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Christchurch International Airport Limited CIAL Facilities Services

Policy & Procedures Manual Mechanical Installation

Authorised By: Compiled By:

Manager Airport Facilities Mechanical Services Engineer

Date Issued: 10 March 2010 Index: G301

s:\operations and infrastructure\facilities services\general\standards\mechanical installation.doc of 15

MECHANICAL INSTALLATION

1 PURPOSE

This document identifies the procedures to be followed for additions, extensions or modifications to

the Mechanical Services at Christchurch International Airport Limited (CIAL) Sites.

2 SCOPE

Intended for use by CIAL Facilities Services Staff, every contractor, consultant and sub-contractor

(including employees of every contractor, consultant and sub-contractor) who carry out work on

the CIAL Site.

3 CONTINUOUS IMPROVEMENT

It is the policy of CIAL Facilities Services to continually improve (for example as needs or

technology changes). This then creates an ongoing need to make alterations to this document. The

reader must ensure that the current version is being used.

To assist CIAL Facilities Services to continually improve, please advise the Manager Airport

Facilities if there is something in this document that is missing or that can be improved upon.

4 COPYRIGHT

Please feel free to copy this document, however before doing so, ensure:

Approval is obtained from the Manager Airport Facilities.

The document is copied in its entirety.

CIAL Facilities Services are acknowledged as the original source.

5 INFORMATION CONTACTS

CIAL Facilities Services staff and the Manager Airport Facilities may be contacted by telephoning

CIAL Facilities Services (ph: 353-7080). The fax number is 353-7090 and the E-mail address is

[email protected]. CIAL Facilities Services is located at 818 Wairakei Rd.

6 ASSOCIATED DOCUMENTS

CIAL Facilities Services Procedure – “Requirements for Contractors” document.

CIAL Facilities Services Procedure – “Preferred Electrical & Mechanical Materials” document.

CIAL Facilities Services Procedure - “Electrical Installation & Electrical for Mechanical Work”

CIAL Facilities Services Procedure – “Gas Installations” document.

CIAL Facilities Services Procedure - “Operating, Maintenance and As-Built Manuals” document.







7 GENERAL

7.1 This protocol covers the procedures to be adopted for additions, extensions or modifications to the

mechanical services at CIAL Sites. Services include the installation and commissioning of plant,

pipework, ductwork, etc. associated with the following:-

− domestic hot and cold water

− flushing water

− heating water

− chilled water

− condenser cooling water

− ventilation

− air conditioning

− LPG / Diesel

− artesian cooling water

7.2 The mechanical contractor or subcontractor (hereinafter referred to as the Contractor) shall

complete and fully commission all work required to the true intent and meaning of the Drawings

and Specification taken together. Any items necessary for the correct operation of the systems but

not shown or specified shall be included.

7.3 The Contractor shall take responsibility for the Electrical for Mechanical services installation. In this

regard, in addition to the specific clauses contained within this document, reference should be

made to the Airport Maintenance Services Standard Procedure entitled “Electrical Installation &

Electrical for mechanical Work at CIAL Sites ".

7.4 The completed installation and its execution shall comply in full with the requirements of the NZ

Building Code, in addition to the following documents:-

− NZ Electrical Wiring Regulations

− NZS4302 Codes of Practice for the Control of Hygiene in Air and Water Systems in

Buildings

− NZS4303 Ventilation for Acceptable Indoor Air Quality

7.5 This document shall be read in conjunction with the CIAL Maintenance Services Procedure entitled

“Requirements for Contractors”.

8 MATERIALS & WORKMANSHIP

8.1 The work shall at all times be carried out in a neat and tradesman-like manner and to the accepted

best trade practice by experienced, qualified, and adequately supervised tradesmen. All materials

and equipment shall be installed, commissioned and maintained strictly in accordance with

manufacturers recommendations.







8.2 In all cases, materials listed in the Airport Maintenance Services Procedure entitled “Preferred

Electrical & Mechanical Materials” shall be used. If not listed, all materials shall be of the best

quality and comply with the current issue of the relevant NZS, AS or BS specifications, ESR:1993,

Electrical Codes of Practice.

9 CONTINUITY OF SERVICES

9.1 No work connected with, nor interconnections to, existing CIAL services shall be undertaken in any

circumstances without formal, prior approved, authorisation. In the event that services are

required to be interrupted, it is a requirement that these interruptions are for the minimum

reasonable duration, at times most convenient to CIAL, and are arranged with the Airport

Maintenance Services, using the "Permit to Work" form, at least 48 hours prior to the work

commencing.

10 WORKS PROTECTION, DAMAGE, CLEARANCE AND MAKING GOOD

10.1 The Contractor shall store their materials and equipment in a secure and orderly manner, and shall

take all reasonable steps to protect completed work from damage by others or natural elements.

The contractor is also to remove promptly from site all trade wastes and surplus materials.

The contractor shall make good, at their own expense, all damage done by them to work of other

trades, remove promptly from site all trade wastes and surplus materials and maintain the site

clear of all trade wastes and debris associated with this Contract.

The Contractor shall make good all damage done by them to the Building and make repairs to

reinstate surfaces to their original condition.







11 PIPEWORK

11.1 PIPEWORK

Pipework shall be as follows:-

Heating water Black medium mild steel pipe to BS1387

Chilled Water Black medium mild steel pipe to BS1387

Steam Black heavy grade mild steel pipe to BS1387

Domestic Hot & Cold water Domestic Grade copper tube to NZS3501

Condensate Drains Unplasticised PVC pipe to NZS7648

Flushing Water Domestic grade copper tube to NZS3501

Refrigeration Copper tube to NZS5325

Purified Water ABS Plastic

Cooling Tower Circuits ABS, hot dip galvanised, or stainless steel pipework

Artesian Water Circuits ABS pipework

LPG (underground) Copper - wrapped with densotape (55% overlap) and yellow plastic overwrap

Black Mild Steel - wrapped with densotape (55% overlap) and yellow overwrap Polyethylene

LPG (above ground) Copper, Black Mild Steel - welded

Galvanised Steel - screwed joints - must be accessible

Diesel (underground) Black Mild Steel with secondary containment as per ECAN requirements (i.e. double contained).

Liquid pipe to be wrapped with Densotape (55% overlap).

Diesel (above ground) Black Mild Steel

NOTE: No Galvanised pipe or fittings to be used on Potable Water

11.2 PIPEWORK INSTALLATION

Exposed pipework shall follow the lines of walls, be installed in one plane where possible and

adjacent pipes shall be parallel. Grade all pipework to ensure venting and drainage. Concealed

pipework is to be run neatly in parallel lines and diagonal runs of pipework are to be avoided.

Risers are to be plumbed accurately. Horizontal pipework within wall cavities is to be avoided

wherever possible. Great care is to be taken to provide a neatly executed layout of good

appearance.

All pipework is to be concealed unless prior written agreement is received from the Facilities

Services Manager.







All valves, strainers, controls and items of equipment are to be located in conveniently accessible

locations and are to be arranged to be readily removable.

Blank off open ends during the progress of work and take all reasonable care to prevent any scale

or loose material being left in the pipework.

Connections above 50mm diameter, or where access will cause difficulty in tightening a union, shall

be flanged. Connections up to and including 50mm diameter shall be made with ground-in

spherical seated unions generally to BS1740.

Flanges shall comply with BS1560, table E. Welding flanges shall be welded in the neck and bore.

Fit reducers where pump or valve connections are not the same size as the pipes. Ensure that

these connections do not transmit stress to the pump or valve casings. Reducers in horizontal

pipework shall be eccentric and in vertical pipework shall be concentric.

Where bends are to be formed in lengths of pipe a hydraulic bender shall be used having formers

of the correct size for the particular pipe. Flattening or distortion of the bore will not be accepted.

Contractors shall have completed supplier accreditation processes where appropriate for pipework

installations. This applies particularly to ABS pipework.

11.3 PIPEWORK SUPPORTS

Support pipework adequately allowing free movement for expansion and contraction. The spacing

of supports shall not exceed the following:-

Size (mm) Mild Steel Copper PVC

15 1.8 1.4 0.6

20 & 25 2.4 1.7 0.6

32 2.4 1.7 0.8

40 & 50 3.0 2.0 0.9

65 3.7 2.0 1.2

80 & 100 4.1 2.4 1.3

Chilled water pipework is to be supported by purpose made insulated hangers so that the vapour

barrier of the insulation is maintained. eg. Polyurethane blocks or timber ferrules.

Size (mm) ABS (based on 20�C average pipe wall temperature and PN15 pipe)

15 1.0 20&25 1.2 / 1.3 32 1.6 40&50 1.7 / 2.0 65 22 80&100 2.4 / 2.8







ABS pipe support centres decrease for increased operating temperatures and lower pressure rating

pipe classes. Support centres shall be in accordance with the manufacturer’s recommendations.

11.4 PIPEWORK JOINTING

11.4.1 GENERAL

All pipe and fittings shall be thoroughly cleaned before erection and shall be free from burrs, rust,

scale and other defects. After cutting, whether by pipe cutters or hacksaw, the end of every pipe

shall be reamed clean and full bore. No pipe joints shall be made in the thickness of walls, floors,

etc.

Where pipework is to become inaccessible or have limited access all joints shall be made by

welding or brazing as appropriate.

All pipework shall be provided with flanges or unions as appropriate for reasonable assembly and

dismantling of pipework. All screwed valves are to fitted with a union on the dead side.

Where copper tubing is to be connected to mild steel or galvanised mild steel tubing this shall be

carried by means of an intermediate brass spacer and care is to be taken to prevent any direct

metal to metal contact of copper and steel.

11.4.2 MILD STEEL

Weld pipework wherever possible using welding fittings. Screwed work shall be limited to valves,

union connections, pipework inaccessible to welding.

All welds are to be of the highest quality free from slag inclusions, under cutting and surface

irregularities and no deposit of weld material is to be allowed to restrict the bore of pipes.

Flanges in pipework are to be made with Klinger or equal packing selected for the particular service

and applied with suitable compound.

Welding fittings shall be to BS1965 with thickness not less than the pipe wall thickness. No sharp

or mitred bends will be permitted. Where branch joints, bosses and drain pockets are made, there

shall be no obstruction to the bore of the pipe by welding metal or tube projections.

Threads for screwed joints shall comply with BS21. Not more than one full thread shall be visible

beyond the end of the fitting. Make joints with PTFE tape applied to an oil free surface.

11.4.3 COPPER PIPEWORK

Joints in copper pipework are to be made by brazing using Silphos filler rods. All brazed joints are

to be of capillary nature and care is to be taken to maintain pipe bores especially at branches.

Brazing metal is not to be allowed to build up within the pipe bore.

Compression fittings (up to 50mm) are to be "Starkie". On refrigeration service flare type fittings

may be used with annealed copper up to 19.05mm OD. The flare fittings shall be machined from

brass forgings or extruded brass rod. Flare fittings used on suction lines shall be frost-free type.

For refrigeration pipework capillary joints shall be brazed while passing dry nitrogen through the

pipework.







11.4.4 PVC PIPEWORK

Joints in PVC pipework shall be made using solvent cement as recommended by the pipe

manufacturer.

Fabrication of PVC pipe fittings is not permitted where stock moulded fittings are available. Where

fabrication of fittings is unavoidable, the work shall be carried out only by a firm specialising in the

fabrication of plastic materials.

11.4.5 ABS PIPEWORK

Joints in ABS pipework shall be in accordance with the manufacturer’s recommendations.

11.5 GRADING, DRAINS AND AIR VENTING

Particular care is to be taken to grade pipework to avoid unvented high points in pipework carrying

fluids, and to prevent undrained low points in pipework carrying vapours or gases and in which

fluids may condense or collect.

Fit Spirax automatic air vents at the highest point of each section of pipework. The automatic air

vent shall be mounted on an equal tee connection on the pipe with a minimum of three times the

diameter in height and of a type suitable for the purpose. All air vents shall incorporate an

isolating valve, strainer and manual bleed valve. No automatic air vents are to be installed within

ceiling spaces. In these locations manuals air bleeds only are to be used.

Drain points shall be fitted at the lowest point of each valved circuit in such a position as to enable

the complete drainage of the system. Drain valves in concealed locations shall be fitted with plugs.

Drain valves in plantroom areas shall have provision for a hose connection.

Low points of all vacuum lines shall be fitted with an Ohmeda suction trap installed in accordance

with the manufacturers recommendations.

11.6 PRESSURE TESTING

All pipework shall be hydraulically pressure tested on completion. Pressure tests shall be carried

out to 450 kPa or 1.5 times the working pressure, whichever is the greater, by sealing off the ends,

applying the pressure and holding for a minimum of 24 hours. On application the pressure the pipe

shall be inspected for leaks. Any leaks shall be repaired and the pressure test repeated.

11.7 WATER TREATMENT

Shall be installed for new standalone systems. To discuss with Facilities Services Manager.

12 VALVES

12.1 ISOLATING AND CONTROL VALVES - GENERAL SERVICE

On water services these valves shall be gate, ball or butterfly pattern with lever arm or handwheel

and are used for isolating circuits for maintenance. On steam and condensate services these shall

be globe pattern. Where these valves are used to isolate plant they shall remain fixed to the

pipework.







Unions are to be provided on the ‘dead’ side of every valve to allow the isolated pipework to be

disassembled.

Valves shall be provided as required to allow maintenance of services with the minimum of

disruption to adjacent areas.

Valves shall be flanged if larger than 50mm.

12.2 COMBINED ISOLATING AND REGULATING VALVES

These shall be Tour and Anderson STA-D isolating and regulating valves. These valves shall be

locked in their balanced position at the completion of commissioning and the settings recorded.

12.3 BINDER TEST POINTS

Binder test points are to be provided to allow pressure and temperature measurements to be taken

across all items of plant. Binders must not be installed on the underside of pipes or fittings.

12.4 VALVE IDENTIFICATION

Each valve shall have an engraved label fixed to it with and approved metal ring or chrome plated

ball chain. The label shall show the service and the area served.

12.5 ARTESIAN COOLING AND COOLING TOWER CONDENSING WATER CIRCUIT VALVE REQUIREMENTS

For artesian cooling and cooling tower condensing water circuits non-corroding type valves

(including control valves) shall be used with only non-ferrous materials exposed to the liquid.

13 PUMPS, FANS AND MOTORS

2 pole motors are to be avoided wherever possible.

All motors larger than 1 kW shall have a Microtemp or Thermistor protection fitted as standard.

Differential pressure gauges and Trafag PD3.4 differential pressure switches are to be installed

across all circulating pumps. These are to be mounted on white powder coated gauge panels and

connected to pipework by means of 6mm copper tubing, brass compression fittings and ball valves.

Where gauges are likely to be exposed to rapidly fluctuating pressures, gauges shall be oil filled

and snubbers are to be installed.

The pressure switches are to be wired to the Building Management System.

14 AIR CONDITIONING AND VENTILATION

14.1 DUCT CONSTRUCTION

Ductwork shall comply with the SMACNA DUCT MANUAL - SECTION 1 - LOW VELOCITY SYSTEMS

with the following exceptions:-







− the minimum sheetmetal thickness to be used is 0.8mm.

− do not use self tapping screws for duct construction. Blind pop rivets only are to be

used.

− close any small holes in the ductwork by soldering or by approved sealant (e.g.

Metalseal). Such treatment shall not destroy the galvanising.

All ductwork shall be constructed from best quality galvanised sheets of lockforming grade. Open

ends of ductwork are to be sealed during construction to prevent the ingress of dust and debris.

All ductwork is to be airtight, is to be free from internal edges and projections, and shall be

constructed with care to ensure low resistance and absence of noise. All ductwork shall be

machine bent and shall, when installed, be free from deformations with the exception that all flat

surfaces of ductwork shall be cross-broken for rigidity.

Bends and branches are to be constructed with a centreline radius minimum of 1.5 times the duct

width in the plane of the turn. Changes of duct section, expanders and contractions are to be

made with sides at a maximum included angle of 20 degrees.

14.2 INTERNALLY INSULATED DUCTWORK

Where required to be internally insulated, ductwork is to be lined with 25mm Soundtuf or Acousorb

secured in accordance with the manufacturers instructions. Under no circumstances is fibreglass

based insulation to be used for internal duct insulation.

14.3 DUCT SUPPORTS

Duct supports shall be as detailed in the SMACNA Duct Manual. Provision shall be made on ducts of

sides larger than 450mm or over 450mm diameter for seismic restraint in compliance with

NZS4219.

14.4 DAMPERS

Balancing and motorised dampers are to be proprietary opposed blade type with galvanised

sheetmetal or aluminium blades. Axles are to be bright zinc plated mild steel or stainless steel.

Each balancing damper shall have an operating quadrant in an accessible position capable of

moving the blades from the fully open to the fully shut position, and shall have a locking nut so

that the blades can be secured in any position. "Open" and "Shut" positions are to be clearly

marked on all dampers. All automatic dampers are to have a neat axial cut, 1mm deep across the

end of the operating shaft to indicate the blade position. Balancing dampers are to be clearly

marked to show their commissioned position.

14.5 FIRE DAMPERS

Fire dampers shall be to AS1682, of approved make (Holyoakes IBD curtain type or similar

approved) and have the rating certified by a recognised fire rating laboratory. Fusible links are to

operate at 70EC .

Fire dampers are to be installed strictly in accordance with the manufacturers instructions and in a

manner to maintain the fire rating of the partition being penetrated.







14.6 DUCT ACCESS PANELS

Provide access panels at all items of plant, including balancing dampers, fire dampers, motorised

dampers, coils etc. Access panels are to be of double skinned construction fixed by means of

camlock latches, as supplied by Airmech, Holyoakes etc.

14.7 FLEXIBLE DUCT CONNECTIONS

Flexible connections shall be at least 100mm long and manufactured from Wavebar 148-4000 or

similar approved. The flexible connections shall be secured to the ducts by way of 25mm wide

1.0mm thick gms strips riveted at 75mm centres.

Fan flexible connections are not to be tensioned axially in a manner likely to allow the transmission

of vibration.

14.8 FLEXIBLE DUCTWORK

All flexible ductwork shall be of the aluminium spirally wound type, e.g. Holyoakes Spiroflex or

similar All flexible supply ductwork shall have factory applied 25mm thick, 24 kg/m3 density

fibreglass. A length of no more than 3 metres is allowable for any one branch.

All bends made in flexible ductwork shall be formed to manufacturers recommendations and shall

have a centre-line radius of not less than 1.5 times the diameter of the duct. Bends shall remain

at full diameter throughout the length of the bend and all bends deformed or damaged in any way

during installation shall be replaced. All fittings such as tee-pieces, Y-pieces and reducers shall be

of galvanised sheet metal.

All joints between lengths of flexible ductwork shall be made with short spigots of galvanised sheet

metal circular duct to form a slip joint. Similarly all connections to fittings and terminal boxes etc,

shall be of the spigotted slip joint type. All joints shall be sealed with Band-it type clamps c/w

screw seal type fixings. All flexible ducts shall be adequately supported with hangerstrips located

at a maximum of 2 metre centres to prevent undue sagging.

14.9 GRILLES AND DIFFUSERS

All grilles, registers, door grilles, diffusers and louvres are to be fixed using concealed fixings.

Where this is not possible these are to be fixed with exposed screws treated by the manufacturer

to match the finish of the outlet. All outlet margins are to effectively mask openings in surrounding

wall finishes.

All outlets are to fixed plumb, square, level or parallel to other features as appropriate for the

particular outlet.

14.10 FILTERS

All filters shall be in 300mm or 600mm modules and are to be housed within purpose built

enclosures fitted to provide an adequate seal to the filter frame. Filter box access doors are to be

fitted with quick release catches. Screw fixed access doors are not acceptable.

Hepa filter enclosures are to be fitted with the standard CIAL DOP test port on the inlet side of the

filter and a proprietary access panel on the outlet side. This is to allow the injection of DOP, and

the scanning of the filter surface once installed into the housing.







All panel filters shall be mounted in approved angle or pressed frames of metal with all joints

sealed airtight. Stainless steel shall be used for holding and panel frames.

No work is to be undertaken on any systems incorporating Hepa filters until these have been

fumigated and a clearance given.

14.11 FILTER DIFFERENTIAL PRESSURE GAUGES

All filters are to be fitted with Dwyer Magnahelic series 2000 differential pressure gauges of an

appropriate range to suit the pressure drop of the filters in a dirty condition, mounted on a powder

coated gauge panel. These gauges are to be installed in accordance with the manufacturers

instructions and connected to both sides of the filter box using 6mm soft copper tubing. The copper

tubing is to be adequately supported.

14.12 VAV TERMINALS

VAV terminals are to be of the pressure independent type incorporating BMS Controllers. The

control damper in the VAV terminal is to be designed to provide a tight shut-off when required. In

addition to the VAV terminal control damper, a duct mounted opposed blade damper is to be

installed prior to the VAV to allow the system volume to be balanced. This damper is to be

installed with adequate separation from the VAV to prevent velocity turbulence at the control

sensor. The circular inlet duct section is to be at least four duct diameters in length prior to the

control sensor.

15 THERMAL INSULATION

15.1 GENERAL

Prior to the application of insulation, all surfaces shall be thoroughly cleaned of scale, rust, grease,

oil and dirt. All insulation material, regardless of the methods of fixing, shall be in close contact

with the surfaces to which they are applied. Edges and ends of insulated sections shall be arranged

to butt up close to one another over the whole insulated surface. Joints in insulation shall be

properly sealed. Refer also to Section 15.2.

15.2 EXTERNAL DUCTWORK INSULATION

Thermal insulation shall be applied to all air conditioning supply ductwork except where this is

internally insulated. Insulation shall comprise 25mm thick Ductwrap flexible fibreglass, covered

with aluminium foil, firmly adhered to ducts with an approved type of non-flammable adhesive.

The insulation shall be applied to form an effective vapour barrier over the whole surface of the

ductwork including flanges, stiffeners and support angles with all joints butted together with

aluminium foil overlapping at least 50mm, sealed with a vapour impervious tape.

Pins shall be used on the underside of large ducts to prevent sagging of the insulation, provided

that the pin is covered and sealed with aluminium foil and vapour impervious tape.

15.3 CHILLED WATER PIPEWORK INSULATION

Thermal insulation shall be fitted to all chilled water pipework, including fittings, valves, pumps,

hangers and cold feed. Insulation shall be 19mm Armstrong Armaflex applied strictly in accordance







with the manufacturers recommendations. The insulation shall be preformed for the required pipe

size, and in particular the insulation shall not be stretched or compressed.

Insulation at elbows shall be made by use of a mitre box or developed from sheet material to

provide a clean neat cover. Compression or folding of the insulation around the fitting will not be

accepted. Foamglass blocks, Silica gel spacers or timber ferrules are to be used to isolate the

pipework at all hangers and supports. Under no circumstances are supports to be directly attached

to the pipework.

The whole of the insulation system except where concealed in ceiling space, wall cavities, shall be

finished with an appropriate vinyl or acrylic paint system.

15.4 HOT SURFACE INSULATION

All insulation of hot pipe and fittings is to consist of fibreglass rigid pipe sections of 80 kg/m3 with a

factory applied aluminium foil facing.

Insulation of valves, pumps and other items of equipment shall be by the use of ceramic fibre

muffs held in place with quick release fasteners.

16 PROTECTION AND FINISHES

Surface treatments shall be appropriate for the corrosion protection of the specific surface being

treated.

Equipment supplied in factory finished condition will be accepted, provided that the finish is of a

high standard, acceptable in colour and does not require extensive touching up. Otherwise factory

finished equipment shall be cleaned, wirebrushed and painted on site with not less than two coats

of approved finishing paint.

Welding will not be permitted after a corrosion protection coating has been applied, unless the

coating is restored to its original condition after welding. Coating restoration shall be completed in

accordance with the specified requirements of the original coating.

Surfaces of metalwork that will be in contact with other metal work or concrete after assembly

shall be cleaned and primed before assembly.

17 LABELLING AND IDENTIFICATION

All instruments, gauges, indicators, control equipment, valves and switchboard equipment shall be

clearly labelled using engraved traffolyte labels. Lettering shall be upper case and black in colour

on a white background. All items of equipment such as pumps, fans, air handling equipment and

similar items shall be labelled in accordance with standard symbolism to clearly show the purpose

of the equipment and the name of the Service/System. eg. Cold water supply from Riverside

tanks.

All pipework shall be colour banded and labelled in accordance with NZS5807. Where pipework

passes through walls, labels are to be fitted adjacent to each side of the obstruction.

Duct access panels are to be labelled to show their purpose, and to warn of any risks involved with

them being opened.







18 CONTROLS

See CIAL Maintenance Services Procedure “BMS Specifications & I.O. Programming Methodology”.

The Contractor is responsible for supplying, installing and commissioning all control hardware

necessary for the CIAL's Staefa BMS control system to be extended to achieve the required control

functions. Liaison with the Electrical Services Engineer will be required to ensure the correct

interface with the existing CIAL system and programming requirements.

All field mounted control items shall be installed strictly in accordance with manufacturers

instructions. Special care should be taken in siting velocity and pressure sensors to ensure that

these are not subject to fluctuating conditions. Where sensors are to be connected to duct or

pipework by means of capillary tubes, these tubes shall be in copper.

All field mounted control items are to be labelled to show their purpose.

19 COMMISSIONING

19.1 GENERAL

The Contractor shall fully test all systems installed, in the presence of the Engineer. The tests shall

include the full sequential operation of all components installed, and demonstrations of their

competence to perform to the requirements as laid down.

All tests required by Statutory authorities such as the Local Fire Authorities and Health Authorities

shall be carried out to prove that the systems operate to their satisfaction, and in accordance with

the appropriate Codes or Regulations.

Special care is to be taken to fully recommission all systems that are altered as part of any work

undertaken.

19.2 PRE-COMMISSIONING PROCEDURES

Prior to the commencement of commissioning of the systems the following procedures shall be

carried out:-

− Ductwork - pressure and leak test all ductwork

− Pipework - pressure and leak test all water systems

− Water Systems - thoroughly clean and flush out all water systems.

Flushing shall be carried out using a non-foaming

detergent compatible with the final selected water

treatment chemicals.

− Air Systems - all ducting shall be thoroughly cleaned out before fans

are turned on.

− Domestic Water - all domestic hot and cold water systems are to be

cleaned and disinfected in accordance with NZS4302.

− Electrical Switchboards - each board shall be cleaned of all drilling swarf,

spare wiring, wire cutoffs, dust etc.







19.3 COMMISSIONING PROCEDURES

19.3.1 AIR SYSTEMS

All air systems shall be adjusted and balanced so that airflows at all points in the system are within

-5% to +10% of the specified design flow rates. In addition air distribution from supply air outlets

shall be checked and adjusted as necessary, to ensure that the direction and throw of air is

adequate for the application, free from unacceptable draughts and generally uniform over the face

of each outlet.

Wherever possible balancing is to be carried out using the main balancing dampers in ductwork

hence it is essential that these are located with operating mechanisms in accessible positions. The

integral volume adjustment at individual outlets shall only be used for the regulation thereof.

19.3.2 WATER SYSTEMS

All temperature control valves shall be fully opened during balancing of water flows. Final settings

of all regulating valves shall be permanently marked in an appropriate manner. Particular care

shall be taken to achieve the correct balance at all zones.

19.3.3 CONTROLS, GAUGES AND INSTRUMENTATION

All controls shall be adjusted and commissioned by competent personnel provided by the

manufacturer of their authorised agent. A complete log of the settings and readings of all controls,

gauges and instrumentation shall be maintained.

Readings shall be taken of the following:-

− ammeter reading of all motors

− air pressure drops across all fans, through all filter banks etc.

− speeds of all fans, motors etc.

− ambient and internal dry and wet bulb temperatures

− water flow rates through all pumps, calorifiers, regulating valves etc.

19.3.4 ELECTRICAL CONTROL PANELS AND SWITCHBOARDS

The operation of all indicating and recording instruments and associated equipment and the

indicating lights and associated timing devices, relays etc. shall be proved under full working

conditions.

19.3.5 CONTROL SYSTEMS

The operation of each control system and all control equipment shall be proved under all operating

conditions.

19.3.6 COMMISSIONING AND PERFORMANCE DATA

Copies of all data recorded during commissioning of the installation, together with all necessary

inspection certificates from local authorities shall be provided in an approved form. Handwritten

reports will not be permitted.







20 REMOVING OF EXISTING SERVICES

Where systems or services are to be removed, all redundant items, including cabling shall be

removed from the site unless exempt by the Mechanical Services Engineer. Items not removed

shall be labelled clearly describing the previous function they performed, where they are

terminated etc

21 AS-BUILT DOCUMENTATION

Refer to CIAL Maintenance Services Procedure for As-Built Documents.

It is imperative that all CIAL records are kept in an up-to-date condition and hence all modifications

to services are to be recorded on the as-built drawings held in the Airport Maintenance Services

office. Where these drawings are in Microstation format the appropriate files are to be updated,

and a revised copy of the files supplied.