1 Pipework

(a) Vertical ductwork shall be enclosed in a continuous sheath of welded 6 mm

thick mild steel pipework in accordance with methods acceptable to Relevant
Authorities and reviewed without objection by the Project Manager.

(b) Unless otherwise reviewed without objection by the Project Manger and
Relevant Authorities, horizontal pipework shall be enclosed in an airtight
continuous 2 hours fire rated metal sheath vented at both ends to outside in
accordance with methods acceptable to Relevant Authorities and reviewed
without objection by the Project Manager.

General Materials & Workmanship Specification 6/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 96 – Town Gas Reticulation
 (c) Short lengths of horizontal pipework between risers and kitchen cabins, and
similar arrangements, shall be enclosed in 6 mm thick mild steel sheaths in a
similar manner to that required for risers.

(d) Pipework associated with the town gas installation shall be fully welded. All
joints shall be tested using non-destructive methods incorporating X-ray
techniques or similar. The testing method shall review without objection by
the Project Manager.

(e) Vertical risers in sheaths shall be wrapped in an anti-corrosion, self-adhesive

tape or similar. The material of tape shall review without objection by the
Project Manager.

(f) Adequate access panels shall be provided in the sheaths for access and
maintenance of the automatic gas detectors.

(g) All horizontal sheaths shall be pneumatically tested in accordance with

DW/144 for medium pressure ductwork. Vertical sheaths shall be
pneumatically tested to 12 kPa gauge pressure.

96.6.2 Pipe Supports

(a) Installation of pipe support for town gas reticulation and installation works shall
refer to Section 95 of this General Materials and Workmanship Specification.

General Materials & Workmanship Specification 7/7 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 96 – Town Gas Reticulation
[this page not used]
SECTION 97 PUMPS AND TANK LEVEL CONTROLS

97.1 GENERAL

This section of General Materials and Workmanship Specification covers the

general requirements for all pump, tank and relevant accessories.

(a) All pump, tank and necessary materials and workmanship shall generally
comply with all regulations and requirements of the Relevant Authorities (e.g.
Drainage Services Department-DSD, Buildings Department-BD, Electrical and
Mechanical Services Department-EMSD and the like). The Works shall
comply with the following standards:

(i) Cap 123 – Building (Standards of Sanitary Fitments, Plumbing, Drainage

Works and Latrines) Regulations; The Hong Kong Waterworks Standard
Requirements (February 2002); and

(ii) relevant British Standards as detailed below.

97.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials and Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 970 : Part 1 Specification for Wrought Steels for Mechanical and

Allied Engineering Purposes. General Inspection and
Testing Procedures and Specific Requirements for
Carbon, Carbon Manganese, Alloy and Stainless
Steels.

BS 3134 Metric tapered roller bearings. Specification for

dimensions and tolerances of single row bearings

BS 4164 Specification for coal-tar-based hot-applied coating

materials for protecting iron and steel, including a
suitable primer.

BS 5512 Method of calculating dynamic load ratings and rating

life of rolling bearings

BS 559 Specification for design, construction and installation of

signs.

General Materials & Workmanship Specification 1/18 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
97.3 MATERIALS

97.3.1 Pump

(a) Pumps shall be electrically operated and directly driven.

(b) The pumps shall be able to deliver water at flow rates as indicated on the
equipment schedules on the Employer’s Drawings. The pump duty heads
indicated on the equipment schedules are for guidance only.

(c) Water pumps shall operate normally under automatic control, by water level
control switches and / or pressure switches. A manual overriding switch shall
be provided for each pump.

(d) The pumps selected shall have a relatively flat characteristic suitable for both
of the combined parallel operation and single-pump operation. Curves
indicating excessive shut-off head shall not be permitted.

(e) Pumps speeds shall not exceed 2900 r.p.m. unless otherwise specified.

(f) Each complete pump unit including motor and drive shall be supplied from a
single manufacturer.

(g) All pumps shall be factory painted in accordance with the manufacturer’s
recommendations.

(h) Pump manufacturers shall have been in manufacturing pumps for at least five
years.

(i) The friction head shall be evaluated based on the total flow when the duty
pumps are operating simultaneously.

(j) Pumps shall be close-coupled units comprising a single stainless steel in

grade 316 to BS 970 shaft, a squirrel cage electric motor, and a single entry
end suction pump.

(k) Lifting frames or eye bolts shall be fitted to casings for the connection of lifting
chains.

(l) Two mechanical seals shall be fitted on the shaft between the electric motor
and the pump impeller. The space between these two seals shall be oil filled
and an oil seepage detector shall be provided.

(m) Motor terminals shall be contained in a separate IP 68 protection terminal box.

97.3.2 Type of Pump

(a) Cold Water Upfeed Pumps

(i) Pumps shall be of multi-stage centrifugal type, arranged with horizontal

shaft.

(ii) Impellers shall be gunmetal or bronze mechanically balanced and keyed

to the shaft. Renewable guide rings shall be provided in the casing,
keyed to prevent rotation.

General Materials & Workmanship Specification 2/18 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
 (iii) Shafts shall be stainless steel, grade 316 to BS 970. Gunmetal sleeves
shall be provided to protect the shaft in the water space and through the
sealing glands. Sleeves shall be keyed to prevent rotation and secured
against axial movement.

(iv) Cast iron stuffing boxes housing shall comply with BS EN 1561 and shall
be of ample length with bronze lined gland and neck bush, fitted with
packing reviewed without objection by the Project Manager and lantern
ring water seal. Drain piping to remove gland leakage shall be provided.

(v) The pump casings shall be of close-grained cast iron accurately

machined and assembled with metal-to-metal joints.

(b) Pneumatic Cold Water Booster Pump Sets

(i) Pump sets shall comprise duplicate pumps, and complete with pressure
vessel, motor starter panel and control unit. Pump set shall a package
unit. Locally assembled pump sets will not be accepted.

(ii) Pumps shall be horizontal end-suction type, directly driven through

flexible couplings by electric motors or close-coupled back pull out
centrifugal with mechanical shaft seal, horizontally mounted. The pumps
shall be of multi- stage construction with each stage/section to be
renewable.

(iii) Impellers shall be gunmetal or bronze mechanically balanced and keyed

to shaft. Renewable guide rings shall be provided in the casting, keyed
to prevent rotation.

(iv) Shafts shall be stainless steel grade 316 to BS 970. Gunmetal sleeves
shall be provided to protect the shaft in the water space and through the
sealing glands. The sleeves shall be keyed to prevent rotation and
secured against axial movement.

(v) Cast iron stuffing boxes housing shall comply with BS EN 1561 and shall
be of ample length with bronze lined gland and neck bush, fitted with
packing reviewed without objection by the Project Manager and lantern
ring water seal. Drain piping to remove gland leakage shall be provided.

(vi) The pump sets shall be complete with inter-connecting pipework,

isolating and non-return valves, flexible connectors and with flanged
connection ready for connection to the pipework system.

(vii) One or more pressure vessels shall be provided and installed on the
same mounting. The vessels shall be of adequate capacity to
accommodate a considerable fluctuation in water demand by the system
and shall minimize the start/stop cycles of the pumps.

(viii) The vessels shall be constructed of steel plate built to ASME Standards
for Unfired Pressure Vessels. All ancillary internal parts shall be copper
and bronze. The vessel cell body and the jointing/welding part shall be
free from scale and sharp edge.

(ix) A rubber diaphragm shall be provided in the pressure vessel separating

the water and the gas therein. The diaphragm shall be corrosion
resistant. The life of the diaphragm shall be at least 15 years.

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Section 97 – Pumps & Tank Level Controls
 (x) The vessels shall be pre-charged with nitrogen at factory at a pressure
to suit the systems. The pre-charge pressure shall be adjustable and a
charging port with non-return device shall be provided in each vessel.

(xi) The unit shall be complete with control panel and all accessory controls,
including starters, isolators, overload relay, selector switch, low level out-
out for pumps and pressure switches. The complete control panel shall
also be mounted on the common bed plate fabricated from mild steel.

(xii) The operation of the working pumps shall be initiated by the pressure
sensors/switches in sequence. If the pressure in the system drops to
the predetermined level, the working pumps shall cut in automatically.
Pump start/stop frequency shall not be more than 6 times per hour at the
rated output.

(xiii) The pump casings shall be of close-grained cast iron accurately

machined and assembled with metal-to-metal joints.

(c) Flushing Water Upfeed Pumps

(i) Pumps shall be of centrifugal type, with horizontal shaft.

(ii) Impellers shall be of stainless steel 316 to BS 970 mechanically

balanced and keyed to the shaft. Renewable guide rings shall be
provided in the casing, keyed to prevent rotation.

(iii) Shaft shall be stainless steel grade 316 to BS 970. Zinc-free bronze
sleeves shall be provided to protect the shaft in the water space and
through the sealing glands. The sleeves shall be keyed to prevent
rotation and secured against axial movement.

(iv) Cast iron stuffing boxes housing shall comply with BS EN 1561 and shall
be of ample length with bronze lined gland and neck bush, fitted with
packing reviewed without objection by the Project Manager and lantern
ring water seal. Drain piping to remove gland leakage shall be provided.

(v) The pump casings shall be of stainless steel grade 316 to BS 970
accurately machined and assembled with metal-to-metal joints.

(d) Hot Water Return Pumps

(i) Pump shall be close-coupled in-line type end suction pumps, with a
mechanical shaft seal. The working pressure shall be as specified or as
shown on the Employer’s Drawings. The hot water temperature shall be
up to 100°C.

(ii) Impellers shall be gunmetal bronze material mechanically balanced and

keyed to the shaft. Renewable guide rings shall be provided in the
casing, keyed to prevent rotation.

(iii) Shaft shall be stainless steel grade 316 to BS 970. Stainless steel
sleeves shall be provided and be keyed to prevent rotation and against
axial movement.

(iv) The pump casings shall be of close-grained cast iron accurately

machined and assembled with metal-to-metal joints.
General Materials & Workmanship Specification 4/18 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
 (e) Drainage Sump Pumps

(i) Drainage sump pumps shall be centrifugal submersible type. The pump
shall be capable of removal from the sump without draining the sump or
disconnecting the pipework in the sump.

(ii) Facilities shall be provided for raising and lowering the pump, and the
discharge pipe connection shall be automatic.

(iii) The coupling between the pump and motor shall be a double mechanical
seal. The seal shall be enclosed in an oil fill chamber for dissipation of
heat.

(iv) The pump impeller and water chute shall be a non-clog type and
capable of pumping both soil or waste water containing solids up to ∅65
rnm and high viscosity sludge.

(v) Pump motors greater than 3.7kW shall incorporate with thermo
protection devices to protect the motor from over heating.

(vi) The pump shall be provided with integrated submersible power cable of
adequate length to connect to the power supply point for the pump.
Intermediate junction/jointing/connection of this cable shall not be
accepted.

(vii) The pump casing shall be of stainless steel grade 316 to BS 970 with
impeller of stainless steel grade 316 to BS 970 or other approved
materials. Shaft sleeves shall be of zinc free bronze, and shaft of
stainless steel grade in 316 to BS 970.

(f) Pneumatic Cleansing Water Booster Pump Sets/Flushing Water Booster

Pump Sets

(i) Each pump set shall comprise duplicate pumps, and come complete
with pressure vessel, motor starter panel and control unit as a
packaged unit.

(ii) Pumps shall be of centrifugal type, complete with vertical or horizontal

shaft.

(iii) Impellers shall be manufactured in either gunmetal or bronze,

mechanically balanced and keyed to the shaft. Renewable guide rings
shall be provided in the casing, keyed to prevent rotation;

(iv) The shaft shall be manufactured in stainless steel grade 316 to BS 970.
Gunmetal sleeves shall be provided to protect the shaft in the water
space and through the sealing glands. The sleeves shall be keyed to
prevent rotation and secured against axial movement;

(v) Cast iron stuffing box housings shall comply with BS EN 1561 and
shall be provided with a bronze lined gland and neck bush, fitted with
packing and lantern ring water seal. Drain piping to remove gland
leakage shall be provided;

General Materials & Workmanship Specification 5/18 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
 (vi) The pump casings shall be of stainless steel grade 316 to BS970
accurately machined and assembled with metal-to-metal joints.

(vii) The pump sets shall be complete with inter-connecting pipework,

isolating and non-return valves, flexible connectors, with flanged
connection ready for connection to the distribution system;

(viii) Two pressure vessels shall be provided at equal capacity and installed
on the same mounting. The Contractor shall select the vessels to be
of adequate capacity to accommodate fluctuation in water demand by
the system and minimize the start/stop cycles of the pumps;

(ix) The operation of the working pumps shall be initiated by the pressure
sensors/switches in sequence. If the pressure in the system drops to
the predetermined level, the working pumps shall cut in automatically.
Pump start/stop frequency shall not be more than 6 times per hour at
the rated output.

(x) The vessels shall be constructed of steel plate built to ASME

Standards for Unfired Pressure Vessels. All ancillary internal parts
shall be copper and bronze. The vessel cell body and the
jointing/welding part shall be free from scale and sharp edges;

(xi) A rubber diaphragm shall be provided in the pressure vessel

separating the water and the gas therein. The diaphragm shall be
corrosion resistant. The life of the diaphragm shall be at least 15 years;

(xii) The vessels shall be pre-charged with nitrogen in the factory at a

pressure to suit the systems. The pre-charge pressure shall be
adjustable and the vessel shall be complete with a charging port with
non-return device;

(xiii) The unit shall be complete with control panel and all accessory
controls, including but not limited to, starters, isolators, overload relay,
selector switch, low level cut-out for pumps and adjustable pressure
switches to control pump operation. The complete control panel shall
also be mounted on a common bed plate fabricated from mild steel.

97.3.3 Pump Fitting

(a) Pump Bearings

(i) Bearings shall be sealed ball or rolled type, oil or grease lubricated.
Means shall be provided to protect the bearing from ingress of dust and
water. Appropriate lubrication nipple/connections or oiler sump with drain
plug shall be provided.

(ii) Bearings shall confirm to BS 3134 and shall be readily available in Hong
Kong. The bearings housing shall be cast iron and easily removable.
The bearing cover shall provide a labyrinth seal to contain grease / oil in
housing. For flushing water pumps, all bearings shall be stainless steel
grade 316 to BS 970.

(iii) At design conditions, bearings shall have a minimum L10 life of 100,000
hours. Rolling bearings shall be selected in accordance with BS 5512.

General Materials & Workmanship Specification 6/18 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
 (b) Pump Packings

(i) Pump packing shall be square plait construction and contain no

asbestos. Braids shall not be liable to become loose or peel off
throughout their life.

(ii) The packing shall be suitable for use in fresh water, potable water, sea
water and flushing water applications as appropriate. Size of the
packing shall be commensurate with the size of the pump.

(c) Pump Casing

(i) The pump casings for flushing water system and drainage sump pump
shall be stainless steel grade 316 to BS 970 accurately machined and
assembled with metal-to-metal joints. All other casings including potable
water and hot water shall be of close-grained cast iron.

(d) Flexible Connectors

(i) Each pump shall be connected to the pipework with flanged flexible
connectors to prevent the transmission of vibration to the pipework. The
flexible connectors and connecting flanges shall be capable of
withstanding at least 2 times the operating pressure. Supports for piping
between the pump and the flexible connectors shall be mounted on the
base whilst supports for piping beyond the flexible connectors shall be
attached to structural members such as beams and columns in
preference to floor slabs or walls and shall be provided with rubber or
neoprene pads for vibration isolation.

(e) Bed Plates

(i) The common bed plates for pumps and motors shall be from the same
manufacturer as for the pump. The complete assembly shall be skid
mounted on spring type vibration isolators.

(f) Strainers

(i) Strainers shall be installed in all pump suctions. The strainers shall be
of same size as the pipeline. Strainers shall be full line size, "Y" or
"BASKET" type as shown on Employer’s Drawings with flanged ends,
readily removable for cleaning. Pressure rating suitable for the system
served.

(ii) The total open area of basket perforation shall be 3 times the inside area
of pipes.

(iii) Strainers shall have cast-iron body and stainless steel, grade 316 to BS
970, basket with 1.5mm perforation.

(iv) Strainers at pump suctions shall be fitted with removable channel

magnets secured to the screen or basket by stainless steel, grade 316 to
BS 970 retaining lugs and threaded rods, and placed to provide a
continuous magnetic field around the entire circumference of screen.

General Materials & Workmanship Specification 7/18 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
 (v) The strainers shall be fitted with a breech-locking arrangement to
maintain the screen in place when moving the cover plate. The screen
cover plate shall be bolted using studs with hex nut and fitted with
special hinges.

(vi) Initially each screen shall be fitted with lined baskets, reinforced on both
sides with an open bottom. After initial cleaning, they shall be replaced
with standard basket, suitable for service. All “Y” type strainers shall be
complete with 25 mm isolating valve for drain or blow-off.

(g) Pressure Gauges

(i) Baked enamel iron case with dials not less than ∅100 mm, threaded
chromium plated brass ring with heavy glass, bronze spring tube,
precision movement and micrometer adjustment. Furnish pulsation
dampers, steel pipe fittings and shut off cocks of needle point globe type
all brass contactor, for 1,000 kPa working pressure.

(ii) The pressure gauge shall be calibrated in kPa to a maximum of not less
than 1-1/3 times and not more than 2.5 times the operating pressure.
Divisions of scale shall not exceed 20 kPa for a maximum scale value of
1,000 kPa, 50 kPa for a maximum scale value of 1,600 kPa and 100 kPa
for maximum values in excess of 1,600 kPa. An isolating valve/cock
shall be provided for each pressure gauge. Accessories and gauges for
flushing water system shall be stainless steel grade 316.

(h) Pump Motor Couplings

(i) A coupling shall be provided between the pump and motor, and shall be
semi-flexible of the steel pin/rubber bush type, accurately aligned. The
coupling shall reduce shock to the bearings etc. and shall not
compensate for misalignment. The pin and bush coupling shall be
installed to the same accuracy of alignment as rigid coupling,

97.3.4 Pump Control

(a) General

(i) Controls for the pumps shall consist of watertight float switches mounted
on stainless steel rods (separate on and off switches for each pump).

(b) Upfeed Pumps

(i) Unless otherwise stated the system shall include a duty and a standby
pump. The pumps shall be automatically controlled to maintain the
water level in the gravity water tanks.

(ii) When the water level in the gravity tank is drawn to below half of the full
storage levels, the duty pump shall operate and continue to run until the
water level reaches 25 mm below the invert of the overflow pipe, when
the tank is at full storage capacity.

(iii) Float type mercury switches shall be used for both potable water and
flushing water tanks.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
 (iv) An overriding differential float switch in the sump tank shall cut off the
pump’s operation when the tank has been exhausted.

(v) An automatic changeover facility shall start the stand-by pump upon
failure of the duty pump.

(vi) Lead/lag selection and automatic alternation shall be provided for the
control circuit. After one pump has finished one operation, the other
pump shall stand as the duty pump for the next cycle.

(vii) Duty/standby and auto/off/manual selectors shall be provided.

(c) Pneumatic Booster Pump

(i) Unless otherwise stated the system shall include a duty and a standby
pump. The pumps shall be automatically controlled to maintain the
water level in the gravity water tanks.

(ii) The duty pump shall be started when the pressure switch senses a
pressure drop in the pressure vessels to the preset low level or the high
level water control switch in the water tank senses high water level in the
tank.

(iii) When the duty pump is overloaded, the standby pump shall be brought
into operation automatically by an overload relay.

(iv) The pumps shall be operated alternately, that is, changing between the
duty/standby status by an alternate relay.

(v) Variable frequency drive shall be used for all pump motor starting.

(vi) As item (b) iii).

(vii) As item (b) iv).

(viii) As item (b) v).

(ix) As item (b) vi).

(d) Sump Pumps

(i) Unless otherwise stated, there shall be two sump pumps in each sump
pit, one as duty and one as standby. The pump(s) shall be automatically
controlled to transfer the soil or waste water to the manhole or the
nearest drainage pipe connections.

(ii) Automatic controls shall be of float type mercury switches suitable for
use with soil or wastewater. In each pit, mount an assembly with three
(for single pump) or four (for duplicated pump sets) switches at different
levels to correspond with the required depths of water to energise
relevant controls to operate the pump and/or raise the alarm suitably.

(iii) When the water level in the sump pit reaches the first predetermined
high level, the duty pump shall operate and continue to run until the
water level drops back to the low level.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
 (iv) If the water level continues to rise to the second predetermined level, the
stand-by pump shall also operate in parallel with the duty pump. The
pumps shall only stop when the water level drops back to the low level.

(v) An extra high level alarm shall be provided at the vicinity of the pit or on
the control panel, when the water raises up to the level, an audible and
visual alarm shall be raised.

(vi) Automatic and manual change-over facilities shall be provided for the
pumps.

(vii) A lead/lag selection and an automatic alternation facility shall be

provided for the duplicated pump sets. After one pump has finished one
operation, the other pump shall act as a duty pump for next cycle.

(e) Float Switches

(i) High/low level float switches shall control pump starting and stopping.
Float switches shall also initiate the level alarm system.

(ii) Float switches in the water tanks and sump pits shall be directly
connected to the motor control panels.

(iii) All the alarms of the sump pits shall be wired back to the associated
motor control panels in the pump rooms or at the vicinity of the pit
respectively. Should any one of these alarms be actuated, an audible
and a visual alarm shall be indicated on the pump control panel.

(f) Alarm and Remote Indication

(i) The following status and alarm signals for remote indication at both local
control panels and the central control panel shall be provided:

- pump failure (one signal for each pump);

- pump running (one signal for each pump);

- pump stop (one signal for each pump);

- high level warning alarm for water tanks; and

- low level warning alarm for water tanks.

97.3.5 Control Panel

(a) General

(i) A pump control panel shall be provided for each set of pumps.

(ii) Control panels shall be constructed of pressed steel of 2mm thick and
have lockable front covers. The panel front shall have an indicator light
to show that power is available to the panel, run and trip indicators for all
rotating machinery.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
 (iii) Inside each control panel shall be mounted individual isolators, individual
starters with overload relays, line fuses, water level electrodes, pressure
switches, alternate operation relay and auxiliary relays for pump
operation. Fitted into the panel door shall be two ammeters for the
pumps, manual-off-auto switch for pump, two sets of on and off buttons
for manual operation, individual pump run and trip lights and panel alive
(power on light).

(iv) Volt free terminal strips shall be provided in each control panel for
connection by the GBMS for monitoring of the following status.

- pump operation – pumps on, off and overload; and

- overflow and low water levels in water tanks (if necessary).

(v) An overall interior plate shall be provided with cut-outs to suit the fuse
carriers, operating face of contactors and switch dollies to present a neat
appearance within the enclosure and to ensure that all wiring, live
terminals etc., are contained behind the panel.

(vi) The panel shall be fixed by knurled screws for easy removal. If the
panel is of metal construction adequate bonding with the main enclosure
body shall be provided; in addition it shall not be possible to make
contact with the panel to any live parts while removing the panel.

(vii) In general the enclosures shall be IP 54 protection class and suitable for
wall mounting.

(b) Indicating Lights

(i) Indicating lights shall be domed glass type with LED’s behind.

(ii) Indicating lights shall have black bezels.

(iii) The bodies of indicating lights shall be ventilated to ensure efficient heat
dissipation. Connection to lights shall be screw or clamp terminals;
soldered terminations shall not be used.

(iv) Color codes shall be:

- plant de-energized : green;

- plant energized :white;

- abnormal condition :red; and

- other function :blue or yellow

97.3.6 Vibration Control

(a) General

(i) Vibration isolators shall be elected to produce uniform deflection.

(ii) The mountings shall be selected to provide adequate isolation of

vibration at the lowest operating speed for rotating components.
General Materials & Workmanship Specification 11/18 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
 (b) Spring Type Isolators

(i) Spring type isolators shall be free standing and laterally stable without
any housing and complete with 6 mm neoprene acoustic friction pads
between the baseplate and the support.

(ii) All mountings shall have levelling bolts that shall be rigidly bolted to the
equipment.

(iii) Spring diameters shall be no less than 0.8 of the compressed height of
the spring at rated load.

(iv) Springs shall have a minimum additional travel to solid equal to 50% of
the rated deflection.

(v) Mountings shall be type SLF.

(c) Vibration Hangers

(i) Vibration hangers shall contain a steel spring and 8mm deflection
neoprene element in series. The neoprene clement shall be moulded
with a rod isolation bushing that passes through the hanger box.

(ii) Spring diameter and hanger box lower hole sizes shall be large enough
to permit the hanger rod to swing through a 30° arc before contacting the
hole and short circuiting the spring.

(iii) Springs shall have a minimum additional travel to solid equal to 50% of
the rated deflection.

(iv) Hangers shall be type 30N.

(d) Flexible Neoprene Connectors

(i) Provide flexible neoprene connectors to the inlet and outlet of pumps,
boilers and other equipment.

(ii) Manufacturer of multiple plies of nylon tire cord fabric and neoprene both
molded and cured in hydraulic rubber presses.

(iii) Steel wire or rings shall not be used as pressure reinforcement.

(iv) Straight connectors shall have two spheres unless otherwise specified.

(v) Manufacture with floating steel flanges recessed to lock the connector's
raised face neoprene flanges.

(vi) All connectors shall be rated a minimum of 1.5 times the working
pressure of the system.

General Materials & Workmanship Specification 12/18 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
 (vii) All connections shall be made with flanged sphere properly pre-
extended as recommended by the manufacturer to prevent additional
elongation under pressure. Provide control tie-rods for all flexible
connector, as recommended by the manufacturer.

(viii) Connectors shall be type MFTNC.

(e) Vibration Pads

(i) Neoprene in-shear multi-layer waffle type with steel shims shall be used
in between waffles.

(f) Horizontal Thrust Restraints

(i) Horizontal thrust restraint shall consist of a spring element in series with
a neoprene pad. The spring element shall be contained within a steel
frame and shall allow a maximum of 6 mm movement from start to stop.

(g) Bellows Expansion Joints

(i) Bellows type expansion joints shall be provided for all pipework where
passing through building expansion joints.

(ii) Expansion joints shall be of stainless steel multi-bellows type complete

with all necessary guides etc., as recommended by the manufacturer to
give a working life of not less than 20 years.

(iii) During sectional testing, the expansion joints shall be adequately tied,
anchored or removed to avoid damage to the bellows.

(iv) Design working pressure shall not be less than 2,000 kPa unless
otherwise specified.

(v) The lateral and axial movements of the expansion joint shall not be less
than +/- 6 mm.

(vi) Where pipework penetrates the building fabric the penetration shall be
detailed as follows:

- An oversize sleeve shall be built into the construction leaving a

consistent clearance of 12-15mm all round the pipe when installed.
This gap shall be packed carefully with 80 kg/m3 mineral wool and
the ends of this packing are to be caulked using a non-setting
sealant.

(h) Pump Plinths and Inertia Blocks

(i) The base depth shall be as recommended by pump manufacturer for

mass or rigidity, but shall not be less than 150 mm.

(ii) Upfeed and booster pumps shall be mounted on a floating inertia block
having a weight of two times the pump assembly.

(iii) Anti-vibrating spring for supporting the inertia block shall have a
minimum deflection not less than 20 mm.

General Materials & Workmanship Specification 13/18 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
97.3.7 Tank

(a) General

(i) Water tank shall be furnished by manufacturers normally supplying this

type of equipment that has been in successful operation for at least five
years.

(b) Fibreglass Reinforced PVC (FRP) Tank

(i) Field assembled FRP tank shall be provided as indicated on the

Employer’s Drawings.

(ii) Tank shall be assembled from pre-molded FRP panels of minimum 5mm
thickness with bolted joints. Non-toxic, non-hazardous material for
sealing at joints shall be used.

(iii) Stainless steel or chrome plated bolts, washers and nuts on joints shall
be used.

(iv) Pre-molded pipe connections and accessories as per the following shall
be provided:

- tank inlet(s);

- tank outlet(s);

- drain;

- overflow(s);

- level controllers;

- air vent;

- internal and external ladder; and

- tank access & cover.

(v) Modular type shall be used.

97.3.8 Tank Level Control

(a) The Contractor shall supply and install flow switches in water tanks as
indicated below and shown on the Contractor’s Drawings.

(i) roof tanks

- high level alarm (over-flow);

- low level alarm;

- high level cut-out for the upfeed water pump;

- low level cut-in for the upfeed water pump;

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
 - earthing probe;

- low level lock-out for booster pump set; and

- high level reset for booster pump set.

(ii) sump tanks

- high level alarm (over-flow);

- low water level lock-out for the upfeed water pumps;

- high water level reset for the upfeed water pumps;

- earthing probe;

- low level alarm; and

- all alarm signals shall be linked to control room.

(b) Water level controller shall be fitted in water tanks for monitoring the water
levels in the tank and to give the appropriate control / warning signals for the
system.

(c) Controller shall be of submersible maintenance-free type. Contact shall be of

mercury, and be totally enclosed in a water proof rubber body.

97.4 SUBMISSIONS

97.4.1 Particulars for Pump

(a) Submit Contractor’s Drawings showing plant room details, sump pit details,
plans, elevations, sections dimensions and operation weights of equipment,
electrical wiring and control diagram, pipework connections and flange details,
mounting and fixing details.

(b) Submit Contractor’s Drawings for mounting and fixing details shall include
details and dimensions of pump bases, fixing bolts, flexible connections and
vibration isolators.

(c) Submit certified characteristic curve to show total kW loading against pressure
head at specified operating speed.

(d) Submit calculation to indicate the exact pump head required according to the
pressure drops equipment being offered for review without objection by the
Project Manager.

(e) Submit calculation to justify the capacity of pressure vessels. Only effective
gas volume will be considered for the calculation.

(f) Submit complete manufacturer’s printed catalogue and complete material

specification.

(g) Submit manufacture’s operation and maintenance manual.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
 (h) Submit all technical details for review without objection by the Project Manager
before the plinth/inertia block is being cast.

(i) Pump capacities, heads, working pressures, minimum efficiencies and motor
kW are indicated on the Employer’s Drawings, but submission for review
without objection by the Project Manager before ordering is required for all
pump duties and horsepower against the requirements of the systems as
finally installed.

(j) The Contractor shall calculate the pump heads and provide pumps with
adequate capacities, having submitted their detailed calculations to the Project
Manager for review without objection, before ordering.

97.4.2 Particulars for Tank

(a) Submit Contractor’s Drawings and manufacturer’s data.

(b) Submit Contractor’s Drawings for tank openings, location and tank support
details.

(c) Submit calculation to justify the capacity of the tank.

(d) Fibre glass tank when used for fresh water storage must be accompanied with
letter of compliance/certificate proving the tank material is non-toxic and is
entirely suitable for storage of water for potable use. An review without
objection letter from the WSD. is required.

(e) Tanks shall be secured and rest on concrete plinth provided by the Contractor.
Details of tank plinth and required builder's work shall be submitted to Project
Manager for review without objection.

97.4.3 Particulars for Pump/Tank Control

(a) Submit complete catalogue information and Contractor’s Drawings for all
material and equipment including wiring and control diagram for each system
and control panels.

(b) Submit complete electrical schematic diagrams of each system and identifying
each internal and external circuiting.

(c) Submit the sequences of operation for permission of the Project Manager.

(d) Submit the operation of alarm for review without objection by the Project
Manager.

(e) Submit the installation detail of the sensing elements such as float switches for
review without objection by the Project Manager.

97.4.4 Particulars for Vibration Control

(a) Submit complete catalogue information and Contractor’s Drawings for all
material and equipment, test certificate for review without objection by the
Project Manager.

(b) Submit spring deflections, isolating efficiency, spring type and mounting
methods for all equipment.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
 (c) Submit complete calculations to confirm the correct selection of equipment
mountings, including but not limited to, inertia blocks, pads, springs and/or
other vibration control equipment for review without objection by the Project
Manager.

(d) The minimum design isolation efficiency shall be 95%.

(e) Submit static deflection calculations to confirm the correct selection of the
AVM design for the pumps and/or other equipment likely to transfer loads,
through operational movements, into the structure and/or connecting
equipment. The submitted information shall include:

(i) Schedules for pumps

(ii) Operating characteristics of pumps (including weight, speed, dimensions)

(iii) Radiated sound power data of the pumps at the various operational
speeds

(iv) Resultant sound pressure levels in the associated equipment room

(v) A schedule of vibration isolator equipment including type, static

deflections, rated loading

(vi) Catalogues of the proposed vibration isolators

97.5 WORKMANSHIP FOR PUMP INSTALLATION

97.5.1 General

(a) Pump alignment shall be factory checked. Alignment shall be verified, and
corrected as required on Site after the pumps have been placed in position
with pipework connections made, pipework filled with water and tested at
pressure.

(b) The pipework assembly connected to pumps shall be separately supported

and anchored so that no load is imposed on the pump assembly. Base
elbows shall be fitted at each pump as required.

(c) Each pump shall be provided with suction and discharge isolating valves and
where connected in parallel with other pumps, non-return check valves. Each
pump shall be provided with two pressure gauges, one connected to the
suction side, the other to the discharge.

(d) Pipework vibration isolators shall be provided on the suction and discharge
side of each pump.

(e) Pumps shall be “Type-tested”’ in accordance with the requirement of BS 559.

(f) Nameplate: Securely attached on each pump set showing manufacturer’s

name, serial and model number and data of manufactures.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
 (g) Cover the inlet and openings of the pump. Store pumps in rates and well
cornered and protected until ready to install.

(h) Protect pumps from mechanical and corrosive damages during construction.
Damaged equipment shall not be accepted.

General Materials & Workmanship Specification 18/18 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 97 – Pumps & Tank Level Controls
SECTION 98 ELECTRICAL EQUIPMENT AND INSTALLATION

98.1 GENERAL

(a) This section covers the specific requirements for electrical equipment and
installation for hydraulics services system. The general requirements for the
same shall be referred to Section 44.6.

(b) The Works and materials described herein shall comply with Sections 46, 48,
49, 53, 57, and 59 of the General Materials and Workmanship Specification
(General Materials and Workmanship Specification) for general requirements
and details regarding the electrical installation including the following:

(i) The Works and materials described herein shall comply with other
relevant sections of this General Materials and Workmanship
Specification including the sections which specify:

- Section 53 “Motors”; and

- Section 99 “Inspection, Testing and Commissioning – Hydraulic

Services”.

98.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
that edition of the document stated below, including all amendments issued by
the relevant authority.

BS 88 : Part 2 Cartridge fuses for voltages up to and including 1,000V AC

and 1,500V DC. Specification for fuses for use by authorized
persons (mainly for industrial application)

98.3 MATERIALS

98.3.1 Pump Control Panels and Associated Enclosures

(a) General

(i) The degree of protection for pump control panels (PCPs), control panels
and similar enclosures shall be to IP 54 as specified in BS EN 60529.

98.3.2 Electrical Circuit Protection

(a) Cable shall comply with Section 48 of the General Materials and Workmanship
Specification.

(b) Electrical circuit protection devices, including but not limited to, circuit
breakers, isolators, switches and fused switches, shall comply with Section 46
of the General Materials and Workmanship Specification.

General Materials & Workmanship Specification 1/2 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 98 – Electrical Equipment & Installation
98.3.3 Cable Type and Installation

(a) Cable shall comply with Section 48 of the General Materials and Workmanship
Specification.

(b) Cables shall be sized for the rated current of the connected load.

(c) All main and sub-main armoured cables shall be Cu/XLPE/SWA/LSF type.

(d) Colour coding of all cables shall comply with the New Cable Colour Code for
Fixed Electrical Installations published by the EMSD.

98.3.4 Low Voltage Electric Motors

(a) Maximum motor speed shall be 1500 rpm.

(b) The Works and materials described herein shall comply with section 53.

98.4 WORKMANSHIP

98.4.1 Cabling and Wiring

(a) Cabling and wiring shall comply with Section 48 of the General Materials and
Workmanship Specification.

(b) The minimum conductor size shall be 2.5 mm2 for phase, neutral conductors
and earth conductors. Control circuit cabling conductor size shall be 1.5 mm2
minimum subject to voltage drop limitations.

98.4.2 Conduits and Fittings

(a) Conduits and fittings shall comply with Section 49 of the General Materials
and Workmanship Specification.

98.4.3 Cable Trays, Cable Trunkings and Fittings

(a) Cable Containment systems, including but not limited to, cable trays, cable
trunkings, conduits and fittings installations shall comply with Section 49 of the
General Materials and Workmanship Specification.

98.5 SUBMISSIONS

The Contractor shall submit the following documents to the Project Manager for
review without objection:

(a) details of pump control panels shall be submitted to the Project Manager for
review without objection. The Contractors Drawings of the pump control
panels shall include, but not be limited to, all necessary wiring, all indication
signals, visual/audio alarms, control, functions and component arrangements.
Labelling shall be in English and Chinese.

General Materials & Workmanship Specification 2/2 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 98 – Electrical Equipment & Installation
SECTION 99 INSPECTION, TESTING AND COMMISSIONING – HYDRAULIC SERVICES

99.1 GENERAL

(a) The Plant shall be inspected, tested and commissioned to confirm that Plant
performance complies with the requirements of the Contract.

(b) All such inspection, testing and commissioning shall, in particular but without
limitation, be planned, carried out and documented in accordance with:

(i) General Conditions of Contract;

(ii) Volumes 1-4 of the General Materials and Workmanship Specifications,

General Specification, Particular Specification, Particular Technical
Specification and other contract documents (if any); and

(iii) the construction quality plans and inspection and test plans prepared by
the Contractor in accordance with the relevant ISO standard and
reviewed without objection by the Project Manager.

99.2 TERMINOLOGY

(a) The following terms shall be used in all programmes, quality plans, reports
and other documents produced:

(i) Manufacturing Phase - the period during which the manufacture,

fabrication and assembly of the Plant, or a discrete element of the Plant,
is carried out off-Site;

(ii) Installation Phase - the period during which the fabrication, assembly
and installation of the Plant, or a discrete element of the Plant, is carried
out on-Site;

(iii) Pre-Commissioning Phase - the period when, in relation to the Plant or a

discrete element of the Plant, component tests and commissioning are
carried out in preparation for the plant commissioning phase;

(iv) Plant Commissioning Phase - the period when commissioning and

reliability tests are carried out to ensure that the Plant fully complies with
the design and operational requirements of the Contract;

(v) Plant Integration Phase - the period prior to issue of the Completion
Certificate when Plant integration tests and commissioning are
conducted to integrate the Plant with all work completed or being
undertaken by the Other Contractor, if any, in full compliance with the
design and operational requirements of the Contract;

(vi) Confidence Trial Phase - the period after issue of the Completion
Certificate when the Confidence Trials are carried out;

(vii) Phase - one or other of the phases identified in (i) - (iv) above;

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Section 99 – Inspection, Testing & Commissioning –
Hydraulic Services
 (viii) Type Tests - tests undertaken on similar equipment or components in
lieu of individual unit tests;

(ix) Factory Tests - tests carried out on items of Plant at the manufacturer's
works or elsewhere before they are dispatched to Site;

(x) Site Tests - tests on static items of Plant and systems (e.g. inspection
and testing of welds and hydraulic testing of pipework) to ensure correct
and safe installation before setting to work;

(xi) Component Tests - tests on components to be incorporated in the Plant;

(xii) Commissioning - the advancement of the Plant or an element of the

Plant from the stage of static completion to full working conditions and to
meet the specified design requirements. This shall include setting to
work and regulation;

(xiii) Setting to Work - the process of setting a static system into motion;

(xiv) Plant Integration Tests - the measuring, recording and proving of correct
integration between the Plant and all other systems as detailed in the
Specification.

(xv) Regulation - the process of adjusting a system (e.g. the rates of fluid
flow and heat transfer in a distribution system) within specified
tolerances;

(xvi) Reliability Tests - tests carried out over ser trial periods and under
simulated operating conditions to prove reliability;

(xvii) Deferred Seasonal Tests - tests conducted at certain times of the year to
suit seasonal climatic conditions;

(xviii) Confidence Trials - tests undertaken after the issue of the Certificate of
Completion when the Plant is operational and being operated by the
Employer under the supervision of the Contractor

(xix) Inspection, Testing and Commissioning Programme - the sub-network of

the Works Programme prepared by the Contractor and reviewed without
objection by the Project Manager, detailing the programme for the
inspection, testing and programme for the inspection, testing and
commissioning of the Plant;

(xx) Phase Notice - a notice prepared by the Contractor in accordance with

the requirements of the Specification;

(xxi) Phase Report - a report prepared in accordance with the requirements of

the Specification; and

(xxii) Test Results Form - a form prepared in accordance with the

requirements of the Specification.

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Section 99 – Inspection, Testing & Commissioning –
Hydraulic Services
 (b) The term "Tests on Completion" as defined and used in the General
Conditions of Contract refers to the Plant Integration Tests and such further
tests, if any, identified as such in the Specification.

(c) The term “Performance Tests” as defined and used in the General Conditions
of Contract refers to the Confidence Trials and such further tests, if any,
identified as such in the Specification.

99.3 TESTING AND COMMISSIONING PHASES

(a) In order to facilitate the orderly management of the testing and commissioning
of Plant and the Project Manager’s monitoring of progress of the Project as a
whole, the Contractor shall structure his construction quality plans (see section
14 of the General Specification), inspection and test plans (see section 15 of
the General Specification), the General Materials and Workmanship
Specification, and the Inspection, Testing and Commissioning Programme
(see section 10 of the General Specification) into the following Phases with the
tests to be carried out during each Phase identified under the following
categories:

(i) Manufacturing Phase:

- Factory Tests; and

- Type Tests.

(ii) Installation Phase:

- Site Tests.

(iii) Pre-Commissioning Phase:

- Component Tests; and

- Commissioning of elements of the Plant.

- Setting to work

(iv) Plant Commissioning Phase:

- integration of elements of the Plant;

- Commissioning; and

- Reliability Tests.

(v) Plant Integration Phase:

- Plant Integration Tests; and

(vi) Confidence Trails Phase.

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Section 99 – Inspection, Testing & Commissioning –
Hydraulic Services
 (b) Any Deferred Seasonal Tests shall also be clearly identified in all plans and
programmes.

(c) For the duration of the Defects Liability Period, operational and safety controls
shall be sealed if adjustment beyond defined limits could result in malfunction
and give rise to a defect.

(d) The Contractor shall provide attendance and technical support during testing
and commissioning of any work with which the Contractor has an interface
during the confidence trails period in accordance with this General Materials
and Workmanship Specification.

99.4 QUALITY PLANS

(a) The Contractor shall identify in his construction quality plans any division of
the Plant into discrete elements to facilitate the preparation and service of
Phase Notices as called for in this General Materials and Workmanship
Specification.

(b) Refer to General Specification Section 14.

(c) The Project Manager, in reviewing any inspection and test plan, may require
further and better inspection, testing and Commissioning documentation as
may be considered reasonably necessary to record these processes.

99.5 PHASE NOTICES

(a) For each element of the Plant identified in the Contractor's construction quality
plans or, as the case may be, for the Plant as a whole:

(i) The Contractor shall prepare and submit to the Project Manager for
review a Phase Notice at the end of the Manufacturing Phase, the
Installation Phase and the Pre-commissioning Phase.

(ii) Each Phase Notice shall contain a statement by the Contractor

confirming that all inspections and tests required during the relevant
Phase have been performed satisfactorily or identifying any non-
conformities or tests that have been failed and confirming that all reports
of such inspections and tests have been filed in his records office (in
accordance with Section 15 of the General Specification).

(iii) The Phase Notice relating to a Manufacturing Phase shall confirming

that the Contractor is satisfied that the relevant equipment or system or
part of a system is ready for release from the manufacturer's works.

(iv) The Phase Notice relating to an installation Phase shall confirm that the
Contractor is satisfied that the equipment or system or part of a system
is ready for starting the pre-commissioning tests.

(v) The Phase Notice relating to a Pre-Commissioning Phase shall confirm

that the Contractor is satisfied that the system or part of a system is
ready for Commissioning and Reliability Tests.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 99 – Inspection, Testing & Commissioning –
Hydraulic Services
99.6 TEST RESULTS FORMS

(a) In addition to the requirement in Section 15 of General Specification, each

report of an inspection or test shall indicate the following:

(i) the system or item being tested;

(ii) the identification reference for an item being performance tested;

(iii) the test acceptance criteria;

(iv) the tolerances;

(v) the test units of measurement;

(vi) the actual test results;

(vii) pass/fail;

(viii) whether a concession shall be requested under Section 14 of the

General Specification;

(ix) any concessions or variations made pursuant to Section 14 of the

General Specification; and

(x) whether a design review is requested.

(b) Test acceptance criteria shall be prepared by the Contractor in accordance

with the General Materials and Workmanship Specification and included as
part of each Test Results Form. Acceptance criteria may not be changed by
the Contractor except with the consent of the Project Manager in writing.

(c) The Contractor shall prepare and submit his proposed Test Results Forms as
part of his submission of the relevant Inspection, Testing and Commissioning
Plan.

99.7 PHASE REPORTS

(a) Without prejudice to the Contractor's obligations to produce summaries of test

data and other information in the General Conditions and the General
Specification, the Contractor shall upon completion of each Phase complete
and submit to the Project Manager for his information a phase report (the
“Phase Report”) setting out and detailing the test results including
performance figures obtained, graphs, charts, tabulated computer output, and
supporting narratives describing any special events, occurrences and other
discrepancies or deviations not expected in the original plan or programme.

(b) In particular, the Phase Report shall include a chronological diary of findings
and incidents including:

(i) workmanship;

(ii) Plant operating peculiarities and observations;

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Section 99 – Inspection, Testing & Commissioning –
Hydraulic Services
 (iii) any measurement and checks which may be required by operating and
maintenance personnel; and

(iv) results of any statutory testing and inspection, e.g. earth grid
measurements.

(c) All hazardous conditions shall be corrected by the Contractor prior to or during
Commissioning. Comments shall be included on any observed deficiencies in
Plant design and performance.

(d) Any modifications to circuitry, instrumentation, etc. carried out any time shall
be recorded in detail in the Phase Reports and shown on the Contractor’s
Drawings.

(e) Any conclusions that would be helpful to the Employer's operating and
maintenance staff shall be summarised at the end of the Phase Reports.

(f) The Phase Reports shall be prepared and submitted in the Employer’s
standard format as soon as practicable after the completion of each Phase.

99.8 STANDARDS AND REGULATIONS

(a) All testing and commissioning carried out by the Contractor shall be
undertaken using the International System of Units (S.I.) and shall comply, as
appropriate, with the latest and most up to date edition at the date of the Letter
of Acceptance, of the following standards, regulations and guides:

(i) the relevant "British Standard Codes of Practice" or "British Standard

Specifications" where applicable to the Works published by the British
Standards Institution;

(ii) the IEE Wiring Regulations issued by the Institution of Electrical

Engineers (U.K.);

(iii) "Code of Practice for Electricity (Wiring) Regulations" published by the

HKSAR;

(iv) the relevant codes and guides published by the National Environmental
Balancing Bureau (NEBB-USA); and

(v) the relevant codes and guides published by the Building Services
Research and Information Association (BSRIA-UK).

(vi) Cap 123 – Building (Standards of Sanitary Fitments, Plumbing, Drainage

Works and Latrines) Regulations; Cap 102 – Waterworks Regulations;

(vii) The Hong Kong Waterworks Standard Requirements;

(viii) The Institute of Plumbing – Plumbing Engineering Services Design

Guide; and

(ix) the relevant CIBSE Commissioning Code;

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Section 99 – Inspection, Testing & Commissioning –
Hydraulic Services
99.9 CONTRACTOR’S TESTING AND COMMISSIONING STAFF

(a) All testing and Commissioning shall be undertaken by the Contractor's

appropriate testing and Commissioning specialist or by a competent
independent Commissioning specialist nominated by and acting for the
Contractor and reviewed without objection by the Project Manager.

(b) The Contractor shall provide all necessary skilled labour and assistance for
testing, operating, adjusting, Commissioning and verifying the performance of
all Plant.

(c) The Contractor's testing and Commissioning staff shall have had previous
experience with testing and Commissioning similar Plant of comparable duty.

(d) The Contractor's relevant specialist testing and Commissioning staff including
supervisors shall be available on Site at all times during testing and
Commissioning of the Plant.

99.10 TESTING AND COMMISSIONING EQUIPMENT AND INSTRUMENTS

(a) The Contractor shall provide all portable and supplementary instrumentation,
recording facilities, consumables and the like required for all Factory Tests
and testing and Commissioning on Site.

(b) Testing and Commissioning instrumentation shall be designed for field use
and to minimize field measurement errors through the use of electronic
sensors, digital displays and similar devices.

(c) The calibration of instruments shall be demonstrated immediately prior to, and
after completion of testing and Commissioning, and current calibration
certification submitted to the Project Manager for record purposes.

(d) At least one complete set of testing and Commissioning instrumentation,

including all accessories, fittings, attachments and purpose built carrying
cases, shall be made readily available in a calibrated and operation condition
for retesting by the Contractor for the duration of the Defects Liability Period.

(e) The end to end accuracy of instrumentation shall be verified in accordance

with the recommendations of ASHRAE 114.

99.11 NOTIFICATIONS

(a) The Contractor shall, in accordance with section 15 of the General

Specification, give the Project Manager notice in writing, when tests or trials
shall be ready to commence provided that, notwithstanding section 15 of the
General Specification, not less than 48 hours' notice of all tests and trials
carried out on Site shall be given.

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Section 99 – Inspection, Testing & Commissioning –
Hydraulic Services
99.12 INSPECTIONS AND TESTING

(a) Prior to any inspection and testing by the Project Manager, the Contractor
shall inspect and test the Plant to ensure that equipment and facilities are
clean and complete and can reasonably be expected to meet successfully all
inspection and/or testing criteria.

(b) Prior to setting to Work, testing and Commissioning, the Contractor shall clean
all Plant and shall confirm in writing to the Project Manager that all the work is
complete and satisfactory for the purpose of testing and Commissioning.

(c) In the event that the Contractor considers that any testing is not appropriate or
required, the Contractor may submit alternative proposals to the Project
Manager for review without objection.

99.13 TYPE TEST CERTIFICATES

(a) Type Test certificates shall be submitted by the Contractor to the Project
Manager for:

(i) electric motors;

(ii) water pump;

(iii) valves;

(iv) L.V. cables;

(v) protective devices, relay and contactor;

(vi) fuseswitches/switch fuse; and

(vii) pump control panels.

99.14 FACTORY TESTS

(a) Wherever practical, Factory Tests shall cover subsystems rather than just
individual components

(b) Unless otherwise reviewed without objection by the Employer, factory testing
of low voltage electrical Plant shall be undertaken at 380V, or 220V as
appropriate and 50 Hz.

(c) Pumps shall be Factory Tested in accordance with BS EN ISO 9906

(d) Performance results from Factory Testing shall be recorded at a minimum of 4

representative operating points across the range including both the maximum
and minimum flow rate condition.

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Section 99 – Inspection, Testing & Commissioning –
Hydraulic Services
99.15 SITE TESTING AND COMMISSIONING

99.15.1 Pipework

(a) The Contractor shall test each drainage stack as soon as practicable after
installation.

(b) All pipework shall be tested by the Contractor for leaks before any pipework is
enclosed, insulated, or concealed in any way.

(c) Pipework shall remain completely watertight during the testing time. Pipework
shall be filled with water sufficiently in advance of the test to allow it to come to
room temperature so that any sweating can evaporate.

(d) Supply and install all necessary testing junctions and bends for underground
pipework, and seal off or remove them as directed by the Project Manager.

(e) The Works shall be tested as scheduled Table 99.15.1e.

Table 99.15.1e : Testing of Services

Working Testing
Services Testing Pressure Pressure
Kpa (Gauge) Kpa (Gauge)
(i) Potable Water/ Flushing
1. Underground 1500
2. Upfeed Hydrostatic test Refer item 1.5 time the
as item 99.15.1f 99.15.1g working
pressure or
1500 kPa
which one is
greater
3. Distribution 1500
4. Valves 1500
(ii) Soil, waste and rain water
1. Above Ground Air and water test
as items 99.15.1
h & i requirement
2. Underground Water test of
1.5M height
Mirror test and
colour water test
for alignment
3. Pumped drain Hydrostatic test Refer item 1200
pipe as item 99.15.1f 99.15.1g

(f) Hydrostatic Test

(i) All pipework shall be hydrostatically tested for a period of not less than
24 hours without leakage. The Contractor shall record all test figures
together with schedules of pipe lengths.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 99 – Inspection, Testing & Commissioning –
Hydraulic Services
 (g) The working pressure shall be the system static pressure plus the surge and
operation pressure of the system whilst the testing pressure shall be at 50%
higher than the working pressure or as stated in table 99.15.1e whichever is
higher.

(h) Air testing above the level of the lowest sanitary appliance shall be carried out
by the Contractor as flows:

(i) fully charge water seals of all sanitary appliances;

(ii) insert test plugs in open ends of pipework being tested;

(iii) test with air using approved testing equipment, at a pressure equal to
38mm water gauge; and

(iv) maintain the test pressure for one hour.

(i) Water testing below the level of the lowest sanitary appliance shall be carried
out by the Contractor as flows:

(i) insert test plug in lower end of pipe;

(ii) fill pipe with water up to flood level of lowest sanitary appliance;

(iii) static head should not exceed 1200 mm at the high point of the test and
be a maximum of 2400 at the low point; and

(iv) maintain this pressure for 1 hour.

(j) Smoke Test

(i) All underground drainage pipes exceeding ∅450 mm shall be smoke

tested. The pipes shall be sealed at both ends and smoke introduced
either by cartridge or smoke machine, the details of which have been
reviewed without objection by the Project Manager. The installed
pipework shall be completely smoke tight.

99.15.2 Noise and Vibration Levels

(a) Testing and commissioning shall be undertaken to ensure that acoustic and
vibration performance requirements of the Specification are met.

(b) Noise measurements shall be conducted with the system operating at design
conditions.

(c) Noise measurements shall be made using a meter complying with ‘Type 1’
requirement of BS EN 60651 standard. The meter shall be calibrated using an
acoustic calibrator, before and after all sets of measurement.

(d) Vibration shall not be perceptible to occupants sitting or standing. An RMS

surface vibration velocity of 0.1 m/s shall be taken as the reference limit of
perception.

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Section 99 – Inspection, Testing & Commissioning –
Hydraulic Services
99.15.3 Automatic Controls

(a) In addition to Factory Testing and Commissioning requirements specified, the

complete automatic controls system, including all GBMS facilities, field
devices, instrumentation and control algorithms, shall be tested and
commissioned on Site by the Contactors independent commissioning
specialist.

(b) The Contractor shall confirm, by field observation and measurement, that all
programme functions and routines operate correctly and that all controlled
devices respond accordingly.

(c) All GBMS inputs and outputs shall be tested and witnessed by the Contractor
through field observations to confirm the correct measurement and operation.
Confirmation of readings recorded by the GBMS shall include, but shall not be
limited to, the following:

(i) stop start commands and GBMS interlock; and

(ii) control valve response to controlling devices.

99.15.4 Low Voltage Electrical Installation

(a) Testing and commissioning of the electrical installation shall be in accordance

with the requirements of BS 7671 and the EMSD Code of practice for
Electricity (Wiring) Regulations.

(b) Current readings shall be determined in the field at starters, junction boxes or
similar.

(c) Test the operation of bimetallic overloads by winding down the set point
adjustment until the device trips.

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Section 99 – Inspection, Testing & Commissioning –
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[this page not used]
SECTION 100 GENERAL BUILDING MANAGEMENT SYSTEM

100.1 GENERAL

(a) The “General Building Management System” (GBMS) monitors all electrical
and other miscellaneous systems as listed below:

(i) electrical and lighting system;

(ii) hydraulic system;

(iii) fire alarm system;

(iv) lifts, escalators and walkways;

(v) communication systems;

(vi) aircraft loading bridges;

(vii) fixed ground power system; and

(viii) aircraft cabin pre-air-conditioned air system.

(b) Any system changes in the GBMS shall involve changes to the system
configuration and programming of the GBMS as well as the screen graphics in
the BSI PC/workstations.

(c) Any system changes in the GBMS shall not degrade the MTBF of the existing
equipment.

(d) The GBMS is only adopted for PTB. The GBMS, when used in outside the
PTB and GTC, is called the SCADA system. This SCADA system is an
identical system to the GBMS and its function is to control and monitor the
following facilities:

(i) Apron high mast lighting;

(ii) pumping stations;

(iii) potable water flow;

(iv) tunnel facilities;

(v) electrical distribution; and

(vi) fixed ground power facilities.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 100 – General Building Management System
100.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

ANSI/TIA/EIA 568-A Commercial Building Telecommunications Cabling

Standard

BS 7671 Requirements for electrical installations. IEE Wiring

Regulations. Sixteenth edition

100.3 SYSTEM DESCRIPTION

100.3.1 Existing System Description

(a) The GBMS performs the following functions:

(i) monitoring and controlling its internal system performance;

(ii) electrical system:

- monitoring of individual distribution panel boards to indicate

operational alarms and status including lighting circuits, power
availability, and load shedding and restoration;

- monitoring of individual main switchboards to indicate power status,

alarm and load shedding and restoration;

- monitoring of lighting levels using photocell sensors and perform

other user functions to automatically control area lightings and
intensity control requirements;

- monitoring of substation alarms and power availability condition by

interfacing with the High Voltage Supervisory Control and Data
Acquisition (HV SCADA) system and perform load shedding and
restoration functions; and

- monitoring of UPS power status;

(iii) hydraulic system:

- level monitoring and pump status of potable water tanks and flushing
water tanks;

- status and level monitoring of sump pits, soil and grey water pits; and

- status monitoring of roof overflow detection;

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 (iv) fire alarm system for monitoring of fire tanks water levels and general
equipment status;

(v) lifts, escalators and walkways:

- status monitoring of individual lift and dumb waiter to indicate fault

and availability;

- status monitoring of individual escalator to indicate movement

direction, availability and emergency stop; and

- status monitoring of individual moving walkway to indicate movement

direction, availability and emergency stop;

(vi) communication systems:

- monitoring of major and minor alarms from various communications

systems, including PABX/ telephones system, trunked mobile radio
(TMR) system, public address system, master antenna television
(MATV) system, access control system, closed circuit television
(CCTV), network management system including information network
and host LAN system, and time-of-day clock system;

(vii) aircraft loading bridges and airport operation systems:

- status monitoring of individual aircraft loading bridges to indicate

availability, fault, and emergency indication;

- status monitoring of fixed ground power system to indicate

operational status and availability; and

- status monitoring of aircraft cabin pre-conditioned air system to

indicate individual operational status and availability;

(viii) provide and facilitate data exchanges with other computer by:

- exchange of data with the AODB via interface with the host LAN;

- terminal mode emulation from workstations of other systems( e.g.

utilities control center, information network) via interface with the host
LAN to enable other user to log on to the GBMS;

(b) The GBMS operates as a stand-alone system such that the loss of
functionality of any of the systems it interfaces and associates with will not
affect the functionality of the GBMS.

(c) Any system changes in the GMBS shall involve changes to the system
configuration and programming of the GMBS

(d) The mean time between failures of equipment or components of systems

provided shall not affect the overall system performance.

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Section 100 – General Building Management System
100.3.2 System Architecture

(a) It consists of central headend equipment, loop controllers, field control units,
distributed input/output (I/O) panels, battery back-ups and computer
workstations as a skeleton of the system architecture. I/O modules shall be
GE Fanuc 90.30 or equivalent mounted in wall-mounted panels.

(b) Communication links between field control units and I/O panels shall be Cat 5
UTP cables or fibre optic cables as specified in Section 102.

(c) Interconnecting cables for data, signal and power between I/O panels and field
devices being monitored and controlled shall be shielded twisted pair cable as
specified in Section 102.5

(d) The details of the system architecture and protocols shall refer to Employer’s
Drawings and the Employer’s existing Operation and Maintenance manuals.
The Contractor shall reconfigure the database and the associated screen
graphics for any changes to the system.

100.4 MONITORING AND CONTROL I/O POINTS

100.4.1 Digital Input

(a) Points monitoring function activated by digital input (DI) signals to the GBMS
shall be in the form of voltage free contact type for relay, and configured in
“Normally Open” (N/O) or “Normally Close” (N/C) status as selected.

(b) The control voltage associated with the GBMS remote switching facility shall
be maximum 24V DC or AC.

100.4.2 Digital Output

(a) Points control function activated by digital output (DO) signals from the GBMS
shall be in the form of voltage free contact type rated at 24V DC and 2A
inductive, and are the change-over type to provide both normally open and
normally close connections.

(b) The control voltage associated with the GBMS remote switching facility shall
be maximum 24V DC or AC.

(c) The contact points of mechanical contact switches shall be gold plated,
protected and free from corrosion. They shall be designed and manufactured
for at least 100,000 operations and/or for 15 years life span.

(d) All DO shall be provided with manually positioned override facilities for
isolation and maintenance. At the GBMS I/O panels, manual auto switches for
manual isolation and visual indication for overriding shall be provided.

100.4.3 Analogue Input

(a) Points monitoring function from sensor data measured by analogue input (AI)
signals shall be in the form of 2-wire at 4 to 20mA at 24V DC signals.

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Section 100 – General Building Management System
 (b) Analogue to digital conversion shall be performed for the use of GBMS with
the following requirements:

(i) Absolute accuracy : ± 0.29% of full scale;

(ii) Long term drift : ± 0.05% of full scale (per 6 months);

(iii) Input impedance : Greater than 200 kOhms; and

(iv) Isolation input to : 850V.

frame

100.4.4 Analogue Output

(a) Points control function activated for driving actuator by analogue output (AO)
signals shall be in the form of 4 to 20 mA capable of operating into a 500
Ohms resistive load or 0 to 10V DC capable of operating into a 500 Ohms
resistive load.

(b) Digital to analogue conversion shall be performed with at least an absolute

accuracy of ± 0.133% of full scale for voltage and ± 0.425% of full scale of
current.

(c) All AO shall be provided with manually positioned override facilities for
isolation and maintenance. At the GBMS I/O panels, manual auto switches for
manual isolation and visual indication for overriding shall be provided.

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Section 100 – General Building Management System
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SECTION 101 MECHANICAL BUILDING MANAGEMENT SYSTEM

101.1 GENERAL

(a) This section specifies the equipment and materials of the existing Mechanical
Building Management System (MBMS) in the Hong Kong International Airport.

(b) Any system changes in the MBMS shall involve changes to the system
configuration and programming of the MBMS.

(c) Any system changes in the MBMS shall not degrade the MTBF of the existing
equipment.

101.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as at the date of the Letter of Acceptance.

ANSI/TIA/EIA 568-A Commercial Building Telecommunications Cabling

Standard
BS 7671 Requirements for electrical installations. IEE Wiring
Regulations. Sixteenth edition

101.3 SYSTEM DESCRIPTION

101.3.1 General

(a) The Mechanical Building Management System (MBMS) for the Passenger
Terminal Building at Hong Kong International Airport provides for the
centralized control, monitoring and user interfacing of the mechanical systems
serving the AA areas. These mechanical systems include the chilled water
system, the air conditioning and ventilation systems, and other miscellaneous
systems.

(b) In summary, the MBMS control and monitoring functions for the mechanical
systems comprise:

(i) Automatic sequencing of the water chillers and associated secondary

chilled water pumps, with operator sequence selection and chilled water
circuit monitoring facilities;

(ii) Automatic control of air handling units, with operator control and
monitoring facilities;

(iii) Automatic control of fan coil units, with operator control and monitoring
facilities;

(iv) Automatic control of ventilation fans, with operator control and

monitoring facilities;
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Section 101 – Mechanical Building Management System
 (v) Various automatic and operator control and monitoring facilities for
miscellaneous airport systems including carbon dioxide and baggage
hall spill air control;

(vi) Remote operator control facilities, including plant group operation, load
management and fire mode reset;

(vii) Control of smoke dampers and motorized dampers in fire mode.

101.3.2 System Architecture

(a) The MBMS utilizes a dual redundant computer system acting to effect central
processing of the following functions:

(i) Data exchanges with the mechanical/electrical subsystems (loops)

(ii) Operator interfaces via LAN connected workstations

(b) The dual redundancy configuration adopted utilizes a pair of computers that
are configured such that one PC acts the primary computer with other acting
as a ‘hot standby’ computer. Online database duplication is performed (on a
per transaction basis) from the primary to the standby computer via an
interconnecting Ethernet link. It is possible to remove one of the redundant
systems for maintenance without interrupting operation, and upon the
reinstatement of that system, to re-synchronize the databases again without
interruption to system operation. A method of manually initiating a failover is
provided to assist with such maintenance operations.

(c) The MBMS is divided into mechanical loops. Each loop is supported by a loop
controller formed from a dual redundant computer system.

(d) Each loop controller has a number of building network adapter (BNA)
connected to it via a local area network (LAN) for interfacing to the
input/output (I/O) panels. Each of these BNA is located in a communications
room.

(e) The I/O panels are connected directly to the mechanical plant and general
interfaces with a number of I/O panels connected via a bus to the designed
BNA computer.

(f) The system is widely distributed and makes extensive use of both optical fibre
and Category Type 5 cable for communications between the various nodes.

(g) Access to the system is restricted and cascaded for levels of accreditation.
The system supports graded levels of security with varying degrees of
functional access available for each level to system operation and
configuration functions.

(h) Any actions initiated by the operator are logged in the Event Database by
operator identifier. In addition, any control actions to a given point are allowed
only if the control level configured in the operator's profile exceeds the level
assigned to the controlled point.

(i) Utilities are provided to allow administration of the operator user profile.

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Section 101 – Mechanical Building Management System
101.4 HARDWARE

101.4.1 Overview

(a) The MBMS system consists of central redundant computer servers, operator
workstations and one system maintenance workstation, together with
redundant servers for each of the loop BNA situated in communications rooms,
controllers for specific local control, and a programmable logic controller (PLC)
for integration with the chiller manufacturer PLCs. In addition each of the six
workstations has its own black and white laser printer, and there is one colour
laser printer connected to the system for use by all operators.

(b) The Ethernet communications network is supported by two HUBs with all
central, loop controller and BNA having a redundant transceiver providing dual
communication paths on the network.

101.4.2 Central Computers

(a) The central servers are configured as redundant PC’s operating in a hot-
standby arrangement where one PC is designated as the “primary” and the
other as the “hot standby” computer. The central servers are situated in
communications rooms 2. Each central computer contains hard disks
configured in a RAID 1 array, a CD-ROM, an Ethernet network interface card
for redundant communications to the central HUB.

(b) The central servers function to:

(i) provide the central database for the MBMS system

(ii) provide central control and monitoring functions for the MBMS system

(iii) communicate with the loop controllers to continuously update its

database

(iv) reflect the current status of all field equipment, sensors, and alarm
activity

(v) transfer global information between the loops

(vi) serve the operator station clients

101.4.3 Workstations

(a) The MBMS operator workstations are PC’s with 21” monitors, together with an
Ethernet network interface card and a transceiver for communications to the
hubs. In addition each operator station is provided with a black & white laser
printer which is attached to the PC via its parallel port. These workstations
form an operator interface to the central system. The workstations run
software, which allows operators to monitor and control aspects of the
operation. Operator access to the MBMS system is controlled by graded levels
of password security.

101.4.4 Building Network Adapter (BNA)

(a) The Building Network Adapter (BNA) are units located in each of the
communications rooms and are effectively data collectors and concentrators
for the lower level I/O controller.
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Section 101 – Mechanical Building Management System
101.4.5 Input/Output Controllers

(a) Each I/O controller incorporates visual indicators of controller status and
provides a pluggable port for maintenance with the portable notebook
computers.

(b) The I/O controllers are used for

(i) Secondary Chilled Water control

(ii) AHU, FCU and ventilation fan control

(iii) Other miscellaneous HVAC control and monitoring

(iv) Other general building services monitoring

101.5 MONITORING AND CONTROL I/O POINTS

101.5.1 Digital Input

(a) Points monitoring function activated by digital input (DI) signals to the MBMS
shall be in the form of voltage free contact type for relay, and configured in
“Normally Open” (N/O) or “Normally Close” (N/C) status as selected.

(b) The control voltage associated with the MBMS remote switching facility is a
maximum of 24V DC/ AC.

101.5.2 Digital Output

(a) Points control function activated by digital output (DO) signals to the MBMS
shall be in the form of voltage free contact type rated at 24V 2A inductive, and
are the change-over type to provide both normally open and normally close
connections.

(b) The control voltage associated with the MBMS remote switching facility is a
maximum of 24V DC/ AC.

(c) The contact points of mechanical contact switches shall be gold plated,
protected and free from corrosion. They shall be designed and manufactured
for at least 100,000 operations and/or for 15-year life span.

(d) All DO shall be provided with manually positioned override facilities for
isolation and maintenance. At the MBMS I/O panels, manual auto switches
for manual isolation and visual indication for overriding shall be provided.

101.5.3 Analogue Input

(a) Points monitoring function from sensor data measured by analogue input (AI)
signals shall be in the form of 2-wire at 4 to 20mA in 24V DC signals.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 101 – Mechanical Building Management System
 (b) Analogue to digital conversion shall be performed for the use of MBMS with
the following requirements:

(i) Absolute accuracy : ± 0.25% of full scale;

(ii) Long term drift : ± 0.05% of full scale (per 6 months);

(iii) Input impedance : greater than 1 Mohms; and

(iv) Isolation input to : 1500V

frame

(c) Any intelligent transducer of digital over analogue selected shall be supplied
with all associated signaling and calibration equipment.

101.5.4 Analogue Output

(a) Points control function activated for driving actuator by analogue output (AO)
signals shall be in the form of 4 to 20mA capable of operating into a 500 Ohms
resistive load or 0 to 10V DC capable of operating into a 500 Ohms resistive
load.

(b) Digital to analogue conversion shall be performed with a least an absolute

accuracy of ± 0.25% of full scale for voltage and current.

(c) All AO shall be provided with manually positioned override facilities for
isolation and maintenance. At the MBMS I/O panels, manual auto switches
for manual isolation and visual indication for overriding shall be provided.

101.6 SYSTEM INTERFACES

101.6.1 Electrical Power Supplies

(a) The MBMS central servers, loop controllers, and other headend networking
equipment are fed from UPS backed fused spur units in the communications
rooms.

(b) The MBMS I/O controllers are fed from the essential supplies in MCCs.

101.6.2 Not Used

101.6.3 Mechanical Plant and MCCs

(a) The MBMS interfaces to mechanical plant and systems for control and
monitoring via the Excel controllers.

101.6.4 Chiller PLC

(a) The MBMS has a high level interface to the Chiller PLCs for monitoring and
control via the Data Highway Plus connection.

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Section 101 – Mechanical Building Management System
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SECTION 102 VOICE AND DATA CABLING

102.1 GENERAL

This section specifies technical and performance requirements for the voice and
data cabling system for the Hong Kong International Airport.

102.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as at the date of the Letter of Acceptance.

ANSI/TIA/EIA 568-A Commercial Building Telecommunications Cabling

Standard
ANSI/TIA/EIA 455- Fiber Optic Test Standards
164 /167/170
EIA/TIA 606 Administration Standard for the Telecommunications
Infrastructure of Commercial Buildings
EIA/TIA 607 Commercial Building Grounding and Bonding
Requirements for Telecommunications
BS 7671 Requirements for electrical installations. IEE Wiring
Regulations. Sixteenth edition
BS 7718 Installations of Fibre Optical Cabling (Code of Practice) –
Sept. 1996.

102.3 SYSTEM DESCRIPTION

102.3.1 Existing System Description

(a) The voice and data network in Hong Kong International Airport comprises of
copper and optical fibre cables to provide “Voice and Data” transmission
connectivity. The basis of the design is compliant with the standards laid
down within EIA/TIA-568-A.

(b) Communication Rooms are situated in various locations throughout the

passenger terminal building (PTB) and within other buildings, both airside and
landside, across the Airport campus. These rooms (commonly known as
“Comms Rooms”) are the main connecting points for hardware driving the
Airport Voice and Data systems. These systems range from low speed
telephone networks to sophisticated high speed information networks.
Comms Rooms can be sub-divided into two main types:

(i) “Primary” Comms Rooms for voice and low speed data (Group A),
Primary Comms Rooms for high speed data (Group B); and

(ii) “Secondary/ Satellite” Comms Rooms for both low and high speed
service distribution.

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Section 102 – Voice & Data Cabling
 (c) Primary Comms Rooms Group A comprises of the Airport Authority’s “Private
Automatic Branch Exchanges” (PABX) and “Fixed Telecommunications
Network Suppliers” (FTNS).

(d) Primary Comms Rooms Group B comprises of all other systems utilizing the
Voice and Data cabling network for connectivity to terminal devices.

(e) Secondary Comms Rooms are located throughout the PTB. These, together
with a number of associated communications cupboards, providing the radial
and backbone cabling topology necessary to meet the Voice and Data cabling
distribution. These Comms Rooms are referred to as Satellite Comms
Rooms.

(f) In general, the use of fibre optic cabling accommodates data connections
between the main Comms Rooms inside the PTB and the Satellite or regional
Comms Rooms throughout the PTB. The category 5 UTP (unshielded twisted
pair) is used for distribution (Voice and Data) from the Satellite Comms Rooms
intermediate distribution frames (IDF) to house distribution frames (HDF),
tenant distribution frames (TDF) and voice/data outlets (VDOs).

(g) The category 3 UTP cable is used in the same configuration as the fibre optic
backbone cable but used for voice connection to ISDN primary rate standard.
The category 3 UTP provides connection between the main distribution frames
(MDF) in Comms Rooms 4A, 4B, 22A and 22B Satellite Comms Room IDFs.

102.3.2 Availability Design Criteria

(a) The central communications role of the Plant servicing a range of user
applications concerned with safety of human life, security of the airport
environs, efficiency of airport operations, and other purposes demands that a
high level of intrinsic availability shall be exhibited by the network components.

(b) Due to the demands of critical user applications associated with safety which
will require very high operational availability, versus other applications
requiring lower levels of operational availability, the network shall provide for
selective allocation of relative user access priorities and quality of service
(QOS) objectives.

(c) The intrinsic availability of optical fibre cables shall be high due to cable routes
being restricted to defined utility reserve area within the airport. Therefore, the
calculated intrinsic network availability shall be determined by the intrinsic
availability of active Plant, and the use of defined availability figures for
supporting facilities.

(d) All Plant and optical cables routes destined to carry airside communications
traffic shall be restricted to locations within the airside areas of the airport to
ensure highest operational availability.

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Section 102 – Voice & Data Cabling
102.4 FIBRE OPTIC CABLES

102.4.1 Multimode Fibre

(a) All multimode cable shall comply with the following standards:

ANSI/TIA/EIA 568-A
ANSI/EIA/TIA 455-164/167/170
IEC 793-2

(b) All multimode cable for indoor use shall comply with the following requirement:

No. of Core : Internal Grade 6/12/36 core

Fibre Mode : Multimode
Fibre Size : 62.5/125/250 μm
Core Diameter: : 62.5±3 micron
Attenuation (max.) : 3.75 dB/km @850 nm @160 MHz.km;
: 1.5 dB/km @1300 nm @500 MHz.km
Strain Relief : Central non-metallic
Outer Sheath : LSF/OH
Cable Construction : Tight buffered, central strength member
Installation : In conduits, trunking or on cable tray

(c) All multimode cable for outdoor use shall comply with the following
requirement:

No. of Core : External Grade 12 core

Fibre Mode : Multimode
Fibre Size : 62.5/125/250 μm
Core Diameter : 62.5±3 micron (at 1310 nm)
Attenuation (max.) : 3.75 dB/km @850 nm @160 MHz.km;
: 1.5 dB/km @1300 nm @500 MHz.km
Strain Relief : Central non-metallic
Inner Sheath : Polyethylene sheath
Armour barrier : Plastic Coated Steel Tape
Outer Sheath : Polyethylene sheath
Cable Construction : Tight buffered, central strength member
Installation : In external underground ducts

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Section 102 – Voice & Data Cabling
102.4.2 Singlemode Fibre

(a) All single-mode cable shall comply with the following standards:

ANSI/TIA/EIA 568-A
ANSI/EIA/TIA 455-164/167/170
IEC 793-2

(b) All single-mode cable for indoor use shall comply with the following
requirement:

No. of Core : Internal Grade 12/36 core

Fibre Mode : Single-mode
Fibre Size : 8/125/250 μm
Mode Field Diameter : 9.3±0.5 micron (at 1310 nm)
Attenuation : 0.7 dB/km @1310 nm;
: 0.7 dB/km @1550 nm
Strain Relief : Central non-metallic
Outer Sheath : LSF/OH
Cable Construction : Tight buffered, central strength member
Installation : In conduits, trunking or on cable tray

(c) All single-mode cable for outdoor use shall comply with the following
requirement:

No. of Core : External Grade 12/36 core

Fibre Mode : Single-mode
Fibre Size : 8/125/250 μm
Core Diameter : 9.3±0.5 micron (at 1310 nm)
Attenuation (max.) : 0.7 dB/km @1310 nm;
: 0.7 dB/km @1550 nm
Strain Relief : Central non-metallic
Inner Sheath : Polyethylene sheath
Armour barrier : Plastic Coated Steel Tape
Outer Sheath : Polyethylene sheath
Cable Construction : Tight buffered, central strength member
Installation : In external underground ducts

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Section 102 – Voice & Data Cabling
102.4.3 Connectors, Patch leads and Pigtails

(a) The connector for the termination of optical fibre shall be the T568-SC as
specified in the recommendation ANSI/TIA/EIA 568-A Commercial Building
Telecommunications Cabling Standard.

(b) The design of these connectors and their usage shall be fully in accordance
with the ANSI/TIA/EIA standard.

102.5 TWISTED PAIR CABLES

102.5.1 Category 6 UTP Cable

(a) All Category 6 UTP cables shall comply with the following standards:

ANSI/TIA/EIA 568-B
BS 7671, 7718

(b) Category 6 UTP Unshielded Twisted Pair internal grade cable for indoor use
shall comply with the following requirements:

ANSI/TIA/EIA category : Category 6

No. of pairs per cable :4
Outer Sheath : LSF/OH

102.5.2 Category 5 UTP Cable

(a) All Category 5 UTP cables shall comply with the following standards:

ANSI/TIA/EIA 568-A
BS 7671, 7718

(b) Category 5 UTP Unshielded Twisted Pair internal grade cable for indoor use
shall comply with the following requirements:

ANSI/TIA/EIA category : Category 5

No. of pairs per cable : 50, 25, 4 (as appropriate to the application)
Outer Sheath : LSF/OH

102.5.3 Category 4 Cable

(a) All Category 4 cables shall comply with the following standards:

ANSI/TIA/EIA 568-A
BS 7671, 7718

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Section 102 – Voice & Data Cabling
 (b) Category 4 UTP Unshielded Twisted Pair internal grade cable for indoor use
shall comply with the following requirements:

ANSI/TIA/EIA category : Category 4

No. of pairs per cable : 4 pairs minimum
Outer Sheath : LSF/OH

(c) Category 4, 100ohm, STP Shielded Twisted Pair external grade cable for
outdoor use shall comply with the following requirements:

ANSI/TIA/EIA category : Category 4

No. of pairs per cable : 10
Outer Sheath : Medium density polyethylene
Description : In cable ducts

102.5.4 Category 3 UTP Cable

(a) All Category 3 UTP cables shall comply with the following standards:

ANSI/TIA/EIA 568-A
BS 7671, 7718
(b) Category 3 UTP Unshielded Twisted Pair internal grade cable for indoor use
shall comply with the following requirements:

ANSI/TIA/EIA category : Category 3

No. of pairs per cable : 50 pairs minimum
Outer Sheath : LSF/OH

(c) Category 3 UTP Unshielded Twisted Pair external grade cable for outdoor use
shall comply with the following requirements:

ANSI/TIA/EIA category : Category 3

No. of pairs per cable : 25, 12
Outer Sheath : Polyethylene
Description : In cable ducts

102.5.5 Jumper Leads

(a) Category 5, 4 pair unshielded twisted pair jumper wire shall comply with the
following standards and requirements:

ANSI/TIA/EIA : 568-A
ANSI/TIA/EIA category : Category 5
BS : 7671, 7718
No. of pairs of cable :4

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 Connectors : N/A (leads directly terminated)
Outer Sheath : LSF/OH
Description : Jumper leads

(b) Category 3, unshielded twisted pair jumper wire shall comply with the following
standards and requirements:

ANSI/TIA/EIA : 568-A
ANSI/TIA/EIA : Category 3
category
BS : 7671, 7718
No. of pairs of cable : As appropriate for the connection circuit (1, 2,
or 4)
Connectors : N/A (leads directly terminated)
Insulation : PVC
Description : Jumper leads

102.6 DISTRIBUTION FRAMES

102.6.1 General

(a) The intermediate distribution frames (IDF), house distribution frames (HDF),
tenant distribution frames (TDF) are used to transmit data among Comms
Rooms and voice/data outlets (VDO) through Cat 5 UTP cables. HDF and
TDF shall be located at various locations throughout the airport complex. Fibre
distribution frames (FDF) are used to transmit data among Comms Rooms
and remote locations via fibre cables.

(b) The main distribution frames (MDF) provides connection for category 3 UTP to
satellite communication room. These frames provide both the primary link and
service distribution for voice communication.

102.6.2 Fibre Distribution Frames (FDF)

(a) Wall mounted “Fibre Distribution Frames” (FDF) shall be installed throughout
the airport complex both within Comms Rooms and in the field and shall
comply with the recommendation ANSI/TIA/EIA 568-A Commercial Building
Telecommunications Cabling Standard and they shall be designed to provide:

(i) means to interconnect backbone cabling runs with cross connect patch
cords to equipment cabinets;

(ii) means to cross-connect fibre-to-fibre connections to facilitate extended

end to end connections;

(iii) means to identify and label individual circuits in accordance with the
cable and fibre numbering system used by the cable management
system; and

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Section 102 – Voice & Data Cabling
 (iv) means of incorporating the handling of optical fibre cable and patch
leads to permit orderly cable management in accordance with the cable
manufacturer’s specifications for bending radii, maximum pulling strain
etc:

Number of ports : minimum capacity shall be 24 fibres

Port type : LC-connector
Mounting (small frames) : wall mounted; and
Mounting (large frames) : floor mounted – single sided

102.6.3 Intermediate Distribution Frames (IDF)

(a) Intermediate Distribution Frames (IDF) shall be installed within Comms

Rooms. Two configurations of frames shall be installed with single and double
verticals being employed as necessary.

(b) Type A frame:

- ANSI/TIA/EIA 568-A
- Single and double verticals
- Termination capacity for double vertical (excluding space taken by
backmount label holders)

Cat 5 x 8 pair blocks : 1280 pairs (maximum)

Cat 3 x 10 pair blocks : 1600 pairs (maximum)

- Used for the block mounting and termination of the category 3 x 50 pair
cables feeding in from the MDF’s located in Comms Rooms 4 and 22.

(c) Type B frame:

- ANSI/TIA/EIA 568-A
- Single and double verticals
- Termination capacity for double vertical (excluding space taken by back-
mount label holders)

Cat 5 x 25 pair blocks : 3500 pairs (maximum)

- Used for the block mounting and termination of the category 5 x 25 pair
House Services Connection Blocks.

(d) A “Telecommunication Earth Grounding Busbar” (TGB), to TIA/EIA 607, shall

be fitted at the base of each frame in each Comms Rooms.

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102.6.4 House Distribution Frames (HDF) and Tenant Distribution Frames (TDF)

(a) “House Distribution Frames” (HDF) and “Tenant Distribution Frames” (TDF)
shall be installed at various locations across the airport complex generally in
the field. These frames shall have the following requirements:

- ANSI/TIA/EIA 568-A
- Single and double verticals
- Termination capacity for double vertical (excluding space taken by
backmount label holders)

Cat 5 x 25 pair blocks : 3500 pairs (maximum)

- Used for the block mounting and termination of the category 5 x 25 pair
house services connection blocks.

(b) A “Telecommunication Earth Grounding Busbar” (TGB), to TIA/EIA 607, shall

be fitted at the base of each frame in each Comms Rooms.

102.6.5 Main Distribution Frames (MDF)

(a) Main Distribution Frames (MDF) shall be installed within Comms Room 4 and
22 located in the PTB. These frames shall provide the PABX distribution
points for the PTB category 3 cabling network and shall have the following
requirement:

- ANSI/TIA/EIA 568-A
- Single and double verticals
- Termination capacity for double vertical (excluding space taken by back-
mount label holders)

Cat 3 x 8 pair blocks : 1600 pairs (maximum) / 690 pairs

Cat 3 x 10 pair blocks : 2000 pairs (maximum) / 1380 pairs

(b) A Telecommunication Earth Grounding Busbar (TGB), to TIA/EIA 607, shall be

fitted at the base of each frame in each Main Distribution Comms Rooms or
independently wall mounted at high level.

102.7 VOICE & DATA OUTLETS (VDO)

(a) All category 5 voice and data RJ45 outlets shall comply with the following
standards:

ANSI/TIA/EIA 568-A
BS 7671

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 102 – Voice & Data Cabling
 (b) The VDOs shall be installed in two groups. Group 1 shall be for installation
directly into the lid types House Distribution Frames (HDF) and shall be the
insert type RJ45 single outlets. Group 2 shall be for mounting onto standard
back boxes and either manufactured with a plastic or satin-brushed stainless
steel finish facia, which is fixed with a simplex or duplex RJ45 adaptor module.
All VDOs shall comply with the following requirements:

ANSI/TIA/EIA : Category 5
category
Connector type : RJ45 (incorporating IDC connecting
technology)
Number of pins :8
Cover type : Shuttered
Pinouts : T568A
Faceplates : Brushed stainless steel for public areas
PVC type and white in colour for non-public
areas
Metal clad for plant rooms and industrial areas
Installation : Flushed or surface mounted depends on
location

(c) Each RJ45 connector outlet shall be manufacturer configured to enable

category 5, 4 pair UTP, 100 ohm horizontal cable to give a pin-out connector
presentation compliant with T568A, as defined within ANSI/TIA/EIA 568-A as
follows:

Pin No. Cable Colour Code Pair No.

1 White/ Green 3
2 Green 3
3 White/ Orange 2
4 Blue 1
5 White/ Blue 1
6 Orange 2
7 White/ Brown 4
8 Brown 4

(d) The details of conduits and trays shall refer to Section 49 and 50 of this
GMWS.

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Section 102 – Voice & Data Cabling
102.8 CABLE MANAGEMENT AND IDENTIFICATION

102.8.1 Numbering

(a) In order to successfully operate and maintain the cable system at the Airport,
a structured and efficient numbering scheme has been employed. The
numbering scheme is fully compatible with the cable management system for
sorting and tracing of circuits, paths, routes and the like.

(b) The numbering scheme shall be fully compatible with the ‘cable management
system’ and EIA/TIA 606 Administration Standard for Telecommunications
Infrastructure of Commercial Buildings.

(c) The Contractor shall adopt the same system used during the initial
construction and fit-out of the Airport.

(d) Unless otherwise specified, all cables shall be labeled according to Section 48
of this General Materials and Workmanship Specification and they shall be
labeled using the source code, destination code, cable number and cable
type.

(e) The numbering scheme shall include (where applicable) but not be limited to
cables, management modules, verticals, frame numbers, pairs or cores
(fibres), cable trays, riser numbers, ducting, conduits, etc, to fully describe
physical elements routes, electrical circuit connections and cross connections,
voice data outlets and terminal equipment.

(f) The detailed numbering scheme employed shall use the following hierarchy in
structuring the numbering scheme ranging from the highest level to the lowest
level:

(i) Comms Rooms 2 and 3;

(ii) Comms Rooms 4(A) and 4(B);

(iii) Satellite Comms Rooms and cupboards;

(iv) external cables entering the PTB;

(v) HDF (House Distribution Frames);

(vi) TDF (Tenant Distribution Frames); and

(vii) VDO(Voice Data Outlets).

(g) Abbreviations used in the numbering scheme shall where possible be

descriptive and shall be used for the physical labeling of equipment and
cables (e.g. HDF 07-603 is the third HDF on level 6 and is parented from
Comms Room no 7).

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Section 102 – Voice & Data Cabling
102.8.2 Labeling of Cables

(a) The Contractor shall clearly and indelibly label each end of every cable.
Where a cable consists of multiple cores, labeling of the outer sheath only
shall be considered adequate, provided that individual cores are identified at
the point of termination.

(b) The Contractor shall select the colour of lettering to contrast with the cable
sheath.

(c) Lettering shall be at least 20% of the sheath circumference or 4mm in height,
whichever is the greater, and located approximately 100mm from the end in
the insulation.

102.9 CABLE INSTALLATION

102.9.1 Cable Installation

(a) All cables shall be installed in accordance with the requirements of Section 48
of this GM&WS and the COP (Wiring) of EMSD, Hong Kong SAR.

(b) Separate cable management systems or components of systems shall be

provided to ensure segregation of data cables from power cables.

(c) Fibre optic cable shall be used instead of copper UTP cable when the data
cable length is longer than 90 meters to guarantee the data transmission
performance.

102.9.2 Cable Installation in Ducts

(a) The design and installation of the cabling system shall be in accordance with
the requirements of the cable manufacturer and the IEE Regulations.

(b) Contractor’s Drawings showing the general cable arrangement and support
details shall be submitted to the Project Manager for review without objection
prior to cable installation.

(c) Within ducts, cable stockings shall be used for hauling.

(d) When a cable is drawn into a duct a new draw rope shall be installed by the
Contractor to permit future cable installation. Draw ropes shall consist of
multifilament nylon cord in a woven nylon sheath with a typical minimum
breaking load of 4.4 kN.

(e) After the installation of all cables the ends of all ducts and pipes rising to the
surface, or entering draw pits, shall be sealed to form a gas tight waterproof
barrier. For ducts or pipes entering a tunnel or building, the seal shall be gas
tight, waterproof and have a 2 hour fire resistance.

(f) Gas tight, waterproof and fire resistant seals in ducts or pipes shall be made
using a proprietary system that provides the necessary resistance.

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Section 102 – Voice & Data Cabling
 (g) Every precaution shall be taken to ensure that the cables and accessories are
not installed in a manner or under conditions likely to cause electrolytic or
other corrosive action or damage to the cables, or be detrimental to the
performance of the cable during operation.

(h) The cable system shall be fully protected from mechanical damage and shall
be readily accessible for inspection at all pits and termination frames.

(i) All cables shall be provided with identification markers, at each end of the
cable, at entry and exit point of cable ducts and conduits, including in every
draw pit, and in other such positions as are necessary to identify and trace the
route of the cables.

(j) Where twisted pair copper cables are terminated onto distribution frames, the
Contractor shall ensure that after striping back the outer sheath, the correct
twist of each individual pair is maintained as close as is practically achievable
to the actual point where the wires are terminated.

102.10 CABLE TESTING

(a) The quality control procedures for all optic fibre, STP and UTP cable including
design, cable and termination manufacture, installation, inspection, testing and
commissioning shall be implemented to ensure that the final installation meets
the requirements of Section 108 of this General Materials and Workmanship
Specification. The Contractor shall propose and submit to the Project Manager
for review without objection quality control measures and a testing and
commissioning plan which include as a minimum the following:

(i) testing and commissioning plan shall include:

- validation of cable manufacturers specifications for each cable

type;

- test methods of cables and acceptance criteria after manufacture

at the factory;

- test and inspection acceptance criteria for on Site delivery handling

and storage;

- test and inspection acceptance criteria to be adopted during

installation, termination and commissioning; and

(ii) a report shall be submitted by the Contractor to the Project Manager

evidencing the effectiveness of the testing and commissioning plan
including the submission of signed test certificates as required by the
plan.

(b) Fibre optic cables – All cable shall be tested in accordance with the
requirements as specified in Section 108.14.1 (a). Optical power loss criteria
shall also be referred to Section 102.4.1 (b).

(c) Copper cables – All cable shall be tested in accordance with the requirements
as specified in Section 108.14.1 (b).

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 102 – Voice & Data Cabling
[this page not used]
SECTION 103 PUBLIC ADDRESS SYSTEM

103.1 GENERAL

(a) This section specifies the equipment and materials of the existing Public
Address (PA) System in the Hong Kong International Airport.

(b) Any system changes in the PA system shall involve changes to the system
configuration and programming of the PA system.

(c) Any system changes in the PA system shall not degrade the MTBF of the
existing equipment.

103.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as at the date of the Letter of Acceptance.

BS 5839 Fire Detection and Alarm Systems for Building

BS 6259 Code of Practice for the Design, Planning, Installation,
Testing and Maintenance of Sound System
BS 6840 Sound System Equipment
BS 7671 Requirements for Electrical Installations. IEE Wiring
Regulations. Sixteenth Edition
BS EN 60268 Sound System Equipment
BS EN 60801 Electromagnetic Compatibility for Industrial-process
Measurement and Control Equipment
BS EN 60849 Sound Systems for Emergency Purpose

103.3 SYSTEM DESCRIPTION

103.3.1 Existing System Description

(a) The public address (PA) system provides audio signals typically voice
announcements and alarm tones, including fire warnings and evacuation
messages, to all public areas of the passenger terminal building (PTB).

(b) Audio sources include live microphone announcements from gate desks,
control, operational centers and pre-recorded announcements (including
background music) from other sources.

(c) The PA zones in the PTB shall correspond to the fire zones. The PA zones
can be accessed either individually or in selectable combinations.

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Section 103 – Public Address System
 (d) The speakers are connected such that the different PA zones are driven from
independent power amplifier modules. Each amplifier module is a twin unit
(consisting of two separate amplifiers) and has a dual output (i.e. A and B
circuits). Speakers in each zone shall be connected as interleaved circuits so
that alternate speakers are driven by the A and B amplifiers respectively.

(e) All speakers shall connect to “Public Address Distribution Frames” (PAF) and
through which connect back to Comms Room racks in Comms Room.

(f) The PA system is categorized as a Type 3 system according to BS 6259.

(g) Any system changes in the PA system shall involve changes to the system
configuration and programming of the PA.

(h) The mean time between failures of equipment or components of systems

provided shall not affect the overall system performance.

103.3.2 System Performance

(a) The quality of equipment and materials to be used in the PA system shall
achieve a RASTI performance 0.5 or better during the commissioning phase
of the modified system.

(b) RASTI performance shall refer to BS 6840-16 and BS EN 60268-16.

(c) The PA system shall be designed to meet the requirements of BS EN 60849

for emergency purposes. Special attention of the design shall be paid to the
following points:

(i) system reliability and fail-safe;

(ii) system damage caused by defective appliance and components;
(iii) system feedback of sound level of operation for audio signals;
(iv) adequate output levels; and
(v) variable input levels.

(d) The system shall have a minimum SPL of 80 dB(A) sound pressure level
(SPL) at 1.5m above finish floor level, when all power amplifiers are driven to
< 70% of rated power.

(e) The PA system shall be designed to ensure matching between amplifier and
load. The variation in available power shall not exceed 3 dB between the
outlet nearest to the amplifier and any other outlet in the system. Suitable and
acceptable repeaters and signal conditioner shall be installed as necessary to
maintain the sound power level. A load variation of 50% shall not affect the
quality of sound or cause the output voltage at any outlet to vary by more than
6 dB.

(f) The PA system shall be provided with pre-amplifier and amplifier of sufficient
power to drive all the loudspeakers. Each pre-amplifier and amplifier shall
have a 100% standby unit, so arranged that if any one unit failed, the
corresponding standby unit shall take up the duty for the respective operation
automatically within fifteen seconds.

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Section 103 – Public Address System
 (g) An audio alarm message in Cantonese and English shall be announced
repeatedly with the audio alarm bell signal in sequence. The message shall be
as required by FSD and will be similar to the following:

“This is a fire alarm message. Please keep calm. Follow the flashing lights to
the nearest exit. Do not use the lift.”

(h) The message shall be audible in all areas within the specified zone. The signal
to noise ratio shall not be less than 40 dB when the loudspeaker output level
in the area concerned is not less than 20 dB above the background noise level
normally expected in the respective area during fire conditions. The variation
in sound power level between the outlet nearest to and farthest from the
amplifier shall not exceed 3 dB.

103.4 PERFORMANCE CRITERIA OF EQUIPMENT

103.4.1 Microphone

(a) Microphones shall exhibit the following performance criteria:

(i) On-axis frequency : Within +6dB to –10dB over the frequency

response range of 100 – 10000Hz, relative to 1 kHz
(ii) Sensitivity : Not less than 1.0mV/Pa (-77dB ref. 1
V/　bar) at 1kHz
(iii) Distortion : Less than 0.5% at 1 kHz, at 30 Pa sound
pressure level input
(iv) Front-to-back : greater than 15dB over 300 to 5000Hz for
discrimination ratio unidirectional microphones
(v) Impedance : 200 – 600 Ohms at 1 kHz and balanced

103.4.2 Power Amplifier

(a) Power amplifiers shall provide a minimum SPL in the space of 10dB(A) higher
than the nominal background noise level when driven by a nominal + 4dBm
line signal. The continuous power handling level shall be 3dB and the peak
power handling level be 6dB above this value.

(b) The line output for a single channel power amplifier shall be 100V to match
with existing system

(c) Power amplifiers shall exhibit the following performance criteria:

(i) Input sensitivity : Maximum 0.77V for rated output for

source impedance of 600 Ohms
(ii) Frequency response : Within ±3dB over the frequency range 20
to 20000Hz
(iii) Total harmonic distortion : Maximum 1% over frequency range 50 to
15000Hz at rated output

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Section 103 – Public Address System
 (iv) Noise level : Better than 70dB below rated output with
input shorted, over the frequency range
50 to 15,000Hz unweighted
(v) Output regulation : Less than 2dB from no load to full load
with good stability

103.4.3 Loudspeakers

(a) Loudspeakers shall be dimensioned such that the SPL over 95% of the zone
area is at least 10dB(A) above the nominal background noise level when
driven by a nominal + 4dBm signal at the test points. Under these conditions,
a loudspeaker shall run at least 3dB below it’s rated continuous power
handling capacity, and shall be 6dB below its short term peak power handling
capacity.

(b) Each loudspeaker type shall include an integral 70V/100V line transformer
with tappings for 100%, 50% and 25% full power.

(c) The pattern type of the loudspeakers shall be cardioid unless otherwise
specified.

(d) For column and projection (horn) loudspeakers, the directivity factor Q and the
–6dB vertical beamwidth within a range of bandwidth shall match the installed
location and application to achieve the required performance.

(e) For ceiling mounted loudspeakers, it shall meet the following performance
criteria:

(i) Rated power : At least 6 watts RMS continuous

(ii) Nominal coverage angle : 140° or to match the location
(iii) Directivity factor Q : At least 5 at 1kHz
(iv) Sensitivity : At least 86dB/W at 1 meter on axis
(v) On-axis frequency : ± 3dB over frequency range 100-15kHz
response

103.4.4 Cables

(a) Microphone cables shall be flexible twisted pair of tinned annealed copper
conductors, PVC insulation, tinned copper braided shield, and PVC outer
sheath. They shall meet the following characteristics unless otherwise
specified:

(i) Number of strands per : At least 16

conductor
(ii) Strand diameter : At least 0.15mm
(iii) Nominal outer diameter : 50mm maximum
(iv) Capacitance between : 110 pF/m maximum
conductors
(v) Insulation thickness : At least 0.25mm
(vi) Inner conductor d.c. : 36 Ohm/km maximum at 20°C
resistance

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Section 103 – Public Address System
103.4.5 Local Zone Console
(a) The local zonal console shall provide zone selection, paging and status
indication. They are capable of addressing the zones that have been
programmed in the system controller and can be used for live broadcasting.
(b) The console shall be compatibility with existing system, Media matrix Q-Host
System.
(c) The local zone console shall be flush mounted desk-top unit, terminated by
means of a multi-pin plug allowing easy removal for servicing or replacement.
(d) The local zone console shall allow locally generated broadcast to one paging
zone. The single zone console shall consist of:-
(i) Hand mic with coiled cord
(ii) Zone select push button
(iii) Zone PTT push button
(iv) Zone status LED indicators
(v) Panel OK LED
(vi) Panel Fault LED
(vii) Fault monitoring
(e) The number of zone selection buttons shall be available from 4 to 20 for
different local zone console model.
(f) The Technical requirements of the single zone and multi-zone local zone
console are as follows.
(i) Microphone frequency response: 30Hz to 20kHz
(ii) Microphone polar response Cardioid
(iii) Microphone element Electret
(iv) Microphone sensitivity -50±3dB (0dB = 1mW/Pa)
(v) Console audio output 0dBm
(vi) Compressor 20:1 slope with automatic attack
and release constants
(vii) Equalisation 12 dB/Octave shelving filters
at 100Hz, 1kHz and 10kHz
(g) Power supply shall be provided which can be installed locally or installed in
the nearest communication room with dedicated power cable connected the
local zone console
(h) The console shall communicate with the existing system controller via. RS485
serial link.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 103 – Public Address System
 (i) Indoor loudspeaker cables shall be flexible and multicore in general, and
exhibit low smoke zero halogen as well as flame retardant properties to BS
6387 Cat. CWZ. They shall have the following characteristics:

(i) Number of strands per : At least 19

conductor
(ii) Strand diameter : At least 0.21mm
(iii) Signal loss between : 0.5dB maximum
zone amplifier and
marshalling frame
(iv) Insulation thickness : At least 0.5mm

(j) The loudspeaker cables shall be normally wired in steel conduits unless
otherwise specified.

(k) For loudspeaker cables installed underground and externally, they shall be
shall be PVC insulated, armoured, with one or two twisted pairs of tinned,
annealed copper conductors, tinned copper braided shield and complete with
an overall protective jacket of PVC.

103.5 ELECTROMAGNETIC INTERFERENCE

(a) All equipment supplied shall be immune from and shall not radiate signals
exceeding the limits of BS EN 60801.

(b) No part of the PA installation shall be within a distance of less than one sixth
of a wavelength away from the disturbing source of voltage lines carrying
more than 220V. PA cables shall segregated from all other cables by at least
300 mm in any direction as far as practical. Long parallel runs of PA and
mains cables and of microphone and loudspeaker shall be avoided. Cables
shall only across at right angles.

(c) Protection shall be provided by means of surge suppressors to any equipment

including cables which may be vulnerable to voltage transients. This shall
include the incoming mains connections to the power supply unit. The
equipment manufacturers’ instructions shall be observed in applying the
protection.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 103 – Public Address System
SECTION 104 ACCESS CONTROL SYSTEM

104.1 GENERAL

(a) This section specifies the equipment and materials of the existing Access
Control System (ACS) in the Hong Kong International Airport.

(b) Any system changes in the ACS shall involve changes to the system
configuration and programming of the ACS.

(c) Any system changes in the ACS shall not degrade the MTBF of the existing
equipment.

104.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as at the date of the Letter of Acceptance.

ANSI/TIA/EIA 568-A Commercial Building Telecommunications Cabling

Standard
BS 7671 Requirements for Electrical Installations. IEE Wiring
Regulations. Sixteenth Edition

104.3 SYSTEM DESCRIPTION

104.3.1 Existing System Description

(a) The access control system (ACS), together with closed-circuit television
(CCTV) system, provides the primary security systems for the airport
buildings. The ACS is designed to provide, among others, the following range
of facilities:

(i) security control of fire escape stairs throughout the Passenger Terminal
Building (PTB);

(ii) security control of loading bridge entrances at arrivals and departures

levels;

(iii) security control of lifts where required;

(iv) security control of plant rooms;

(v) after hours securing of public areas that are not required for passenger
processing (e.g. transfer areas);

(vi) validation of staff entering and leaving the airside areas; and

(vii) security control of the airside / landside boundary.

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Section 104 – Access Control System
 (b) The above facilities are provided by a network of computer equipment,
communications and access control panels distributed throughout the airport
complex.

104.3.2 System Architecture

(a) The system architecture of the ACS comprises 5 levels of distributed

computing components:

(i) level 1 : ACS Users;

(ii) level 2 : ACS Master Central database Controller (CDC);

(iii) level 3 : Regional Central Database Controller (Regional CDC)

and Real Time Computer (RTC);

(iv) level 4 : S9032 access controller; and

(v) level 5 : field security devices.

(b) Each Regional CDC is linked to the S9032 access controllers via an
Ethernet-based TCP/IP Local Area Network, which shall comply with Section
102.

(c) The field security devices shall be connected to the S9032 access controller
via shielded or unshielded twisted pair cables or to RTC via Ethernet
connections for low or extra low voltage, or via fibre optics with data-optical
transceivers.

(d) Any system changes in the ACS shall involve changes to the system
configuration and programming of the ACS.

(e) The MTBF of equipment or components of systems provided shall not affect
the overall system performance.

104.4 FIELD SECURITY DEVICES

104.4.1 General

(a) Field security devices include but are not limited to the followings devices:

(i) card reader terminals;

(ii) egress/ request to exit buttons;

(iii) emergency break glass units;

(iv) panic alarm button for disabled toilet/ personnel distress;

(v) electric and electromagnetic lock monitor switches/ contacts;

(vi) assistance alarm button/ duress button/ kickbar alarm;

(vii) electric strike monitor switches/ contacts;

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Section 104 – Access Control System
 (viii) door interface units (DIU);

(ix) door switches/ contacts; and

(x) audible alarm sounders.

(b) The materials, mounting method and installation details of the field security
devices shall suit the installation locations and complying with the
manufacturer’s recommendations.

104.4.2 Card Reader Terminals

(a) S610s PicoPass card reader

(i) The card reader/ keypad terminals are S610s PicoPass card readers.

(ii) The S610s PicoPass card reader shall be an intelligent serial card
reader designed for use with integral reading support onboard head
technology for Inside PicoPass smartcard as part of an integrated online
access control system and is used to control access to restricted areas
or in special applications where card activation of machinery is required.

(iii) The S610s PicoPass card reader shall allow 2 additional onboard
Wiegand inputs for connecting other reading technologies externally or
an Exit reader for IN/OUT control.

(iv) The S610S PicoPass card reader shall be an IP 65 rated polycarbonate

enclosure housing the reader electronics with a large 4 x 3 keypad for
configuration and optional PIN, backlit monochrome graphical LCD
display screen and 3 LED indicators.

(v) The S610s PicoPass card reader shall be equipped with 4 analogue
inputs to monitor door and alarm conditions for transmission to the host
AC2000 controller through a RS-485 serial port, and 2 changeover relay
outputs to control the activation of locks or other equipment.

(b) S610fs Fingerprint card reader

(i) The card reader/ keypad terminals are S610f Fingerprint card readers.

(ii) The S610f Fingerprint card reader is fully integrated biometric and
access control reader that is used as part of the access control system
to control access to restricted areas where an additional biometric layer
of security is required.

(iii) The fingerprint card reader shall equip with an on-board 10/100Mbps
Ethernet connection, communicates directly with the AC2000 host server
removing the need for an intelligent control panel in the system design.

(iv) The fingerprint reader shall include biometric template management

software providing a highly accurate algorithm and advanced sensor
technology that works well with scarred, dirty and worn fingers.

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Section 104 – Access Control System
104.4.3 Egress / Exit Push Buttons

(a) The egress / exit push button assembly shall be easy to use with a diameter of
25mm minimum. It shall be green in colour, surface or flush mounted adjacent
to the controlled door to allow egress through the door, to be mounted in a
standard switch box as per Section 50, with face plate to be as 50.1 (b) and
50.12.1 (a).

(b) A label “Press to Exit” in the Chinese and English languages shall be provided
on the face plate adjacent to the push button.

(c) The push button shall directly interrupt power to the door strike or locking
mechanism and simultaneously activate the door forced open alarm shunt
circuit as per card reader terminal.

104.4.4 Emergency Break Glass Units

(a) Emergency break glass units for door release shall be white in colour, surface
or flush mounted. Red colour finish shall not be accepted to avoid confusion
with red fire alarm stations. These units shall be located at any emergency
egress door where egresses are electrically controlled by exit card readers. A
metallic rod for striking the glass shall be included and chained to the
emergency break glass unit.

(b) Emergency break glass units shall be mounted on a standard BS 4662 box,
unless otherwise reviewed without objection by the Project Manager.

(c) A label “Emergency – Break Glass to Exit” in the Chinese and English
languages shall be engraved/ embossed on the break glass unit.

(d) The operation of emergency break glass unit shall act directly on the power
circuit of the electric locking mechanism and interrupt the circuit, causing the
locking mechanism to release. Simultaneously an individual and separately
identifiable “emergency escape activation” alarm shall be initiated. Operating
under 24V DC, the alarm siren tone is 95 dB minimum at one metre.

(e) When these units are used with motorized doors, the unlock / open connection
shall be connected directly into the door control unit. An activation of the break
glass unit shall remove the motorized opening/closing and locking
mechanisms. The door shall be openable by manual operation in an
acceptable manner.

(f) All fixings shall be tamperproof and shall allow replacement of the glass panel
or for service purpose. Fixings with standard flats or star screws are not
acceptable. Two replacement glass plates shall be included for each unit

104.4.5 Disabled Toilet Personnel Distress Button

(a) The disabled toilet personnel distress push button assembly shall be easy to
use with a diameter of 25mm minimum. It shall be surface or flush mounted at
disabled toilets in a standard switch box as per Section 50.

(b) The push button shall be waterproof in nature to IP54.

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Section 104 – Access Control System
 (c) The activation of personnel distress push buttons shall generate an alarm for
the response of ACS workstation operators. Local audible alarm shall be
provided whenever required on the Employer’s Drawings.

104.4.6 Electric Lock Monitor Switches / Contacts

(a) Electric locks shall be monitored for their presence and locking status,
separately from the door open / close status.

(b) The removal or manipulation of any electric lock shall be reported as a “lock
tamper” alarm.

(c) For electromagnetic locks and internal micro-switch in an electric dead-

latching lockset, the lock / unlock status shall be monitored by an integral bond
sensor, preventing activation until the doors are at rest and aligned with the
lock.

104.4.7 Assistance Alarm Button/ Duress Button/ Kickbar alarm

(a) Assistance alarm button/ duress button/ kickbar alarm shall be of the push-to-
activate, self latching and mechanical master-key-only-resettable type.

(b) Assistance alarm button/ kickbar alarm shall be under desk mounted.

(c) Duress button shall be rated for a minimum lifetime of 50,000 operations.

104.4.8 Electric Strike Monitor Switches / Contacts

(a) Electric strikes and latch keepers shall either incorporate a security magnetic
reed switch which shall be operated by a magnet in the lock bolt when the
dead-latching bolt is latched within the keeper, or positive action micro-switch
which shall be mechanically operated by the dead-latching bolt in the strike.

104.4.9 Door Switches / Contacts

(a) Door switches / contacts shall be of the flush mount, recessed “biased”
magnetic reed type installed within the door frames and operating in
conjunction with a matching magnet recessed into the door.
(b) Wide-gap type biased reed-magnet assemblies shall be used to avoid
accidental or intermittent operation by normal movement of doors in closed
latched condition.

(c) Heavy duty glass-sealed reed switches of the biased high security type shall
be fitted to all roller shutters, fold up doors and any other heavy duty gates or
doors as shown on the Employer’s Drawings.

(d) For vertical opening shutters of width over 3 metres, switches shall be
provided on both sides.

General Materials & Workmanship Specification 5/10 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 104 – Access Control System
104.4.10 Audible Alarm Sounders

(a) Audible sounders shall be electrically operated in 24V DC without adjustment.

The sound generated shall be continuous but vary with a second tone for two
stage alarm. The typical sound output level shall be 100 dB (A) minimum at
one metre under 24V DC operation. Synchronized start for these sounders
shall be envisaged. The sounders shall be of ABS construction, with IP54
minimum rating for the shallow base, IP65 rating for both the deep base and U
base.

(b) The sounders shall remain active after activation until a customized program
(such as time-out or overriding keyswitch) or an ACS user command
terminates their activation.

(c) Activation of the sounders could be manually initiated by an ACS workstation

operator or by customized event initiated program in response to reader
terminal duress situations or to control measured for deterring undesirable
access.

(d) Should a fire alarm and/or emergency evacuation occur in any building zone,
the affected audible sounders shall be disabled or silenced in accordance with
customized fire and evacuation response programs.

104.4.11 Door Interface Unit

(a) The existing installation comprises units, Type DIU/700/210. For any new
installations, if the existing models shall no longer be available, an equivalent
unit shall be provided that is both hardware and software compatible to the
existing systems and shall have the same or better performance specification.

(b) The door interface unit (DIU) shall have sufficient 24V DC operational output
power to supply up to two door strike and / or door holder and local power for
the card reader. An auxiliary relay shall be provided to meet additional user
requirements.

(c) The DIU shall have sufficient input/ output capacity to monitor the connected
door, providing standard door modes, when the unit is directly connected to a
S9032 Access Controller.

(d) Each DIU shall maintain its own battery backup sufficiently sized depending
on lock used and rated for full load operation for a minimum period of 4 hours.
The batteries shall be of heavy-duty industrial lead acid type, protected
against deep discharge and overcharge. All battery cells shall be
rechargeable, maintenance free sealed type.

(e) The DIU shall be self-monitoring in terms of tamper and power fail, protected
by tamper sensor and equipped with a power status indicator panel mounted
on the exterior of the enclosure.

(f) The door interface electronics shall be housed in one high impact steel case
enclosure, sealed to IP54.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 104 – Access Control System
 (g) The DIU shall provide 2 master reader inputs and shall provide direct interface
at least to the following devices (up to 8 inputs):

i) card reader or distributed access controller;

ii) electric door strike;

iii) electric door holder;

iv) fire alarm system;

v) break glass unit;

vi) exit push button; and

vii) inputs from alarm devices.

(h) The Sliding Door interfacing requirements include but not limited to the
following:

(i) The ACS system shall be installed to take full remote manual control of
the sliding doors. The system shall place the doors in free access mode
or secure card access control mode. It shall perform the following
automatic and manual control functions during the secure card access
control mode as a minimum:

- off;
- automatic (open-dwell-close)
- open + hold opened; and
- closed.

(ii) Door Motion Sensor shall be supplied and connected directly to the
sliding door operation units. The Door Motion Sensors will be enabled
when the doors are opened and disabled when fully closed. Under no
circumstances will the door motion sensors be disabled or made
inoperative by the ACS system.

(iii) Door Closed and Door Locked conditions shall be monitored by the ACS
system by using heavy duty biased magnetic reed switches for the door
closed monitoring and a voltage free contact from the automatic door
controller for the door locked condition.

(iv) Where automatic sliding doors are fitted with movement sensing devices
to open the doors during the free access mode, these devices shall be
disabled when the doors are in secure card control mode.

(v) The Contractors shall provide all interfacing control relays and timers
within pelmets and door controller cabinets to perform all control
functions.

(vi) All control and interlock functions except safety interlock functions shall
be provided by the ACS to ensure correct and safe operation with the
ACS system.

General Materials & Workmanship Specification 7/10 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 104 – Access Control System
104.4.12 S9032 Access Controllers

(a) The S9032 access controller shall be an intelligent networked device

designed for door entry/exit access control, alarm monitoring and operated
independently and connecting to Regional CDC with the AC2000 system.

(b) The S9032 access controller shall be fully integrated within a standard
Ethernet-based TCP/IP Local Area Network, and configured/monitored
using Telnet/Web-based tools.

(c) The S9032 access controller shall maintain a database of card numbers,
access level and time zones, etc., in order to answer fully autonomously
card access requests from the reader terminals, and it shall report all card
transactions and alarms to the connecting Regional CDC.

(d) The S9032 access controller shall also responsible for determining alarm
conditions on various devices, including (without limitation) tamper
detectors, fire interface activated detectors, panic buttons and door contacts.
It shall report to the Regional CDC immediately upon the occurrence of any
alarm condition.

(e) When the S9032 access controller is off-line to the Regional CDC, the
alarms and events shall continue to be buffered. When the S9032 access
controller is on-line to the Regional CDC, the alarms and events shall be
transferred to the Regional CDC immediately, for it to pass on to the Alarm
Handling CDC.

(f) The internal battery shall provide a minimum 4-hour backup capacity to the
S9032 access controller, in the event of mains failure. When the battery
voltage drops below 85% of the nominal value, a battery low signal shall be
generated and handled as a system alarm. After the battery low alarm is
reported, the remaining backup power shall last for 30 minutes of operation
time. The database shall be retained even in the event of battery backup
failure.

(g) In addition to S9032 access controller tamper, mains failure and battery low,
the S9032 access controller shall also able to detect and report S9032
access controller reboot conditions.

104.4.13 S9032 Lift Controller

(a) The S9032 lift controller shall be an integral component designed to offer the
ability to control the floor access of either one or two lift cabs, each of which
can support access to up to 128 floors with the AC2000 system.

(b) The S9032 lift controller shall provide access control to specific lift floors
with a building when a cardholder presenting a valid access controlled card
to an access control card reader, which in conjunction with the S9032 lift
controller carries out access checks on the AC2000 database to determine
which floors the cardholder is allowed access to.

General Materials & Workmanship Specification 8/10 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 104 – Access Control System
 (c) The S9032 lift controller shall be used to accomplish connection between
the S9032 lift controller and a lift. It shall contain one or more sets of
input/output modules. It shall be available to support up to 128 floors.
Output modules shall be used to signal to the lift which floor selection
buttons to enable. Input modules shall be used to provide a mechanism for
the lift to signal back when floor selection has been made and which floor
was selected.

(d) The S9032 lift controller shall be fully integrated within a standard Ethernet-
based TCP/IP Local Area Network, and configured/monitored using
Telnet/Web-based tools.

(e) The S9032 lift controller shall maintain a database of card numbers, access
level and time zones, etc., in order to answer fully autonomously card
access requests from the reader terminals, and it shall report all card
transactions, floor selections and alarms to the connecting Regional CDC.

(f) The S9032 lift controller shall also responsible for determining alarm
conditions on various devices, including (without limitation) tamper
detectors, fire detectors, panic buttons and door contacts. It shall report to
the Regional CDC immediately upon the occurrence of any alarm condition.

(g) When the S9032 lift controller is off-line to the Regional CDC, the alarms
and events shall continue to be buffered. When the S9032 lift controller is
on-line to the Regional CDC, the alarms and events shall be transferred to
the Regional CDC immediately, for it to pass on to the Alarm Handling CDC.

(h) The internal battery shall provide a minimum 4-hour backup capacity to the
S9032 lift controller, in the event of mains failure. When the battery voltage
drops below 85% of the nominal value, a battery low signal shall be
generated and handled as a system alarm. After the battery low alarm is
reported, the remaining backup power shall last for 30 minutes of operation
time. The database shall be retained even in the event of battery backup
failure.

(i) In addition to S9032 lift controller tamper, mains failure and battery low, the
S9032 lift controller shall also able to detect and report S9032 lift controller
reboot conditions.

104.4.14 sDCM 300 Controller

(a) The sDCM 300 controller shall be an intelligent serial 2-door controller
designed to interface third-party read heads with access control systems.

(b) The sDCM 300 controller shall communicate with the AC2000 host system
via RS-485 communications to the S9032 access controller.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 104 – Access Control System
 (c) The sDCM 300 controller shall be equipped with a 32bit processor with
structured database to allow storage of large amounts of cardholder records
for offline card validation and decision making at the point of entry, even
when host communication is not available.

(d) The sDCM 300 controller shall be configured for 2 read heads on 2 separate
doors, with optional Exit push buttons, or to support an Entry/Exit
configuration for bi-directional control on a single door.

104.5 System Testing and Commissioning

(a) The ACS interfaces with several other systems within the airport buildings.
The Contractor shall liaise and co-ordinate with specialists and others working
on other systems (where necessary) in order to facilitate the provision of
shared data between the ACS and the systems to which it interfaces.

(b) Disconnecting and disabling parts of the system to be taken out of service
temporarily or permanently as part of the works such that there should be no
effect on the operation of the remaining system or on its maintenance. This
shall include but not limited to disabling of alarms, removal of ‘on screen’
ICONS.

(c) The Contractor shall submit details of his commissioning specialist to the
Project Manager for review without objection. This submission shall contain
sufficient details to satisfy the Project Manager of their experience and
expertise.

(d) The test, commissioning and integration of the installed works shall be carried
out by the commissioning specialist who has previous experience of
commissioning an ACS of similar design and complexity and is familiar with
and understands the functional and operational requirements of the already
installed (existing) ACS.

(e) All software/firmware related to the operating and reporting of all additional
ACS equipment installed under the project shall be reconfigured as necessary
to accommodate the equipment, providing a seamless integration into the
existing system. The commissioned system shall not require any additional
configuring of software or firmware by the Project Manager after handover.
The Contractor shall supply any additional firmware required for
Server/Concentrators, DACs and DIUs and configure where necessary to
provide the desired operational performance

General Materials & Workmanship Specification 10/10 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 104 – Access Control System
SECTION 105 TRUNKED MOBILE RADIO SYSTEM

105.1 GENERAL

(a) This section specifies the equipment and materials of the existing Trunked
Mobile Radio (TMR) Systems at the Hong Kong International Airport.

(b) Any system modification and new equipment addition to the existing TMR
systems shall be integrated into the existing systems via a new structured data
cabling, RF leaky cable, optical fibre works that connects to existing system
and not a new ‘stand-alone’ service. The technical performance of the
existing TMR systems shall not be adversely affected as a result of any new
extension work. Also, the existing systems shall be operational at all time
during new extension works. The relocation of any hardware such as antenna
and RF amplifiers shall not adversely affect the overall system performance.

(c) The system of any new expansion shall be configured as per the existing
equipment installed. All protocols and standards shall be the same. All
software/ firmware related to the operating of existing TMR equipment
together with associated cabling installed shall be reconfigured if necessary to
accommodate the additional hardware, providing a seamless integration into
the existing system.

(d) Unless the equipment manufacturer, type and model number is specified
within this GM&WS within appendices or any PTS, the Contractor shall
provide and install new equipment and materials that are entirely compatible
with the existing systems and shall have the same or better performance
specification. The selection of new equipment shall be subjected to review
without objection by the Project Manager.

105.2 RELEVANT CODES AND STANDARDS

(a) Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to
the latest edition of the document, including all amendments issued by the
relevant authority, as at the date of the Letter of Acceptance.

BS 7671 Requirements for Electrical Installations. IEE

Wiring Regulations. Sixteenth Edition
BS EN 50082-1 Electromagnetic compatibility – Generic immunity
standard part 1 : residential, commercial and light
industry
(b) All elements of the system shall be OFTA certified.

General Materials & Workmanship Specification 1/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 105 – Trunked Mobile Radio System
105.3 SYSTEM DESCRIPTION

105.3.1 Existing System Description

(a) The complete TMR network comprises 2 systems:

(i) the Airport Authority TMR (including Wireless Network); and

(ii) the commercial TMR.

(b) The Airport Authority (AA) TMR system is a 3-site Tetra digital trunk mobile
radio system operating in the 800MHz frequency band. This system provides
radio communication facilities for all radio users throughout the whole airport
area It provides portable coverage to both within the Passenger Terminal
Building (PTB) and the outdoor Airfield, comprising a network of indoor
antenna system inside the PTB primarily consisting of multiple low profile
indoor antennas and leaky coaxial cables. This system is operated by AA.

(c) In addition, the AA TMR distributed antenna network also shared with Police
and Fire Services Department (FSD) 400MHz and the upper end 300MHz
frequency band respectively. Both Police and FSD will integrate their RF
signals to the AA TMR distributed antenna network.

(d) The commercial TMR system is an independent system operating in the

800MHz frequency band. A network of antennas inside the PTB and leaky
coaxial cables provides a high degree of portable coverage for commercial
users outside and inside the PTB. This system is operated by a commercial
mobile telecommunication service provider.

(e) System hardware shall include RSX coaxial cable, leaky co-axial cable, bi-
directional amplifiers, splitters, cross band or wide band couplers and antenna
as shown in Employer’s Drawings.

105.3.2 System Performance

(a) The system performance specified in this section shall only apply to indoor
antenna of the AA TMR and commercial TMR systems. Specifications for
others shall refer to PTS of specific projects and/or Employer’s Drawings.

(b) The IMP shall be 110dBc within the operating temperature range of –10°C to
+60°C. The insertion loss for all inputs to output shall be equal, with ± 1dB
tolerance. The test ports for each transmitter port and receiver port shall be 40
dB and 10dB, respectively.

(c) The proposed antenna network shall have a coverage of –85 dBm on
downlink signal path at the worst case, measured by a reference dipole at
1.2m above ground level and free from the effects of body and crowd losses
for 95% of locations, effectively providing a 95% reliability within the intended
areas of coverage. The maximum received signal level shall be –35dBm. A
dynamic range of 70dB shall be allowed for the uplink signal.

(d) The TMR distribution antenna network shall not impart interference to other
radio frequency (RF) systems both inside and outside the PTB. Likewise, the
network shall not itself incur any interference from existing RF systems.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 105 – Trunked Mobile Radio System
 (e) Any system changes to the existing TMR systems shall not degrade the MTBF
of the existing equipment. The MTBF of equipment or components of systems
provided shall not affect the overall system performance.

(f) Any additions to the system shall not degrade the performance of the existing
system.

105.3.3 Indoor Antenna

(a) Indoor antenna shall be low profile, wide band, compact and light weight. The
colour and style shall match the architecture of the surroundings.

(b) Indoor antenna shall exhibit the following minimum performance

characteristics:

(i) frequency range : 806 – 870MHz (AA);

380 – 420MHz (FSD and Police)
(ii) gain : high gain ;
(iii) radiation : omni-directional for wide coverage
applications ;
(iv) power rating : 100 watts minimum;
(v) VSWR : 1.5 : 1 maximum
(vi) impedance : 50 ohms; and
(vii) colour : RAL 9016 or blend in with the architectural
background.

(c) The antenna brackets shall be made of stainless steel and shall be capable of
supporting the antenna securely to the mounting structure.

105.3.4 Transmitter Combiners

(a) Transmitter combiners shall be with low loss and capable of consistent
performance over the entire temperature and power range.

(b) They shall be compact and modular in design and shall enable channel-by-
channel expansion. Transmitter combiners shall meet the following
performance characteristics:

(i) frequency range : 806 – 870MHz (AA);

380 – 420MHz (FSD and Police)
(ii) insertion loss : 5dB maximum;
(iii) transmitter – : 60dB minimum;
transmitter isolation
(iv) VSWR : 1.25 : 1 maximum; and
(v) channel separation : Equal or less than 250kHz.

General Materials & Workmanship Specification 3/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 105 – Trunked Mobile Radio System
105.3.5 Receiver Multicouplers

(a) Receiver multicouplers shall use low noise amplifiers that offer high immunity
to inter-modulation and interference. It shall be modular in design and easily
expandable in small channel increments.

(b) Receiver multi-couplers shall have the following performance characteristics:

(i) frequency range : 806 – 825MHz (AA);

380 – 420MHz (FSD and Police)
(ii) gain : 3dB minimum;
(iii) receiver – receiver isolation : 25dB minimum;
(iv) total noise figure : 5dB maximum; and
(v) power input : 220 V AC / 50Hz.

(c) Unused ports of the receiver multi-coupler shall be terminated with suitable
loads.

105.3.6 Duplexers

(a) Duplexers shall be of compact design and capable of offering high isolation
between transmitter and receiver ports to minimize interference. It shall be
temperature compensated to ensure stability over the entire temperature
range.

(b) Duplexers shall have the following performance characteristics:

(i) frequency range : 806 – 870MHz (AA);

380 – 420MHz (FSD and Police)
(ii) insertion loss : 1.5dB maximum;
(iii) transmitter isolation at receiver : 70dB minimum;
(iv) receiver isolation at transmitter : 70dB minimum; and
(v) VSWR : 1.3 : 1 maximum.

105.3.7 Power Dividers

(a) The power dividers shall operate within the frequency band of 380 – 900MHz
with the same bandwidth requirement. The minimum power rating shall be
500 watts.

(b) Two-way even-split power dividers shall have a maximum insertion loss of
3.5dB.

(c) Three-way even-split power dividers shall have a maximum insertion loss of
5.2dB.

(d) Three-way uneven split power dividers shall have a maximum insertion loss of
20dB at ports 1 and 2. The maximum insertion loss at port 3 shall be 0.5dB.

General Materials & Workmanship Specification 4/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 105 – Trunked Mobile Radio System
 (e) Four-way even-split power dividers shall have a maximum insertion loss of
6.5dB.

(f) Four-way uneven split power dividers shall have a maximum insertion loss of
20dB at ports 1, 2 and 3. The maximum insertion loss at port 4 shall be 0.5dB.

105.3.8 Leaky Coaxial Cables

Leaky coaxial cables are used to distribute RF signals to enclosed areas. They are
low loss cables which shall have the following minimum performance characteristics:

(a) All leaky coaxial cables used shall be broadband and capable of handling a
combined RF signal from 100 MHz to 2.4 GHz simultaneously.

(b) All leaky coaxial cables installed in tunnels and enclosed areas shall have LSF
protective jackets.

(c) Leaky coaxial cables shall be installed in a manner which minimizes

attenuation. The cables shall be supported by standoffs installed at a
maximum spacing of 1 m and using 50 mm standoffs as a minimum. Installed
cables shall be straight and spaced at a constant 50 mm from the supporting
surface throughout the whole cable run.

(d) 7/8-inch leaky coaxial cables shall have the following minimum performance
characteristics:

(i) maximum attenuation @ 900 : 0.055 dB/m;

MHz with 50mm standoff from
concrete
(ii) maximum coupling loss @ 6m : 69 dB;
(iii) maximum outer diameter over : 28mm;
jacket
(iv) impedance : 50 ohms; and
(v) minimum standoff height : 50 mm.

(e) 1 1/4-inch leaky coaxial cables shall have the following minimum performance
characteristics:

(i) maximum attenuation @ 900 : 0.040 dB/m;

MHz with 50mm standoff from
concrete
(ii) maximum coupling loss @ 6m : 71 dB;
(iii) maximum outer diameter : 40mm;
(iv) impedance : 50 ohms; and
(v) minimum standoff height : 50 mm.

General Materials & Workmanship Specification 5/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 105 – Trunked Mobile Radio System
 (f) Coaxial feeder cables shall be of low attenuation and low VSWR type with
great strength and flexibility. Coaxial feeder cables shall completely RFI/EMI
shielded to protect against interference. Connector attachment shall be quick
and reliable with excellent electrical contact. For cables installed in tunnels
and enclosed areas, the outer sheath or protective jackets for the cables shall
be of low smoke zero halogen type. Coaxial feeder cables shall exhibit the
following minimum performance characteristics:

(i) attenuation : Not more than 0.04 dB/m at 850 MHz;

(ii) impedance : 50 ohms maximum;
(iii) minimum bending radius : 250 mm maximum; and
(iv) tensile strength : 145 kg minimum.

105.3.9 Bi-directional Amplifiers

Bi-directional amplifiers provided shall be compact, lightweight and equipped with a

wall-mounted weatherproof housing, and shall have the following minimum
performance characteristics:

(i) frequency range : 806 – 870MHz (AA);

380 – 420MHz (FSD and Police)
(ii) number of passbands : 2;
(iii) passband separation : 45 MHz between centre;
(iv) bandwidth of each passband : 18 MHz;
(v) number of frequencies per : 60;
passband

(vi) gain : 80 dB (AGC disabled);

(vii) AGC range : 50 dB;
(viii) third order : 44 dBm minimum;
(ix) noise figure : 10 dB maximum;
(x) operating temperature : -30 to 60 0C
(xi) impedance : 50 ohms;
(xii) VSWR : 1.5 : 1 maximum;
(xiii) supply input : 220V AC / 50 Hz;
(xiv) maximum size : 400 x 300 x 200 mm (LxWxD); and
(xv) maximum tensile strength : 25 Kg.

General Materials & Workmanship Specification 6/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 105 – Trunked Mobile Radio System
105.3.10 RF/Optical Transceivers

(a) Transceivers to be used to convert RF signal into optical signal and vice versa
shall have the following minimum characteristics:
(i) From trunked site to antenna:
• frequency range : 806-870 MHz (AA);
380 – 420MHz (FSD and Police)
• RF input power range : 0 to 30 dBm;
• minimum RF output power : 30 dBm;per channel (based on a
total of 28 channels)
• minimum S/N ratio : 55 dB;
• third order intermodulation : 55 dBc;
• supply input : 220VAC/50Hz.

(ii) From antenna to trunked site:

• frequency range : 806-870 MHz(AA);
380 – 420MHz (FSD and Police)
• input sensitivity (12dB SINAD): 0.5 uV;
• gain : continuously adjustable
• dynamic range : greater than 60 dB
• spurious emissions : less than -36 dBm
• supply input : 220VAC/50Hz.

105.3.11 Coaxial feeder cables

(a) Coaxial feeder cables shall feature low attenuation, low VSWR as well as
great strength and flexibility. They shall be completely RFI/EMI shielded to
protect against interference. Connector attachment shall be quick and reliable
with excellent electrical contact.

(b) All coaxial feeder cables installed in tunnels and enclosed areas shall have
LSF protective jackets.

(c) Coaxial feeder cables shall exhibit the following minimum characteristics:

(i) maximum attenuation @ 850 MHz : 0.04 dB/m;

(ii) maximum outer diameter : 28 mm;

(iii) impedance : 50 ohms;

(iv) minimum tensile strength : 145 kg; and

(v) minimum bending radius : 250 mm maximum.

General Materials & Workmanship Specification 7/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 105 – Trunked Mobile Radio System
105.3.12 System Testing and Commissioning

(a) For the TMR systems, the majority of commissioning will be based around
transmission and reception performance of the new antenna installed (leaky
coaxial and discreet antennae), ensuring an acceptable level of coverage is
achieved in all new (expansion) areas.

(b) The Contractor shall be responsible for the testing and commissioning all TMR
and related equipment installed under their scope of works. The Contractor
shall review the new antenna network to ensure that the required level of
coverage can be obtained. In the event that antennas need to be added,
deleted, or relocated, the Contractor shall submit to the Project Manager for
review without objection the signal strength, readings and calculations to
justify such additions, deletions or relocations.

(c) The testing, commissioning and integration of the installed works shall be
carried out by a commissioning specialist who has previous experience of
commissioning a TMR system of similar design and complexity and is familiar
with and understands the system requirements laid down in the original O&M
manuals for the existing system.

(d) The Contractor shall submit details of his/her commissioning specialist to the
Project Manager for approval without objection. This submission shall contain
sufficient details to satisfy the Project Manager of their experience and
expertise. Only after final permission by the Project Manager shall the testing
and commissioning be allowed to proceed.

(e) Prior to any modification to the system taking place the Contractor shall
undertake signal strength tests in locations to prove the overall performance.
The test points shall be agreed with the Project Manager. Following
completion of the works the Contractor shall carry out further signal strength
measurements in the same locations to prove that the addition of the new
service has not degraded the existing service.

(f) The Project Manager shall reserve the right to choose his/her own
commissioning specialist whom he/she shall then instruct the Contractor to
employ.

General Materials & Workmanship Specification 8/8 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 105 – Trunked Mobile Radio System
SECTION 106 CLOSED CIRCUIT TELEVISION SYSTEM

106.1 GENERAL

(a) This section specifies the equipment and materials of the existing Closed
Circuit Television (CCTV) System in the Hong Kong International Airport.

(b) Any system changes in the CCTV system shall involve changes to the system
configuration and programming of the CCTV system.

(c) Any system changes in the CCTV System shall not degrade the MTBF of the
existing equipment.

106.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as at the date of the Letter of Acceptance.

BS 800 Specification for limits and methods of measurements of

radio interference characteristics of household electrical
appliances, portable tools and similar electrical apparatus
BS 3573 Specification for polyolefin copper conductor
telecommunication cables
BS 7671 Requirements for Electrical Installations. IEE Wiring
Regulations. Sixteenth Edition
BS EN 50082-1 Electromagnetic compatibility – Generic immunity
standard part 1 : residential, commercial and light
industry
BS EN 60529 Specification for degrees of protection provided by
enclosures (IP code)
CCITT G 703 General aspects of interfaces
EIA RS-170 Specification for timing and synchronization of CCTV
signals
EIA RS-232D Recommended standard for the interface between data
terminal equipment and data communication equipment
employing serial binary data interchange
EIA RS-422D Recommended standard for electrical characteristics of
balanced voltage digital interface circuits

General Materials & Workmanship Specification 1/12 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 106 – Closed Circuit Television System
106.3 SYSTEM DESCRIPTION

106.3.1 Existing System Description

(a) The existing closed circuit television (CCTV) system is a PAL-I colour system
conforming to CCIR Recommendation 472-3.

(b) The CCTV system is a Hybrid Analogue / Digital CCTV System provides
central video storage with Network Video Recorder System (NVRS). The
CCTV matrix switcher is interfaced with the NVRS using the Interfacing Server,
such that cameras could be controlled via both the matrix switcher and
through the network. For the analog system, video matrix switcher bay is used
to collect video signals from one of the outputs signals of the VDA. For the
digital system, video encoder will be used to convert the video analogue signal
from one of the VDA output to NVRS through the digital signal and then
transmit through the Gigabit network for video achieve purpose.

(c) The CCTV cameras are fixed or pan/tilt/zoom (PTZ) cameras installed in
indoor or outdoor environment.

(d) All CCTV cameras are connected to switching matrices. The video switches
are user-programmable to provide software barring of inputs to particular
outputs.

(e) All monitors are able to view any camera in the system as designated on a
database table by the system administrator.

(f) The CCTV video signals shall be 1 volt peak-to-peak composite video signal
utilizing BNC type connectors and are transmitted via fibre optics and coaxial
cables.

(g) All control signals and data for the CCTV system shall be one or more of ISO /
IEC 10BaseT, RS232 or RS422 type.

(h) The CCTV system is accessed and controlled through PC/workstation or

control console keyboard. The PC/workstation provides a graphic based,
user-friendly man-machine interface for the operation of the CCTV system.

(i) Video Content Analysis (VCA) function is software application embedded in

each video encoder and monitors 1-channael video. Each of the Content
Analysis channels act as a proactive alert system and are capable of
supporting the Baggage Detection, Intrusion Detection and Tail Gating.

106.3.2 Overall System Performance

(a) The overall system performance shall be defined as the performance from a
CCTV camera output to a switched video monitor input including all equipment
in the communication path. This may include, but not limited to, the following
items:

(i) fibre optic transceiver;

(ii) video distribution amplifiers;

(iii) video switchers;

General Materials & Workmanship Specification 2/12 January 2011
Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 106 – Closed Circuit Television System
 (iv) video encorder / decorder;

(v) optical fibre transmission links;

(vi) coaxial transmission links; and

(vii) optical fibre and coaxial patch panels.

(b) The overall performance for all possible communication paths as defined
above shall meet the following requirements:

(i) signal-to-noise ratio : 43 dB minimum (unweighted);

(ii) picture signal : 0.7±0.03 V;

(iii) sync signal : 0.3±0.009V;

(iv) pulse-to-bar ratio : 4 % maximum;

(v) 2T pulse response : 3 % maximum;

(vi) 2T bar response : 3 % maximum; and

(vii) luminance to chrominance;

- gain inequality : ± 4 % maximum; and

- delay inequality : ± 25 ns.

(c) The time delay between initiating the movement of a PTZ CCTV camera from
an operator console and the movement of camera shall be less than 150ms.

(d) In the event of a power failure to any part of the system, full system operation
shall be restored to normal within 2 minutes.

(e) All equipment shall function properly under the operation temperature range
from –10° to +54°C and relative humidity up to 95% non-condensing. The
voltage requirement of each piece of equipment shall match with others and
the existing system.

(f) Any system changes in the CCTV system shall involve changes to the system
configuration and programming of the CCTV system as well as the screen
graphics in the PC/workstations.

(g) The MTBF of equipment or components of systems provided shall not affect
the overall system performance in order to achieve a total system availability
of the CCTV.

(h) The data protocol of the CCTV system shall be compatible with Pelco
Coaxitron Protocol.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 106 – Closed Circuit Television System
106.3.3 Interfaces to Other Systems

(a) The CCTV system is interfaced to the “Access Control System” to provide
automatic switching of cameras on alarm. An alarm which will trigger the PTZ
cameras initiate preset camera positioning and zoom controls in addition to
switching to the selected monitor.

(b) Depending on the type of alarms generated by the access control

system, different alarms shall generate different actions for the CCTV
system. Based on the type of alarms generated and the pre-
programmed information in the access control database, the access
control system will select the appropriate action for the CCTV system
and send the control commands to the CCTV system in a format that
can be recognized by the CCTV video switch controller for subsequent
action. The CCTV video switch controller shall, essentially, act as slave
to the access control system in this respect.

(c) The CCTV system is interfaced to the baggage handling system to provide
automatic switching of cameras on alarm. An alarm generated by the
baggage handling system that may be caused by a conveyor jam that will
trigger the CCTV system to display an associated video image or a sequence
of images on one or more monitors in the baggage handling control centre.

(d) The CCTV system shall be interfaced to with GBMS system for monitoring of
CCTV equipment status to alert maintenance personnel of equipment failures.
Such that power failure, bad contact and not connected of the newly installed
equipment rack can be detected and alerted.

106.4 CCTV CAMERAS AND ACCESSORIES

106.4.1 General

(a) Each CCTV camera shall house the lens, image pickup devices, electronic
circuitry and sync pulse generation circuit. The camera imaging devices shall
be of the solid state charge-coupled device (CCD) sensor and the whole unit
shall transmit colour images. The construction of the camera shall be rugged
and compact suitable for mounting into camera housing with other accessories.
The camera shall be designed for industrial application.

(b) The colour camera shall operate from a single CCD sensor.

(c) Suitable optical filter or other means shall be included to reduce the spurious
alisaing components apperating in the video bandwidth (up to 6 MHz) to
negligible quantities. Anti-charge-accumulation devices or other means shall
be provided to reduce any abnormalities such as red vertical line smearing
when bright objects move across the image plane in a dark background.

(d) All cameras shall be well shielded against radio frequency pickup. The
construction of the camera shall satisfy the relevant emission and immunity
requirements of the IEC 61000 series standard on electromagnetic
compatibility. The sensors shall be firmly fixed to minimize microphonic
interference.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 106 – Closed Circuit Television System
 (e) All cameras may operate directly from 220V AC 50Hz or 24V AC 50 Hz unless
otherwise specified. They shall be of low power consumption and have a
“Power ON” indication.

(f) The image transfer mechanism of the CCD sensor shall be interline transfer
(IT).

(g) The choice of the dimension of the CCD sensor shall satisfy the minimum
luminance resolution requirements such that the illuminance on the test chart
shall be set to produce full video output at a lens setting of f/5.6 +2 stop or -1
stop.

(h) All cameras shall have phase adjustments to allow different electrical phases
to be used to feed cameras in the system without causing synchronization
problems.

106.4.2 CCTV Cameras

(a) The CCTV cameras shall have the following characteristics:

(i) TV standard : CCIR System I (PAL), 625 lines, 50

fields/second;

(ii) active picture : 750 (H) X 580 (V) minimum;

elements (sensor pixel
content)

(iii) horizontal resolution : 480 TV lines;

(iv) signal-to-noise ratio : Better than 50 dB (AGC off);

(v) white balance : Fixed or full-time automatic;

(vi) Automatic gain control : On/off selectable;

(AGC)

(vii) backlight : On/off selectable;

compensation

(viii) lens mount : C-mount or CS-mount;

(ix) output impedance : 75 ohms;

(x) output signal voltage : 1 volt peak-to-peak; and

(xi) video connector : BNC.

(b) The sensitivity (minimum scene illumination) of the cameras shall comply the
following requirements

(i) indoor camera : 3 lux for good picture at f/1.4 (AGC off); and

(ii) outdoor camera : 0.1 lux for good picture at f/1.4 (AGC off).

General Materials & Workmanship Specification 5/12 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 106 – Closed Circuit Television System
106.4.3 CCTV Camera Housing

(a) All CCTV cameras shall be installed in camera housing with suitable mounting
method. Cameras in the out-of-gauge lifts shall be covered by a protective
enclosure.

(b) The housing shall accommodate the camera provided, complete with lens and
other accessories. The housing shall be made from a rigid, not-corrosive
metal, and shall be sturdy and tamper-proof. Notwithstanding, with the aid of
tools, operation and maintenance staff shall gain ready access to the camera
and other accessories of the cameras or housing for maintenance, cleaning
and/or water-filling purposes.

(c) All power, control and video cables entering or leaving the housing externally
shall be protected by a flexible conduit. Cables shall be terminated in plug
and socket arrangements within the housing.

(d) The field of view of the camera shall not be obstructed by the housing. The
housing shall not cause degradation of the performance of the camera under
any operating conditions.

(e) The colour of the camera housing shall conform to RAL 9016 unless otherwise
specified.

(f) The minimum index of protection (IP) of the camera housing shall be:

(i) indoor : Dust proof to IP 54; and

(ii) outdoor : Water and dust proof to IP 65 and should not

admit water in typhoon condition.

(g) Outdoor camera housing shall exhibit the following additional requirements:

(i) sunshield, washer, wiper, water-jet, minimum 1.5 litres wash fluid
reservoir, heater and de-humidifier; and

(ii) it shall be corrosion-resistant for a minimum of 7 years

(h) Dome type cameras shall be used for public areas unless otherwise
specified.

(i) The inner dome shall be black in colour for enhanced security.

(j) The dome camera housing shall either be pendant mounted or in-ceiling
mounted.

General Materials & Workmanship Specification 6/12 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 106 – Closed Circuit Television System
106.4.4 CCTV Camera Mountings

(a) Each camera shall be provided with a camera mounting which mechanically
couples the camera housing (or pan/tilt head) to a wall or ceiling or some other
form of mechanical support (e.g. a pole) so that the camera assembly can be
installed in a stable and neat manner.
(b) The mounting shall be designed to allow the motion of the pan and tilt
movements of the camera assembly to the following degrees:

(i) pan : 360° minimum;

(ii) tilt up : 15° minimum; and

(iii) tilt down : 65° minimum.

(iv) Adjustable camera : 120° horizontal and 120° vertical

viewing position

(c) The design of the mounting shall be compatible with the structural or
architectural support on which it shall be fixed.

(d) For cameras with remotely controlled pan and tilt heads, the mounting shall
provide a field adjustable mechanism and a suitable mechanical joint so that
the camera assembly can be swung or tilted to the appropriate surveillance
direction and locked into this particular position.

(e) The tensile strength of the mounting and the method used to connect the
mounting to the architectural or structural support must withstand the total
weight of the camera, plus housing and the pan/tilt head in a safe manner.

106.4.5 Lens

(a) There are 2 types of lens : fixed focal length and adjustable focal length. The
characteristics of the each type of lens shall be as follows:

Fixed focal length lens

(i) focus : fixed focus;

(ii) iris : motorized auto-iris, with manual override; and
(iii) equivalent focal length : Horizontal angle (field of view) indicated on
the Employer’s Drawings.

Adjustable focal length lens

(i) focus : Motorized focus, maximum 5 seconds for full

range operation;
(ii) iris : motorized auto-iris, maximum 2 seconds for
full range operation; and
(iii) equivalent focal length : Horizontal angle (field of view) from 45° to 5°
maximum 5 seconds for full range operation.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 106 – Closed Circuit Television System
 (b) Accuracy of equivalent focal length shall be within ±3%. If a zoom lens is
specified, the zoom ratio shall be accurate to within ±4%.

(c) The near focusing distance shall not be higher than 1m for fixed equivalent
focal length lens and 1.5m for zoom lenses.

(d) Speed of zoom shall be such as to double the field of view in less than 2.5
seconds.

(e) Operation of motorized drives for these controls shall not cause any radio
frequency radiation or interference to the video signal, e.g. patterning, noise
streaks, etc.

106.4.6 Pan/tilt Units

(a) All pan/tilt units shall be low profile compact units constructed with corrosion-
resistant materials. For outdoor operation, they shall be completely sealed
and weatherproof to IP 66.

(b) They shall produce output torques which is compatible with the total weight of
the camera assembly including camera, lens, housing and related accessories
such as wiper set and water reservoir. They shall have preposition accuracy
of less than ± 2° as well as minimum backlash better than 0.5°.

(c) No electrical or mechanical parts of the pan/tilt unit shall be damaged when
the unit is driven beyond the pan or tilt stop positions.

(d) All video, control and power cables into the pan/tilt units shall be terminated in
plug and socket type arrangements. The pan/tilt head shall be controlled
remotely at the control console via on-site receiver/driver (OSRD). The control
signals shall be 24V DC.

(e) The pan/tilt unit shall possess the following characteristics:

(i) duty cycle : continuous;

(ii) degree of panning : 300° minimum with mechanical stops;
(iii) pan speed : typically 6° per second;
(iv) degree of tilt : +15° to –65° minimum from horizontal; and
(v) tilt speed : typically 3.5° per second.

106.4.7 On-Site Receiver/Driver (OSRD)

(a) The on-Site receiver/driver (OSRD) shall be of modular construction housing

in weatherproof enclosure to IP66 according to IEC 529 for cameras external
to PTB. It shall be microprocessor based unit to decode the control data and
driving the motor for pan/tilt units and zoom lenses. Other functions like
programmable lens polarity, autopan, pre-position setting, focus and iris
control etc. shall be included.

(b) The OSRD shall accept the bi-directional control data via shielded twisted pair
cables from the existing video switching system. It shall accept RS-232 data
protocol as well.

General Materials & Workmanship Specification 8/12 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 106 – Closed Circuit Television System
 (c) It shall have minimum 8 programmable relays for auxiliary control such as
wiper for camera housing.

(d) It shall have minimum 16 preset positions with the lens output for zoom, focus
or iris control matching the lens voltage and current requirement. In particular
the voltage output for different equipment shall be:

(i) pan/tilt control : 24V DC;

(ii) lens control : 6V DC or 12V DC; and
(iii) auxiliary output : 24V AC.

(e) The OSRD shall accept power supply of 220V AC 50Hz.

106.5 CCTV CABLING NETWORK

106.5.1 General

(a) For cameras external to the PTB, the CCTV system shall utilize paths for both
video and control either via direct cabling or via the fixed communications
system (FCS). Note: the FCS is a data transmission network, transparent to
the user, that provides connectivity for a wide variety of data, voice and video
signals throughout the airport platform.

(b) For cameras internal to the PTB and Ground Transportation Centre: (GTC),
video and control signals shall be transmitted to/from the control console via
video switches through dedicated cables.

106.5.2 Fibre Optic Transceiver

(a) Fibre optic transceiver is a multiplexer / demultiplexer that transmits and

receives real-time video and bi-directional data simultaneously over one fibre
optic cable utilizing frequency modulation. The fibre optic transceiver shall be
compatible to the existing CCTV system.

(b) Unless otherwise specified, one transceiver shall comprise of four video
channels and one bi-directional data channel. Status indicating LED’s for
each individual channel for system performance monitoring shall be provided.
It shall be hot-swappable rack modules suitable for mounting in racks and
cabinets. The circuit board shall be meet IPC standard.
(c) Power supply to transceiver shall be 12V DC from integral transformer. The
transformer shall receive 220V AC 50 Hz power supply by plugging into 13A
socket outlet. Automatic resettable fuses on all power lines shall be
incorporated by overcurrent protection.

(d) The operating temperature range shall be –10°C to +54°C with RH 0% to 95%
non-condensing. The MTBF shall be larger than 100,000 hours.

(e) The transceiver shall comply with the following requirements on video signal:

i) characteristic impedance : 75 ohms

ii) video input / output signal : 1 Volt peak-to-peak
iii) video bandwidth : 10 Hz to 10 MHz (per individual channel)

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 106 – Closed Circuit Television System
 iv) signal-to-noise ratio : 55 dB
v) video connector : BNC (gold-plated centre pin)
vi) Differential gain : < 5%
vii) differential phase : < 5°

(f) The transceiver shall comply with the following requirements on control data
signal:

(i) data interface : RS-232 (data line only) or RS-422,

RS-485 (2-wire or 4-wire)
(ii) data format : Coaxitron
(iii) data transmission rate : Up to 100 kbps

(g) The transceiver shall comply with the following requirements on optical signal:

(1) Multimode:

(i) wavelength : 850nm or 1300nm (multimode)

(ii) number of fibre connection : 1
(iii) optical connector : ST connector
(iv) optical power budget : 10 dB in 62.5/125　m multimode fibre
optic cable
(v) transmission distance : up to 2 km or signal loss within the optical
power budget

(2) Singlemode:

(i) wavelength : 1310nm or 1550nm (singlemode)

(ii) number of fibre connection : 1
(iii) optical connector : ST connector
(iv) optical power budget : 20 dB in 9/125　um singlemode fibre
optic cable
(v) transmission distance : up to 60 km or signal loss within the
optical power budget

106.5.3 Fibre Optic Cables

(a) Fibre optic cables shall be provided from the communication rooms to the fibre
distribution frames (FDF) which then shall connect to the fibre optic
transceivers to separate the signals into video and data. The fibre optic
cables for CCTV system from the fibre optic transceivers to the
communication rooms will be dedicated for CCTV system usage while from
communication rooms to the control system will be a part of the structural
cabling network.

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Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 106 – Closed Circuit Television System
 (b) All fibre optic cable for the CCTV system shall comply to Section 102 of this
General Materials and Workmanship Specification and compatible with the
existing CCTV system.

(c) All patch cords provided shall comply with the optical characteristics listed in
Section 102 of this General Materials and Workmanship Specification.

106.5.4 Coaxial Cables

(a) The coaxial cables shall be used to link the CCTV cameras to the fibre optic
transceiver for video signal transmission. The length of coaxial cable shall not
exceed 100 meters.

(b) The core conductor shall be made of copper with solid polyethylene insulation
and plain copper wire braid screen under the outer sheath.

(c) The coaxial cables shall exhibit the following characteristics:

(i) characteristic impedance : 75 ± 3 Ohms;

(ii) attenuation : Less than 3dB/100m at 50 MHz;

Less than 4dB/100m at 100MHz;

(iii) minimum bending radius : 60mm; and

(iv) insulation resistance : Not less than 30M Ohm/km at 25°C.

(d) All video patch cords shall have the above coaxial cable characteristics.

106.5.5 Control Cables

(a) The control cables shall be shielded twisted pair cables from the OSRD to the
local fibre optic transceiver or to the nearest communication rooms. The
number of pairs shall be determined by the usage and the exact equipment
connected.

(b) The conductor shall be tinned copper. The cable shall be screened with an
aluminium/polyester tape in contact with a tinned copper drain wire under the
outer sheath.

(c) The control cables shall exhibit the following characteristics:

(i) DC loop resistance : Less than 110 ohm/km;

(ii) Normalized impedance : 600 ohms;

(iii) attenuation : Less than 3dB/km at 10kHz;

(iv) minimum bending radius : 100mm;

General Materials & Workmanship Specification 11/12 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 106 – Closed Circuit Television System
 (v) insulation resistance : Not less than 20M ohm/km at 25°C; and

(vi) capacitance : Less than 100 pF/m at 1kHz between

conductors;
Less than 170 pF/m at 1kHz between
one conductor and other conductors
connected to the shield.

106.5.6 Outer Sheath Properties of Cables

(a) For cables installed in buildings or service tunnels, the outer sheath shall be
PVC with the property of low smoke zero halogen.

(b) For cables running externally, PVC sheath suffices.

(c) For cables running in external underground ducts or exposed to air, the outer
sheath shall withstand water ingress and sunlight exposure.

106.6 VIDEO RECORDING SYSTEM

(a) The CCTV system shall be equipped with 24-hour digital video recording
system. The new recording system shall be of modular design and be easily
expandable. Expansion of the new recording system shall not cause any
interruption on the normal operation of the new CCTV system.

(b) The recording capacity of the digital video recording system shall be adequate
for the no. of camera as required in this project plus 20 % spare capacity.

(c) The video recording shall be of at least 25 frames per second with video
resolution of 2CIF.

(d) The video recording equipment shall be the same or compatible with the
existing one.

106.7 TESTING AND COMMISSIONING

106.7.1 General

(a) The testing and commissioning of the CCTV system shall be in accordance
with the Section 108 in this General Materials and Workmanship Specification
in general.

(b) The exact details to be included in the testing and commissioning shall be
submitted by the Contractor and to be agreed with the Project Manager
without objection.

106.7.2 Particular Items

(a) The exact details to be included shall be submitted by the Contractor and to
be agreed with the Project Manager without objection.

General Materials & Workmanship Specification 12/12 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 106 – Closed Circuit Television System
SECTION 107 MASTER ANTENNA TELEVISION (MATV)

107.1 GENERAL

This section specifies the equipment and materials of the existing Master Antenna
Television (MATV) in the Hong Kong International Airport.

107.2 RELEVANT CODES AND STANDARDS

Reference in this General Materials & Workmanship Specification to British

Standards, British Standard Codes of Practice and other standards shall be to the
latest edition of the document, including all amendments issued by the relevant
authority, as at the date of the Letter of Acceptance.

BS 7671 Requirements for Electrical Installations, IEE Wiring

Regulations, Sixteenth Edition

107.3 GENERAL PERFORMANCE REQUIREMENTS

(a) The MATV system shall be designed to operate over the 54 to 750MHz
bandwidth in the forward path, and the 5 to 30MHz band in the reverse path.

(b) The system shall be designed to provide a sound and vision impairment rating
of no less than 5 throughout the system according to CCIR
Recommendations.

(c) Minimum MATV network standards, measured from the television outlet shall
be:

(i) carrier to noise ratio : 46dB;

(ii) carrier to cross modulation : 54dB; and

(iii) carrier to composite triple beat : 54dB.

(d) The following levels shall be used for the system:

Description Outputs Inputs

Amplifiers 38-44dBmV 14.0dBmV
Distribution Taps 3-14 dBmV Varies

(e) The system shall be designed such that the channel outlet signal level shall be
within the range of 3dBmV and 14dBmV, and that the maximum signal level
difference of any channel on any outlet or between various outlets on the
system shall be 6dB.

General Materials & Workmanship Specification 1/4 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 107 – Master Antenna Television (MATV)
107.4 CABLE

107.4.1 Distribution Cable

(a) Distribution coaxial cables for the distribution of analogue television or sound
signals in single and multiple unit installations shall have the following
specification:
(i) copper clad aluminum or copper clad steel center conductor;

(ii) expanded micro-cellular foam dielectric;

(iii) solid aluminum or copper sheath;

(iv) nominal center conductor diameter 3.48mm;

(v) nominal outer cable diameter 13.72mm;

(vi) polyethylene or PVC jacket;

(vii) nominal capacitance 15.3pF/ft;

(viii) nominal impedance 75 ohms; and

(ix) nominal velocity of propagation 85 to 88%.

(b) Attenuation characteristics at 20°C shall be comparable with the following:

Frequency (MHz) Maximum (dB/100m)

5 0.46
55 1.54
300 3.75
450 4.63
750 6.10

(c) At 20°C, maximum DC bias resistance shall be comparable with the following:

(i) inner conductor : 3.34 ohms/km;

(ii) outer conductor : 1.94 ohm/km; and

(iii) loop conductor : 5.28 ohm/km.

General Materials & Workmanship Specification 2/4 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 107 – Master Antenna Television (MATV)
107.4.2 Amplifiers

(a) All amplifiers shall have the following minimum characteristics:

Characteristics Forward Reverse

Pass Band (MHz) 54 – 750 5 - 30
Operating Level (dBmV)
- Frequency 750/54 33/5
- Input (min) 12/12 17/17
- Output 33/30 34/34
Noise Figure (dB) 9 6.5
Minimum Full Gain (dB) 25 20
Carrier to Interference Ratios (dB)
- CTB 102 -
- Discrete 2nd order 90.5 85
- XMOD 97 94
- Third Order Beat - 104
- CNR 59.5 69.5
AGC Dynamic Range ±3 -
Return loss (minimum dB)
- Input 16 16
- Output 16 16

(b) The system shall be designed such that amplifiers shall not operate above
80% of their rated value.

107.4.3 Drop Cable

(a) Coaxial drop cables shall be RG-6 type with the following characteristics:

(i) gas expanded polyethylene dielectric;

(ii) inner shield aluminium-polypropylene-aluminium laminated type with

overlap bonded to the dielectric;

(iii) 34 AWG bare alumium braid wire;

(iv) non-bonded aluminium-polypropylene-aluminium type with overlap;

(v) PVC jacket;

(vi) nominal outer diameter 7.06mm;

(vii) 18 gauge copper covered steel center conductor;

(viii) nominal capacitance 16.2pF/ft;

(ix) nominal impedance 75 ohms; and

(x) nominal velocity of propagation 82%.

General Materials & Workmanship Specification 3/4 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 107 – Master Antenna Television (MATV)
 (b) Attenuation characteristics at 20°C shall be:

Frequency (MHz) Maximum (dB/100m)

5 1.90
55 5.25
300 11.64
450 14.43
750 24.00

General Materials & Workmanship Specification 4/4 January 2011

Issue No. 5, Volume 3 – Electrical & Mechanical Works
Section 107 – Master Antenna Television (MATV)
SECTION 108 INSPECTION, TESTING AND COMMISSIONING SYSTEMS

108.1 GENERAL

(a) The Plant shall be inspected, tested and commissioned to confirm that Plant
performance complies with the requirements of the Contract.

(b) All such Inspection, Testing and Commissioning shall, in particular but without
limitation, be planned, carried out and documented in accordance with:

(i) General Conditions of Contract;

(ii) the Specification; and

(iii) the construction quality plans and inspection and test plans prepared by
the Contractor in accordance with the relevant ISO standard and
reviewed without objection by the Project Manager.

108.2 TERMINOLOGY

(a) In this Contract, and in all programmes, quality plans, reports and other
documents produced in the course of this Contract, the following terms shall
be used:

(i) Manufacturing Phase - the period during which the manufacture,

fabrication and assembly of the Plant, or a discrete element of the Plant,
is carried out off-Site;

(ii) Installation Phase - the period during which the fabrication, assembly
and installation of the Plant, or a discrete element of the Plant, is carried
out on-Site;

(iii) Pre-Commissioning Phase - the period when, in relation to the Plant or a

discrete element of the Plant, Component Tests and Commissioning are
carried out in preparation for the Plant Commissioning Phase;

(iv) Plant Commissioning Phase - the period when Commissioning and

Reliability Tests are carried out to ensure that the Plant fully complies
with the design and operational requirements of this Contract;

(v) Plant Integration Phase - the period prior to issue of the Completion
Certificate when Plant Integration Tests and Commissioning are
conducted to integrate the Plant with, existing plant and systems and all
work completed, existing, or being undertaken by Other Contractors in
full compliance with the design and operational requirements of this
Contract;

(vi) Confidence Trial Phase - the period after issue of the Completion
Certificate when the Confidence Trials are carried out;

(vii) Phase - one or other of the phases identified in (i) - (vi) above;

General Materials & Workmanship Specification 1/12 January 2011

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Section 108–Inspection, Testing & Commissioning Systems
 (viii) Type Tests - tests undertaken on similar equipment or components in
lieu of individual unit tests;

(ix) Factory Tests - tests carried out on items of Plant at the manufacturer's
works or elsewhere before they are dispatched to Site;
(x) Site Tests - tests on static items of Plant and systems (e.g. inspection
and testing of welds and hydraulic testing of pipeworks) to ensure
correct and safe installation before Setting to Work;

(xi) Component Tests - tests on components to be incorporated in the Plant;

(xii) Commissioning - the advancement of the Plant or an element of the

Plant from the stage of static completion to full working conditions and to
meet the specified design requirements. This shall include Setting to
Work and Regulation;

(xiii) Setting to Work - the process of setting a static system into motion;

(xiv) Plant Integration Tests - the measuring, recording and proving of correct
integration between the Plant and all other systems, whether installed by
Other Contractors or existing, as detailed in the Specification;

(xv) Regulation - the process of adjusting a system (e.g. the rates of fluid
flow and heat transfer in a distribution system) within specified
tolerances;

(xvi) Reliability Tests - tests carried out over set trial periods and under
simulated operating conditions to prove reliability;

(xvii) Confidence Trials - tests undertaken after the issue of the Certificate of
Completion when the Plant is operational and being operated by the
Employer under the supervision of the Contractor;

(xviii) Inspection, Testing and Commissioning Programme - the sub-network of

the Works Programme prepared by the Contractor in accordance with
section 10 of the General Specification and reviewed without objection
by the Project Manager, detailing the programme for the inspection,
testing and programme for the inspection, testing and commissioning of
the Plant;

(xix) Phase Notice - a notice prepared by the Contractor in accordance with

the requirements of the Specification;

(xx) Phase Report - a report prepared in accordance with the requirements of

the Specification; and

(xxi) Test Results Form - a form prepared in accordance with the

requirements of the Specification.

(b) The term "Tests on Completion" as defined and used in the General
Conditions of Contract refers to the Plant Integration Tests and such other
tests, if any, identified as such in the Specification.

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 (c) The term "Performance Tests" as defined and used in the General Conditions
of Contract refers to the Confidence Trials and such further tests, if any,
identified as such in the Specification.

108.3 TESTING AND COMMISSIONING PHASES

(a) In order to facilitate the orderly management of the testing and commissioning
of Plant and the Project Manager's monitoring of progress of the Project as a
whole, the Contractor shall structure his construction quality plans (see section
14 of the General Specification), inspection and test plans (see section 15 of
the General Specification, this General Materials and Workmanship
Specification, and the Inspection, Testing and Commissioning Programme
(see section 10 of the General Specification) into the following Phases with the
tests to be carried out during each Phase identified under the following
categories:

(i) Manufacturing Phase:

- Factory Test; and

- Type Tests;

(ii) Installation Phase:

- Site Tests;

(iii) Pre-Commissioning Phase:

- Component Tests; and

- Commissioning of elements of the Plant;

(iv) Plant Commissioning Phase:

- Integration of elements of the Plant;

- Commissioning; and
- Reliability Tests;

(v) Plant Integration Phase:

- Plant Integration Tests; and

(vi) Confidence Trails Phase.

(b) Any Deferred Seasonal Tests shall also be clearly identified in all plans and
programmes.

(c) For the duration of the Defects Liability Period operational and safety controls
shall be sealed if adjustment beyond defined limits could result in malfunction
and give rise to a defect.

(d) The Contractor shall provide attendance and technical support during the
confidence trails period in accordance with the Specification.

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108.4 QUALITY PLANS

(a) The Contractor shall identify in his construction quality plans and division of
the Plant into discrete elements to facilitate the preparation and service of
Phase Notices as called for in this General Materials and Workmanship
Specification.

(b) Refer to General Specification Section 14.

(c) The Project Manager, in reviewing any inspection and test plan, may require
additional inspection, testing and commissioning documentation as may be
considered reasonably necessary to record these processes.

108.5 PHASE NOTICES

(a) For each element of the Plant identified in the Contractor's construction quality
plans or, as the case may be, for the Plant as a whole:

(i) The Contractor shall prepare and submit to the Project Manager for
review a Phase Notice at the end of the Manufacturing Phase, the
Installation Phase and the Pre-Commissioning Phase.

(ii) Each Phase Notice shall contain a statement by the Contractor

confirming that all inspections and tests required during the relevant
Phase have been performed satisfactorily or identifying any non-
conformities or tests that have been failed and confirming that all reports
of such inspections and tests have been filed in his Records Office (in
accordance with section 15 of the General Specification).

(iii) The Phase Notice relating to a Manufacturing Phase shall confirm that
the Contractor is satisfied that the relevant equipment or system or part
of a system is ready for release from the manufacturer's works.

(iv) The Phase Notice relating to an Installation Phase shall confirm that the
Contractor is satisfied that the equipment or system or part of a system
is ready for starting the pre-Commissioning tests.

(v) The Phase Notice relating to a Pre-Commissioning Phase shall confirm

that the Contractor is satisfied that the system or part of a system is
ready for Commissioning and Reliability Tests.

(b) Upon receipt of an application for a Completion Certificate or Stage Certificate,

the Project Manager may carry out a detailed inspection of each element of
the Plant in the presence of the Contractor to check the soundness and state
of the Plant and identify the extent of any rectification work required. The
Contractor shall ensure that, prior to such inspection, all work has been
properly and thoroughly cleaned, painted where specified and generally tidied
up to present a clean and workmanlike installation.

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108.6 TEST RESULTS FORMS

(a) In addition to the requirements of section 15 of the General Specification, each

report of an inspection or test shall indicate the following:

(i) the system or item being tested;

(ii) the identification reference for an item being performance tested;

(iii) the test acceptance criteria;

(iv) the tolerances;

(v) the test units of measurement;

(vi) the actual test results;

(vii) pass/ fail;

(viii) whether a concession shall be requested under section 14 of the

General Specification;

(ix) any concessions or variations made pursuant to section 14 of the

General Specification; and

(x) whether a design review is requested.

(b) Test acceptance criteria shall be prepared by the Contractor in accordance

with the Specification and included as part of each Test Results Form.
Acceptance criteria may not be changed by the Contractor except with the
consent of the Project Manager in writing.

(c) The Contractor shall prepare and submit his proposed test Results Forms as
part of his submission of the relevant Inspection, Testing and Commissioning
Plan.

108.7 PHASE REPORTS

(a) Without prejudice to the Contractor's obligations to produce summaries of test

data and other information under the General Conditions and section 15 of the
General Specification, the Contractor shall upon completion of each Phase
complete and submit to the Project Manager for his information a Phase
Report setting out and detailing the test results including performance figures
obtained, graphs, charts, tabulated computer output, and supporting narratives
describing any special events, occurrences and other discrepancies or
deviations not expected in the original plan or programme.

(b) In particular, the Phase Report shall include a chronological diary of findings
and incidents including:

(i) workmanship;

(ii) plant operating peculiarities and observations;

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 (iii) any measurement and checks which may be required by operating and
maintenance personnel; and

(iv) results of any statutory testing and inspection, e.g. earth grid
measurements.

(c) All hazardous conditions shall be corrected by the Contractor prior to or during
Commissioning. Comments shall be included on any observed deficiencies in
Plant design and performance.

(d) Any modifications to circuitry, instrumentation, etc. carried out at any time shall
be recorded in detail in the Phase Reports and shown on the Contractor’s
Drawings.

(e) Any conclusions that shall be helpful to the Employer's operating and
maintenance staff shall be summarised at the end of the Phase Reports.

(f) The Phase Reports shall be prepared and submitted in the Employer's
standard format as soon as practicable after the completion of each Phase.

108.8 STANDARDS AND REGULATIONS

(a) All testing and commissioning carried out by the Contractor shall be
undertaken using the International System of Units (S.I.) and shall comply, as
appropriate, with the latest and most up to date edition at the date of the Letter
of Acceptance, of the following standards, regulations and guides:

(i) the relevant "British Standard Codes of Practice" or "British Standard

Specifications" where applicable to the Works published by the British
Standards Institution;

(ii) the IEE Wiring Regulations issued by the Institution of Electrical

Engineers (U.K.);

(iii) "Code of Practice for Electricity (Wiring) Regulations" published by the

HKSAR;

(iv) "Code of Practice for minimum fire services installations and equipment
and inspection, testing and maintenance of installations and equipment"
published by the HKSAR;

(v) the relevant circular letters issued by the Fire Services Department
(FSD);

(vi) "Rules for automatic sprinkler installations" published by the Loss

Prevention Council;

(vii) the relevant codes and guides published by the American Society of
Heating, Refrigerating and Air Conditioning Engineers (ASHRAE-USA);

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108.9 CONTRACTOR’S TESTING AND COMMISSIONING STAFF

(a) All testing and commissioning shall be undertaken by the Contractor's

appropriate testing and commissioning specialist or by a competent
independent commissioning specialist nominated by and acting for the
Contractor and reviewed without objection by the Project Manager.

(b) The Contractor shall provide all necessary skilled labour and assistance for
testing, operating, adjusting, commissioning and verifying the performance of
all Plant.

(c) The Contractor's testing and commissioning staff shall have had previous
experience with testing and commissioning similar Plant of comparable duty.

(d) The Contractor's relevant specialist testing and commissioning staff including
supervisors shall be available on Site at all times during testing and
commissioning of the Plant.

108.10 TESTING AND COMMISSIONING EQUIPMENT AND INSTRUMENTS

(a) The Contractor shall provide all portable and supplementary instrumentation,
recording facilities, consumables and the like required for all Factory Tests
and testing and commissioning on Site.

(b) Testing and commissioning instrumentation shall be designed for field use and
to minimize field measurement errors through the use of electronic sensors,
digital displays and similar devices.

(c) The calibration of instruments shall be demonstrated immediately prior to, and
after completion of testing and commissioning, and current calibration
certification submitted to the Project Manager for record purposes.

(d) At least one complete set of testing and commissioning instrumentation,

including all accessories, fittings, attachments and purpose built carrying
cases, shall be made readily available in a calibrated and operational
condition for retesting by the Contractor for the duration of the Defects Liability
Period.

(e) The end-to-end accuracy of instrumentation shall be verified in accordance

with the recommendations of ASHRAE 114.

108.11 NOTIFICATIONS

(a) The Contractor shall, in accordance with section 15 of the General

Specification, give the Project Manager notice in writing, when tests or trials
shall be ready to commence provided that, notwithstanding section 15 of the
General Specification, not less than 48 hours' notice of all tests and trials
carried out on Site shall be given.

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108.12 INSPECTIONS AND TESTING

(a) Prior to any inspection and testing by the Project Manager, the Contractor
shall inspect and test the Plant himself to ensure that equipment and facilities
are clean and complete and can reasonably be expected to meet successfully
all inspection and/or testing criteria.

(b) Prior to setting to Work, testing and Commissioning, the Contractor shall clean
all Plant and shall confirm in writing to the Project Manager that all relevant
work by Other Contractor is complete and satisfactory for the purpose of
testing and Commissioning.

(c) In the event that the Contractor considers that any testing is not appropriate or
required, the Contractor may submit alternative proposals to the Project
Manager for his review.

108.13 SPECIFIC INSPECTION, TESTING AND COMMISSIONING REQUIREMENTS

108.13.1 General

(a) The Contractor shall prepare a complete inspection testing and commissioning
plan as specified above which shall fully detail the specific tests that shall be
conducted on the Works. As a minimum requirement the inspection, testing
and commissioning plan shall include but not be limited to the tests described
herein at the particular phase of the Works.

(b) During installation staging, configuration and customisation shall be completed

on the system before any physical workstations, printers, and PLCs are
installed, fitted, connected and made live. This customisation shall cover
hardware configuration, default and initial point and alarm settings, response
instructions, graphical map and line diagrams, queries and reports. All
operator displays and reports shall be functional except that all items of
unconnected hardware shall be flagged as being in the unconnected state.

(c) Interactive, on-line, dynamic, non-disruptive customisation shall be provided to

eliminate airport operator distractions during system installation staging,
testing, commissioning and maintenance repairs. New connections to
unoccupied spare ports, additions and removal of workstations, etc, shall be
carried out `hot' without any degradation and risk to any other parts of the
system.

108.13.2 Manufacturing Phase

(a) Testing of this phase of the Works shall include all off-Site Factory Tests and
off-Site model testing as required by the Specification and the Project
Manager. The Contractor shall include in the test plan the details of all factory
and model tests and submit the same to the Project Manager for review. This
shall include detailed test procedures on all hardware, firmware and software
and the quality assurance methods used during manufacture. Manufacturing
tests shall be completed in two stages.

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 (b) Factory Tests

(i) “Factory Acceptance Tests (FATs) shall be carried-out on all

components and sub-assemblies. Component functional tests shall
include fully assembled plug-in printed circuit boards and plug-in
assemblies.

(ii) Factory functional acceptance tests shall be carried-out on all completed

sub-assemblies.

(iii) Burn-in tests shall be carried out.

(iv) Software tests shall be fully detailed on all existing software that shall be
used in the works;

(v) Software and hardware tests shall be carried out to ensure interworking
of the Works with other systems.

(vi) Any software that is required to be specifically designed, coded and

configured for the works shall be fully tested in accordance with the
software development standards.

108.13.3 Installation Phase

(a) Installation Phase Site tests shall be detailed in the Contractor's test plan and
shall include but not be limited to:

(i) continuity tests of complete circuits, if applicable, to include attenuation,

noise and bandwidth measurements by the Contractor; and

(ii) physical tests to ensure that cabinets are correctly installed and all sub-
assemblies and sub-racks within the cabinets are correctly installed and
are removable for maintenance.

108.13.4 Pre-commissioning Phase

(a) Pre-commissioning phase tests shall be detailed in the Contractor's test plan
and shall include but not be limited to:

(i) functional tests of model equipment following Site installation;

(ii) functional tests of all equipment delivered from the factory and not used
in the model tests; and

(iii) functional tests of all links, patch panels, UTP and fibre connections that
interconnect sub-assemblies, sub-racks, cabinets and external
connections.

108.13.5 Plant Commissioning Phase

(a) Plant Commissioning Phase tests shall be used as the primary tests to ensure
that the plant fully complies with the design and operational requirements of
the Contract. During these tests the plant shall be tested without being
interfaced to other systems.

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108.13.6 Plant Integration Phase

(a) The Plant Integration Phase tests shall include integration with other systems.
These tests shall be detailed in the test plan and shall include but not be
limited to:

(i) functional test of communications and valid data transfers between each
and every interface with other systems; and

(ii) a reliability test of no less than 4 weeks. During this test all Plant shall
be connected and operational and interfaces with other systems shall be
fully operational simultaneously. Availability measurements shall be
taken during the test and any failure shall cause the complete test to be
restarted. Testing shall continue until the availability required is
achieved.

108.14 TESTING AND COMMISSIONING REQUIREMENTS FOR FIBRE OPTIC AND

UTP CABLES

108.14.1 Minimum End-To-End Cable Segment Performance

(a) The following minimum end-to-end performance parameters shall be applied

to determine acceptable performance of all individual fibres within single-mode
optical fibre cables for purposes of testing and commissioning:

(i) optical return loss shall be greater than 40 dB measured at the pigtail
connector of all optical fibres with the opposite end pigtail connector
unterminated;

(ii) chromatic dispersion shall not be at variance by more than 1

pSec/km/nm from the nominal characteristic curve for the particular
optical fibre cable type provided;

(iii) measured zero chromatic dispersion wavelength of supplied optical

fibres shall be within five percent (±5%) of that specified for the particular
optical fibre cable type provided;

(iv) optical time domain reflectometry shall indicate that optical cable
segment lengths supplied shall be equal to or greater than that specified
herein, and actual lengths measured shall be recorded within the cable
management system for later cable management purposes to an
accuracy of 0.5m or better;

(v) maximum longitudinal attenuation loss of 0.4 dB/km; and

(vi) electrical continuity of the outside armouring and any internal metallic
longitudinal strengthening members.

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 (b) The following end-to-end performance parameters shall be applied to
determine acceptable performance of all individual fibres within multi-mode
optical fibre cables for purposes of testing and commissioning:

(i) optical return loss shall be greater than 40 dB measured at the pigtail
connector of all optical fibres with the opposite end pigtail connector
unterminated;

(ii) cutoff frequency shall not be at variance by more than 1% from the
nominal specification for the particular optical fibre cable type provided;

(iii) operational bandwidth shall as a minimum cover the range from 850
nanometre to 1300 nanometre;

(iv) optical time domain reflectometry shall indicate that optical cable
segment lengths supplied shall be equal to or greater than that specified
herein, and actual lengths measured shall be recorded within the cable
management system for later cable management purposes to an
accuracy of 0.5m or better;

(v) maximum longitudinal attenuation loss of 3.75 dB/km when measured at

a wavelength of 850 nanometre and 1.5 dB/km when measured at a
wavelength of 1300 nanometre; and also

(vi) electrical continuity of the outside armouring and any internal metallic
longitudinal strengthing members.

(c) The following end-to-end performance parameters shall be applied to

determine acceptable performance of all individual twisted pairs within copper
cables for purposes of testing and commissioning:

(i) continuity;

(ii) insulation resistance between each conductor and all other conductors
(including the metallic sheath where it is provided) shall be greater than
20 megohms, at 25 degrees C when tested at 500 V d.c.;

(iii) characteristic impedance shall be 100 ohms +/- 15% for frequencies
between:

- 1MHz and 20 MHz for Category 4 cable;

- 1MHz and 10 MHz for Category 3 cable,

(iv) worst pair near-end cross talk shall be greater than:

- 56 dB / 100m at 1MHz and 36 dB / 100m at 20 MHz for Category 4

cable;
- 41 dB / 100m at 1MHz and 26 dB / 100m at 10 MHz for Category 3
cable;

(v) longitudinal attenuation shall be less than

- 2.1 dB/ 100m at 1MHz and 10.2 dB / 100m at 20MHz for Category 4
cable; and
- 2.6 dB / 100m at 1MHz and 9.8 dB / 100m at 10MHz for Category 3
cable.
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108.14.2 Inspections and Testing

(a) Prior to any inspection and testing by the Project Manager, the Contractor
shall inspect and test the Plant himself to ensure that equipment and facilities
are clean and complete and can reasonably be expected to meet successfully
all inspection and/or testing criteria.

(b) Prior to setting to Work, testing and Commissioning, the Contractor shall clean
all Plant and shall confirm in writing to the Project Manager that all relevant
work by Other Contractors is complete and satisfactory for the purpose of
testing and Commissioning.

(c) In the event that the Contractor considers that any testing is not appropriate or
required, the Contractor may submit alternative proposals to the Project
Manager for his review.

108.14.3 Specific Cable Testing Requirements

(a) The cable systems specified and described in this General Materials and
Workmanship Specification are high quality fibre and UTP systems. Quality
control procedures including design, cable and termination manufacture,
installation, inspection testing and commissioning shall be implemented to
ensure that the final installation meets the requirements of this General
Materials and Workmanship Specification. The Contractor shall submit quality
control measures and a testing and commissioning plan for review by the
Project Manager. Upon receipt of a notice of no objection the Contractor shall
adopt the quality control measure and the testing and commissioning plan
which shall include as a minimum the following:

(i) the provision of an independent and ISO accredited cable testing

organisation, acceptable to the Project Manager;

(ii) testing and commissioning plan shall include:

- validation of cable manufacturers specifications for each cable type;

- test methods of cables and acceptance criteria after manufacture at

the factory;

- test and inspection acceptance criteria for on Site delivery handling

and storage; and

- test and inspection acceptance criteria to be adopted during

installation, termination and commissioning ; and

(iii) regular reports shall be submitted by the Contractor to the Project

Manager evidencing the effectiveness of the testing and commissioning
plan including the submission of signed test certificates as required by
the plan.

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