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CD MATERIALS AND WORKMANSHIP SPECIFICATIONS

DEDICATED CD ECS COMPONENTS

4.1 CD cooling towers

Forced draft, counterflow, blow-through CD Cooling Tower

4.1.1 The CD cooling tower (CD CLT) shall meet the same requirements as
specified for the peacetime outdoor cooling towers as well as the
following:-

a) CD cooling tower shall be of the force draft, counter flow, blow-through

design, with single side air entry and suitable for indoor installation and
operation inside the station structure so that they are protected from
the blast pressure. CD cooling tower booster fans shall be provided to
assist the CD cooling tower fans to overcome excessive air pressure
losses through the ventilation shaft and blast valves.

b) The CD cooling towers shall be interlocked with the CD cooling tower

booster fans so that they are started up automatically whenever the
CD cooling towers are started. However, provisions shall be made to
disable the interlock such that the fans shall not be restricted to one-
to-one “straight line” interlocking with the CD CLTs but must be enable
for flexible fan-to-CD CLT operation such as Fan 2 with CD CLT 1 and
Fan 1 with CD CLT 2.
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c) Anti-condensation heaters shall be provided for the fan motors. The

heaters shall be terminated in a robust terminal box electrically and
mechanically separate from any other terminal boxes. The anti-
condensation heater terminal boxes shall be fitted with an un-drilled
gland plate suitable for conduit termination or cable entry. Heaters
control circuits shall be arranged such that the heater is off when the
motor is on and vice versa. The heaters control circuits shall operate
on single-phase power supply and shall have an indicating lamp each
on respective motor control center (MCC).

d) Water shall enter the tower through a single inlet comprising an

enclosed, low pressure, non corrosive Polyvinyl Chloride (PVC),
minimum Schedule 40 piping system. The spray nozzle shall be of
High Density Polyethylene (HDPE) or Acrylonitrile Butadiene Styrene
(ABS) copolymer and of even spray, non-clogged, full conical spray
pattern distribution. In addition, the internal tower water distribution
piping system shall be easily removable for maintenance and have
threaded end caps for removal of residuals and debris.

e) Stainless steel bolts and nuts shall be used. Unless otherwise

specified, all components of the CD cooling tower shall be made of SS
316 stainless steel. The CD cooling towers shall be shock mounted in
compliance with the CD shock requirements. Any factory test report
such as shock resistant test certificate for the CD cooling tower shall
be submitted for review and acceptance.

f) The CD Cooling Tower performance shall be tested in an

independent, established and reputable CTI approved Laboratory in
compliance with the latest edition of the Cooling Tower Institute (CTI)
Acceptance Test Code ATC-105 and ATC-128 or approved
equivalents by an independent CTI certified test agent, subjected to
the acceptance by the Authority. Prior to ATC-105 and ATC-128
testing, the Contractor shall submit Test Method Statements
including Test Objectives, Instrumentation, Set-up, Procedures,
Acceptance Criteria, Test forms, copies of valid calibration certicates
of measuring instruments and meters, etc. and the safety measures
and provisions while conducting these tests.

All tests and measurements shall be in SI units. Within one (1) month
completion of the testing in the laboratory, a comprehensive formal
test report shall be submitted by the certified CTI tester for the review
and acceptance by the Authority.
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4.2 Generator AHU

4.2.1 The air handling units (AHUs) for the generator shall meet the same
requirements as specified for peacetime AHUs as well as the following:-

a) The AHU fan motor and drive shall be installed outside the hot air
stream to ensure sufficient motor cooling

b) AHUs shall be shock mounted in compliance with the CD shock

requirements. Any factory test report such as shock resistance test
certificate for the AHU shall be submitted for review and acceptance.

c) Anti-condensation heaters shall be provided for the fan motors. The

heaters shall be terminated in a robust terminal box electrically and
mechanically separate from any other terminal boxes. The anti-
condensation heater terminal boxes shall be fitted with an un-drilled
gland plate suitable for conduit termination or cable entry. Heaters
control circuits shall be arranged such that the heater is off when the
starter is on and vice versa. The heaters control circuits shall operate
on single-phase power supply and shall have an indicating lamp
each on respective motor control center (MCC).

d) The generator AHUs shall be interlocked with the generator sets so

that they are started up automatically whenever the generator sets
are started.

4.3 CD ventilation system fans

4.3.1 CD ventilation system fans include but are not limited to the CD gas filter
fans, CD cooling tower booster fans, CD Generator intake and exhaust air
booster fans, CD pantry fan, CD toilet exhaust fans, and CD fuel tank and
pump room ventilation fan. They shall have similar requirements as
specified for peacetime fans as well as the following:-

a) Ventilation fans serving areas with corrosive environment e.g. CD

cooling tower room, CD fuel tank and pump room, etc. shall be
explosion proof and corrosion resistant.

b) For the CD gas filter fan, it shall be the centrifugal type. All
components, which are in contact with the intake air, shall be made up
of materials, which are resistant to warfare bio-chemical agents. For

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CD fuel tank and pump room fan, all components which are in contact
with the corrosive fuel vapour shall be made up of materials which are
resistant to fuel vapour.

c) All frames and supports for the fans shall be made of hot-dipped
galvanised steel.

d) Fans shall be shock mounted in compliance with the CD shock

requirements. Any factory makes and models of the test reports
including shock resistance test certificates for all the CD fans shall be
submitted for review and acceptance.

e) Anti-condensation heaters shall be provided for the fan motors. The

heaters shall be terminated in a robust terminal box electrically and
mechanically separate from any other terminal boxes. The anti-
condensation heater terminal boxes shall be fitted with an undrilled
gland plate suitable for conduit termination or cable entry. Heaters
control circuits shall be arranged such that the heater is off when the
motor is on and vice versa. The heaters control circuits shall operate
on single-phase power supply and shall have an indicating lamp
each on the respective motor control center (MCC).

f) For CD Cooling Tower Booster Fans, Generator Intake and Exhaust

Fans, Factory Acceptance Tests (FAT) to verify the airflow, acoustic,
overspeed (whirl) and vibration performances of all CD Gas Filter
Fans, AHU Outdoor Air Intake Fans, Cooling Tower Booster Fans,
Generator Intake and Exhaust Fans shall have to be conducted.
Besides, for the Generator Exhaust Fans, FAT for high temperature
performances of these exhaust fans at the designed operating
temperature of the exhaust fans and over a minimum duration of 2
hours shall be conducted. In any case, the high temperature at which
the exhaust fans shall be tested shall not be less than 70ºC. These
Factory Acceptance Tests shall be witnessed by the representative(s)
of the Authority.

4.4 Condensate water transfer pumps

4.4.1 The pump heads specified in the equipment schedules in the Authority’s
Drawings are for tendering purpose only, and are calculated based on
assumed equipment pressure drops and indicative pipe routing as shown
on the Authority’s Drawings. The Contractor shall be required to recalculate
and submit for the Engineer’s acceptance the exact pump head required
according to the pressure drops of equipment being offered and the actual
pipework routing before ordering the pumps. Any additional cost on the
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modification of any part of the system (such as pumps, motors, switchgears,

cables, etc.) necessary to meet the actual required duties, shall be deemed
to have been allowed for.

4.4.2 The pumps and pump installations in the Civil Defence stations shall also
comply with the “Civil Defence Requirements” section of the Technical
Specification. All equipment and associated accessories and services such
as pipework, cabling, etc shall be shock mounted in compliance with the CD
shock requirements. The Contractor shall submit a full set of shock load
calculations to Engineer for review and acceptance.

4.4.3 Stainless steel, flexible corrugated connector shall be used for connecting
the piping to the pump.

4.4.4 During CD modes (Conventional and Filtration), closing/opening of the

appropriate isolation valves shall transfer the condensate water from the
AHUs to the CD Cooling Tower Make-up Tanks for recycling purpose.

4.5 Gas-tight shut-off valves

4.5.1 General

a) Gas-tight shut off valves shall be provided and installed at the

followings locations for the purpose of closing off the air flow in the
supply and exhaust air ducts and preventing contaminated air to
enter the shelter through these ducts.

i) At the gas filter intake air ducts where they terminate at the
Intake Air Plenums (IAP);

ii) At the CD dry toilets, CD permanent toilets, CD pantry and

other CD ventilation ducts before they penetrate into the CD
cooling tower rooms, Generator rooms, etc.

b) The following requirements cover gas-tight shut-off valves with and

without air barrier for use in CD shelter air conditioning and
mechanical ventilation systems. Gas-tight shut-off valves with air
barrier shall be used on air ducts which bypass the gas filters.

4.5.2 Technical requirements

a) All parts of the gas-tight shut-off valves shall be manufactured using

materials which can resist warfare bio-chemical agents, ageing, mold
formation and corrosion. Alternatively, the materials of the valves
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shall be provided with durable protective coatings of sufficient

thicknesses and designed to resist warfare bio-chemical agents,
ageing, mold formation and corrosion. The operation of the valves
shall not in any way damage or affect the protective coating(s). The
valve body shall be made of stainless steel or a light metal alloy with
epoxy powder coating. It shall be supplied complete with 2 counter-
flanges and a rubber gasket for each of them. The closing flap (or
disc) shall be installed in the valve body on a spindle with bearings.
The flap and spindle shall be made of stainless steel. Smaller parts
shall be hot dipped galvanized.

b) The gas-tight shut-off valve shall not open or close independently. It

shall be able to stay in the opened or closed position or can be
locked in any partially opened position using an external stopper pin.
It shall be designed to provide a minimal increase in the frictional
loss into the air flow. Gas-tight shut-off valve shall be the type such
that in the closed position the valve is completely closed with no
leakage. It shall be provided with padlock and key such that it can be
kept in the closed and locked position.

c) The gas-tight shut-off valve shall be the electrically -supervised type

such that its position (i.e. opened or closed) can be monitored
remotely from the LSC in ECS Control Room. If the valve is stuck in
the open position when the CD operation mode requires it to be
closed and vice versa then an audio visual alarm shall be activated
the LSC in the ECS Control Room.

d) The air flow direction shall be clearly and conspicuously marked with
an arrow on the gas-tight shut-off valve body.

e) During operation it shall be possible to close the gas-tight shut-off

valve without the need for excessive force when the air flow speed is
20 m/s with the valve in an opened position.

f) The gas-tight shut-off valve shall be able to withstand a static over-

pressure or under-pressure of 1 bar in the closed position. The gas-
tight shut-off valve shall be tight against the air flow direction when
under a differential pressure of 0 - 3500 Pa. Gas-tight shut-off valve
with air barrier shall be tight under an internal pressure of 0 - 3500
Pa. The maximum allowable leakage rate through the valve shall not
exceed 0.27 x 10-4 m3 per sec for every m2 of valve opening cross
sectional area when subject to a pressure difference of 1000 Pa.

g) Gas-tight shut-off valve without air barrier in the closed position

subject to the static pressure in the air flow direction and shut-off
valve with air barrier subject to the pressure between the two discs
shall not experience any deformation or any other damage. In the
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case of larger valves, the test pressure and other conditions shall be
defined on a case-by-case basis by the Independent Test Authority.

h) The gas-tight shut-off valve in the closed position shall be able to

withstand a test blast of over-pressure and impulse density at not
less than 2 bars and 1.5 bar-millisecond (bar ms) respectively
without any damage or leakage. The shock wave pressure and
impulse shall be measured at a distance of 300 mm from the position
of the valve flap or disc along its axis. The valve shall also be
subjected to the shock design requirements stated elsewhere in
these specifications. After the shock test, the valve shall be
inspected visually to ensure no damage or loosening of its
components.

i) The casing of gas-tight shut-off valve shall be provided with at least 2

suspension lugs such that the valve can be installed on-site by
suspending the valve indendently from the ceiling slab instead of by
the sandwiched method i.e. valve clamped by ducts on both sides to
hold up the valve.

4.5.3 Approvals

a) The gas-tight shut off valve shall be designed and type tested by an
Independent Testing Authority which has been appointed by the
national civil defence authority of the country of origin of the valve to
carry out such tests and which has the necessary expertise,
experience, equipment and apparatus to carry out the required tests.
The Independent Testing Authority shall be required to certify that
the valves have successfully passed the type tests in accordance
with the requirements specified herein. The Contractor shall submit
all relevant information relating to the Independent Testing Authority
including organisation structure, testing facilities, track record, etc.,
for the Engineer’s review and acceptance.

b) Alternatively, the Contractor may propose gas-tight shut off valves

which have been approved for use by the national civil defence
authority of the country of origin of the valves for consideration and
acceptance by the Engineer. All relevant information such as
certificates, test reports and any other documentation which show
that the valves satisfy the requirements specified herein shall be
submitted for review.

c) For the submission of the type test results, the following documents
shall be submitted:-

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i) Detailed and labelled sectional drawings of the valve, test

arrangement, test procedure, test instrumentation, etc.

ii) Installation Manual.

iii) Operating and Maintenance Manual.

iv) Parts list

v) Certificates, test reports and any other documentation which

show that the valve satisfies the requirements specified herein.

d) Batch test of each production batch of gas-tight shut-off valves shall

be carried out on 1 valve randomly selected from their batch. The
test shall comprise shock test, blast test and air-tightness test.

i) For the shock test, the valve shall be fixed onto a mechanical test
bed and subject to a shock of no less than 12.5 g’s in both directions
(one at a time) along each of the 3 major axes. After the shock, the
valve shall be inspected for any damage or loosening of its
components.

ii) For the blast test, valve shall be subjected to a test blast of
overpressure and impulse at no less than 2 bars and 1.5 bar-
millisecond (bar ms) respectively inside a shock tube. After the blast
test, the valve shall be inspected for any damage or loosening of its
components and tested for air tightness.

iii) For the air tightness test, the valve shall be closed and subject to a
static overpressure of 1 bar using compressed air. The maximum
valve leakage rate shall not exceed 0.27 X 10-4 m3 per sec for every
m2 of valve opening cross sectional area when subject to a pressure
of 1000 Pa.

4.5.4 Information

On the gas-tight shut-off valve, a clear and visible label with the following
information shall be provided:-

i) Make and model number.

ii) Name and address of Manufacturer.

iii) Production batch number.

iv) Serial number

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v) Valve Certification number.

vi) Date of manufacture.

vii) Nominal air flow rate when fully opened (in CMH).

viii) Test pressure subjected to after manufactured.

4.6 VCDS for OVS

4.6.1 The main purpose of the volume control dampers is for adjusting and
balancing the air passing through the OVs as the damper is fixed manually
in the required position between fully opened and fully closed.

4.6.2 Iris dampers or approved equivalent type shall be provided on the OVs for
air adjustment and balancing.

4.6.3 All VCDs shall comply with DW/142 or approved equivalent standard and
shall each be provided in separate purpose-made flanged casing of rigid
construction conforming to the same standard of air-tightness.

4.6.4 Dampers shall be of rigid construction, free from vibration in any position
and shall be substantially air tight when closed. Dampers shall be accurately
installed in relation to their quadrants so as to permit the free movement of
up to 90 degrees for indicating open and closed position. Materials for
dampers in all cases shall be mild steel (hot-dip galvanized) or extruded
aluminum.

4.6.5 The diameter of the dampers shall be the same as the diameter of the OVs.

4.6.6 Immediately after final CD testing (ORAT and IST) and adjustments, all
dampers shall be clearly marked on the surface in a permanent manner for
both the Conventional and Filtration mode positions.

4.6.7 All VCDs for OVs shall be shocked mounted in compliance with the CD
shock requirements. The Contractor shall submit a full set of shock load
calculations to Engineer for review and acceptance.

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4.7 Overpressure gauges

4.7.1 The over-pressure gauges each of a suitable operating pressure range (in
Pascals) shall be provided at the various locations for the following
purposes:-

a) Measure the shelter overpressure against outside atmosphere.

b) Measure the overpressure from inside of the shelter to an Air Lock

and from the inside of the Air Lock to the outside.

c) Measure the pressure difference between access locks and

decontamination chambers.

d) Measure the pressure difference between decontamination chamber

and separation room.

e) Measure the pressure drop across each bank of gas-filters as a

means to determine the filtered air quantity.

f) Measure the pressure drop across each bank of BVFs as a means to

determine the intake air flow quantity.

4.7.2 The Contractor shall allow in his Tender Price for the supply and installation
of approximately twenty-five (25) numbers of pressure gauges (dial type)
per station that are suitable for CD use and acceptable to the Engineer. The
exact quantity of pressure gauges shall be determined from the Authority’s
Drawings of each station. The supply and installation of all the necessary
copper tubes and fittings such as 3-way isolation valves, etc for
measurement of the pressures as described in Clause 4.7.1 shall also
deemed to have been included in the Tender Price. The exact location of
the pressure gauges shall be determined at a later stage after Contract
Award as agreed by the Engineer.

4.7.3 The pressure gauges shall be of the dial type with a spring action
membrane and scale indication. It shall be possible to read pressure values
of between 0 and 450 Pa (0 to 45 mm of water gauge) with an accuracy of ±
10% from the gauges. The smallest graduation unit on the gauge shall not
be more than 10 Pa.

4.7.4 The pressure differential gauges shall be mounted on the wall of the test
area about 1.5 metres above the finished floor level and about 2 metres
away from CD doorway leading from the test area to the adjacent room with
which the room pressure is to be compared with. The pressure differential
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gauge shall be connected by means of a measuring tube with blast

attenuator which leads to open air outside the test area, or to the air of the
neighbouring measured area. The measuring tubes shall be made of
copper and shall have an outer diameter of minimum 5 mm. The tubes shall
be installed in such a way that they can be drained. When the tube is
terminated outside, it shall be furnished with a dust screen or shall be
installed with its opening facing downward. When penetrating an external
wall the tube shall be installed in a sealing device (SD).

4.7.5 The measuring tube must be drained before measurements are carried out,
since water in the tube will give to an erroneous measured value.

4.7.6 Every over-pressure gauge with its measuring tube protruding into an
unprotected area shall be fitted with a pressure attenuator to prevent any
let-through blast effects from damaging the gauge. The gauge shall be
subjected to a test blast of overpressure and impulse at no less than 2 bars
and 1.5 bar-millisecond (bar-ms) respectively inside a shock tube.

4.7.7 Instructions accompanying the gauge indicating how it shall be assembled,

disassembled and handled during use shall be mounted next to each
gauge. When the gauge is not in use, the measuring tubes shall be secured
to prevent the ingress of air/gas into the protected area.

4.7.8 All over-pressure gauges, associated accessories and services such as

tubings, etc shall be shock mounted in compliance with the CD shock
requirements. The Contractor shall submit a full set of shock load
calculations to Engineer for review and acceptance.

4.7.9 Batch test of each production batch of overpressure gauges shall be carried
out on 1 gauge randomly selected from their batch. The test shall comprise
shock test, blast test and functional test.

a) For the shock test, the gauge shall be fixed onto a mechanical test
bed and subject to a shock of no less than 12.5 g’s in both directions
(one at a time) along each of the 3 major axes. After the shock, the
gauge shall be inspected for any damage or loosening of its
components.

b) For the blast test, gauge shall be subjected to a test blast of

overpressure and impulse at no less than 2 bars and 1.5 bar-
millisecond (bar ms) respectively inside a shock tube. After the blast
test, the valve shall be inspected for any damage or loosening of its
components and tested for air tightness.

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c) For the functional test, the gauge shall be tested for its accuracy and
precision when subject to a range of test pressures (but not less than
0 to 450 Pa) which the gauge is designed for.

4.8 Gas filter intake ductwork

4.8.1 Intake air ducts from the Intake Air Plenum (IAP) to the Gas Filters shall
be constructed of heavy-duty, AISI type 316L stainless steel schedule 10
pipes to ASTM or approved equivalent standards. For pipes of diameter
equal or less than 150 mm, it shall be seamless type. All joints shall be
continuously welded. The Gas Filters shall be connected to the intake air
ducts of the Gas Filters by means of flexible rubber connectors (using
gas-tight connector clips) supplied by the Gas Filter supplier as part of the
Gas Filter assembly. The maximum allowable leakage rate of the Gas
Filter ducts including the intake air ducts shall be 0.27 × 10-4 m3/(sec.m2)
at 1000Pa.

4.8.2 All Gas Filter Intake Ductwork shall be shock mounted in compliance with
the CD shock requirements. The Contractor shall submit a full set of shock
load calculations to Engineer for review and acceptance.

4.9 Flexible ducts

4.9.1 Flexible ducting used to connect the air distribution equipment and terminals
to distribution system ducts shall comply with the FSSB requirement of
resistance to fire penetration and spread of flame.

4.9.2 Flexible ducts shall not exceed 3m length except for the flexible ducts
designed for connection to the trains in the track ways during CD operation.
CD flexible ducts shall be of lightweight construction but must be durable
and not tear or hole easily.

4.9.3 The bending radius must be sufficient to prevent tensioning of the outside of
the bend and restriction of the throat, which will likely to cause deformation
and/or leakage. In no case shall the flexible ducts be used to connect
misaligned ducts.

4.9.4 Flexible ducts shall be of non-corrosive metallic material.

4.9.5 Jointing and connection of the flexible ducts to the air distribution equipment
and rigid distribution ducts shall be to the manufacturer's recommendation
and shall be submitted for acceptance by the Engineer.

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4.9.6 The specifications and materials for the flexible duct insulation and vapour
barrier shall be similar to the insulation requirement specified for the supply
air ducts in the “Insulation” section of the Technical Specifications.

4.9.7 All flexible ducts including CD ducts for air supply to the trains shall be
shock mounted in compliance with the CD shock requirements. The
Contractor shall submit a full set of shock load calculations to Engineer for
review and acceptance.

May 2008