ATS

EGYPT
ENGINEERING DEPARTMENT

MECHANICAL SECTION

LESSONS LEARNED & CASE STUDIES

CATEGORIES 2

1.Engineering
2.Execution
3.Test & Commissioning
 1.Engineering 3

1.1 Chillers
Case:
 Installing the chiller water headers @ the same level or lower than
chiller inlet & outlet causes air pockets & damages chiller coils in the
long run.

Recommendation:
 The chilled water headers into & out of the chillers levels shall be
above the chillers to avoid the following:
A- Creating air pockets within the chiller coil.
B- Poor maintenance space.
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1.2 Cooling Towers (CTs)
1.2A Condenser Water Header
Case:
Condenser water header feeding CTs installed higher or @ the same levels
of cooling tower inlets.
1- Condenser water high drain volume.
2- CT high flooding.
3- High make-up volume.
4- High chemical consumption.
Recommendation:
The condenser water header feeding CT from the condenser water pump
must be lower than the CT to avoid the above mentioned issues.
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1.2B Cooling Towers Placement

 It is highly recommended to consider a minimum
of 1m below CT , as during assembling the cells ,
installation access below CT is required to fix any
water leaks.
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1.3 Chilled Water & Condenser Water Pumps
Shaft Rotation
 Pumps shaft rotation either CW or CCW are required to be
checked & confirmed to confirm parallel & proper placing to
ensure:
1- Proper Placing.
2- Proper Maintenance Access.
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1.4 AHU & Box Fans Placing

 During placing the AHUs & fans , we have to maintain access
path all around the unit & especially beside the walls where
there are fixed panels (no access doors) to apply mastic to fix
any air leaks through the panels.
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1.5 Generator Daily Fuel Tanks Levels

Case:
Generator shutting down due to fuel injectors dripping which is caused
by high inlet pressure due to the level difference between the daily tank
& generators.

Recommendation:
 In some congested areas, the daily tanks are located in a level higher
than the generator, that lead to fuel dripping from the generator
injectors causing the generator to stop working, so it is
recommended to place the daily tanks in same level of the generator.
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1.6 CHW External Networks.
Case:
Buried networks flushing taking too long & not being effective.
Recommendation:
For external buried networks it is recommended to install wash
out valves at the end of CHW path to collect any scales or dirt &
improve external CHW flushing.
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1.7 Minimum Pipe Size

Case:
 Chilled water pipes entering fan coils are repeatedly
being blocked.
Recommendation:
 For the chilled water loops, the recommended
minimum pipe size is 20mm, as the 15mm size
suffers from blocking because of scales & rust.
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1.8 CHW Expansion & Contraction

 For CHW expansion & contraction compensation it is
recommended to use the loop geometry to distribute
anchor points & guides instead of flexible joints as
they may cause leakage.
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1.9 Ceiling Tiles & Square Diffusers

For ceiling tiles, it is highly recommended to confirm
face size to be 595x595 mm to be inserted within
ceiling tile inner dimensions.
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1.10 Public Toilets Exhaust

Case:
 Bad toilet smell & high toilet
temperature:

Recommendation:
 For public toilets exhaust , it is
recommended to replace door undercut
with door louver or supply air at lavatory
area to avoid bad smell & high toilet
temperatures.
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1.11 Duct Risers
Case:
 Low air flow rates & balancing issues @ the lowest floor.
Recommendation:
 For duct risers , it is recommended to make lowest branch
connection with the riser by take off with plug instead of
elbow to facilitate cleaning the riser in case of any dirt.
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End Cap

Recommended Not Recommended

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1.12 Duct Networks Feeding Areas Protected

by Gas Systems
 for duct works systems feeding gas FF systems , all duct
networks must be equipped with smoke dampers to avoid gas
leakage through open duct networks.
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1.13 Kitchen Exhaust Hoods
 For kitchen exhaust hoods , it is recommended to serve each
hood by one fan, as one fan serving multiple hoods will
prevent proper balance as VDs are not recommended for
greasy exhaust air.
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RECOMMENDED
Not Recommended
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1.14 HVAC Shop Drawings

 During the preparation of HVAC shop drawings & base plans ,
we have to consider fire zoning plans to add any fire /smoke
dampers on duct networks.
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1.15 Motorized & Smoke Dampers Voltage
Case:
 Motorized & smoke dampers failing repeatedly.
Recommendation:
 for all motorized & smoke dampers, it is recommended that actuators
voltage to be about 220V instead of 22V as the transducers
(220/24V) may be damaged causing the dampers to be stopped.
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1.16 Smoke, Fire Smoke &
Motorized Dampers Normal
Position
 All smoke /fire smoke dampers that are
connected to life safety smoke or
combined return smoke fans blades
position are safe open positon in case
of no power applied to actuators to
secure fans operation even there are
problem within the actuator termination
or power supply connection.
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1.17 Buried Fuel Lines
Case:
Buried fuel pipes lifetime are less than required.
Recommendation:
 in case of buried fuel lines, it is recommended to be black steel
schedule 80 to increase it’s life time.
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1.18 Integration Matrix & Cause & Effect
Matrix:
 It is recommended to prepare cause & effect matrix & BMS
Integration Matrix @ the beginning of all projects to ensure
compliance & integration of all systems & equipment with the
project requirements & specifications (sample of each matrix
are attached)
 2.Execution 34

2.1 Toilets Pipes Testing

 After the construction of toilets & after tests , it is
recommended to remove temporary pressure test
bypass pipes to avoid mixing of hot & cold water
during operation.
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2.2 Steam Lines
 All steam lines should avoid traps looking down in steam as it
will filled with condensate water , & for FF lines it can be
accepted subject to be provided with drain plugs to remove
dust.
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2.3 Free Return Systems

 For free return systems , it is recommended to close all
penetrations or sleeves with all other service areas as kitchens
to avoid bad odor in front of house areas.
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2.4 Volume Dampers Installation

 AFTER installing VDs, it is recommend to
operate the damper as installed to check if the
rotation of blades is matching with the manual
actuator & also to check if the blades are stuck
because of bolts, nuts…etc.
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2.5 Water Tanks & Pump Rooms

( Below Grade)
It is recommended to place water leak detectors
mounted at 20 cm from pump room FFL with
external horn & strop lights to alarm the operator
that leakage & flooding takes action inside the room
to warn them to close filling line valves & fix any
leakage .
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2.6 Fan Coil Units (FCU) Pipes Flexible
Connection
 The CHW pipes flexible connection must be straight not to be
connected forming elbow shapes to avoid burst.
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2.7 Electric Water Heaters

 During electric connections , tests & start up, it is highly
recommended to assure that the plumbing works are finished
& all heaters are filled with water to avoid heaters elements
damage.
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2.8 CHW Pump Room Headers.

 For CHW pump room headers, it is recommended to install
bolted plugs instead of welded flanges to facilitate the removal
of any large volume scales or missing tools.
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2.10 Flexible Duct Connections

 All air outlets flexible connections to be straight & short to
avoid high pressure drop & further minimize air flow rate.
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2.11 Linear Slot Diffusers

 For linear slot diffusers , it is recommended to replace neck
volume dampers by flapper dampers to facilitate balancing
activities.
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 3.Commissioning 50

3.1 CHW Secondary Pumps VSD

Case:
 Chillers cutting out &/or high space temperatures.

Recommendation:
 During start up & commissioning activities , the VSD setting is required to be
set in a way the secondary CHW flow to be equal or lower than the primary
flow , to avoid:
1. A-Secondary flow circulation through the load loop with high flow rates &
circulation through the chillers will be decreased. causing the load CHW
temp & space temp to be elevated.
2. B-Chillers may be stopped due to low primary CHW flow.
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