ACMV SERVICES

SECTION 15 – WATER PIPING AND PIPE INSULATION

1 GENERAL

This section of the Specification covers the materials and installation of pipes, valves and
accessories. Supply and install instrumentation for various piping system.

The installation of pipework shall be carried out only by skilled and competent workers and
comply with the relevant by-laws and regulations of the authorities who have jurisdiction
over the final approval of the installation.

The piping system shall be graded as required for efficient venting and draining. Chilled and
condenser water piping shall rise in the direction of flow towards vent points with a grade
not less than 1 in 300 where applicable.

2 MATERIALS

All pipes and pipe fittings used shall be the best of their respective kinds manufactured in
accordance with the relevant British Standard Specifications and with the local authorities
specifications.

Materials shall conform to the services requirements as specified herein and shall be
basically conforming to the service pressure encountered.

Chilled water pipework, shall be heavy grade galvanized steel pipes to B.S. 1387.

Condenser water pipework shall be heavy grade galvanized steel pipes to B.S. 1387.

Refrigerant piping below 65mm bore shall be copper to BS 2871, 65mm bore and above
shall be black steel heavy gauge to B.S. 1387.

Hot water piping up to including 50mm shall be seamless copper pipes to B.S. 2871.

Drain piping shall be galvanised steel medium gauge to B.S. 1387.

Gate and Globe valve shall be flanged cast iron body for over 75mm dia. Flanged bronze
body for 60mm dia. to 75mm dia. screwed bronze body for 50mm dia. and below.

Supply and install one (1) flushing valve and one (1) fine mesh type strainer at the take off
to each zone of chiller water system and also one (1) no. flushing valve at the return. The
flushing valve shall be insulated with superlon or equivalent, tapped from the top of piping
and down with extension for hose connection.

3 INSTALLATION

All pipes, pipe fittings, valves and accessories shall be cleaned just prior to installation,
particularly the inside of pipes and pipe fittings. No section of the pipework shall remain
"open" overnight or for longer period. All exposed ends shall be adequately sealed against
ingress of dust, etc. by the fixing of plastic or galvanised iron sheet cap securely held.

Straight pipe runs shall be in continuous lengths as far as practicable, with the number of
joints kept to the absolute minimum. All straight vertical run of pipe more than 30m in length
shall have dirt pockets formed from equal fees with plugs at the low point of the risers.

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SECTION 15 – WATER PIPING AND PIPE INSULATION

In general, galvanised pipe fittings shall be used on galvanised pipework and black pipe
fittings on, black steel pipework.

All exposed pipeworks shall be installed so that clearance of approximately 80mm is left
between the outside of the pipe or insulation and the nearest wall, ceiling or equipment
surface. Pipes shall be run at a minimum distance apart to enable them to be individually
insulated and painted. Combined insulation of two or more pipes will not be permitted.
Pipes joints or fittings will not be permitted within the thickness of walls, floors, any
partitions or below a beam.

For all pipe connections to valves, strainers and equipment, flanged or screwed joints shall
be used. All screwed joints shall be made with Teflon or equally acceptable thread seating
tape; hemp or similar organic substance shall not be used.

The minimum nominal pipe diameter to be used for all drain and air vent connections shall
be 15mm unless otherwise shown in the Specification Drawings. All drain pipes shall be
terminated visibly over the floor grating provided for drainage purposes. Condensate shall
drain to soil waste pipes unless shown otherwise in the Specification Drawings.

All fixing of pipe hangers or brackets to the building structure shall be by means of metal
expansion plugs. Suitable receiving holes shall be cut by rotary-percussion electric drills to
give true and accurate drilling.

4 STEEL PIPE JOINTING & FITTINGS

On black steel pipework and fittings, all joints up to and including 65mm diameter shall be
made. by means of screwed or welded connections. Pipes and fittings above 65 mm shall
be joined by means of welded flanges or of Victaulic Coupling unless otherwise indicated in
the Specification Drawings.

On galvanising steel pipework and fitting, joints up to and including 65mm diameter shall be
made by means of screwed connections. Pipes and fittings above 65mm diameter shall be
joined by means of galvanised flanged connections or of galvanised Victaulic Couplings.

In all cases where pipes are joined to flanged equipment, the appropriate mating flanges
shall be used. Flanges in accordance with B.S. 4504 Part 1 shall be of mild steel. All
flanged joints shall be flush and aligned, and shall be made with corrugated jointing rings,
coated on both sides with the rec0mmended jointing compound. All bolts shall be of
galvanised hexagonal-headed steel in accordance with B.S. 916 with galvanised washers
and galvanised nuts.

Reduction in diameter for through-flow pipes shall be made by means of reducing sockets
for vertical pipes only; for horizontal connections to pump suction, eccentric reducing
sockets shall be used.

9 PIPE SUPPORTS

Pipe supports shall be provided as required for the stable and sufficient support of the pipe
work. These supports shall allow free movement for expansion and contraction and shall be
graded to required levels for air elimination and drainage. Spacing of supports both vertical
and horizontal shall not exceed the centres given in the following table.

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SECTION 15 – WATER PIPING AND PIPE INSULATION

Ferrous pipes shall have ferrous brackets and copper pipes shall have brass or gun metal
brackets.

Additional supports shall be provided adjacent to mixing valves etc., and other large
pipeline mounted items to prevent undue strain on adjoining pipework. Additional supports
shall also be provided adjacent to pump connections etc., to prevent undue strain on plant.

The Contractor shall be responsible for the building in of all supports etc. and Tenderers
should allow for using 'Philips Red-head Bolt' or similar fixings for concrete and cutting
away and building in of brackets in brickwork etc. Tenderers should note that it may not be
possible to fix bolts directly above the pipes to be supported and cantilever angles above
the pipe channels are to be used where required.

All supports, hangers brackets, etc. shall be of hot-dipped galvanised mild steel
construction to BS729:1971 Part 1 with min. coating of 85 and 210 for indoor and outdoor
installation respectively.

All bolts and nuts shall be electroplated with zinc or cadmium to BS 3382 : Parts 1 and 2
with minimum plating thickness of 25.

For chilled water and hot water piping use clamp and foamglass or wood block spacer to
pipe insulation diameter, or saddle if preinsulated is used.

In all cases, saddle for pipes 150mm and larger, and clamps for pipes below 150mm
diameter shall support the pipe independent of any lagging. Special care shall be taken with
vapour seals and lagging to ensure they are continuous at points of support. Clamps shall
be lined internally with 15mm thickness neoprene strip.

Pipe support on rollers shall be used in cases of long straight pipework and/or where
expansion joints are provided to cater for pipe expansion and contraction.

The maximum spacing of pipe support and the minimum diameter of hanger rod shall be as
follow:-
Hot rolled
Pipe-Size Spacing Steel Rod Sizes
Up to 20mm 1.2m 6 mm
25mm to 50mm 1.8m 10 mm
65mm to 100mm 3.Om 16 mm
125mm to 150mm 3.Om 20 mm
200mm and above 3.Om 22 mm

Pipe hangers shall not be placed not more than 600mm from each change of direction
where possible.

All pipeworks connected to pump sets, chillers and cooling towers, shall be isolated from
the building structure by using flexible pipe hangers, anchors and pipe guides as specified.
No direct connection between the building structure and any part of the pipework shall be
allowed. Where pipes pass through walls or floors a clearance of 12mm around the pipe
shall be maintained. Where it is required to seal around the pipes, vibration isolating
packing shall be used.

Vertical -support for pipe riser shall be by a riser clamp at each floor that the riser passes
through and braced laterally at every floor or mid-span. The riser shall be supported by riser
clamps which in turn shall be spring mounted.

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SECTION 15 – WATER PIPING AND PIPE INSULATION

At the lowest point, the riser shall be supported on hanger at the elbow (up to 32mm bore),
concrete block (40mm to 150mm bore) or foot elbow (above 150mm bore).

All vertical pipe anchors shall be resiliently mounted with a layer of minimum 25mm thick
neoprene impregnated duck pads for loads up to 8.28 MPa (1200 psi). For loads up to 0.35
MPa (50 psi), two layers of 40 durometer, 8mm thick neoprene waffle pads should be used.

Spring and/or rubber hangers and restraints shall be used where necessary to take up
expansion contraction and vibration.

6 UPVC PIPE

Unplasticised P.V.C. (UPVC) pipeworks shall be to B.S. 5255 and installed complete with
standard moulded fittings.

UP.V.C. pipes shall be odourless type and shall not taint and shall be suitable for the
service and duty specified. UP.V.C pipes shall be resistant to all external and internal
corrosions and shall not attack or be subject to attack by insects and rodents. Pipe material
shall be suitable for use with thermal insulating materials and vapour sealing compounds.

Pipe runs shall be fabricated using cemented sockets, bushes, bends, elbows and tees but
flanged or screwed joints shall be used at connections to plant items and valves.

Generally pipe fixing shall be in accordance with Clause 4.0 and particular care and
attention shall be paid to the greater degree of expansion and contraction of UP.V.C. pipes
in comparison with that of metal pipes. Hangers or supports spacing shall comply with the
manufacturer's rec0mmendations but in any case shall not exceed the following:

Up to and including 40mm bore ........................................1 m apart

50mm bore to 80mm bore ................................................1.5m apart
100mm bore to 150mm bore ............................................2m apart

Valves, cocks, etc. for UPV.C. piping systems shall be applicable to UP.V.C. pipes.
UP.V.C. pipes shall be flanged connected to metal valves and metal systems. Screwed
connections will not be accepted.

7 PIPE INSULATION

The insulation of chilled water pipework shall be rigid polyurethane. Unless otherwise
specified, all chilled water pipes shall be pre-insulated pipe insulation.

Hot water pipes and hot water condensate pipe insulation shall be mineral wool pre-formed
sectional pipe insulation of 25mm thick, 144 kg/m3 density, and sheathed with 24G
aluminium sheeting. The thermal conductivity shall not exceed 0.027 W/m K at 20 deq.C.

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SECTION 15 – WATER PIPING AND PIPE INSULATION

Pre-insulated pipe insulation shall be of rigid polyurethane foam, machine injected into the
annular space between carrier pipe and outer spiral jacket by a one shot method. Physical
properties of foam shall be as follows :

Physical Property ASTM Test

Density : 50 Kg/cu. m. D1622

Thermal conductivity : 0.022 W/m. deg. K C51 8
at 20deg. C mean
Compressed strenght : 2 Kg/sq. cm. D1621
Water vapour permeability : 3.7 perm-cm C356

The thickness of insulation shall be 40mm for pipes up to 100mm bore and 50mm for pipes
exceeding 100mm bore.

The outer jacket shall be inside lock seamed galvanised steel. For pipework exposed to
weather, aluminium outer jacket shall be provided. The width of strip to be formed shall be
maximum 140mm and the thickness shall be 0.6mm. For pipes running underground or in
trenches, the outer jacketing shall be of high density polyethylene (HDPE).

All fittings shall be prefabricated and pre-insulated. Where required, expansion loops or
bellows shall be provided of proper design reinstalled in accordance with stress limits
indicated by the code for pressure piping ANSI B311.1

All pipe ends shall be protected by plastic sheet cover.

All preinsulated pipes must be approved by the local fire authority.

The site installation including field joints shall be performed strictly in accordance with
manufacturer's instruction with field G.I. cladding and foaming. A manufacturer's field
service instructor is to be present during critical period of installation.

Condensate drain pipe insulation shall also be of quality closed cell elastomer compound
and galvanised steel claded to approval of the S.O.

8 AIR VENTS AND DRAIN

Air vents and drain lines shall be provided at each high point the piping system connect a
10mm manual pet-cock or automatic float type 10mm air relief vent of pressure rating
appropriate for the duty intended, At the top of all risers automatic vents shall be used.

At each low point install a valve and in which water may collect, shall be drained to waste
with drain line.

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