mechanical services design standard

(Uncontrolled when printed) MAS-MCH-001

MAS-MCH-001…-… Mechanical Services Design Standard Australia Pacific Airports (Melbourne) Pty Ltd

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Document Number MAS-MCH-001 Mechanical Services Design Standard

Approver Jeffrey Mansfield, Senior Development Manager

Utilites & Bld Services APAM

Date 10/10/2020

Maintainer Shane Kilroy, Mechanical Maintenance Manager,

+61 488 551 572, [email protected]

Date 10/10/2020

Revision 2 Final Approved Date 10/10/2020

Next Review Date 09/01/2021

Mechanical Services

Design Standard



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DISCLAIMER This procedure has been developed by Australia Pacific Airports (Melbourne) Pty Ltd (Melbourne

Airport) for use in the construction and maintenance of works at Melbourne Airport in order to:

Provide guidance to persons planning and performing those works as to airport specific

requirements; and

Promote consistency in utilities infrastructure across the airport generally.

While Melbourne Airport expects users to comply with this procedure, users should be cognisant that

in some circumstances a higher standard than the minimum set out in this procedure may be

warranted. In particular, users are also required to:

Exercise their professional judgement and due diligence as to whether this procedure is

appropriate to the particular circumstances;

Bring to the task their knowledge of other relevant industry standards and practices that

should also apply; and

Request from Melbourne Airport, authority to deviate from this procedure, and advise why

such deviation is appropriate.

The use of the information contained in this Standard is at the user’s sole risk. Melbourne Airport, its

officers, employees and agents:

Make no representations, express or implied, as to the accuracy of the information contained

in this procedure;

Accept no liability for any use of the information contained in this procedure or reliance placed

on it; and

Make no representations, either express or implied, as to the suitability of the information

contained in this procedure for any particular purpose.

Melbourne Airport does not endorse, or in any respect warrant, any third-party products or services by

virtue of any information, material or content referred to, included in, or accessible from this

procedure.

Please note that this Standard may be updated from time to time without notice and shall be subject

to Periodic Review. Users are required to check they are referring to the most recent version.

Copyright in this document belongs to Melbourne Airport.



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CONTENTS

1. OVERVIEW ................................................................................................................................................... 7

1.1. PURPOSE .......................................................................................................................................... 7

2. SCOPE .......................................................................................................................................................... 7

2.1. MANDATRY AND NON-MANDATORY REQUIREMENTS .................................................................... 7

2.2. LIMITS OF STANDARD ...................................................................................................................... 7

2.3. DEVIATION FROM STANDARD .......................................................................................................... 8

3. REFERENCES ................................................................................................................................................ 8

3.1. STATUTORY REQUIREMENTS ........................................................................................................... 8

3.2. AUSTRALIAN STANDARDS ................................................................................................................ 9

3.3. MELBOURNE AIRPORT STANDARDS ............................................................................................... 11

3.4. MELBOURNE AIRPORT DRAWINGS ................................................................................................ 11

3.5. RULES, CODES OF PRACTICE AND GUIDELINES .............................................................................. 12

3.6. SELECTION AND INTERPRETATION OF STANDARDS ....................................................................... 12

4. GENERAL REQUIREMENTS ......................................................................................................................... 13

4.1. SUSTAINABILITY.............................................................................................................................. 13

4.2. SAFETY IN DESIGN .......................................................................................................................... 13

4.3. FIT FOR PURPOSE ........................................................................................................................... 13

4.4. LIFE CYCLE COSTING ....................................................................................................................... 13

4.5. MAINTAINABILITY .......................................................................................................................... 14

4.6. TESTING AND COMMISSIONING .................................................................................................... 15

4.7. DURABILITY .................................................................................................................................... 15

4.8. ASSET MANAGEMENT .................................................................................................................... 15

4.9. BUILDING INFORMATION MODELLING .......................................................................................... 16

4.10. APAM ACCREDITED SUPPLIERS & SPECIALISTS .............................................................................. 16

4.11. CONSTRUCTION STAGE PROTECTION ............................................................................................ 17

5. OPERATIONAL PHILOSOPHY ...................................................................................................................... 18

5.1. MECHANICAL SERVICES OVERVIEW ............................................................................................... 18

5.2. DISTRIBUTION NETWORK ............................................................................................................... 18

6. MECHANICAL SERVICES DESIGN CRITERIA ................................................................................................ 19

6.1. INTERNAL & EXTERNAL DESIGN CONDITIONS ................................................................................ 19

6.2. MECHANICAL HVAC INTERNAL DESIGN ......................................................................................... 20

6.3. DESIGN OCCUPANCY AND VENTILATION RATES ............................................................................ 21

6.4. MECHANICAL SERVICES GENERAL DESIGN CRITERIA ..................................................................... 22

7. THERMAL PLANT ....................................................................................................................................... 29

7.1. WATER CHILLERS ............................................................................................................................ 29

8. AIR CONDITIONING EQUIPMENT............................................................................................................... 31

8.1. AIR HANDLING UNITS ..................................................................................................................... 31



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8.2. FAN COIL UNITS .............................................................................................................................. 32

8.3. PACKAGED AIR CONDITIONING UNITS ........................................................................................... 33

8.4. VARIABLE REFRIGERANT VOLUME (VRV) SYSTEMS ....................................................................... 34

9. MECHANICAL EQUIPMENT ........................................................................................................................ 38

9.1. PUMPS ............................................................................................................................................ 38

9.2. FANS ............................................................................................................................................... 39

9.3. HEAT EXCHANGERS ........................................................................................................................ 42

9.4. EXPANSION TANKS ......................................................................................................................... 45

10. DUCTWORK AND ASSOCIATED EQUIPMENT ............................................................................................. 47

10.1. KITCHEN EXHAUST ......................................................................................................................... 48

10.2. ATTENUATORS ............................................................................................................................... 50

10.3. DAMPERS, DIFFUSER’S, GRILLES AND REGISTERS .......................................................................... 51

10.4. AIR FILTERS ..................................................................................................................................... 57

10.5. SPACE HEATING EQUIPMENT ......................................................................................................... 57

11. PIPEWORK AND ASSOCIATED EQUIPMENT ............................................................................................... 59

11.1. PIPEWORK DESIGN CRITERIA ......................................................................................................... 59

11.2. VALVE PROVISIONS ........................................................................................................................ 60

12. CONTROL VALVES ...................................................................................................................................... 63

12.1. AUTOMATIC FLOW CONTROL VALVES ........................................................................................... 63

12.2. DIFFERENTIAL PRESSURE CONTROL VALVES .................................................................................. 63

12.3. PRESSURE INDEPENDENT CONTROL VALVES ................................................................................. 64

12.4. CONTROL VALVE ARRANGEMENTS FOR AHU’S & FCU’S ................................................................ 65

12.5. HIGH TEMPERATURE HEATING HOT WATER CONTROL VALVES .................................................... 67

13. THERMAL ENERGY METERING REQUIREMENTS ........................................................................................ 68

14. MECHANICAL ELECTRICAL INSTALLATIONS ............................................................................................... 69

14.1. MECHANICAL SERVICES SWITCHBOARDS ...................................................................................... 70

14.2. VARIABLE SPEED DRIVES ................................................................................................................ 73

14.3. HARMONIC DISTORTION ................................................................................................................ 74

15. LABELLING AND IDENTIFICATION .............................................................................................................. 75

16. PAINTING AND CORROSION PROTECTION ................................................................................................ 76

16.1. GENERAL ........................................................................................................................................ 76

16.2. HOT DIP GALVANIZING ................................................................................................................... 76

16.3. PAINTING ........................................................................................................................................ 76

16.3.1. GENERAL .......................................................................................................................... 76

16.3.2. GLOSS LEVEL .................................................................................................................... 77

16.3.3. SURFACE PREPARATION .................................................................................................. 77

16.3.4. PAINTWORK SCHEDULE ................................................................................................... 77

16.3.5. APPLICATION OF PAINT ................................................................................................... 77

16.3.6. DAMAGED SURFACES ...................................................................................................... 77

16.3.7. PRE-FINISHES ................................................................................................................... 77

16.4. MATERIALS ..................................................................................................................................... 78

16.4.1. PAINTS ............................................................................................................................. 78



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16.4.2. TOXIC INGREDIENTS ........................................................................................................ 78

16.5. FACTORY APPLIED FINISHED .......................................................................................................... 78

16.6. CLEANING ....................................................................................................................................... 78

17. NOISE & VIBRATION CONTROL REQUIREMENTS ....................................................................................... 79

18. WATER TREATMENT REQUIREMENTS ....................................................................................................... 80

18.1. DESIGN & INSTALLATION REQUIREMENTS .................................................................................... 80

18.2. CLOSED SYSTEMS ........................................................................................................................... 81

18.3. OPEN LOOP SYSTEMS ..................................................................................................................... 82

18.4. FILTER SYSTEMS ............................................................................................................................. 83

18.5. EXECUTION ..................................................................................................................................... 84

19. ACCESS REQUIREMENTS ............................................................................................................................ 87

19.1. DESIGN ........................................................................................................................................... 87

19.2. PLANT ROOMS/ENCLOSURES ......................................................................................................... 87

19.3. ELEVATED ROOF AREAS AND PLANT ACCESS ................................................................................. 87

19.4. WALKWAYS AND GUARD RAILS ..................................................................................................... 88

19.5. CEILING SPACE PLANT ACCESS ....................................................................................................... 88

19.6. SPECIALISED ACCESS ...................................................................................................................... 88

19.7. COMPLIANCE .................................................................................................................................. 88

20. OPERATION OF MECHANICAL SERVICES UNDER FIRE ALARM .................................................................. 90

21. TESTING, BALANCING & COMMISSIONING REQUIREMENTS .................................................................... 91

21.1. ALLOCATION OF COMMISSIONING RESPONSIBILITIES ................................................................... 91

21.2. PRODUCTION OF HANDOVER INFORMATION................................................................................ 95



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Glossary of Terms

Item Description

AHU Air Handling Unit

BMS Building Management System

CFC Chlorofluorocarbon

CHW Chilled Water

CRAC Computer Room Air Conditioning Unit

CU Condensing Unit

db Dry Bulb

DDC Direct Digital Control

DN Diameter Nominal

DOL Direct On Line

FCU Fan Coil Unit

HCFC Hydro chlorofluorocarbon

HTHHW High Temperature Heating Hot Water

HVAC Heating, Ventilation and Air Conditioning

LCD Liquid-Crystal Display

LTHHW Low Temperature Heating Hot Water

MCC Motor Control Centre

MSSB Mechanical Services Switchboard

NCC National Construction Code

TSB Terminal Services Building (Central plant building at Melbourne Airport)

VRV Variable Refrigerant Volume

VSD Variable Speed Drive

wb Wet Bulb



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1. OVERVIEW

1.1. PURPOSE

This Standard has been developed to ensure projects incorporate appropriate APAM

operational and construction requirements in conjunction with best practice.

The Standard is intended for use by APAM, Melbourne Airport tenants, consultants and

contractors undertaking projects within Melbourne Airport’s land.

This Standard must not be used to supersede or replace minimum regulatory Standards or

procedures such as those required by Australian Standard documentation or Work Safe. In

the instance the Standard conflicts with regulatory Standards, please contact the relevant

Project Manager for clarification.

2. SCOPE

The Standard applies to:

Mechanical Services

Air Conditioning Cooling and Heating Systems

Central Chilled Water Plant

High Temperature Heating Hot Water Plant including local Heat Exchangers

Please confirm the relevance of this Standard for your project with the relevant APAM

contact.

2.1. MANDATRY AND NON-MANDATORY REQUIREMENTS

The following terminology describes the requirements of imperative statements within this

Standard:

MUST - describes mandatory requirements;

SHOULD - describes non-mandatory best practice recommendations; and

MAY - describes possible options that are not mandatory or best practice.

2.2. LIMITS OF STANDARD

Users of this Standard shall explicitly demonstrate compliance with this Standard.

Compliance must be demonstrated through:

Adopting appropriate standards and providing explicit reasons for their selection; or

Providing an explicit, evidence based, business case supporting compliance with this

standard.

The general statement “in accordance with Melbourne Airport Standards”, shall not be

deemed acceptable without further detail.

Please check on the applicability of this Standard to Terminal 1 as they may not applicable in

some circumstances.

Questions regarding this Standard shall be addressed to your relevant APAM contact.



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2.3. DEVIATION FROM STANDARD

APAM Standards have been developed from a combination of knowledge, professional

judgement and experiences and must be adhered to at all times. Exemptions to this may

only apply in very limited circumstances, if any.

Where the requirements of this Standard are not able to be met through the design process,

evidence of APAM’s approval for deviation MUST be sought.

Approval of a deviation from this Standard is not guaranteed. Approval of a deviation does

not set a precedent for the same deviation in other projects.

3. REFERENCES

The following normative documents contain requirements which, through reference in this

text, constitute requirements of this Standard. For dated references, subsequent

amendments or revisions must not apply. For undated references, the latest edition of the

normative document referred to applies.

3.1. STATUTORY REQUIREMENTS

All works must be in accordance with the requirements of any Authority having jurisdiction

over them and Melbourne Airport Standards.

National and local Statutory Authorities include:

Victorian Building Authority;

Australian Communications and Media Authority (ACMA);

WorkSafe Victoria;

Safe Work Australia;

Energy Safe Victoria;

The Electrical Regulatory Authorities Council (ERAC

Fire Authority; and

All Local Council regulations.

National and local Regulations include:

OHS Regulations;

Airport (Building Control) Regulations;

Building Regulations;

Public Health Regulations;

Other Codes and Statutory Requirements:

National Construction Code;

Regulatory Compliance Mark (RCM)

Minimum Energy Performance Standards (MEPS



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3.2. AUSTRALIAN STANDARDS

All works must be in accordance with the Australian and other relevant standards such as

those listed below;

AS1055 Acoustics - Description and measurement of environmental

noise

AS 1170.4 Structural design actions, Part 4: Earthquake actions in

Australia

AS 2107 Acoustics - Recommended design sound levels and

reverberation times for building interiors

AS 1324.1 Air filters for use in general ventilation and air conditioning -

application, performance and construction.

AS 1324.2 Air filters for use in general ventilation and air conditioning -

methods of test

AS 1432 Copper tubes for plumbing, gas fitting and drainage applications

AS 1530.3 Methods for fire tests on building materials, components and

structures, Part 3: Simultaneous determination of ignitability,

flame propagation, heat release and smoke release

AS 1571 Copper - Seamless tubes for air-conditioning and refrigeration

AS 1670.1 Fire detection, warning, control and intercom systems - System

design, installation and commissioning Fire

AS 1668.1 Fire and smoke control in multi-compartment buildings

AS 1668.2 Mechanical ventilation for acceptable indoor air quality

AS 1668.4 The use of ventilation and airconditioning in buildings, Part 4:

Natural ventilation of buildings

AS 2310 Glossary of paint and painting terms

AS 2311 Guide to the painting of buildings

AS 3000 Electrical installations (known as the Australian/New Zealand

Wiring Rules)

AS 3666.1 Air-handling and water systems of buildings - Microbial control,

Part 1: Design, installation and commissioning

AS3666.2 Air-handling and water systems of buildings - Microbial control,

Part 2: Operation and maintenance

AS 4041 Pressure Piping

AS 4254.1 Ductwork for air-handling systems in buildings, Part 1: Flexible

duct

AS 4254.2 Ductwork for air-handling systems in buildings, Part 2: Rigid

duct



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AS 4417.1 Regulatory compliance mark for electrical and electronic

equipment Use of the mark

AS 4417.2 Regulatory compliance mark for electrical and electronic

equipment Specific requirements for particular regulatory

requirements

AS 4426 Thermal insulation of pipework, ductwork and equipment -

Selection, installation and finish

AS 4536 Life cycle costing - An application guide

AS 5149.1 Refrigerating systems and heat pumps - Safety and

environmental requirements, Part 1: Definitions, classification

and selection criteria (ISO 5149-1:2014, MOD)


environmental requirements - Part 3: Installation site (ISO 5149-

3:2014, MOD)


environmental requirements - Part 4: Operation, maintenance,

repair and recovery (ISO 5149-4:2014, MOD)

AS 5601.1 Gas installations - Part 1: General installations

Other Relevant Standards:

ANSI/ASHRAE Standard 55 Thermal Environmental Conditions for Human Occupancy

ANSI/ASHRAE Standard 140 Standard method of test for evaluation of building energy

analysis computer programs

AHRI 460 Performance rating of remote mechanical -draft air-cooled

refrigerant condensers

AHRI 551/591 Performance rating of water chilling and heat pump water

heating packages using the vapour compression cycle

EU Regulation 547/2012 Ecodesign requirements for water pump

EU Regulation 622/Ann II, 2 Ecodesign requirements for glandless circulators and

glandless circulators integrated in products

https://www.standards.org.au/standards-catalogue/sa-snz/manufacturing/me-006/as-slash-nzs--5149-dot-1-colon-2016--amd--2-colon-2018



https://www.standards.org.au/standards-catalogue/sa-snz/manufacturing/me-006/as-slash-nzs--5149-dot-3-colon-2016








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3.3. MELBOURNE AIRPORT STANDARDS

All works must be in accordance with the requirements of key APAM Engineering Standards

listed below as a minimum but not necessarily limited to

MAS-ELC-001 Low Voltage Systems

MAS-ELC-002 High Voltage Systems

MAS-ELC-003 Low Voltage Switchboard Design

MAS-ELC-004 High Voltage Safety and Operational Procedures

MAS-ELC-005 Aeronautical Ground Lighting

MAS ELC 006 EMCS Engineering Standard

MAS-FPR-001 Fire Protection, Public Address, EWIS and Hearing Loops

MAS-GEN-004 Maintainability

MAS-GEN-005 Computer Aided Drafting

MAS-GEN-006 Asset Identification Information

MAS-GEN-008 Employer’s Information Requirements for Digital Engineering

MAS-GEN-009 Digital Engineering Technical Standard

MAS-GEN-010 Survey to BIM Technical Standard


MAS-MCH-001 Mechanical Services Design Brief

MAS-MCH-007 Automated Controls and Building Management System

MAS-ITC-001 APC Comms room equipment layout and commissioning standard

MAS-ITC-002 CCTV Design Standard

MAS-ITC-003 Airport Comms Distributor Spatial Requirements

MAS-ITC-004 Communications Rooms & Spaces - Standard

MAS-ITC-005 Radio Communications Installation Standards

MAS-ITC-006 Structured Cabling Standard

MAS-ITC-007 Access Control

MAS-ICT-008 CCTV Camera Design Standard

3.4. MELBOURNE AIRPORT DRAWINGS

Master Electrical & Mechanical drawings are controlled by APAM which include site-wide

schematic drawings and zone layouts. For tender documentation the engineer is to ensure

any proposed changes are marked up for APAM Digital Engineering Team team to update.

On completion of the project the head contractor is to ensure as-built changes are marked

up for APAM CAD team to update.



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3.5. RULES, CODES OF PRACTICE AND GUIDELINES

The Mechanical Services should be designed in accordance with AIRAH Application

Manuals where applicable;

DA01 Centrifugal Pumps

DA02 Noise Control

DA03 Ductwork for Air conditioning

DA09 Air Conditioning load estimation

DA13 Fans

DA15 Air Filters

DA16 Air Conditioning Water Piping

DA17 Cooling Towers

DA18 Water Treatment

DA26 Indoor Air Quality

DA28 Building Management and Control Systems

3.6. SELECTION AND INTERPRETATION OF STANDARDS

All mechanical works must be carried out in compliance with appropriate legislation and

standards and APAM requirements. The order of precedence must be as follows:

1. Legislation,

2. Standards and Codes required by legislation,

3. APAM standards,

4. Standards and reference documents referred to in APAM standards

Consultants must accept responsibility for the selection and use of relevant Australian,

International and APAM standards. Although a number of standards and drawings are

specified in this document they are not definitive and it is the responsibility of Consultants to

fully acquaint themselves with the various standards and select those that are relevant in

meeting specific APAM project requirements.



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4. GENERAL REQUIREMENTS

4.1. SUSTAINABILITY

Users of this Standard must demonstrate that consideration for the whole of life has been

undertaken ensuring sustainability has been optimised. Whole of life includes

implementation and operation through to decommissioning and disposal.

Works in accordance with this Standard must consider both its effect on and how it will be

affected by the following:

Economic

Social

Environmental

Security

Operation and Maintenance

The User of this Standard must make use of historical, current and projected / forecasted

information when assessing the Sustainable Design for the whole of life.

Users must apply the principles of harm minimisation. Wherein scientific doubt must not be

used as a reason to avoid undertaking preventative measures

4.2. SAFETY IN DESIGN

All design and construction activities must appropriately consider and incorporate safety in

design and construction. This must include construction work, accessibility, operational and

maintenance consideration.

All projects must incorporate Safety is Design requirements in accordance with Occupational

Health and Safety Act 2004 and Occupational Health and Safety Regulations 2017. Also

refer to Model Work Health and Safety Act and Regulations 2019.

4.3. FIT FOR PURPOSE

All services, equipment and devices to be installed on APAM projects must be fit for the

intended operational purpose.

Fit-for-purpose means in the context of the Works, that the Works are fit for their intended

purposes, functions and uses as specified in, or reasonably inferred from, standard industry

practice.

The fit-for-purpose must incorporate the life cycle cost elements, in particular accessibility,

maintainability, operational factors to ensure ease of maintenance, minimisation of energy

consumption, economic considerations and effective utilisation of operational personnel

4.4. LIFE CYCLE COSTING

A whole of life view must be taken for all design decisions taken during the design of

mechanical systems. Consequently, the specification and selection of systems, products and

materials must be considered over a product life cycle and not merely based on initial capital

cost. Therefore, Life Cycle Costing (LCC) must consider the initial capital cost, operational



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costs (e.g. energy usage and cost), and longevity and maintenance costs. This can be

described as:

LCC = Cost of (initial capital + repairs + maintenance + operation + energy + disposal)

Where:

Initial Capital Cost includes removal of redundant existing equipment and

pipework/ductwork, design, project management, installation/construction, testing and

commissioning and handover.

Repairs include unplanned non-maintenance activities.

Maintenance includes such items as recurrent work (e.g. filter replacement), lubrication,

calibration, software upgrade or replacement. Note that some systems or equipment

elements may have a reduced life compared with the rest of the installation. These need to

be replaced at appropriate times and due allowance is required to be made in maintenance

plans and procedures.

Operation relates to those activities that are required to ensure proper on-going functionality

of the installation and equipment. It is important that Designers consider this aspect fully;

otherwise additional downtime, staffing and shift work may be unnecessarily required.

Energy is total energy (usually in kWh) required to effectively operate the plant, system or

installation over their operational life.

Disposal is the activity incurred at the end of the equipment or installation life and includes

demolition, removal from site and appropriate disposal. In addition, some equipment may

contain toxic or hazardous components which may require to be disposed by specialist

organisations at significant cost.

In most instances there are competing products, services and systems available in the

market and it is expected that various options are considered and suitable recommendations

and selections made on a life cycle costing basis. Any design change must be able to be

justified in this way.

LCC is required to consider that equipment or systems may have elements incorporating

different useful lives. It is expected that comparative LCC be demonstrated as the basis for

the selection of all systems, products and materials when fitness-for-purpose has been

established.

Refer to AS/NZS 4536-1999 Life Cycle Costing for guidance of what factors must be

considered in assessing life cycle costs.

4.5. MAINTAINABILITY

All mechanical services systems and equipment must be designed to easily facilitate safe

and efficient maintenance to be carried out by competent APAM staff and Licensed

Mechanical Contractors. Due consideration must be made regarding equipment location and

clearances to ensure safe working practices can be implemented during routine

maintenance.

Ensure that all As-Built documentation and Operation & Maintenance manuals are created

or updated as part of the project works.



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All equipment and system to incorporate Maintainability requirements as specified in APAM

Standard MAS-GEN-004 Maintainability

4.6. TESTING AND COMMISSIONING

Testing and commissioning must be carried out in accordance with appropriate APAM,

ASHRAE, CIBSE, Australian Regulations and Australian Standard guidelines as follows;

AS 1668.1 Fire and smoke control in multi-compartment buildings (commissioning of

smoke control systems)

NEBB (National Environmental Balancing Bureau) Procedural Standards

CIBSE Code A: Air Distribution Systems

CIBSE Code B Boilers

CIBSE Code C: Automatic Controls

CIBSE Code M Management

Code R: Refrigeration

CIBSE Code W: Water distribution systems

ASHRAE Standard 111 - Measurement, Testing, Adjusting, and Balancing of Building

HVAC Systems

ASHRAE Guideline 0 –Commissioning Process for Existing Systems

ASHRAE Guideline 1.1 – The HVAC Commissioning Process

4.7. DURABILITY

The minimum design life requirements for Mechanical Services systems must be as listed

below:

Boilers >25 years

Chillers (water cooled) >25 years

Cooling Towers >25years

DX Air Conditioning Systems >15 years

HEX >25 years

Pipework and valves >40 years

Where equipment is not listed above, the minimum design life requirements must be as in

accordance with AIRAH’s Economic Life of Equipment:

4.8. ASSET MANAGEMENT

APAM aims to maintain international best practice in Asset Management by aligning out

projects and standards with ISO55000. The APAM Design Standards for Mechanical

services aims to deliver assets that provide lowest lifecycle costs for APAM and our

stakeholders. To achieve our objectives, accurate Asset Information is crucial. The lifecycle

management of our assets is governed by our Asset Management Framework, which

defines the APAM Asset Management Policy, Strategic Asset Management Plan and the

Asset Management Plan.



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The Asset Management Plan (AMP) defines the minimum Asset Management System

Requirements that form part of the Contractor’s deliverable, including but not limited to:

MAS-GEN-006 Asset Identification Information Standard

MAS-GEN-008 Employer’s Information Requirements for Digital Engineering

Standard

4.9. BUILDING INFORMATION MODELLING

APAM’s vision for utilising BIM extends beyond documentation of drawings, but is intended

to be leveraged to:

Improve stakeholder engagement during the design process

Improve coordination between services during design and construction phases

Facilitate Safety in Design and Hazard review issue identification and issue tracking

Asset Capture and management (refer Section 4.8)

Improve program planning

Allow consistent use of industry recognised classification system – Uniclass2015

Production of As Built information

In order to achieve the above vision, all works are to be implemented in accordance

with the following reference documents;

MAS-GEN-008 Employer Information Requirements for Digital Engineering Standard

APAM Information requirements to enable the creation and management of the

Project Information Model to support the ongoing Asset Information Model


The APAM template to be used by Delivery Teams to define their approach to the

Project Information Requirements. The document outlines who is responsible for

what in the BIM process, when in the process they are responsible for it, and how

they will execute APAM requirements as specified in the MAS-GEN-008 EIR for

Digital Engineering.


APAM Digital Engineering technical requirements outlining specific technical

requirements in relation to delivery of the APAM Information Requirements

4.10. APAM ACCREDITED SUPPLIERS & SPECIALISTS

APAM aims to maintain consistency with design and operational practices. The following

stakeholders / specialist suppliers are to be coordinated with during design development of

Mechanical services systems;

Accredited suppliers and specialist contractors are listed as “Manufacturer” within this

standard. Any diversion from APAM preferred manufacturer list must be agreed formally in

writing with APAM prior to installation.



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4.11. CONSTRUCTION STAGE PROTECTION

Construction work at Melbourne Airport will typically involve systems and areas in operation.

All works must consider the operational nature of the airport with an aim of reducing impact

to areas that are required to maintain continuous operation.

The design and installation considerations must include, but not be limited, to the following:

Relocation and protection of temperature sensors during construction including

reinstatement of sensors at completion of works.

Continued provision of Chilled Water and Heating Hot Water to existing air

conditioning equipment as required when installing new air conditioning plant,

including use of hot tapping into live systems when safe to implement,

Continued operation of life safety equipment, such as smoke exhaust systems, with

any shut down period to be coordinated with APAM and the Fire Engineer,

All existing air intakes must be protected from construction activities with filters, etc.



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5. OPERATIONAL PHILOSOPHY

5.1. MECHANICAL SERVICES OVERVIEW

Terminals 1, 2, 3 & 4 are currently served via central thermal energy plant located within

three Terminal Services Buildings (TSBs); TSB1, TSB2 and TSB3.

TSB 1 was initially constructed in 1970 as part of the original airport works. TSB2 was

subsequently built as part of the Qantas Domestic terminal Expansion Project in 1999. TSB

3 was built adjacent to TSB 1 in 2015/2016 and houses Trigeneration plant and absorption

chillers.

Terminal Services Building No 1 (TSB1) - Serves part of Terminals T1 & T4 and all of

T2 and T3 which comprises of Chilled and High Temperature Heating Hot Water

services

Terminal Services Building No 2 (TSB2) - Serves Qantas Domestic Terminal Stage 2

and Qantas Domestic Concourse B which comprises of Chilled and High

Temperature Heating Hot Water services

Terminal Services Building No 3 (TSB3) - Tri-generation System which provides

Chilled and Heating Hot Water via TSB1.

5.2. DISTRIBUTION NETWORK

The chilled and heating hot water is distributed throughout the airport via underground

pipework distribution tunnels that run beneath the terminal buildings.

The tunnels run parallel to the main terminal buildings and feed each zone via field

branches. See sketch for further indication.

The CHW and HTHHW sub mains have pipework branches that feed mechanical services

plantrooms typically located on Apron level. From these plantrooms the CHW and LTHHW

(via heat exchangers) is distributed to other plantrooms and local air conditioning equipment.



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6. MECHANICAL SERVICES DESIGN CRITERIA

The recommended design criteria for the mechanical services at Melbourne Airport are

provided in the tables below:

6.1. INTERNAL & EXTERNAL DESIGN CONDITIONS

Table 6-1 Mechanical Services – External Design Conditions

Season Temperature °C

Summer 39.8 °C Dry bulb

23.5 °C Wet bulb

Winter 0.6°C Saturated

Table 6-2 Mechanical Services – Internal Design Conditions

Area Temperature Humidity

Landside Arrivals, Baggage

Reclaim, Landside Departures,

Airside Departures and Arrivals

(“Terminal”)

22.5 °C ±2°C Not Controlled

Circulation Area 22.5 °C ±2°C Not Controlled

Aerobridge 22.5 °C ± 4°C Not Controlled

Fixed Link Bridge 22.5 °C ± 4°C Not Controlled

Retail 22.5 °C ±2°C (subject to tenant

requirements) Not Controlled

Office Tenancies 22.5 °C ± 1.5°C Not Controlled

Border Force 22.5 °C ± 1.5°C Not Controlled

Customs 22.5 °C ± 1.5°C Not Controlled

Comms Rooms 20 - 25°C 40-80%

WCs (where air conditioning is

provided) 22.5 °C ± 2°C Not Controlled

Internal Plantrooms Not Conditioned Not Controlled

Notes:

1. Relative humidity is used as a design target for peak sensible load conditions for specifying

plant. Relative humidity is not directly controlled (unless specified) and actual space humidity

conditions may vary depending on external ambient conditions and occupancy level.

2. Nominal tenant conditions. Final conditions under tenant control.

3. Refer to APAM for further Aerobridge requirements



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4. Refer to MAS-ICT-004 for further Comms Room requirements, including duty / standby

provision.

5. Larger WCs must be air conditioned. Single/small WCs to be provided with exhaust only with

makeup air from adjacent space.

6.2. MECHANICAL HVAC INTERNAL DESIGN

The following table details typical indoor heat loads at Melbourne Airport that must be

considered during design of HVAC equipment:

Table 6-3 Internal Design Loads

Space

Occupants

Power W/m² Additional

Gains W/m² Sensible

W / person

Latent W /

person


Reclaim, Landside

Departures, Airside

Departures and Airside

Arrivals (“Terminal”)

70 80 5 2

Circulation Area 70 80 5 2

Aerobridge 64 86 5

Fixed Link Bridge 64 86 5

Retail (General) 70 60 5

Retail (Food & Beverage) 80 80 5

Office Tenancies 70 60 15

WCs 70 60 5

Border Force 70 60 15

Customs 70 60 15

Comms/Server Rooms - - 50 To be advised

by APAM

Unallocated Area

Total allowance

for internal gains:

50 W/m²

Notes:

1. Baggage Handling areas are unconditioned spaces. Radiant heaters and fans should be

provided for occupant comfort.

2. Internal Plantroom loads must be assessed on an individual basis dependant on the

equipment located within.

3. Lighting Load allowance to be in accordance with NCC Part J6



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6.3. DESIGN OCCUPANCY AND VENTILATION RATES

The following table details design occupancy and ventilation rates at Melbourne Airport that

must be used design of HVAC equipment:

Table 6-4 Occupancy and Ventilation rates

Space Occupancy

(m²/person)

Outside Air

Supply Rate

(L/s/m2

Outside Air

Supply Rate

(L/s/person)

Design Exhaust

Rate


Reclaim, Landside

Departures, Airside

Departures and Airside

Arrivals(“Terminal”)

To be assessed on

a project basis in

conjunction with

APAM

7.5

Circulation Area 10 7.5

Fixed Link Bridge 1 10

Retail (General) 3.5 10

Retail (Food & Beverage) 1.5 10

Office Tenancies 10 7.5

Border Force 10 7.5

Customs 10 7.5

WCs Nil or 90% of

Exhaust rate

where conditioned

As per AS 1668.2

Notes:

1. Generally, ventilation for all areas to comply with 1668.2. Where space requirements are not

defined in either the above table or AS1668.2 then APAM to confirm requirements.

2. Notional outside air ventilation rate to tenancies. Actual rate under tenant control. Minimum

requirements in accordance with AS 1668.2.

3. Typically, areas with exhaust systems to have balanced air flow, provide makeup as required.

4. Appropriate air filtration to be provided to enable outdoor air rates to be reduced below

AS1668.2 minimum outdoor air flow rates listed in Appendix A.



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6.4. MECHANICAL SERVICES GENERAL DESIGN CRITERIA

Table 6-5 General Design Criteria

Item Parameter

Chilled Water Operating

Temperatures (TSB1)

CHW Flow Temperature: 6°C

CHW Return Temperature:14°C

Chilled Water Operating

Temperatures (TSB2)

CHW Flow Temperature: 6°C

CHW Return Temperature:13°C

Chiller Condenser Water

Operating Conditions (TSB1)

Entering Water Temperature: 28.5°C

Leaving Water Temperature: 34.2°C

Chiller Condenser Water

Operating Conditions (TSB2)

Entering Water Temperature: 29.5°C

Leaving Water Temperature: 35.0°C

High Temperature Heating Hot

Water Primary Operating

Temperatures (TSB1)

HTHHW Flow Temperature: 165°C

HTHHW Return Temperature: 140°C


Water Secondary Operating

Temperatures (TSB1)




Water Primary Operating

Temperatures (TSB2)




Water Secondary Operating

Temperatures (TSB2)



Low Temperature Heating Hot

Water Operating Temperatures

LTHHW Flow Temperature: 80°C

LTHHW Return Temperature: 60°C



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Item Parameter

Pipework Design Pressure

Drop/Velocity

CHW

Pressure Drop:≤300Pa/m

Min Velocity: ≥0.75m/s

Max Velocity:≤2.4m/s

Minimum Pipework size: 20mm

LTHHW

Pressure Drop: ≤300Pa/m

Min Velocity: ≥0.75m/s

Max Velocity: ≤2.4m/s

Minimum Pipework size: 20mm

HTHHW

Pressure Drop:<300Pa

Max Velocity: 2.4m/s



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Item Parameter

Pipework Materials

CHW

Pipework ≤100diameter to be copper

Pipework ≥125diameter to be steel

Copper pipework

hard drawn AS 1432 Type A or B

Steel:

ANSI/API Spec 5L grade B / ASTM A53M grade B

Schedule 40 ASME B36.10

CCW

Stainless steel

ASTM A312 grade 316

schedule 40S ASME B36.19M, or

Steel

ANSI/API 5L grade B / ASTM A53M Grade B;


LTHHW:

Pipework ≤100diameter to be copper

Pipework ≥125diameter to be steel

Copper pipework

hard drawn AS 1432 Type A or B

Steel:

ANSI/API Spec 5L grade B / ASTM A53 grade B


HTHHW:

Pipework to be steel seamless type

ANSI/API Spec 5L grade B / ASTM A106M grade B


Gas

Copper or Steel AS5601

Drains

Copper AS1432 Type A or B



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Item Parameter

Pipe Jointing

Copper

≤50mm Crimp/Press Fit Veiga

>50mm Brazed

CHW Steel

≤50mm Screwed

>50mm Victaulic/Welded

LTHHW Steel

≤50mm Screwed

>50mm Welded (Victaulic joints are not permitted)

HTHHW

Welded (The use of Flanges is limited to the connection of equipment

and is typically not permitted unless approved by APAM)

Note:

Victaulic joints are not permitted for HTHHW pipework

Where flanges are installed in HTHHW systems gaskets to be

supplied by; Donit Tesnit, Type; Grafilt SP (graphite with a

tonged stainless steel insertion)

Radiographic Inspection (HTHHW): 10% of all welds must be

radiographic tested by independent testing organisation

Heating Pipework – Expansion

Fittings Design of expansion fittings to be in accordance with AS4041

Expansion Bellows To be supplied by Aflex

Pipework – Working Pressure

CHW

1,000kPa

LTHW:

1,000kPa

HTHHW:

1,500kPa



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Item Parameter

Pipework Hydrostatic Test

Pressure

CHW

The greater of 1000kPa or 1.5 x working pressure

CCW

1.5 x working pressure

LTHHW


HTHHW


Diversified Cooling and Heating

Capacity (For Infrastructure

assessment only)

Diversity rates to be used for future thermal plant assessments;

CHW: 60% (nominal)

HTHHW: 60% (nominal)

APAM to confirm specific diversity rates to be applied for each project

CHW/HHW Energy Meters

Provide energy meters for the following;

All branches from main distribution pipework

All main branches ≥100mm

Heat exchanger (LTHHW side)

APAM to confirm requirements for each project

Air Filters

FCUs / Supply Air Systems <1000l/s

Panel filter F5 (100mm deep). Max Initial Pressure Drop: 60Pa @

2.5m/s, Dirty Filter Pressure 125Pa

AHUs / Supply Air Systems >1000l/s

Pre filter: G4 Panel (100mm deep). Max Initial Pressure Drop: 60Pa @

2.5m/s. Dirty Filter Pressure 125Pa

Secondary Filter: F7 Deep bed (600mm deep). Max Initial Pressure

Drop: 80Pa @ 2.5m/s. Dirty Filter Pressure 200Pa

Carbon filters

Where required, provide Activated Carbon filters in addition to the air

filters specified above: Airpure Australia PM18 (450mm deep). Max

Initial Pressure Drop: 120Pa @ 2.5m/s (refer filter section 10.4 for

details).

Kitchen Exhaust

Kitchen Exhaust: Ultra-violet filtration system, refer section 10.1



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Item Parameter

Comms Rooms

Redundancy N+1

Where CHW cooling is utilised for Comms rooms also provide DX air

conditioning units for redundancy. In this scenario redundancy to be

2N.

Air conditioning units to include the following;

Auto restart on power failure

Proprietory controls that enable duty/standby operation

Leak detection

BMS HLI

Pipework must not to be installed within Comms rooms where possible.

Where pipework is installed within Comms room drip tray to be installed

below all pipework complete with leak detection sensors.

For Comms rooms with gas suppression provide locally controlled

mechanical exhaust (discharge to outside) and pressure relief.

Central Plant Redundancy Chillers, Boilers, Cooling Towers and Secondary pumping systems

redundancy: N+1

Ductwork Pressure

Classification (AS4254.2)

Pressure Class: 501-750Pa, Seal Class: B

Small unitary systems: Pressure Class: 251-500Pa, Seal Class: C

Ductwork Leakage

All ductwork must be sealed and air leakage tested in accordance with

AS4254.2 section 2.2, and

Air leakage tested in accordance with: <1.25l/s/m2 surface area at

750Pa

Air distribution performance ADPI >80% ASHRAE 113

Motor Rating High efficiency motors minimum: IE3 ICC Standard 6034

Motors to be >130% of motor power input

Equipment Spare Capacity

Pump: impeller <90% of the largest impeller the casing can

accommodate

Fans: ≥ 10% above the design flow rate

Pipework Mains: ≥20% design flow rate

Pipework and Ductwork

Insulation In accordance with BCA Part J

Metal Sheathing All pipework insulation: 0.5mm zinc anneal

All metal sheathing must be painted



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Item Parameter

Internal Noise Criteria

(mechanical services)

Maximum Mechanical Equipment noise level: 85dBA @ 1m

Landside Arrivals, Baggage Reclaim, Landside Departures, Airside

Departures: 45 NR

Circulation: 45 NR

Offices: 40 NR

Baggage Handling: <70 NR Security Check: 45 NR

Mezzanine Plant Areas: 45 NR (External to room) Comms/Server

Rooms: 45 NR (External to room) Internal Plantrooms: <75 NR

WCs: 45 NR

Infiltration 0.5 ACH

2ACH - Where space is adjacent to external entry/exit

Mechanical Plant Efficiency In accordance with NCC Section J

Vibration Isolation

Rotating equipment >98% efficiency

pumps to have inertia base

All equipment to have seismic mounts

Seismic Restraints Provide seismic restraints to ensure compliance with AS 1170.4

Tundish Provide trapped drain Tundish to all relevant equipment

BMS Refer to APAM Standard – MAS-MCH-007 – Automatic Controls and

Building Management Systems for requirements



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7. THERMAL PLANT

7.1. WATER CHILLERS

Below are the general requirements for the thermal and hydronic plant and equipment at

Melbourne Airport:

Table 7-1 Chillers

Item

General Water cooled chillers must be in accordance with the following standards: BCA

2012 Part J requirements; AS 1210; AS 1677; AS3666; AS 4776.2

Requirements

Chillers to be factory-assembled packaged fully automatic chiller sets, of proven

performance for the specified capacity and operating conditions

Comprising a single centrifugal variable speed compressor, motors, flooded shell

and tube evaporator(s) and condenser(s)

Full colour screen using advanced active-matrix display technology control

centre and equipped with the components and accessories necessary for

satisfactory operation, including but not necessarily limited to, integral piping,

unit-mounted controls, electrical wiring, thermometers, LCD screen display and

the like.

Compressor

Single-stage centrifugal compressor must be powered by either a direct drive

hermetic, oil free, permanent magnet type, refrigerant cooled motor which are all

factory pre-aligned

To maximise chiller performance, the Adaptive Control logic must have the

capability to memorise and map all friendly surge conditions thereby providing

stable operation with the slowest motor speed relevant to the operating

conditions.

Compressor must be equipped with discharge and suction shutoff (isolating)

valves as standard

Capacity control must be provided by variable speed drive and inlet guide vanes,

capable of reducing unit capacity to 15% of full load (at ARI 550/590 standard

part load conditions). Compressor must start unloaded and current inrush must

be limited by control to less than 105% of full load amps

Cooler

Must be flooded shell and tube type with high-efficiency enhanced copper tubes

which are rolled expanded into mild steel tube plates. Tubes must be

mechanically cleanable.

Shell must be insulated with 19mm closed-cell, foam (max K factor of 0.28) and

fitted with a vapour barrier

Condenser

Marine water boxes must be factory inclusive with hinged end plates and be a 2

Pass arrangement, inclusive with a water-side drain and vent.

As part of the chiller package, an Impressed Current Condenser Protection

System must be provided with each centrifugal, including installation,

commissioning and periodic maintenance.

Provide Water Boxes



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Item

Operating Unit must be capable of starting up with 30C entering fluid temperature to the

evaporator

Characteristics cooler and maintain continual stable operation with a minimum 10.0C entering

condenser water temperature.

Condenser Water

Temperature

Entering 28ºC

Leaving 36 ºC

Evaporator Water

Temperature Refer to section 6.4 Design Criteria

Refrigerant GWP Low GWP (<10 GWP) refrigerant

Consult manufacturer for guidance

Refrigerant Safety

Classifications

AS/NZS ISO 817

Preferred: A1

Acceptable: A2L - if installed in accordance with relevant standards and

regulations, including but not limited to AIRAH Flammable Refrigerants Safety

Guide (FRSG-2018-Update)

Evaporator Hazard

Class AS 4343 E

Evaporator Internal

Inspection Required

AS 3788

No

IPLV Rating Full Load: 12 (AHRI conditions)

Cathodic Protection Impressed Current

Electrical

Unit will be provided with an external main power disconnect switch located on

the VSD door.

Unit must operate on 3-phase power at the 400 ± 10% volts 50Hz. Control

voltage must be 24 V.

Unit must be shipped with factory control and power wiring installed.

Power factor must be a minimum 0.97 (compressors only) at all operating loads.

Each VSD must be provided factory inclusive with an Active Harmonic Filter

complying with IEEE Standard 51992.

Selection of HV or LV subject to review with APAM

Manufacturer Trane, Carrier or York



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8. AIR CONDITIONING EQUIPMENT

Below are the general requirements for the mechanical Air Conditioning plant and equipment

at Melbourne Airport:

8.1. AIR HANDLING UNITS

Table 8-1 Air Handling Units

Item

General AHU’s must be in accordance with: AS1668.1; AS1668.2, AS4254.2, AS3666.1

Construction

Rigid extruded aluminium frame;

Fully welded galvanised steel channel base Panels of Colorbond inner and

outer skin with rigid polystyrene core;

Hinged access doors with handles;

Fan motor and drive mounted on a common rigid base;

Fan assembly mounted on springs;

Flexible connection between fan and unit air outlet spigot;

Stainless steel condensate tray;

Coils are copper tube, aluminium fins and galvanized steel frame

construction;

Space with access doors between heating and cooling coils for

maintenance and cleaning;

Horizontal and vertical configurations;

Access doors for accessing filters and both side of the coils;

Weatherproofing for external applications;

Accessible internal sections to be provided with dedicated lighting with

switches mounted externally to the unit.

Arrangement of

Components

Even air distribution maintained across face of all components, air speed not to

vary by more than ±20% of the mean value

Drain trays must be provided having water-sealed traps with outlets extended to

the edge of the unit. Trap seals must be equal to the maximum operating

pressure within the relevant section of the unit.

Corrosion-resistant drain trays must be incorporated to collect and fully drain

away condensate, including any condensate from adjacent sections and internal

pipework.

Removal of

Components

Pipe connections must be arranged to allow individual components to be removed

without disturbance to other items of equipment and pipework.

Sufficient access space must be provided on the maintenance access side of the

unit to allow any individual component to be removed and replaced.



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Item

Access Doors &

Panels

Removable panels must be provided not be more than 0.5m high. A hinged

lockable door must be provided above 0.5m.

Lockable access doors or pane for each section of the air handling plant that is

not readily accessible by other means must be provided. All access openings

must be sized for man access.

Corrosion A corrosion resistant finish must be provided with a minimum 2 coat paint finish

Protection to mild steel frame sections.

Cooling Coils Face Velocity of coils limited to 2.5m/s at design conditions

Heating Coils Face Velocity of coils limited to 3.5m/s at design conditions

Maximum Pressure

Drop

Cooling coils: Max Water ΔP = 45kPa, Air ΔP = 100Pa Heating coils: Max Water

ΔP = 30kPa, Air ΔP = 50Pa

Direct Expansion

Cooling Coils Copper tube must be of refrigeration quality in accordance with AS 1571

Heat Recovery

Devices

Provide Air to Air or Thermal Wheel Heat Recovery units

Where airside energy recovery devices are provided, a dedicated 100% outside

air bypass must also be provided to allow central air handling equipment to

operate in full economy mode

Fans and Drives EC Plug Fans preferred

Manufacturer GJ Walker, Air Change or Trane

8.2. FAN COIL UNITS

Table 8-2 Fan Coil Units

Item

General FCU’s must be in accordance with: AS 1668.1; AS1668.2, AS 4254.2;

AS3666.1, ASHRAE 79 & AHRI 440

Construction

1.2mm thick galvanised sheet steel panels;

25mm insulation at 32kg/m³;

U factor : 1.0W/m2/K;

Stainless steel condensate tray;

Forward curve double inlet direct drive fans;

Coils are copper tube, aluminium fins and galvanised steel frame

construction; and

Horizontal and vertical configurations.

Coils

Copper tube, aluminium fin and heavy gauge steel construction Max Water ΔP =

40kPa

Coils must be fitted with bleed valves



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Item

Fans and Drives EC Plug Fans preferred

Drip Trays

An insulated corrosion resistant drain pan must be graded to a screwed outlet

extending beyond cooling coil and chilled water or refrigeration connections.

Leak detection tape or a high level switch must be provided to all drain pans and

linked to the BMS to facilitate early identification of significant leaks and / or

drain blockages.

Manufacturer Trane, GJ Walker or Temperzone.

8.3. PACKAGED AIR CONDITIONING UNITS

Table 8-3 Packaged Air Conditioning Units

Item

General

Package units include one piece and split direct expansion (DX) packaged air

conditioning plant.

PAC Units must be in accordance with: AS 1217; AS 1530.3; AS 1571; AS

1668.1; AS 1668.2; AS5149.3; AS 1861.2; AS 3350.2.40; AS/NZS 3823.1.1

Type

PAC Units must comprise of cooling coil, fan, compressor, condenser, filter and

pre-wired electrical panel with controls

Units must be reverse cycle type

PACs must be mounted on anti-vibration neoprene pads. Intake and discharge

ducts must have flexible connections Provide a trapped condensate drain to

each cooling coil

Coils

Direct expansion coils must be selected for a minimum of 3°C superheat at full

load.

Condenser coils must be corrosion protected with Heresite or Melbourne Airport

approved equal treatment.

Condensing coils must be arranged so that liquid refrigerant can gravitate to the

outlet header without being trapped in the coil.

Air Filters Differential pressure monitoring must be provided across filter beds, complete

with BMS connection for remote monitoring, such that filter cleanliness can be

monitored and preventative maintenance flagged.

Fan Supply air fan must be forward curved centrifugal type with adjustable speed

drive complete with vibration isolation mountings.

Compressor

Single compressor: If the condensing unit incorporates only one compressor,

provide inverter speed control of the compressor to vary the unit capacity over a

range from the maximum capacity of all indoor units combined to the minimum

capacity of the smallest capacity indoor unit.

Multiple compressors: If the condensing unit incorporates more than one

compressor, provide inverter speed control on at least one compressor so that

the combination of compressors can vary the unit capacity over a range from

the maximum capacity of all indoor units combined to the minimum capacity of

the smallest capacity indoor unit



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Item

Refrigerant Refrigerant type must be a single component, azeotropic or zeotropic mixture.

Units must use R407c or R410a or R134a refrigerant.

Mounting Location The external unit must be installed in a suitable location that does not cause any

detrimental impacts due to jet fuel residue/fumes.

Manufacturer Mitsubishi or Daikin

8.4. VARIABLE REFRIGERANT VOLUME (VRV) SYSTEMS

Table 8-4 VRV Systems – General

Item

General

VRV systems must be air cooled, split type multi system air conditioner

Equipment must consist of singular condensing units connections to multiple fan

coils, the condensing unit must be able to control multiple different type and

capacity fan coil units to be controlled individually

Units must be Heat Recovery type

Control

To incorporate the following:

On/off switching

Fan speed selector

Thermostat setting and LCD indicating temperature setting

Operational mode

Malfunction code and filter cleaning timing.

Individual controller per room Grouped unit control must include:

Establishment of a building zone management system

Individual controller functions except fan speed selection per zone

Enable or inhibit individual controller functions of on\off switching

Temperature setting and operational mode

Minimum 7 days, 8 time schedules, 2 on \ off per day allocated by zone

Individual room on\off switching per room.

Central Controller

Provide BACnet gateway for HLI interface to BMS system

Branch Selector Unit

Each BSU capable of controlling 1-6 FCUs

Each selector unit must have 2 solenoid valves which are opened by a signal to

cool or heat from the remote controller

BMS Units to be provided with BACNET HLI interface to enable connection to existing

BMS network



35 of 98

Item

Manufacturer Daikin Industries, Mitsubishi or Fujitsu

Table 8-5 VRV systems – Outdoor Units

Item

General

Reverse cycle air cooled condensing units must incorporate the following:

Condenser coil

Motors

Air discharge fans

Compressor

Refrigerant circuit pipework and all components including distribution

headers

Electronic expansion valve

Solenoid valves

4 way valve

Capillaries

Filters

Shut off valves

Service ports

Receivers

Minimum Safety

Features

High pressure and low pressure cut out

Control circuit fuses

Crank case heater

Fusible plug

Thermal protections for compressor and fan motors

Current overload protection for the inverter

Anti-recycling timers

Automatic oil recovery

Oil separator

Oil equalisation system

Oil pressure gauge

Oil failure switch.



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Item

Additional

Requirements

Oil recovery must operate automatically 1 hour after start of operation and

every 8 hours of operation

Units must be mounted on a condensate drip tray, on a concrete plinth.

Water proof separation must be required between equipment and

concrete.

Mounting Location The external unit must be installed in a suitable location that does not cause any

detrimental impacts due to jet fuel residue/fumes.

Table 8-6 VRV systems – Indoor Units

Item

General

Indoor units must be reverse cycle DX type

Units must consist of a fa, filter, evaporator coil and electronic proportional

expansion valve

Provide access panels to filter, coils, fan, valves

Provide drain tray and 25mm copper or UPVC connection

Electrical

Requirements

230V, single phase, 50Hz

Power must be provided to each indoor unit capable of isolation from both the

MCC and a local isolator behind the unit casing.

At the VRV, MCC must provide single phase DOL motor starters with no-volt

and thermal overload protection equal to Klockner-Moeller PKZM.

A single phase circuit breaker must provide protection for manual motor starters.

Fan Fans must be direct driven, forward curve centrifugal with statically and

dynamically balanced impellers

Filters

Filters must have minimum 60% efficiency (no. 2 dust test) in accordance with

AS 1324

Provide differential pressure monitoring across filter beds, complete with BMS

connections

Coils

Coils must be copper with aluminium fins Working Pressure: 100kPa

Max face velocity: 2.5m/s

Max water velocity: 1.5m/s

Expansion Valve Expansion valve must be controlled via return air temperature, refrigerant inlet

and outlet temperature



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Item

Controller

Requirements

On / off switching;

Fan speed selection (high, low and medium);

Thermostat setting;

Malfunction indication;

Dirty filter indication;

Automatic heating to cooling changeover mechanism; and Auto swing of

supply air for wall, cassette and under ceiling units

Provide 1 temperature sensor per room

Refrigerant Piping

Safety must be in accordance with AS/NZS 1677.2.

Piping must be copper in accordance with AS 1571 Copper must be Alloy 122 in

accordance with AS 2738.2



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9. MECHANICAL EQUIPMENT

9.1. PUMPS

Table 9-1 Pumps

Item

General All pumps must be in accordance with the following standards:

AS 2417, ISO2858, DIN EN733

Requirements

Pump duties must be met with the impeller shaft speed not exceeding 24rev/s

(1,450RPM).

Centrifugal type preferred Long coupled centrifugal pump

Duty and standby pumps must have non-return valves on the discharge side

and strainer’s on the suction side

Pump suction and discharge flanges must be drilled and tapped for pressure

gauge connections. Closing plugs must be provided

Drive connections between motors and pumps must be fully protected against

accidental contact. Provision must be made for shaft speed measurement

HTHHW pump impellers must be stainless steel Lifting eyes must be fitted to

components or assemblies >25kg Pump baring’s must be suitable for 50,000

hours working life

Bases

Pumps to be sited on anti-vibration mounts

Pumps and motors must be mounted on rigid bases, capable of preventing

distortion or misalignment during operation.

Provide inertia bases

Design Requirements Pumps must be capable of operating from full flow to 25% of design

Impeller

Material: impellers to be bronze

Impellers size must not exceed 90% of the maximum impeller size that can be

fitted within the casing

Motor Minimum power rating: At least the maximum power required by the pump when

projecting the system resistance curve to the maximum impeller size for the

pump casing size.

Minimum Pump

Efficiency

Pumps must be selected to achieve as a minimum the greater of NCC Part J

requirements

Redundancy Primary pumps – N (Duty only)

Secondary pumps – N+1 (If configured in a header arrangement)



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Item

CHW requirements

Install all chilled water pumps in a stainless steel self-draining (to comply with

AS 3666 ponding requirements) drip tray to catch all condensate formation and

leakage

Drain permanently to waste by a 25mm socket in the bottom of the tray. For

other pumps for condenser water, heating water and the like, provide a drain in

copper pipe from the pump housing to waste.

Electrical

Requirements Provide VSDs for all pumps

Manufacturer Grundfos, Wilo and Goulds (HTHHW Service)

Typical Detail - Pump

9.2. FANS

Table 9-2Fans – General

Item

General Fans must be in accordance with all relevant standards, including the following

as a minimum: AS 1668.1; AS 4429; BS 848.1; and BS 848.2

Energy Efficiency Efficiency must be in accordance with NCC Section J

Fan Performance Fan performance must be in accordance with AS 2936

Fan Sound Power

Levels Fan sound power levels must be in accordance with AS 1217.3



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Item

Smoke Spill Fans Smoke spill fans must be tested in accordance with AS 4429 Motors to be Class

H

Electrical

Requirements Provide VSDs to Smoke Spill Fans

Manufacturers Fantech, Aerovent or Pacific

Table 9-3 Axial Flow Fans

Item

General Axial flow fan casings must be rigid construction of mild steel hot dip galvanised

in accordance with AS 1650, or of aluminium alloy, stiffened and braced where

necessary to minimise drumming and vibration.

Selection

Fans must be selected for high efficiency, low noise level, and a maximum speed

24rev/s (1,440RPM).

Duty point must be selected between 50% and 80% of peak pressure and the

blade pitch angle not less than 5° from the recommended maximum pitch angle.

Fans to be sized 20% above peak flow rate

Electrical Requirements Provide VSDs to Fans

Table 9-4 Centrifugal Fans

Item

General

For fans less than 800mm diameter and of speeds below 20rev/s (1,200RPM),

casing stiffeners may be the folded edges of welded side plates used to form

the pedestal and scroll.

Self-aligning ball or roller type impeller bearings must be provided. Plummer-

block mounted self-aligning roller bearings must be provided in accordance with

AS 2729, with basic rating life with 10% failure, L10 of 35,000 hours with seals

and grease relief or similar split bearing housings, on fans with shaft powers

greater than 10kW. Bearings must be replaceable on belt-driven fans of input

shaft power 5kW and above.



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Item

Selection

Fans must be selected in accordance with the following requirements:

High efficiency, stable and quiet operation;

Supply and return air fans, having a maximum discharge velocity of 10m/s; and

Exhaust fans having a maximum discharge velocity of 11.5m/s.

Motor power rating must be selected in accordance with the following

requirements:

For backward inclined impellers with non-overloading characteristic select for a

minimum of 15% above limit load fan shaft power at design speed plus 10%

drive losses; and

For forward curved impellers, select as for backward inclined together with

additional 20% for overloading characteristic.

Motor

Vee-belt in accordance with AS 2784 with minimum rating of 150% of motor

power.

Provide all motor drives up to 3 kW with adjustable pitch diameter pulleys.

Provide all motor drives above 3 kW with a minimum of two vee belts with taper

lock pulleys and shafts.

Impellers

Impeller blade type selection must be based on the following shaft power

requirements:

<4kW - forward curved or backward inclined laminar type;

4kW to 8kW - backward inclined curved laminar type; and

>8kW - backward inclined aerofoil.

Table 9-5 Roof Mounted Fans

Item

General

Cowls and bases must be of materials resistant to adverse weather and solar

radiation, and appropriate for the location of the fan.

Weatherproof casings must be suitable for direct fixing to the building in

accordance with the manufacturer's instructions.

Back-draught dampers and auxiliary components must be fitted on vertical

discharge fans.

15mm bird-mesh guards must be provided where back-draft dampers are not

fitted.

Direct access must be provided to electrical supply terminals and lubrication

points.

Construction A UV stabilised ABS, polypropylene, polyethylene, glass-fibre reinforced

polyester or zinc-coated steel cowl and base must be provided.



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Smoke Spill Fans

Fans to be used for smoke extract ventilation must be of all steel construction

with fire rated flexible connections and tested to AS 4429.

Motors, electrical cabling and components must be suitable for the application

and in accordance with AS/NZS 1668.1 and the requirements of the Statutory

Authority.

Impeller and casing clearances must be satisfactory at the operating

temperatures.

Units must be type tested in accordance with AS 4429.

9.3. HEAT EXCHANGERS

Table 9-6 Shell and Tube Heat Exchanger’s

Item

General Heat exchanger’s must be in accordance with the following standards: AS 1210,

TEMA Class C

Requirements

Heat exchangers must be Shell and Tube type

The outer shell and tube heat exchanger must be fabricated from carbon steel and

tubes must be fabricated copper

All shell and tube heat exchanger pipe connections shall be flanged or welded.

Design Temperatures Refer to section 7.4 Design Criteria

Design Temperatures

Shell and tubes must be rated for the following minimum design working

temperatures:

Tubes: 165°C (HTHW); and Shell: 80°C (LTHW).

Working and Test

Pressures Refer to section 7.4 Design Criteria

BMS Monitoring Provide BMS flow / return temperature sensors for all pipework connections

(LTHHW and HTHHW)

Spare Capacity Provide 25% Heat Exchanger spare capacity

Access Installation to include adequate clearances around Heat Exchangers for

maintenance including space for tube withdrawal

Manufacturer

Shell and Tube heat exchangers must be manufactured by Britannia Metal

Industries or equal and approved

HTHHW control valves to be supplied by Sauter.

Isolation Valves Provide dual isolation valves for HTHHW pipework branched to HEX

Provide dual isolation valves for HTHHW air vents and drains

Control Valves HTHHW control valves to be supplied by Sauter

Provide motorised safety shut off valve



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Item

Cool Down Box

Provide stainless steel cool down box. All HTHHW bleed vents and drains to

discharge to cool down box.

Minimum cool down box volume: 40 litres

Manufacturer: Automatic Heating

Cool Down Box Detail



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Item

Typical Detail

– Shell and Tube Heat

Exchanger

Table 9-7 Plate Heat Exchanger’s

Item

Requirements

Plate Heat Exchangers must be fabricated from 316 stainless steel herringbone

patterned corrugated plates that form channels when the heat exchanger is

assembled. Individual plates must be separated with clip-in interlocking gaskets,

which are replaceable in the field.

Frame must be sized to allow a 25% increase in Heat Exchange area.

End plates must have screwed connections for piping up to 50mm in diameter

and flanges for 65mm in diameter and above.

Fit condensate trays must be drained to waste, on heat exchangers operating

with fluids at a temperature lower than 15°C.

Manufacturers Plate heat exchangers must be manufactured by Alfa Laval or Melbourne Airport

approved equal.



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Item

Typical Detail Plate

Heat Exchanger

9.4. EXPANSION TANKS

Table 9-8 Expansion Tank’s & Auto Fill Units

Item

General Expansion tanks & Auto Fill Units must be in accordance with the following

standards: AS 1200; AS 3500.1.2; and AS 4343.

Diaphragm Type

Pressurisation Vessels

Sealed diaphragm units must be a complete set and include:

Feed water connection;

Make up tank;

Expansion vessel with replaceable internal flexible diaphragm;

System connections;

All control elements including low and high pressure cut-out switches;

Power connections and mains disconnect switch;

Run and tripped indicator lamps; and

System pressure gauges.

Capacity - Unless otherwise specified size the expansion tank to take up the

potential expansion and contraction of the fluid over the operating temperature

limits with a minimum 20% spare capacity.



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Item

Automatic Refill Units

Automatic pressurisation system refill units must be provided to maintain closed

system water pressurisation, to replace system water losses, and prevent

backflow.

A single-phase centrifugal pump must be provided, controlled by a pressure

sensor, set for minimum system static pressure. The pump must be complete

with suction and discharge isolating valves, pipeline strainer, and discharge

check valve. A break tank with ball float valve, cover, overflow and a removable

system fill connection with backflow prevention must be provided.



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10. DUCTWORK AND ASSOCIATED EQUIPMENT

Table 10-1 Ductwork - General

Item

General All Ductwork must be designed, manufactured and installed in accordance with

the following standards: AS/NZS 1668.1; AS1668.2, AS 4254.1, and AS4254.2

Ductwork Pressure

Classification Refer to section 7.4 Design Criteria

Ductwork Pressure

Tests

Refer to section 7.4 Design Criteria

Pressure test to be witnessed by APAM representative. Contractor to provide

certificate of compliance to APAM

Table 10-2 Ductwork - Design Criteria

Ductwork System Location Max PD in Pa/M Max Velocity in m/s

General Maximum ΔP in ductwork = in accordance with BCA Part J

Supply

Ductwork C/W side wall grilles 0.8 4.5

General ventilation ductwork 0.8 6

Terminal Ductwork 0.8 2.0

Branch Ductwork 0.8 6.0

Riser Ductwork 0.8 8.0

Return

Transfer ductwork 0.5 2.0

Ductwork C/W side wall grilles - 4.5

Free flow through ceiling - 3.0

Terminal Ductwork 0.8 3.0


R/A intake to riser - 5.0

Risers 0.8 6.0

Stair Pressurisation Shaft riser 1.0 8.0

Toilet exhaust Risers 1.0 7.5


Carpark Exhaust Risers 1.0 8.0



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Ductwork System Location Max PD in Pa/M Max Velocity in m/s

Ductwork C/W side wall grilles 6.0

General Exhaust Throughout 1.0 6.0

Kitchen exhaust Throughout 1.0 8.0

Smoke Exhaust / Spill Throughout 1.0 8.0

10.1. KITCHEN EXHAUST

Table 10-3 Kitchen Exhaust

Item

General

All proposed kitchen hood exhaust systems must be submitted to Melbourne

Airport Fire and Life Safety Coordinator for approval.

Required documentation for approval must include drawings and specifications

identifying:

Kitchen equipment / appliances;

Exhaust hoods;

Exhaust fans;

Ductwork layout and slope with access provisions, penetrations through

fire or smoke barriers, flexible connections, duct construction and

material details, and any fire barrier / shaft construction details;

Locations of automatic fire sprinklers and wet chemical suppression

systems;

Filter types and efficiency; and

Design certification in accordance with this Standard



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Item

Ductwork

Ducts must be installed with a minimum grade of 1 in 200, and must be self-

draining back to the concession area as far as practicable with no low points

where condensation can collect. A 25mm drain socket and plug must be

provided at the lowest point of each run of ducting and a 25mm grease arresting

gutter at the bottom of vertical risers.

Ductwork external to the building must be minimised. Where unavoidable,

ductwork must be vertical and insulated to ensure water tightness and

resistance to all weather conditions and temperatures. Gaps between ductwork

and openings formed in the building fabric must be sealed with a non-

combustible material that is water tight and weather resistant.

Access doors must be provided at 3m maximum centres in accordance with AS

1668.1 and at the following locations:

At duct junctions;

Behind hood outlet balancing dampers;

At the bottoms of kitchen exhaust risers;

On each side of changes in direction; and

At sprinkler head locations and drain points.

Installation

Roof coverings around the point of discharge mut be protected with a non-

combustible, cleanable surround for a distance of at least 2.0m from the duct.

Exhaust outlets must not be located where discharge of smoke and fumes could

be drawn into outdoor air inlets or any other openings based on proximity to

openings and prevalent winds.

Exhaust outlets must be at least 6.0m from any other services and plant or as

determined by risk assessment to achieve optimum level of fire safety.

Ducts must not be terminated within 6.0m of any non-fire rated part of the

buildings external cladding, including windows.

Exhaust outlets must be easily cleanable and must not support the build-up of

grease. The discharge must be directed vertically.

Every exhaust duct discharge must have a sign provided adjacent in minimum

50mm upper case lettering, in a colour contrasting to that of the background

with the words:

"KITCHEN EXTRACT SYSTEM - DO NOT INSTALL ANY COMBUSTIBLE

MATERIALS, SERVICES, EQUIPMENT OR PLANT WITHIN 6 METRES"

Makeup Air Kitchen exhaust hoods should be provided with filtered mechanical makeup air

ducted directly from outside.

Filtration

UV exhaust filtrations systems may be used at Melbourne Airport.

Consideration should be given to additional filtration as required to suit the type

of cooking being carried out



50 of 98

Item

Cleaning Access

Kitchen exhaust systems must have cleaning access provisions in accordance

with the following:

Access doors must be provided along the entire length of the ductwork

system and at all bends and fittings to allow all internal surfaces to be

accessed for cleaning. The maximum spacing between access doors in

any circumstances must be 3.0m centres;

Access doors must not be installed in the bottom of ductwork. Where

ducts are not vertical, the bottom edge must be at least 25mm from the

bottom of the duct;

Access doors for cleaning must be a minimum size of 300mm x 300mm.

Where the duct size allows larger access doors than this they must be as

large as practicable;

Access doors must be easily removable and openable without the need

for any special tool or key. Every access door must have a non-

removable label attached to it with the words "KITCHENEXTRACT DUCT

- ACCESS FORCLEANING - DO NOT OBSTRUCT" in minimum 50mm

uppercase lettering in a colour contrasting to that of the background; and

Access panels must be provided to enable internal cleaning of fans. At

the start of cleaning process, electrical switches that could be

accidentally activated must be locked out. A warning label stating "DO

NOT OPEN WITHOUT ISOLATING FAN" in minimum 50mm uppercase

lettering in a colour contrasting to that of the background must be fitted to

each fan access door.

10.2. ATTENUATORS

Table 10-4 Attenuators

Item

General All attenuators must comply with AS 1277

Maximum ΔP across Attenuator = in accordance with BCA Part J

Requirements

Where airway velocity exceeds 10m/s, splitters must be provided with rounded

nose and tapering trailing edge with a maximum angle of divergence of 14°, to

reduce the airway departure velocity to less than 5m/s.

A minimum of 1m separation must be provided between splitter type silencers

and axial fans

Thermal insulation must be provided to attenuators installed in thermally

insulated ducting



51 of 98

Item

Circular Silencers

On each of the silencer ends minimum M8 captive nuts must be fitted to

facilitate the connection of the silencer to ductwork or fan flanges. A minimum of

8 nuts must be used at each end.

Silencers must comprise a galvanized sheet metal case fabricated from not less

than 1.0mm sheet metal.

The casing joints and seams must be either Pittsburgh or welded sheet joints

and in both cases must be sealed with duct sealant

Rectangular Silencers

Silencers must comprise a galvanized sheet metal case fabricated from not less

than 1.2mm sheet metal.

At each end of the silencer, proprietary HVAC ductwork flange systems, or

fabricated angle, flanges must be fitted

The casing joints and seams must be either Pittsburgh or welded sheet joints

and in both cases must be sealed with duct sealant

Kitchen Exhaust kitchen exhaust attenuators must be Mylar lined

Manufacturer Fantech, Australian Silencer Company, NAP

10.3. DAMPERS, DIFFUSER’S, GRILLES AND REGISTERS

Table 10-5 Dampers

Item

General

Dampers must be installed in permanently accessible positions

Balancing dampers must be fitted in each branch from a main or sub-main duct,

and elsewhere as required to satisfactorily commission the system.

Butterfly dampers with single balanced blades must have a maximum 600mm

wide and 250mm high for rectangular or 350mm for circular.

Opposed-blade dampers to have a maximum of 230mm wide x 1,200mm long

blades. Intermediate mullions must be fitted if necessary.

Dampers must be free of rattles, fluttering or slack movement. Design air

pressure differential must be 1kPa

Maximum ΔP of fitting = in accordance with BCA Part J

Volume Dampers

Volume dampers must be provided to permit balancing of all air outlets and

branch ducts as required

Dampers must be rigidly constructed, of the butterfly or opposed blade type, with

blades securely fixed to spindles.

Nylon bearings must be provided.

Dampers must contain a position indicator and locking device



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Item

Automatic Control

Dampers

Opposed multi-blade dampers with maximum 230mm wide and 900mm long

blades having a maximum working pressure differential of 1kPa must be

provided.

Maximum leakage rate must be 150L/s/m2 at 1.5kPa pressure differential.

Dampers must be selected for 10m/s at maximum airflow. Modulating dampers

must not be oversized

Dampers for return air, or other air handling systems incorporating smoke spill

must be tight shut off type capable of limiting leakage to 1L/s/m2 at a pressure

differential of 500kPa

Non-return Dampers

Non-return (self-closing) dampers must be constructed to ensure positive shut-

off and quiet closure. Dampers must have a maximum air resistance of 50Pa at

2.5m/s and a maximum leakage rate of 225L/s/m2 at 500Pa reverse pressure

air.

Fire and Smoke

Dampers

Design, install and commissioning must be in accordance with AS 1682.1

Section 5.

Fire dampers must be installed in all ductwork passing through each and every

fire compartment wall

Damper assemblies must be of corrosion-resistant materials or be protected

against corrosion.

Access panels must be provided adjacent to fire and smoke dampers for

inspection of sufficient size to permit resetting of release mechanism and blades

by 1 person.

Access to fire damper and smoke damper assemblies may be provided through

builders work elements.

Note

1. Refer to the ‘Melbourne Airport Fire Safety Manual’ for further details of requirements for Fire

and Smoke dampers.

Table 10-6 Registers, Diffusers and Grilles

Item

General

Registers, diffusers and grilles must be in accordance with the following standards: Air Diffusion Council ADC 1062 - GRD84; ANSI/ASHRAE 70; and AS 1217 Registers, diffusers and grilles must be aluminium External finish must be thermoset powder coated, colour as selected by the Architect unless stated otherwise. Internal finish must be painted matt black Maximum ΔP of fitting = in accordance with BCA Part J



53 of 98

Table 10-7 Types – General Supply Air Diffusers

Item

General Maximum ΔP of fitting = in accordance with BCA Part J

Cooling Requirements

Conditions must assume 24°C room temperature and 12°C supply air

temperature with:

Constant volume systems - full cooling; and

Variable volume systems - maximum airflow at minimum supply air temperature

and also minimum airflow at coincident supply air temperature

Ceiling diffusers for variable volume cooling duty with horizontal air pattern must

be selected to avoid dumping of cold air at 45% of maximum design airflow.

Heating Requirements Overhead diffusers must be selected to ensure the throw reaches the occupied

zone during heating cycle and that the supply air does not short-circuit into high

level returns

Table 10-8 Types – Diffusers, Grilles & Registers

Item

Low Velocity

Displacement

Ventilation Diffusers

LVDV diffusers used to supply air must be floor mounted. LVDV diffusers must

be semi-circle with horizontal throw.

Material must be galvanised steel. Front panel and flow equalisation element

must be perforated galvanised steel.

All exposed panels must be resistant to damage and marking under normal

operational and maintenance conditions. Surface finish must be polyester epoxy

paint.

Air Pattern must be horizontally air throw through a full 180°.

Diffusers must be complete with circular duct connection with integral gasket.

Front panel must be detachable metallic internal structure to allow cleaning of

the unit and ductwork.

An installation base must be provided complete with kick-plate to prevent

damage to the diffusers.

Where two diffusers are provided on either side of a column, a removable panel

must be provided to fill any gaps between the diffusers. This infill panel must be

of the same material and paint colour as the diffusers



54 of 98

Item

Swirl Diffusers

Swirl diffusers must be used for high level VAV systems and must be ceiling

mounted.

The diffuser must consist of a frame with fixed internal profiled vane rings and a

movable deflector ring or cylinder for throw pattern selection.

The front vane panel and movable cylinder must be made of epoxy-painted

steel and the frame of epoxy-painted aluminium. Colour of diffuser must match

the ceiling colour by the architect.

The airflow pattern must be adjustable automatically using an electrical or wax-

bulb actuator.

Circular Plaque

Diffusers

Diffusers must be circular plaque type with adjustable pattern and must be

ceiling mounted.

Baffles must be fitted for 3-way, 2-way or 1-way pattern. Pattern control must be

by height adjustment of plaque.

Door Relief Air Grilles

Door relief air grillers must be horizontal chevron blades with double sided

telescopic frames to suit a door thickness of 30mm to 50mm used for relief air.

Material must be extruded aluminium.

Blade spacing must be 25mm centres maximum and sight-proof when viewed

from the same level.

Light proof grilles must be horizontal double chevron black finished blades with

double-sided telescopic frames to suit a door thickness of 30mm to 50mm.

Egg Crate Grilles

Egg-crate grilles must be ceiling or high wall mounted and must be used for

return, relief or exhaust air.

Grilled must be of egg-crate type having 1mm thick 12mm x 12mm x 12mm

deep aluminium core and extruded aluminium frame.

Fixed Blade Bar Grilles

Fixed blade bar grilles must be side wall, sill or floor mounted and must be used

for supply and return air.

Type must be continuous multiple slot extruded aluminium bar grilles. Side wall

or sill bars must be 3mm wide at 12.5mm spacing.

Floor bars must be 6mm wide at 12.5mm spacing.

Pattern control must be by fixed longitudinal blades having a 0° or 15°

deflection.

Sidewall supply diffusers must have fitted vertical adjustable blades behind

Plenum must be minimum 0.8mm zincanneal having a maximum length

1,200mm

Half Chevron Grilles

Half chevron grilles must be ceiling or wall mounted and must be used for return

or exhaust air.

Grilles must be straight horizontal blades having 60% minimum free area



55 of 98

Item

Jet Diffusers

Jet diffusers must be circular, with two or more spun aluminium flaring

concentric nozzles in a cylindrical housing.

Pattern control must be throw and spread adjustable by reversing nozzles.

Direction adjustment must be by angling cores.

Light Air Diffusers

Light air diffusers must be in accordance with AS 2946

Diffusers must be ceiling mounted, recessed luminaires and air diffusers -

Interface requirements for physical compatibility and used for supply and return

air

Air pattern must be controlled by a J-blade

Single boots must be oval inlet to suit ≤150mm flexible duct. Double boots must

be oval inlet to suit >150mm flexible duct

Linear Plenum

Diffusers

Linear plenum diffusers must be ceiling mounted and must be used for supply

and return air.

Plenum diffusers must be designed to suit ceiling 2 or 3 slot T-bar system

installed by the ceiling contractor. Jointing of plenums onto T-bar diffuser must

be airtight.

Linear plenums must be arranged with linear outlets and air pattern controls and

oval duct inlets

Inactive sections must be extended as shown. Matt black blanking plates must

be fitted where not used for return air

Linear Slot Diffusers

Diffusers must be continuous single / multiple 20mm slot extruded T-bar

diffusers with pattern control blades and plenum boxes. Adjustable centre

sections must allow full adjustment of air pattern through 180°. Jointing of

plenums onto diffuser must be airtight

Inlets must be centrally located on sides

Inactive sections must extend as shown. Matt black blanking plates must be

fitted where not used for return air.

Louvre Faced Ceiling

Diffusers

Louvre faced ceiling diffusers must be ceiling mounted.

Diffusers must be multi-bladed, circular, square or rectangular complete with a

removable core and cushion head.

Diffusers must be extruded aluminium

Cushion head must be minimum 0.8mm zincanneal having an internal matt

black finish.

Install baffle plates behind circular or four-way faced diffusers to provide 3-way,

2-way or 1-way blow pattern control as required. 3-way, 2-way or 1-way blow

square or rectangular cores must only be used where specified.

Discharge pattern must be by circular diffuser - height adjustment of centre cone

Single Deflection

Universal Grilles

Single deflection universal grilles must be wall mounted and must be used for

return or exhaust air.

Diffusers must be adjustable horizontal aerofoil blades. Material must be

extruded aluminium blades and frame. Blade spacing must be 20mm maximum.



56 of 98

Item

Square Plaque

Diffusers

Square plaque diffusers must be ceiling mounted.

Diffusers must be square plaque type with adjustable pattern. Baffles must be

fitted for 3-way, 2-way or 1-way pattern.

Pattern control must be by height adjustment of plaque.

Universal Supply

Registers

Universal supply registers must be wall mounted.

Registers must be double deflection with longitudinal aerofoil front blades and

vertical aerofoil rear blades. All blades must be individually adjustable. Multi-

bladed stream splitter dampers must be fitted at register take-offs. Multi-bladed

opposed-blade dampers must be fitted at the last register take-off.

Blade Construction must be ±45° adjustment, spacing at 20mm maximum and

supported at 600mm maximum centres.

Weather Louvres

Weather louvres must be wall mounted.

Weather louvres must be provided at all air intakes and exhausts through walls

complete with bird / vermin screens.

Screens must be constructed from 1.5mm thick galvanised steel or bronze wire

at 12mm centres. Fixings are to be concealed.

Ductwork plenums must slope behind louvres towards the louvres ensuring any

carryover moisture will discharge via the louvre.

Plenums must be painted internally with either epoxy resin or bitumastic paint.

Normal duty louvres must have:

Horizontal extruded aluminium louvre blades at 45° with anti-carryover rain trap;

Blade pitch: 50mm to 100mm; and

Blade support: 1,200mm maximum centres. Heavy duty louvres must have:

Horizontal extruded aluminium two-stage louvre blades which divert air through

two 90° bends;

Blade pitch: 100mm; and

Blade support: 1,200mm maximum centres.

Air pressure drop must be 50Pa max at 1.25m/s face velocity.

Water elimination shall be tested with 0.11L/s of water per m2 of louvre

introduced into the airstream at 16m/s with zero water penetration.

Wall Mounted Return

Air Grilles

Wall grilles must be rigidly constructed from extruded aluminium sections and

must be the fixed fin louvre type with 45° blades at not greater than 25mm

Manufacturer Halton, Holyoake, Krantz



57 of 98

10.4. AIR FILTERS

Table 10-9 Air Filters – General

Item

Standards

Air filters must be in accordance with the following standards: AS 1324.1;

AS1324.2; AS/NZS 1530.3; AS/NZS 1668.1; AS 1668.2;

AS 1807.7; AS 1807.9; AS 3666 and AS 4260

General Refer to section 7.4 Design Criteria for filter performance requirements

All supply air and makeup air systems to be provided with air filters.

Carbon Filters

Activated carbon filters must be provided when there is any potential for

air intakes/return air to be exposed to jet fuel/fumes.

Return air systems must be provided with dedicated Activated Carbon

filters where there is any potential for untreated Jet fuel/fumes to

distributed via the supply air system.

Where there is a risk of dust carry over from activated carbon filters, bag

filters must be used before and after the carbon filter

Manufacturer Airepure, Camfil.

10.5. SPACE HEATING EQUIPMENT

Table 10-10 Space Heating – General

Item

General Space heating equipment must be in accordance with the following standards:

AS 1571 and BS EN 442

Baseboard Convectors

Copper heating elements must be in accordance with NZS 3501 or AS 1571 as

applicable. Tubes must be DN20

50mm x 50mm aluminium fins must be provided located at 200fins/m spacing.

Fins must only be fitted to top of flow pipe. Fins must not be provided to return

pipes

Trench Heaters

Copper heating elements must be in accordance with NZS 3501 or AS 1571 as

applicable. Tubes must be DN20

50mm x 50mm aluminium fins must be provided located at 200fins/m spacing.

Fins must only be fitted to top of flow pipe. Fins must not be provided to return

pipes



58 of 98

Item

Convectors

Convectors must be in accordance with BS EN 442-1, BS EN 442-2 and BS EN

442-3

An angle type thermostatic radiator valve complete with isolating valve on flow

and key operated double regulating lock-shield type valve on the return

connections must be provided

Where fitted, control dampers must be capable of reducing the emission to 30%

of maximum rated output

Natural convectors Floor-mounted finned-tube convectors must be supported on purpose- made

pressed steel legs formed to conceal pipe connections and raise the casing a

minimum of 100mm above the floor finish



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11. PIPEWORK AND ASSOCIATED EQUIPMENT

11.1. PIPEWORK DESIGN CRITERIA

Table 11-1 Pipework – Design Criteria

Item

General Refer to section 7.4 Design Criteria

Tundishes Each Tundish must be constructed from not less than 0.6mm thick sheet

copper. Seams must be riveted and brazed and edges must be rolled and

beaded for strength.

Refrigeration pipework Refrigeration pipe work exceeding 10m in length and on branch tee’s must have

isolating valves inserted in the suction and discharge lines.

Table 11-2 Pipework General

Item

Piping Hung from Roof

Structure

Piping not larger than 80NB may be hung from purlins provided the hanger

spacing does not exceed 3,000mm from piping 65NB and less, or 2,500mm

from 80NB piping.

Anchors

Anchors must be provided and must be fixed direct to concrete slab, structural

members or wall brackets. All in accordance with AS 1250

Where pipes are to be run parallel and adjacent to each other they must be

supported from channel sections either case into slabs fixed to structural

members or bracketed from side walls as appropriate.

Expansion

Anchors and expansion joints must be located to control expansions Bellows

must be used for HTHW and must be of stainless steel (3-ply)

construction as a minimum) with external telescopic case and internal stainless

steel sleeve. Bellows must be installed on each side of all anchors.

All expansion guide supports must be roller type.

The first 2 expansion supports on each side of all bellows, and on either side of

all changes in direction of pipe, must be provided with rollers at the following

locations on the pipe:

12 o’clock;

3 o’clock;

6 o’clock; and

9 o’clock.

Steel blocks must be used and welded to the pipe for all HTHW and LTHW

piping and wooden blocks for all other pipe between the rollers and pipe.

Expansion guides must be sized for 3 times the expected movement and

centred at the design operating temperature during commissioning.



60 of 98

Item

Piping Hung from Roof

Structure

Piping not larger than 80NB may be hung from purlins provided the hanger

spacing does not exceed 3,000mm from piping 65NB and less, or 2,500mm

from 80NB piping.

Table 11-3 Pipework Testing

Item

General


All water systems must be hydrostatically tested during construction and after

completion as required by the relevant Australian Standard.

Test pressure must be maintained for a 24hr period.

Melbourne Airport must be advised at least 48hr in advance of any impending test

(typically notification should include the appointed Melbourne Airport Project

Sponsor and the Asset Manager);

Table 11-4 Pipework Insulation

Item

General


Pipework insulation must be in accordance with AS 4426 and insulation.

Performance must be in accordance with BCA Part J requirements

Chilled Water

CHW piping must be insulated with close cell foam sectional insulation of the

minimum thickness of 50mm for pipe size greater than 100mm diameter.

A guaranteed effective vapour barrier must be installed and this must consist of a

layer of factory applied 450mm Sisalation reinforced aluminium foil laminate

applied over the insulation with all joints sealed with 75mm wide pressure

sensitive reinforced tape.

Extreme care must be taken to provide an effective vapour seal at each and every

pipe support. Box all flanges, strainers and valves

Metal Sheathing

All piping insulation must be sheathed with 0.5mm thick zinc anneal sheet steel

and painted to match existing. Band clips must be used for all joints. Rivets or

screws must not be used.

11.2. VALVE PROVISIONS

Table 11-5 LTHW Valves

Valve Type Details

General All valves must be in accordance with AS 1271



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Valve Type Details

Globe stop valves

(Not including radiator valves) Up to and including 50 mm diameter –

screwed ends, bronze body, bronze or stainless steel inside, integral

seat, bronze disc.

Gate Valves Up to an including 50 mm diameter – screwed ends, bronze body,

bronze or stainless steel inside spindle, integral seat, bronze disc.

Vent Valves Forged brass ball valve, hard chromed brass ball, 2 piece chrome

plated body, PTFE stem seal and seats.

Modulating / Shut Off Control

Valves

Must be equipped with matching actuator capable of shutting the valve

against the maximum system pressure differential. The actuator must

be able to give input / output / status information to the BMS.

Manufacturer Kitz

Table 11-6 CHW Valves

Valve Type Details

Butterfly Valves

≥50mm – Cast iron lugged water valve with stainless steel spindle and disc, Buna N seal, handwheel operation. Valve and lugs design to maintain full seal against maximum design pressure when only flanged on 1 side.

Globe Valves ≤50mm diameter – Screwed ends, bronze body, bronze or stainless steel inside screw spindle, bronze seat and disc.

Modulating / Shut Off Control Valves

Must be equipped with matching actuator capable of shutting the valve against the maximum system pressure differential. The actuator must be able to give input / output / status information to the BMS.

Ball Valves Forged brass ball valve, hard chromed brass ball, 2 piece chrome plated body, PTFE stem seal and seats.

Vent Valves Forged brass ball valve, hard chromed brass ball, 2 piece chrome plated body, PTFE stem seal and seats.

Manufacturer

Table 11-7 HTHHW Valves

Valve Type Details

Gate Valves

≤40mm diameter. Flanged ends, forged steel body, outside screw

spindle of bronze, or stainless steel, replaceable stainless steel or nickel

based copper tin allow seat and discs.

≥50mm diameter. Flanged ends, cast steel body, outside screw spindle

of stainless steel or bronze, replaceable stainless steel or nickel based

copper tin alloy seat and discs.



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Valve Type Details

Check Valves

≤50mm diameter – Flanged ends, bronze body, non-hammer type,

replaceable stainless steel seat and disc.

≥65mm diameter – Flanged ends, cast steel body, non-hammer type,

replaceable stainless steel or nickel based copper tin alloy seat and

disc.

Globe Valves

≤50mm diameter – Flanged ends, bronze body, bronze or stainless

steel outside screw rising spindle, replaceable stainless steel seat and

disc.

Modulating / Shut Off Control

Valves

Provided with stainless steel trim and high temperature stuffing box,

flanged ends. Gland packing must be pure PTFE. Each valve must be

equipped with matching actuator which must give input/output/status

information to the BMS.

Additional Notes With the exception of instruments (pressure sensors, gauges etc.), all

valves must be provided with flanged connections.

Manufacturer Velan



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12. CONTROL VALVES

Below are the general requirements for Control Valves at Melbourne Airport:

CHW valves fitted to pipes with diameters ≥100mm must be supplied with gearbox operators. CHW

control valves must be installed with a separate balancing valve.

12.1. AUTOMATIC FLOW CONTROL VALVES

Table 12-1 AFCVs

Item

General

AFCVs must be installed in the supply water line for each item of equipment

utilising HTHW and CHW to limit flow rates to maximum design condition.

AFCVs must automatically control flow rates to within +5% or -0% accuracy.

Valve control mechanism must consist of a stainless steel cartridge with a ported

cup and coil/helical spring to avoid corrosion. Manufacturer must provide tests

verifying accuracy of performance.

All valves must incorporate tappings to facilitate measurement of head across the

valve.

Valves must be selected to suit the operating pressures and temperatures of the

environment in which they will be operating. In the case of HTHW, the valves

must be flange mounted.

No AFCV settings (via cartridge) must be changed without express permission of

the Melbourne Airport Mechanical Asset Manager.

AFVCs must be installed between isolating valves to facilitate core removal.

Straight entering and leaving piping must be provided in accordance with the

manufacturer’s recommendations.

Each valve must be identified with a label indicating type, flow rate, control range

and valve identification.

Function Valves must be self-balancing to automatically limit the flow rate to within 5% of

the specified flow rate over the operating pressure range.

Manufacturer Frese, Tour and Anderson

12.2. DIFFERENTIAL PRESSURE CONTROL VALVES

Table 12-2 DPCVs

Item

General

Differential pressure control valves must be in accordance with Tour and

Anderson STAP.

Valves must be installed between isolating valves to allow servicing. Straight

entering and leaving piping must be provided in accordance with manufacturer’s

recommendations.



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Item

Function Valves must be used for differential pressure control of chilled water and heating

hot water branches.


12.3. PRESSURE INDEPENDENT CONTROL VALVES

Table 12-3 PICVs

Item

Operation

Requirements

PICVs must be used in cooling systems in applications with FCUs, AHUs or other

terminal unit applications for water flow up to 0.83L/s or DN32.

PICVs must provide modulating control with full authority regardless of any

fluctuations in the differential pressure of the system.

Manufacturer Frese Valves

Table 12-4 PICV Properties

Item Detail

Valve body AMETAL®

Valve plug AMETAL®

Valve Seat Seal EPDM / Stainless Steel

Valve insert AMETAL® / PPS / PTFE

Spring Stainless Steel

Spindle Stainless Steel

O-rings EPDM

Pressure class PN16

Max. differential pressure 350kPa

Medium temperature range 20°C to 120°C



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Item Detail

Typical Detail FCU – CHW

Connection with PICV

12.4. CONTROL VALVE ARRANGEMENTS FOR AHU’S & FCU’S

Table 12-5 AHU and FCU LTHW Flow Control Valves

Item

Operational

Requirements

For the terminal control (FCU and AHU) of the LTHW (80°C), 3-way valve control

strategy should be adopted. This strategy must be applied to avoid low flow

situations through the high temperature heat exchangers and overheating of heat

exchangers.

Melbourne Airport has adopted dynamic flow balancing using automatic balancing

systems instead of static balancing. Tour and Anderson STAD or STAF valves

must not be used for balancing.

Tour and Anderson STAD and STAF valves should be used as flow measuring

devices where required.

Dynamic-Automatic Flow Control Valves using stainless steel cartridge to

maintain specific flow rate independent of pressure fluctuations within a system

should be used. These valves should use terminal balancing with factory pre-set

flow rate that is maintained at selected pressure differential range.

Automatic balancing valves should be used in series with the control valves.

Valve accuracy ±5%.

High flows

For higher flows Tour Anderson TA AutoFlow WS should be used in series with 3-

way control valves, from DN65 up to DN350 and from 5L/s to 360L/s.

Automatic balancing valve AutoFlow WS (Wafle-Style) should have ductile iron

body, stainless steel flow cartridge, accuracy of 5% over 95% of the control

range. The number of flow cartridges required must be determined by the L/s

requested. Studs, nuts and 2 drilled and tapped ports with extended

pressure/temperature test points shell be standard.

Energy Efficiency

This 3-way control strategy is not energy efficient and energy saving using VSDs

on the pumps cannot be utilised. As an energy saving option system with by-

pass providing constant minimum flow through heat exchanger could be

designed. 3-way control valves should be provided for the last units on the pipe

run. This option must be discussed and approved by Melbourne Airport.



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Item


Typical Detail – 3 Pot

for LTHW

Table 12-6 AHU and FCU CHW Flow Control Valves

Item

Operational

Requirements

For the CHW AHU terminal control, 2-way control strategy must be adopted with

3-way control valves for the last unit on the end of the pipe run to provide

minimum flow for the pumps and the available designed water temperature to the

rest of the units on that run.

Melbourne Airport has adopted dynamic flow balancing using automatic balancing

systems instead of static balancing. Tour and Anderson STAD or STAF must not

be used for balancing.

Dynamic automatic flow control valves using stainless steel cartridge to maintain

specific flow rate independent of pressure fluctuations within a system must be

used. These valves should use terminal balancing with factory pre-set flow rate

that is maintained at selected pressure differential range.

Automatic balancing valves should be used in series with 2-way control valves.

Automatic balancing valves such as Tour and Anderson TA AutoFlow AC up to

50mm and 4.42L/s or similar must be used.

Valve accuracy ±5%.

High flows

For higher flows Tour Anderson TA AutoFlow WS must be used in series with 2-

way valves, from DN65 up to DN350 and from 5L/s to 360L/s.

Automatic balancing valve AutoFlow WS should have ductile iron body, stainless

steel flow cartridge, accuracy of 5% over 95% of the control range. The number of

flow cartridges required is determined by the l/s requested. Studs, nuts and 2

drilled and tapped ports with extended pressure/temperature test points shell be

standard.

Energy Efficiency

This 3-way control strategy is not energy efficient and energy saving using VSDs

on the pumps cannot be utilised. As an energy saving option system with by-

pass providing constant minimum flow through heat exchanger could be

designed. 3-way control valves should be provided for the last units on the pipe

run. This option must be discussed and approved by Melbourne Airport.



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Item

Manufacturer Tour and Anderson or approved equal

Typical Detail – 2

Port for CHW Coils

Typical Detail – 3

Port Control for CHW

Coils at end of run

12.5. HIGH TEMPERATURE HEATING HOT WATER CONTROL VALVES

Table 12-7 HTHHW Control Valves

Item

Operational

Requirements

HTHW pipework of diameters greater than 50mm must be fitted with 2 control

valves sized for 1/3, 2/3 flow rates respectively to account for low flow conditions.

Branching HTHW pipework must be fitted with flow control valves.

Heat Exchanger

Connections

In addition to control valves, the HTHW side of the heat exchanger must be

provided with a direct acting 2-port safety shut off valve on the incoming flow

pipework to the heat exchanger. The valve should be normally open and linked to

a dedicated temperature sensor (separate to other sensor used for normal

operation) monitoring shell temperature of the heat exchanger. Should maximum

temperature be exceeded (adjustable via the BMS) the shut of valve must be

actuated to the shut position. The shut off valve position should be monitored by

the BMS and an alarm must be raised with the BMS operator if a ‘shut off valve

closed’ signal is returned.

Manufacturer Sauter valves must be VUG (2 way through flange valve) or BUG (3 way flange

valve) to suit AVF234F132 and AVM234F132 series actuators.



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13. THERMAL ENERGY METERING REQUIREMENTS

Below are the general requirements for thermal metering of mechanicals services at

Melbourne Airport

Table 13-1 Thermal Metering Requirements

Item

General


Thermal Energy Meters must be in accordance with all relevant Australian

Standards

Data Points

All thermal meters to provide readings for the following parameters:

Flow (l/s)

Flow Temp (ºC)

Return Temp (ºC)

Energy (kWh)

Water Volume (mᵌ/h)

Meter Class EN1434 Class 2

Requirements

Meters must provide measurements at a 15 minute resolution period or better,

synchronised to perform readings at a common time period at: 00:15:30:45

minutes past each hour.

Provide on board display of measured values.

Provide on board non-volatile memory of current measured values

BMS Interface Provide BMS gateways

Manufacturers

Surface Mounted type; Manufacturer: FLEXIM (PRiCAM) Fluxus F502BT class A

(c/w LON gateway).

In Line type; Manufacturer: Belimo Sontex



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14. MECHANICAL ELECTRICAL INSTALLATIONS

Table 14-1 Mechanical Electrical Installations – General Requirements

Item

General

Mechanical / electrical installations must comply with AS 3000

All electrical equipment must be in accordance with must be RCM compliant.

Contractors must ensure all works are in accordance with: AS 3008.1.1; AS 3013;

AS 3947.2; and AS 3439

Drawings

The drawings must show the following information: Fault current and

discrimination calculations; Full circuit breaker protective level settings;

Manufacturer's name and catalogue number of any standard equipment; The

general arrangement of equipment; Full details of cabinet construction and

dimensions; The method of supporting busbars and protection/control equipment;

A description of all materials to be used; Clearances between live parts and live

parts to earth; Wiring diagrams and schematics of instruments, protection and

control circuits detailing wire and terminal numbers.

Fixing of Electrical

Infrastructure

Proprietary fasteners must be used capable of transmitting loads imposed and

sufficient to ensure the secure fixing of the equipment under all modes of

operation.

Zones where drilling or penetration is prohibited must be avoided.

Continuity of Supply Where electrical facilities exist on the site and / or premises, these facilities must

be maintained to suit the convenience of consumers. Any interruption to the

electricity supply must only be made with the written consent of those affected.

Table 14-2 Electrical Distribution

Item

Cables and Cable

Support

Wiring must be TPI cables in conduit or cable duct, or PVC / PVC or fire rated

cables on cable tray with conductors rated to suit the respective circuit load,

except where specifically stated otherwise.

Wiring must be carried out using the ‘looping in’ principle and the use of

connectors or joining of cables will not be permitted.

Wiring within the plantroom areas must be exposed, enclosed in conduit or wiring

duct or supported on cable tray. Wiring must be concealed within the fabric of the

building in areas external to the plantroom, unless otherwise agreed with APAM.

Wiring installed on cable tray must be mechanically protected to a height of 1.8m

Controls cabling to have dedicated containment.

Minimum size of conductors must of 2.5mm² for power and 1.5mm² for control

wiring using multistrand copper conductors.

Catinary wire used for cable installation will be heavy duty 7 / 125mm² sizes only.



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Item

Conduit and Fittings

Where conduits cross structural joints a section of flexible conduit or similar must

be inserted to extend a minimum of 230mm on each side of the joint, and must

comply with the electrical standard detail drawing enclosed herein.

Conduits run in slabs poured on filling must be contained within the concrete and

not in contact with the fill

Cable Tray Except where otherwise specified the trays selected must allow at least 25%

spare capacity for future cables.

Equipment Power

Supplies

Circuits for equipment to be rated for full connected load. Provide local isolator

adjacent to all equipment (where VSD are installed isolator to be located

upstream of VSD)

Cable Colours

A phase - Red

B phase - White

C phase - Blue

Neutral - Black

Earthing - Green-yellow

14.1. MECHANICAL SERVICES SWITCHBOARDS

Table 14-3 Mechanical Services Switchboards

Item

General

All mechanical services must be powered from dedicated MSSBs

Each switchboard must comprise of a sheet metal enclosure containing the

following equipment: A load break isolator that isolates all incoming supplies to

the switchboard; Means of isolating and protection (circuit breakers and

overloads) for each motor circuit; Contactors or starters for each motor circuit,

including the necessary protection devices; LED cluster pilot lights for run, fault

and fire alarm, complete with lamp test facilities; “auto-off-manual’ double pole

switches for all motor start circuits; and Power metering to all incoming supplies

The switchboard doors must be folded and braced to prevent flexing and

distortion

Segregation Form 2b

>800Amps Form 3b

Degree of Protection Internal: IP54

External: IP65

Colour AS2700 X15 Electric Orange



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Item

Spare Capacity Minimum of 25% spare ways

Minimum 25% spare capacity.

Electrical Metering

Provide kWh Meters for TSB main equipment such as; chillers, Boilers, pumps,

cooling towers, etc.

Power Meters to be provided for MSSBs incoming supply.

Provide metering Gateway to enable meter interface to the BMS/SCADA/PME

network. Gateway to be provided for each MSSB with meters or as required.

The meter setup requires that a modbus address be assigned to each meter and

enter an allocated IP address into the gateway or meter.

Metering Equipment must be supplied by Schneider;

kWh meter: Schneider iEM3250

Power meter (External MSSB): Schneider PM3255 (DIN rail mounted

meter)

Power meter (Internal MSSB): Schneider PM5310 (panel mounted meter

with integral display. IP52)

Gateway: Schneider LINK150

Metering Tariffs

The MSSB main power meters (Schneider PM3255/5310) to have two tariff

registers. (kWh meters are not proposed to have multiple tariff facility).

Tariff 1 – 7am-11pm Monday to Friday

Tariff 2 – 11:01pm to 6:59am Monday to Thursday, 11:01pm Friday to

6:59am Monday



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Item

Meter BMS Interface

BMS to record and log metering data as follows;

kWh Meters (Schneider iEM3250)

Current

Voltage

Power (kW)

Power Factor

Energy (kWh)

Power Meters (Schneider PM3255/5310)

Current (average and per phase)

Voltage (average and per phase)

Power (kW)

Energy (kWh)

Apparent power (kVA)

Reactive Power (kVA)

Power factor

Total Harmonics THDv

Total Harmonics THDi

Frequency

Essential Power

Supplies

Power supplies for TSB HTHHW and BMS systems to be fed from Essential

(generator backed up) MSSB.

Retails Tenancies Retail tenancy to be provided with dedicated MSSB fed from local main MSSB.

Sub-metering not required for Retail tenancies.

Safety Services Provide dedicated Safety Services MSSB for all Smoke Control equipment and all

associated equipment as nominated in AS1668.1

Thermographic

Surveys

Undertake a thermographic survey of all busbars, equipment, terminations and

connections in the MSSBs with a full load current exceeding 200 A/ph.

Fault Current Nominal 25kA (to be confirmed prior to manufacture)



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Item

Labelling

All switchboard labelling must be Traffolyte or similar

Main identification label must include the following:

Manufacturers details;

Rated voltage;

Current;

Frequency;

Short circuit current;

Reference number and description;

Date of manufacture; and

Degree of protection and form.

Manufacturer Decon or Westwoods

Circuit Breakers: Schneider, ABB, Terasaki

14.2. VARIABLE SPEED DRIVES

Table 14-4 Variable Speed Drives

Item

General

Variable Speed Drives (VSDs) must be in accordance with AS/NZS 3947.4.2.

VSDs must be compatible with BMS Lon communication protocol.

Each VSD must be selected on the basis of maximum motor full load “nameplate”

amps and not motor kW rating.

Enclosure

Enclosures must be protected against the ingress of dust and water to IP66 in

accordance with AS 60529

VSD’s above 140A may be a minimum IP54

Environmental

VSD’s must be in accordance with the following environmental limits:

Ambient Temperature (storage): -20ºC to +70°C

Ambient Temperature (operation): Capable of 0ºC to 40°C continuous at motors

FLC

Relative Humidity: 5% to 95% non-condensing

Where higher ambient temperatures are specified the VSD must be de-rated

according to documented manufacturer de-rating requirements.

Power Factor VSD’s must provide an input power factor not less than 0.98.

Harmonic Distortion

The carrier frequency of the PWM inverter must be asynchronous to limit

harmonic distortion of the 5th and 7th bandwidths to < 3%.

VSD’s must include a substantial ‘DC Bus Harmonic Reduction Reactor’ in

accordance with AS/NZS 61000.3.12for applicable to equipment up to 75 A, and

AS 61000.3.4:2007 for equipment above 75A. The DC bus choke must be

integral to the VSD’s IP66 Enclosure and part of the original design (not add-on).



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Item

Control Panel &

Display

Provide a control panel with soft touch keypad and alpha/numeric LCD display to

facilitate commissioning and adjustment of variables and to display status

including faults.

Manufacturer Danfoss VLT Range

14.3. HARMONIC DISTORTION

Table 14-5 Harmonics

Item

Harmonic Distortion

The carrier frequency of the PWM inverter must be asynchronous to limit

harmonic distortion of the 5th and 7th bandwidths to < 3%.

VSD’s must include a substantial ‘DC Bus Harmonic Reduction Reactor’ in

accordance with AS/NZS 61000.3.12 for applicable to equipment up to 75 A, and

AS 61000.3.4:2007 for equipment above 75A. The DC bus choke must be

integral to the VSD’s IP66 Enclosure and part of the original design (not add-on).



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15. LABELLING AND IDENTIFICATION

All equipment and services must be labelled in accordance with APAM’s referencing and

Asset Identification requirements.

Table 15-1 Colour Schedule

System Colour Label Colour

Chilled Water Blue Black

Heating Water Red White

Condenser Water Green Black

HTHHW AS2700 G16 Green White

Feed Water Nil White

Condensate Nil Black

Exposed Ductwork,

fittings, grilles,

attenuators, etc (Other

than plantrooms)

AS2700 White Y35 Black

Ductwork, Conditioner

Casings, Air Handing

Units, Filter Plenums (in

plantrooms)

Nil Black

Electricity (Conduits,

Ducts & Motors) Orange Black

Danger AS1318 Black & Yellow diagonal stripes

(45° 25mm wide)

Equipment To match respective services

Valve & Pipeline Fittings To match respective services Black

Belt guards AS1318 Black & Yellow Diagonal Stripes

(45° 25mm wide)

Switchboards AS2700 Orange X15 Black



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16. PAINTING AND CORROSION PROTECTION

16.1. GENERAL

All metal exposed to the atmosphere and ground must be protected from atmospheric and

soil corrosion in accordance with AS 2312.

Plant and equipment colour schemes and surface finishes used on roofing structures must

be of a non-reflective matt finish to minimise pilot glare

16.2. HOT DIP GALVANIZING

Where specified, hot-dip galvanizing must be in accordance with AS/NZS 4680.

16.3. PAINTING

16.3.1. GENERAL

The painting of all equipment, plant and apparatus which is not factory finished must be

carried out in accordance with the following standards:

AS 2311;

AS/NZS 2310; and

AS/NZS 2312

The Contractor must nominate an appropriate painting system (including surface

preparation, primers and finishes) for each application from a recognised referencing

system, such as GPC or APAS, and submit Melbourne Airport for approval prior to carrying

out works / ordering materials.

Fresh air plenums adjacent to weather louvres must be painted and protected internally with

anticorrosive treatment.

Ductwork and dampers behind registers and diffusers must be internally painted matt black.

The following materials and equipment must not be painted:

chromium;

Anodised aluminium;

GRP;

UPVC;

Stainless steel;

Hot-dipped galvanised steel;

Foil faced insulation;

Non-metallic flexible materials;

Normally lubricated machined surfaces such as pump shafts and valve stems; and

Equipment nameplates.



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16.3.2. GLOSS LEVEL

Unless approved by Melbourne Airport, all paint should result in a high gloss surface finish.

16.3.3. SURFACE PREPARATION

Prior to surface preparation, steel surfaces must be cleaned of any dirt, grease, loose rust

and other contaminants.

Surface preparations must be in accordance with the manufacturer’s recommendations. The

quality of surface preparation specified must be achieved at the time of priming.

Areas to be welded must be masked off prior to priming, and after welding, prepared and

primed as described.

16.3.4. PAINTWORK SCHEDULE

All paints used must be supplied in a single scheme by the same manufacturer.

Primers in which red oxide (red iron oxide) is the primary colouring agent must not be used.

16.3.5. APPLICATION OF PAINT

As soon as the priming coat has dried, an extra stripe coat of paint must be applied to all

edges, corners, crevices, bolt heads, welds and any similar areas, using the same paint as

for the primer but in a contrasting shade.

Paint application must be in accordance with the manufacturer's recommendations.

A method statement together with a description of surface preparation and paint product

technical data sheets for comment must be submitted to Melbourne Airport.

16.3.6. DAMAGED SURFACES

Damaged painted surfaces and test areas must be repaired and made good to the

requirements of the original specification.

16.3.7. PRE-FINISHES

Factory pre-finishes must be applied to the following items:

anodising:

Door relief grilles;

Linear supply air diffusers; and

Weather louvres.

Galvanising:

External platforms, stairs and hand rails; and

Piping and ducting hangers and supports exposed to weather.

Powder Coating:

Air handling units;

Control panels;

Diffusers, grilles and registers;



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Electrical control panels;

Fan coil unit enclosures;

Motor control centres;

Packaged air conditioning units; and

Radiators and convectors.

Self-finished Items:

Insulation with stainless steel, UPVC or foil faced cladding;

Stainless steel kitchen exhaust hoods;

Stainless steel or aluminium ductwork.

16.4. MATERIALS

16.4.1. PAINTS

Paints, and other materials, must be in accordance with the APAS.

16.4.2. TOXIC INGREDIENTS

Paints, and other materials, must be in accordance with the requirements of the SUSMP.

16.5. FACTORY APPLIED FINISHED

Damaged Factory Applied Finishes must be repaired.

Reports must be submitted to Melbourne Airport for factory applied finishes showing specific

procedures have been followed.

16.6. CLEANING

Plant and adjacent surfaces must be cleaned after painting and any paint marks, oil and the

like must be removed.

Bright metal parts, nameplates and identification markers must be cleaned and polished



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17. NOISE & VIBRATION CONTROL REQUIREMENTS

Table 17-1 Acoustic Design Criteria for Mechanical Systems

Item

General

Building services noise levels must be in accordance with AS 2107 and to the

internal noise levels directed by the acoustic consultant.

In no instances must operating mechanical services equipment exceed 85 dBA at

1m.

Vibration Isolation

Mounts

Isolate all equipment incorporating rotating or reciprocating machinery on anti-

vibration mounts. Provide these mounts with transmissibility low enough so as not

to cause excessive vibration of the building structure.

All items of plant, except those located in a basement, must be isolated to a level

of 98% vibration efficiency at the dominant disturbing frequency.

Flexible Connections All items of rotating and reciprocating equipment must be connected to their

respective piping and electrical power supplies with flexible connections

Machinery Bases

Mount all machinery on integral rigid bases which do not deflect excessively

under the weight of the equipment or due to the reactions between motors, driven

machines etc. To avoid base resonances, the natural flexural frequency of the

isolator base must be a minimum of 10% greater than the maximum rotational

speed of the motor or driven machine.

Pipe and Duct

Hangers and

Mountings

Provide isolation mounts and connections for pipework and ductwork

manufactured by approved manufacturers and be of approved materials.

Incorporate in all hangers’ height adjustment by means of a nut on the hanger rod.

Equipment Plinths Concrete plinths must be provided under all items of floor mounted and be a

minimum of 100mm high



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18. WATER TREATMENT REQUIREMENTS

Table 18-1 General Requirements

Item

General Water treatment must be in accordance with the following standards: AS/NZS

3666.1; AS/NZS 3666.2; AS/NZS 3666.3; and HB 32

Regulations Water treatment must be in accordance with the following regulations:

Public Health and Wellbeing Regulations;

18.1. DESIGN & INSTALLATION REQUIREMENTS

Table 18-2 Design & Installation Requirements

Item

Performance

Water treatment systems must be provided for the control of the following:

Open systems: Scale formation, corrosion, sludge accumulation and

microbiological growth including Legionella species; and

Closed systems: Scale formation, corrosion, sludge accumulation and

microbial growth

The water treatment system performance must:

Limit corrosion rates to the following:

Copper: ≤ 12 µm/year.

Mild steel and iron: ≤ 150 µm/year.

Stainless steel: ≤ 5 µm/year, with no pitting.

Be compatible with the fluid being treated and the system construction.

Clean corrosion products and foreign matter from new piping.

Effectively control:

In closed systems: Corrosion, microbiological growth, pH, scale formation

and sludge accumulation.

In open systems: Chlorides, corrosion, fouling, microbiological growth

including Legionella species, control bio film formation, pH, scale

formation, sludge accumulation, total alkalinity and total dissolved solids.

Meet regulatory requirements.

Not be hazardous in normal use.

Not cause components to deteriorate



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Item

Compatibility

Water treatment systems must suit the fluid being treated, and the as-installed

system construction.

Water treatment must be compatible with the current Melbourne Airport dosing

regimen.

The Contractor must submit a dosing implementation plan to Melbourne Airport

for approval prior to commencement on site. This plan must identify the following

as a minimum:

Dosing chemicals / agents to be used;

Dosing chemicals/agents are the same as those currently used by

Melbourne Airport;

Volume of system to be dosed;

Quantity of dosing chemical/agent to be used; and

Dosing method statement including safety measures.

Corrosion Rates

Water treatment must limit corrosion rates to the following:

Mild steel and iron: 0.15mm/year;

Stainless steel: 0.05mm/year, with no pitting; and

Copper: 0.012mm/year.

Chemicals Sufficient quantities of chemicals must be supplied to treat the water from the time

of initial filling to beyond the end of the maintenance period.

Test Loops

Loops must be provided in water circulating systems containing corrosion

coupons representing the respective metals in the system in accordance with

ASTM D 2688.

Coupons must be replaceable every:

Steel 3 months

Copper 6 months

Stainless Steel 6 months

Marking

Piping and storage vessels containing hazardous materials must be identified.

If hazardous chemicals are to be stored, safety signs must be provided in

accordance with AS 1319.

18.2. CLOSED SYSTEMS

Table 18-3 Water Treatment Systems – Closed Systems

Item

Definition A water distribution or circulation system in which the water does not come into

contact with air during circulation and to which, in normal operation, no water is

added



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Item

General For each independent system to be treated, a separate chemical dosing system

must be provided consisting of a by-pass slug-dose feeder vessel employing

discharge flow to flush chemicals into the system.

Feeder Vessels

A storage tank must be provided capable of withstanding the maximum pump

pressure.

The following must be provided:

A funnel;

DN15 piping and valve for adding chemicals;

Vent line with valve;

DN15 drain line with valve discharging to drain; and

DN15 outlet line with valve.

18.3. OPEN LOOP SYSTEMS

Table 18-4Water Treatment Systems – Open Systems

Item

Definition A water distribution or circulation system that is not a closed system

General

For each independent system to be treated, a separate chemical dosing system

must be provided consisting of a storage tank supplying chemicals to a dosing

pump automatically activated by a control unit.

Standard: Comply with AS/NZD 3666.1 Section 4

Storage Tanks

Standard: To AS/NZS 4766.

Size: Low density polyethylene construction with lid, sized to hold more than

150% of estimated monthly usage.

Bund: Provide bunds to AS 3780.

Alarm: Provide a low chemical level alarm.

Dosing System

Dosing Pumps: Provide electrically direct driven, manually adjustable pumps with

clear plastic suction lines.

Dosing Lines: Material must be selected to be suitable for the chemicals being

carried. For lines exposed to sunlight, provide UV resistant plastic or run in

conduit



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Item

Automatic bleed

system

Provide automatic control of total dissolved and non-dissolved solids for each

system, using conductivity control units activating two position or modulating

bleed valves in water bleed lines.

Controller: provide accurate conductivity sensor and control to maintain high total

dissolved solids (TDS) and cycles of concentration.

Provide alarm to indicate TDS exceeding tolerance.

Provide motorised ball type control valves sized for the expected bleed off rate.

Provide upstream Y-type strainers with 1.6 to 3.2mm aperture size and isolation

and throttling valves.

Provide additional bleed lines for manual bleeding with throttle valves.

Adjust bleed rate to maximise the TDS cycles of concentration consistent with

Performance requirements noted in Error! Reference source not found.

Biocide dosing

Provide automatically controlled biocide treatment direct into each system.

Rotate the type of biocide regularly according to schedules prepared by a suitably

qualified person.

Provide an adjustable automatic lockout to prevent the bleed form operating while

biocide is being added to the system.

18.4. FILTER SYSTEMS

Table 18-5 Water filter systems Open Systems

Item

General Provide proprietary filter systems consisting of storage tanks, piping, valves,

instruments timers and controls of the automatic backwash filtration type.

Filters

Backwash cycle must be initiated by automatic timer with provision for manual

override.

Side-stream filtration equipment must be arranged by the WTSP

Automatic pressure initiated self-cleaning Screen filtration such as VAF or

approved equivalent (employing an appropriate screen size no greater than 100

micron) with sufficient agitation of cooling tower basins to ensure silt, sediment

and organic material does not settle in cooling tower basins. Filtration systems

using large volumes of water to backflush such as media filters must not be

acceptable, filtration systems using only timed backflush are not acceptable,

systems that do not remove organic material such as centrifugal or cyclone

separators are also not acceptable. Bag filters are not considered suitable for

cooling tower filtration.



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Item

Requirements

Provide a skid mounted separator filtration system of Lakos manufacture or equal

for each cooling tower to remove suspended solids down to 5 microns of specific

gravities between the ranges of 1.8 to 2.8.

Manufacture the unit from stainless steel suitable for locating in the external

corrosive environment.

Manufacture the unit from powder coated carbon steel, where the unit is protected

from the external corrosive environment.

The unit must incorporate the following:

Separator

Pump

Suction Strainer

Solids Collection Vessel

Indicator Package

Electrical Control

Piping

Valves

Skid Plate

Provide a tank sweeper Eductor system of Lakos manufacture or equal. Size and

configure the system to optimise the separator performance and maximise water

circulation with minimum pump flow.

Manufacture the Eductor nozzles from polypropylene or approved equal highly

corrosion resistant material.

18.5. EXECUTION

Table 18-6 Completion & Acceptance Requirements

Item

Acceptance Tests

For bacteria including Legionella species, sample and test must be completed by

a NATA-accredited testing authority.

Legionella analysis must be in accordance with AS/NZS 3896 & 3666 Bacteria

analysis / total plate count must be in accordance with AS 4276.3.1. Test reports

must be prepared and submitted to Melbourne Airport.

Pre-Treatment Chemicals must be supplied for pre-cleaning, cleaning and flushing of mechanical

piping systems. Instructions and supervision must be provided to ensure correct

use of chemicals.



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Item

Initial Treatment

Chemical Cleaning and Flushing

Detergent flushing must take place once hydrostatic testing has been completed,

release the testing water and flush piping systems using non-foaming alkali

detergent solution.

Cleaning and flushing must be completed by introducing cleaning chemicals to

piping systems and circulate continuously for at least 24 hours, with control and

manual valves open. Systems must be drained and clean strainers and flushed

with clean water until cleaning chemicals are removed.

Initial Treatment

As the water is initially introduced into any section of the system by the

mechanical contractor, the WTSP must simultaneously introduce a suitable

oxygen scavenger/corrosion inhibitor. The chemical is to be added at constant

frequency to the ingress water, at the point of ingress, either manually or by

automation. The mechanical contractor must provide any

mechanical/electrical/plumbing and similar facilities which may be needed for safe

dosing to take place.

When the mechanical contractor begins circulating the water through the System,

the WTSP must test the treated water at different points in the System, given the

presence of proper sampling points. The WTSP must test the treated water at

regular intervals for the duration of the hydrostatic test, dosing more oxygen

scavenger/corrosion inhibitor if required. The hydrostatic test itself must be

performed by the mechanical contractor. The mechanical contractor may choose

to perform the chemical dosing and testing, after consulting the WTSP in respect

of advice on safety and other details.

Alkaline Clean

Subsequent to the hydrostatic test discussed above, and when all galvanised,

aluminium and other sensitive components have been by-passed by the

mechanical contractor, the WTSP must dose the System with a suitable alkaline

chemical clean agent designed to disperse solids, remove oil and grease and

leave a clean waterside surface. The treated water must be circulated for around

24 hours through the entire System, except for the by-passed areas. A water

bleed is then set to flush out undesirable solids, and the System allowed to make-

up with raw water until the pH, clarity and general appearance of the System

water, at any point in the System, is clean and indistinguishable from that of the

ingress raw water. The mechanical contractor must ensure that raw water will

make-up adequately during the bleed process, given the bleed rate.

The mechanical contractor may choose to perform the chemical dosing and

testing, after consulting the WTSP in respect of advice on safety and other

details.

Disinfection Clean

Subsequent to the alkaline clean referred to in Section 1.9, disinfection clean must

be performed, in accordance with the Public Health and Wellbeing Regulations

2019.



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Item

Commissioning

Immediately after the disinfection clean, passivation of the System waterside must

be achieved using a suitable corrosion and scale inhibitor. A slug-dose of a “kill”

amount of a non-oxidising biocide must also be performed immediately after

passivation is achieved. The water treatment equipment must then be activated,

corrosion coupons inserted, and dosing tanks/drums adequately stocked with

chemicals.

Manufacturer Hydrochem or equal and approved.



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19. ACCESS REQUIREMENTS

19.1. DESIGN

The design of the plant access systems should consider the 24/7 access needs of the facility

and should provide safe trade access in all weather conditions. The need for temporary

access systems should be eliminated where possible to reduce risk and potential impact on

operations. Access to valves, inspection panels or control mechanisms, for the purpose of

conducting scheduled maintenance, is to be provided and should not be reliant on the use of

portable ladders, temporary scaffold or mechanical lifting systems (EWP).

The type of access system should be commensurate with the access needs of the site and

any constraints that may be present due to the nature of the facility. Internal access from

existing plant rooms, on the main airport concourse, is the most practical solution while

external stairs and ladders would be preferred on the outer buildings. Where internal access

is selected, it should be configured to have the lowest possible impact on the operations of

the facility. Access control (security) should be considered as a component of the selection

and positioning of any access systems.

19.2. PLANT ROOMS/ENCLOSURES

The priority is for plant systems to be centrally located within plant rooms, plant enclosures

or plant decks. This reduces the requirement for trades to access elevated areas or move

across vast sections of roof area to conduct scheduled maintenance. Access to these types

of areas should be via access doorways linked to fixed stairs and walkways. The use of step

or rung type ladders should be avoided for access to plant rooms or elevated plant

platforms, unless there are constrictions due to available space which makes the installation

of stairs impractical. The outer perimeter of any elevated plant deck is to be enclosed with

AS 1657-2013 compliant guard railing. Where an elevated plant deck is positioned above a

work area, walkway or fall edge then kick boards must be included.

19.3. ELEVATED ROOF AREAS AND PLANT ACCESS

Fixed access should be established to plant systems located on elevated roof areas. The

access is to be passive and allow trades to access the plant units without the use of portable

ladders or harnessed based fall protection systems (vertical ladders with cable safety

systems should be avoided). Fixed ladders should include cages with guarded platforms at

the ladder head. Where the ladder is providing the initial point of access to a roof, the ladder

is to include a lockable gate system to provide access control. Vertical ladders should be

avoided unless there are space constrictions that prevent a ladder from being installed at the

optimal angle in accordance with AS 1657-2013 (75° for rung type ladders).

Internal access through suspended panel or plaster ceilings (where fixed ladders are not

possible) are to include a pull-down ladder system which is suspended from the roof

structure. The internal roof cavity between pull-down ladder and hatch is to have a fixed

access ladder in place and should be configured to allow seamless directional travel (no

change of direction from ground to roof) between the pull down and fixed ladders.

Where internal access via a roof hatch is required, the hatch should have a minimum

opening of 800mm x 1000mm. Sliding hatch mechanisms are preferred; however, if hinged

hatches are utilised then gas struts are required to support the hatch during operation. A

guard rail surround is to be included to enclose the hatch opening and is to have fixed grab



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handles (exit stiles) to aid in transition through the hatch. The use of extendible stile units on

ladders should be avoided.

19.4. WALKWAYS AND GUARD RAILS

Walkways are to be established from the point of roof access (doorway, stair, ladder or

hatch) to each plant unit. Where walkways are located within two meters of a fall edge or

non-trafficable surface, AS 1657-2013 guard railing is required to close out the unprotected

edge or hazard. Where walkways cross non-trafficable skylight sheeting, a minimum of two

meters of mesh protective covers are to be installed on both sides of the walkway.

Alternatively, guard railing can be installed on each side of the walkway to close out the

hazard. Where walkways run within two meters of a non-trafficable skylight sheet, protective

mesh or guard rails are required to close out the hazard.

Walkways are to be of a metal, aluminium (preferred) or Fibre (not preferred) construction

and are to be supported above the roof sheeting on support battens. Fibre walkways are not

to be installed directly onto the roof sheeting and alternate fixing methods should be sourced

from the manufacturer. Fixing of the battens to the roof is to be via bulbtite rivet type and

must include a membrane tape seal.

19.5. CEILING SPACE PLANT ACCESS

Where plant systems are located within ceiling spaces, fixed passive access should be

established. The physical constraints of these types of areas (low headroom or services) will

create obstacles that prevent fully compliant access in accordance with AS 1657-2013;

however, every effort should be made to comply with the standard.

Non-trafficable ceilings should be treated as fall hazards. Areas beneath gantries or celling

space work platforms will be considered drop zones; however, operational constraints may

prevent areas from being closed off. Access gantries should be enclosed with AS 1657-2013

compliant guard railing on both sides which should include kickboards. The gantry flooring

should be constructed to prevent items from being dropped through it.

19.6. SPECIALISED ACCESS

Plant systems should be designed to allow maintenance to be conducted from ground level

or from a fixed platform. All efforts should be made at the design phase to eliminate the

requirement to access plant systems utilising specialist access equipment. However; this is

not always possible due to the constraints of the facility and existence of older plant

configurations. Where these issues arise specialist access systems will be required. The use

of EWP is an effective means of access and can be employed within the facility or externally

to conduct works. The impact, of this type of access system, on operations should be

considered at the design phase.

The use of complex harnessed based fall protection or rope access systems may be

required where there is an inability to access via other means. Where ongoing scheduled

maintenance or critical services are involved, these types of access methods should be

avoided.

19.7. COMPLIANCE

Any designed and installed plant access systems must comply with AS 1657-2013 Fixed

platforms, walkways, stairways and ladders – Design, construction and installation. Purpose



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deigned systems are to be supplied with detailed shop drawings and should clearly state that

the design meets Australian Standards. Where proprietary systems (modular type) are being

utilised, the installed systems must meet manufacturer’s specifications and contracted

installers must be trained and certified to install the products. All installed systems must be

clearly marked with the installer’s information and date of installation. This must be displayed

on a permanent plate or label in a prominent position. Ongoing maintenance should be

conducted to ensure that the access systems, stairs, ladders, guard rails and walkways are

in a serviceable condition.

Handover documentation should be supplied as a component of any plant access system

installation. This should include detail in relation to the products utilised for modular systems

and design loadings for complex purpose-built access system such as suspended or

cantilevered platforms



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20. OPERATION OF MECHANICAL SERVICES UNDER FIRE ALARM

Table 20-1 Fire Mode Operation

Item

Requirements

Mechanical Services equipment must be connected to essential and non-

essential mechanical switchboards or switchboard sections as indicated in the

schedules.

The Project must update the Melbourne Airport Fire/Mech matrix as part of project

delivery

The Designer must submit for approval an updated Fire/Mech Matrix, taking into

account new equipment or modifications to existing equipment, to the Melbourne

Airport Project Sponsor prior to commencement of works on site.

The Contractor must confirm the final Fire/Mech Matrix prior to practical

completion and demonstrate that switching/operation of mechanical equipment

occurs as described under a simulated fire event as part of the commissioning

process.

Operation of Non-

Essential Equipment

The Fire Protection Sub-Contractor will provide wiring to a fire relay in the non-

essential mechanical switchboard or switchboard section.

The Sub-Contractor must provide all necessary interlocks to ensure shut down of

the non-essential air handling plant in a fire alarm situation.

Fire relays must be provided within the mechanical switchboard to operate the

mechanical system as required in fire mode. Co-ordinate with the Fire Protection

Sub-Contractor and obtain details of the required incoming signal voltage prior to

installing the relays.

Relays must be of a type suitable for operation in conjunction with the Fire

Indicator Panel with respect to segregation of voltages and to the requirements of

the relevant Fire Authority.



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21. TESTING, BALANCING & COMMISSIONING REQUIREMENTS

21.1. ALLOCATION OF COMMISSIONING RESPONSIBILITIES

Table 21-1 Responsibilities Table

Specifying System Commissioning Activities

Design Activity Responsibility

Comments

Cons’tant Cont’r Other

Design

D.1) Ensure that the selected

systems will meet the

employer’s brief and that their

commissioning requirements

are compatible with any

project restraint concerning

sectional handover/phasing.

The contractor is responsible for those

services, systems or work elements

design by them and/or specialist sub-

contractors appointed by them.

D.2) Identify and incorporate

into system designs the

essential components and

features necessary to enable

the proper preparation and

commissioning of building

services.

Note as D.1

D.3) Review all designs to

ensure that systems can be

properly prepared, and are

commissionable.

Note as D.1

D.4) Prepare the

commissioning specification. Note as D.1

Management

D.5a) Produce a

commissioning method

statement and logic diagram

for integration into the building

contractor’s construction and

finishes programmes.

It is for the Contractor is to demonstrate

to the local Building Control office that

the person(s) providing this report are

suitably qualified.

D.5b) Produce a

“commissioning plan” as

required by Part L2 of the

Building Regulations.




suitably qualified.

D.6) Produce a flushing,

chemical cleaning and water

treatment method statement,



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Comments


logic diagram and programme

for integration into the building

contractor’s construction,

commissioning and finishes

programmes.

D.7) Attend commissioning

meetings as necessary OR

Arrange and chair

commissioning meetings as

necessary.

Give notice to the Consultant of when

meetings are taking place.

D.8) Comment on the

adequacy of systems for

commissioning as detailed on

specialists’ drawings and

manufacturers’ shop drawings

prior to actual manufacture at

works. Ensure comments are

incorporated into finished

products.

D.9) Carry out site

inspections, to ensure that the

commissioning facilities are

being installed. Check

compliance with specified

guides and standards.

D.10) Monitor the on-going

progress of the procurement,

manufacture, installation and

commissioning of all plant

items.

D.11) Assess the effects of

any anticipated delays to the

services installation and the

completion of interfaces with

the building works critical to

the commissioning

programme. Formulate

strategies to overcome

potential delays.

D.12) Establish an agreed set

of pro forma documentation

relating to the commissioning

and testing of plant and

systems.

Issue to project consultant for

comments.



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Comments


D.13) Approve the proposed

set of instruments of the

commissioning and testing

works

D.14) Ensure that the

instrumentation is periodically

calibrated as necessary and

records retained.

D.15) Witness the flushing,

cleaning and treatment of

systems in accordance with

the specification.

D.16) Witness pre-

commissioning activities in

accordance with the

specification.

D.17a) Commission all

systems to methods, logic and

programme and record

results.

D.17b) Witness specified

demonstration of system

D.18) Witness and record the

specified demonstration and

testing of plant items and

systems in accordance with

the specification.

D.19) Establish procedures to

allow the demonstration of

normal emergency, shutdown

and standby mode operation

of plant and systems.

“Other” refers to manufacturers or

suppliers of plant items.

D.20) Witness demonstration

of same to specified

requirements.

D.21) Demonstrate the partial

load testing of plant to the

employer and designer in

accordance with the

specification.



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Comments


D.22) Witness the operation of

the BMS on site to the

specified requirements.

“Other” = BMS Specialist Designer.

D.23) Witness the functional

testing of all safety interlocks

in accordance with the

commissioning specification

D.24) Witness the

demonstration of acoustic

tests, if any, in accordance

with the specification.

D.25) Witness the operation of

plant and systems for

specified periods of time to

prove plant reliability.

D.26a) Produce

commissioning report detailing

the results of the

commissioning and

commenting on the

performance of systems.




suitably qualified.

D.26b) Produce a

“commissioning report”

D.27) Ensure that all plant

settings are recorded,

including appropriate

reference to plant items. The

records should be

incorporated within the

operating and maintenance

manuals.



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21.2. PRODUCTION OF HANDOVER INFORMATION

Table 21-2 Handover Information

Production of Handover Information


Comments


E.1) Define the scope and

content of operating and

maintenance manuals

appropriate to the size of

project, the employer’s


strategy and the technical

capability of the maintenance

staff

E.2) Define the requirement for

record drawings appropriate to

the employer’s operating and

maintenance strategy.

E.3) Advise on the need for a

specialist author for production

of operating and maintenance

manuals.

E.4) Advise on the need for a

separate survey of installed

systems to facilitate production

of record drawings.

This survey will only be required if the

Contractor has failed in their duty to fully

record the installed services as the work

proceeds and before it is covered up. The

cost of this survey, if required, will be

recovered through the Contract.

E.5) Prepare a specification for


manuals. Specify the section

headings and required technical

content of the manuals.

See Preliminaries for details of the level of

information required.

E.6) Prepare a specification for

record drawings. Specify

content, form of delivery and

the method of production of the

drawings to be produced.

In order to comply with the CDM

Regulations the Contractor is to ensure

that complete O&M information and

Record Drawings are available to the

employer prior to Practical Completion.

See Preliminaries for further information.



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Comments


E.7) Define what level of

documentation, commissioning

results and other information

must be available prior to

practical completion and

handover. Take into account

possible implications of phased

handover and partial

possession.

E.8) Produce operation and

maintenance manuals in

accordance with the specified

requirements.

E.9) Ensure that information

needed for inclusion in the


manuals is obtained as the

works progress. Identify

individual sources of

information

E.10) Establish target dates for

when information must be

available to the author of the


manuals. Advise on timescales

for production of maintenance

information relative to key dates

i.e. installation start date, setting

to work, start dates for testing

and commissioning and

handover dates.

E.11) Monitor the programme

for production of operating and

maintenance manuals and

adjust dates to allow for

progress of the project.



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Comments


E.12) Receive, inspect and

comment on the contents of the


manuals in order to confirm

general compliance with the

specified requirements

The Contractor is to inspect and comment

on the manuals where produced by others

on their behalf prior to submission to the

consultant

The Contractor is to ensure that drafts of

the O&M manual(s) are available for

comment at least 8 weeks prior to

Practical Completion.

E.13) Modify and update

operating details to reflect

commissioning results.

E.14) Accept the completed


manuals on behalf of the

employer.

E.15) Identify key dates and

intervals at which draft record

drawings will be inspected.

Contractor is to provide schedule of dates

for the release of this information.

E.16) Modify the record

drawings as the works progress

so that all alterations from the

installation drawings are

recorded as work proceeds

Contractor is to ensure that the As-

installed Drawings are maintained on site

and updated as the work proceeds. The

As- installed Drawings are to be made

available for inspection when requested

by APAM.

E.17) Receive, inspect and

comment on the Record

Drawings in order to confirm

general compliance with the

specified requirements.

E.18) Accept the completed

record drawings on behalf of the

employer

E.19) Prior to handover, make

recommendations for the

commencement and carrying

out of operation and

maintenance during and after

the Defects Liability Period.

When stated in the preliminaries the

Contractor is to provide a priced proposal

for the maintenance of the installed

services during the period concurrent with

the Defects Liability Period within their

contract price

E.20) Provide the employer with

a log-book

(Uncontrolled when printed) [insert document ID e.g. MAS-...-…]

MAS-…-… [Title] Australia Pacific Airports (Melbourne) Pty Ltd Standard

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mechanical services design standard

Documents