Standard Specifications for Engineering Services

Building Services & Utilities Specifications

BUILDING SERVICES AND UTILITIES

SPECIFICATION

MANUFACTURING &
COMMERCIAL

ISSUE September 2008

Prepared By:
PepsiCo International Europe, Africa & Middle East
Engineering Technical Services
Feature Rd
Thurmaston
Leicester
LE4 8BS
United Kingdom
Fax +44 116 234 2355

Date Section Change Description Ref

Standard Specifications for Engineering Services
Building Services & Utilities Specifications

Date Section Change Description Ref

August 1.1 Introduction modified NG
2008
1.9.1 Building Management Systems NG

4.1 Lighting examples added NG

19 Compressed air systems NG

Standard Specifications for Engineering Services
Building Services & Utilities Specifications

1. MECHANICAL AND ELECTRICAL BUILDING SERVICES & UTILITIES ................................... 2

1.1. Introduction ........................................................................................................................ 2
1.2. Fire Precautions .................................................................................................................. 3
1.3. Co-ordination of Building Services Installations ............................................................... 3
1.4. Standard Workmanship and Conditions ............................................................................ 3
1.5. Regulations and Standards ................................................................................................ 3
1.6. Quality Assurance and Certification .................................................................................. 4
1.7. Design Philosophy/Building Life......................................................................................... 4
1.8. American Institute of Bakers (AIB) ................................................................................... 5
1.9. Sustainability Aims............................................................................................................. 5
1.9.1. Building Management (BMS) Systems ....................................................................... 5
1.10. Existing Services............................................................................................................. 6
2. ELECTRICAL ENGINEERING BUILDING SERVICES ............................................................... 7
2.1. Definitions .......................................................................................................................... 7
2.2. Electricity Supply Infrastructure ........................................................................................ 7
2.3. Electricity Supply Power Distribution HV & LV (General) ................................................. 7
2.3.1. Circuit Breakers........................................................................................................... 7
2.3.2. Sub Station Ringmain Units (RMU) ............................................................................ 8
2.3.3. Power Distribution Transformers................................................................................ 9
2.3.4. Cast Resin Transformers .......................................................................................... 10
2.3.5. Substation and Switchgear Equipment .................................................................... 11
2.3.6. Low Voltage Switchboards ........................................................................................ 11
2.3.7. Power Factor Correction ........................................................................................... 14
2.3.8. Cable Glands and Terminations................................................................................ 14
2.3.9. Earthing ..................................................................................................................... 15
2.3.10. Current Transformers ............................................................................................ 16
2.3.11. Harmonic Testing/Analysis ................................................................................... 16
2.3.12. Instruments ........................................................................................................... 16
2.3.13. Locking & Interlocks .............................................................................................. 17
2.3.14. Environmental Treatments ................................................................................... 17
2.3.15. General Requirements........................................................................................... 18
2.3.16. Installation Requirements of HV & LV Switchboards ........................................... 19
2.3.17. Pre Delivery Inspection at Manufacturers Works ................................................. 20
2.3.18. Site Commissioning ............................................................................................... 20
2.4. Standby Power Systems – UPS, Surge Protection and Generator ................................. 20
3. Small Power Services/Wiring Accessories .......................................................................... 21
3.1. Factory Areas ................................................................................................................... 21
3.2. Plant Rooms...................................................................................................................... 21
3.3. General Use/Cleaners Use ............................................................................................... 21
3.4.General Office Accommodation & Ancillary Areas ........................................................... 21
3.5.Warehouse/Distribution Areas ......................................................................................... 22
3.6.Gatehouse ........................................................................................................................ 22
3.7.Sprinkler Pump House ..................................................................................................... 23
3.8.Wastewater Treatment Plant ........................................................................................... 23
3.9.Process/Packaging Areas ................................................................................................. 23
4. Lighting ................................................................................................................................ 24
4.1. General ............................................................................................................................. 24
4.1.1. Illumination Levels & Glare Indices ......................................................................... 26
4.2. Warehouse Areas ............................................................................................................. 27
4.3. External – Building & Yard Areas .................................................................................... 28
4.4. Office/Administration Areas ............................................................................................. 28
5. Emergency Lighting Systems .............................................................................................. 29
6. Methods of Wiring & Containment Systems (Non Process Areas)..................................... 30
6.1. Cable Installations Underground ..................................................................................... 30
6.2. Cables Installed in Trenches ............................................................................................ 31
6.3. Cables Installed within the Building Structure................................................................ 31
6.4. Conduits Concealed in the Building Structure (Incl. Partitions) .................................... 31
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6.5. Fixing of Cables ................................................................................................................ 32

6.6. Underfloor Cable Trunking and Accessories .................................................................... 32
6.7. PVC Conduits and Accessories ......................................................................................... 33
6.8. Steel Cable Trunking ........................................................................................................ 33
6.9. PVC Cable Trunking (including Dado/Skirting Trunking) ............................................... 34
6.10. Cable Ladders ............................................................................................................... 35
6.11. Cable Trays ................................................................................................................... 35
6.12. Cable Trays and Ladders Installed Within Process Areas ........................................... 35
6.13. Cable Ties and Cable Identification ............................................................................. 36
7. Lightning Protection System ............................................................................................... 36
8. Site Security......................................................................................................................... 38
8.1.1. Security ..................................................................................................................... 38
8.1.2. CCTV system ............................................................................................................. 38
8.1.3. Card access system .................................................................................................. 38
9. Building Management System (BMS) ................................................................................. 39
10. Fire Detection and Alarm System ....................................................................................... 39
11. Electrical Building Services Located within Process Areas ................................................. 41
12. IT & Data Equipment ........................................................................................................... 42
13. MECHANICAL ENGINEERING BUILDING SERVICES ........................................................... 43
13.1. Definitions ..................................................................................................................... 43
13.2. Fuel Supplies ................................................................................................................ 44
13.2.1. Natural Gas ............................................................................................................ 44
13.2.2. Fuel Oil ................................................................................................................... 45
13.2.3. Liquid Petroleum Gas (LPG) .................................................................................. 45
14. Heating ................................................................................................................................. 47
14.1. General .......................................................................................................................... 47
14.2. Heat Pumps................................................................................................................... 47
14.3. Hot Water Heating Systems LTHW, MTHW & HTHW................................................... 47
14.3.1. Boilers .................................................................................................................... 48
14.3.2. Flues and Flue Pipework ....................................................................................... 49
14.3.3. Circulating Pumps ................................................................................................. 49
14.3.4. Pressurisation Units............................................................................................... 50
14.3.5. Radiators................................................................................................................ 50
14.4. Gas Fired Radiant Strip Heating .................................................................................. 51
14.5. Gas Fired Unit Heaters ................................................................................................. 51
14.6. Steam Systems............................................................................................................. 52
15. Building Mechanical Services .............................................................................................. 52
15.1.1. Internal Design Temperatures .............................................................................. 53
15.1.2. Natural Infiltration Rates ...................................................................................... 53
15.1.3. Mechanical Supply/Extract Ventilation Rates ........................................................ 54
15.1.4. Thermal Transmittance ......................................................................................... 54
15.1.5. System Temperatures ........................................................................................... 55
15.1.6. Noise Levels ........................................................................................................... 55
15.1.7. Heat Gains ............................................................................................................. 55
15.1.8. Building Occupancy Levels .................................................................................... 56
16. Ventilation Systems ............................................................................................................. 56
16.1. General .......................................................................................................................... 56
16.2. Process Area Ventilation............................................................................................... 57
16.3. Packaging Area Ventilation .......................................................................................... 59
16.4. Ductwork ....................................................................................................................... 59
16.5. Air Handling Units ......................................................................................................... 61
16.6. Grilles/Diffusers/Louvres .............................................................................................. 63
16.7. Attenuators ................................................................................................................... 64
16.8. Fire Dampers ................................................................................................................ 65
16.9. Testing and Commissioning ......................................................................................... 65
17. Air Conditioning/Direct Expansion (DX) Comfort Cooling Systems................................... 67
17.1. General .......................................................................................................................... 67
17.2. Chilled Water Systems ................................................................................................. 67
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17.3. Comfort Cooling/Heat Pump Installations ................................................................... 67

17.3.1. Refrigeration Pipework (direct expansion) ........................................................... 68
17.3.2. Condensate Pipework ............................................................................................ 69
17.3.3. External Condensing Units .................................................................................... 70
17.3.4. Commissioning ...................................................................................................... 70
18. Domestic Water Services..................................................................................................... 71
18.1. General .......................................................................................................................... 71
18.2. Direct off Mains Electric Water heaters ....................................................................... 71
18.3. Indirect Hot Water Calorifiers ...................................................................................... 71
18.4. Pipework........................................................................................................................ 72
18.5. Valves ............................................................................................................................ 72
18.6. Insulation ...................................................................................................................... 72
18.7. Mains Cold Water Supply ............................................................................................. 73
18.8. Boosted Cold and Domestic Hot Water Service .......................................................... 73
18.9. Packaged Cold Water Booster Set ............................................................................... 74
18.10. Plate Heat Exchanger................................................................................................ 75
18.11. Electromagnetic Water Conditioner ......................................................................... 75
18.12. Urinal Flush Controllers ............................................................................................ 76
18.13. Thermostatic Blending Valves .................................................................................. 76
18.14. Showers ..................................................................................................................... 76
18.15. Secondary Return Circulating Pump ........................................................................ 76
18.16. Chlorination ............................................................................................................... 77
18.17. Testing and Commissioning...................................................................................... 77
18.18. Hot Water Washdown System .................................................................................. 78
18.19. Safety Showers & Eye Wash Facilities ..................................................................... 78
19. Compressed Air Facility ....................................................................................................... 79
20. Automatic Controls For Mechanical Building Services Plant and Equipment .................... 81
20.1. General .......................................................................................................................... 81
20.2. Installation .................................................................................................................... 81
20.3. Control System Panel Types ........................................................................................ 82
20.4. Commissioning and Testing ......................................................................................... 82
20.5. Documentation ............................................................................................................. 83
21. Mechanical Building Services Located within Process Areas .............................................. 84
Standard Specifications for Engineering Services
Building Services & Utilities Specifications

REFERENCES
It is intended that this specification be read in conjunction with the associated
specifications set out below. Please check with PepsiCo International for current
versions
PepsiCo International General Contract Preliminaries: This document deals with
the contractual part of working with PepsiCo International and covers items such as
tender proposals, terms of payment, procedures, deliverables, site safety etc.
PepsiCo International Mechanical Engineering Specification:
This document covers process mechanical services, process machinery, and general
construction and design for food and personal safety, and is related to manufacturing
and logistics areas.
PepsiCo International Electrical Engineering Specifications:
This document covers electrical services, control systems, SCADA & PLC systems,
general electrical construction and design for food and personal safety and is related
to process areas.
PepsiCo International Civil Engineering Specifications
This document covers the design and construction methods.

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BUILDING SERVICES & UTILITIES SPECIFICATIONS

The purpose of this document is to be used for the development of projects with utilities
requirements at PepsiCo existing and new build sites. The contents have been compiled so
that it may be used to structure a briefing document for a design team, or a design and build
contractor.

It recognises that no two PepsiCo Facilities are the same, and that whilst there are ideal
standards which should be complied with where possible, that there are also standards that
may be deemed to be satisfactory. This document is not intended to set out fully detailed
practices.

Building utilities are to be designed and to provide an effective and comfortable working
environment, within the production areas, warehouse and offices. All relevant statutory
codes and standards applicable in local country / region are to be fully complied with

1. MECHANICAL AND ELECTRICAL BUILDING SERVICES & UTILITIES

1.1. Introduction

The design of the Mechanical and Electrical Building Services shall be energy
efficient, emphasise simplicity of layout and control, facilitate and provide ease of
maintenance and include standard, tried and tested components to achieve a
design life of a minimum of 30 years, subject to planned maintenance
requirements.

The location and selection of all items of engineering service works that have an
individual impact on the interior or exterior of the design shall be closely co-
ordinated and integrated into the overall building design.

Engineering and utility plant locations shall be selected to:

• Minimise the cost of services distribution systems.

• Allow for a minimum of 25% future expansion of the buildings or processes.
• Maintain good access for plant movement without effecting building use.
• Give the best visual M&E environment effect.
• Provide flexible and commercial building services solutions

All plant and equipment shall be located/installed to provide adequate means of

access for maintenance purposes, both routine and extraordinary without
impacting on the day to day operations of the Business.

The design and layout of all plant areas shall be considered to permit safe and
economic maintenance, their locations shall comply fully with the requirements of
The Construction Design & Management Regulations.

Where BS/EN numbers are specified these are stated as being correct at the time
of compiling.

This document is written and is intended to provide specification requirements for

the operations undertaken within Europe and the UK, where operations occur in
other countries outside of these standards, the appropriate standards adopted
within the countries outside of these standards shall be utilised.

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Overriding Principle

WHILST THIS DOCUMENT IS INTENDED TO ENCOMPASS ALL ASPECTS AND

REQUIREMENTS, IT IS NOT INTENDED TO BE EXHAUSTIVE AND THE
CONTRACTOR/DESIGNER WILL BE RESPONSIBLE FOR THE FULL DESIGN AND
DEVELOPMENT OF ALL PROPOSALS/SOLUTIONS AND IT WILL BE ASSUMED THAT
THIS IS COVERED WITHIN ANY OFFER PROPOSED BY THE CONTRACTOR/DESIGNER
IT WILL BE ASSUMED THAT THE REQUIREMENTS OF THIS DOCUMENT HAVE BEEN
MET AS A MINIMUM, BUT IN THE EVENT OF DOUBTS, QUERIES AND ALTERNATIVES,
FORMAL ACCEPTANCE AND AGREEMENT SHOULD BE REGISTERED IN WRITING
BEFORE PROCEEDING.

1.2. Fire Precautions

The Fire Strategy specified for all projects shall meet with the requirements of the
Local Fire Authority, the Client’s insurer and Fire Consultant and all documents
pertinent to their requirements.

All materials and surfaces incorporated in the construction of the development

should have the requisite fire resistance, surface spread of flame and other
relevant characteristics appropriate to their location and purpose, as specified by
the above authorities and in accordance with current legislation.

1.3. Co-ordination of Building Services Installations

The Mechanical and Electrical Building Services Specification, design & associated
installation shall be fully coordinated with each other and the Building Structures.

1.4. Standard Workmanship and Conditions

It is an implicit requirement that the all Mechanical and Electrical Building Services
Installations workmanship is carried out to the highest standard and at the time of
handover of the Services to the Client, the condition of the overall installations
shall be as new.

No parts of any of the Mechanical and Electrical Building Services Installations are
to be used/set to operate (with the exception of commissioning purposes) prior to
handover, under conditions that are likely to cause deterioration.

1.5. Regulations and Standards

Conformity with Regulations:

The Mechanical and Electrical Building Services design and installations shall
conform with current requirements and recommendations of all the relevant codes
of practice, statutory regulations, bye-laws, commissioning codes and installation
instructions shall be complied with during the execution of the works, including but
not limited to the following:

The Health & Safety at Work Regulations

The COSSH Regulations
The Factories Act
The Clean Air Act
The Environmental Protection Act

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The Index of Protection

The Building Regulations
The Public Health Act
Workplace (Health, Safety & Welfare) Regulations (1992)
The Offices, Shops and Railway Premises Act
British Standards Institution Publications and appropriate ISO or CEN/CENELEC
Standards
The Water Research Commission
The Water Supply Regulation
The Requirements and recommendations of the local fire officer
The Requirements of any insurance companies concerned
The Electricity at Work Regulations (1989)
The Provision and Use of Work Equipment Regulations (PUWER) 98 & EN 954
The Heating and Ventilating Contractors Association requirements
Potentially Explosive Atmospheres (ATEX)

The Contractor shall also note, in addition to the requirements in respect of

compliance to the regulations, that design standards, calculations, methods of
construction, standards of workmanship, materials, components and the testing
and commissioning of components and systems should, as a minimum, be in
accordance with the recommendations set out in the latest edition of the following:

(a) British Standard Specification and Codes of Practice

(b) The CIBSE Guides, Codes and Technical Memoranda
(c) Construction, Design and Management (CDM) Regulations
(d) The IEE Wiring Regulations BS 7671: 2001
(e) The Safety of machinery, Electrical Equipment of Machines - BS EN 60204
(f) The Dangerous Substances and Explosive Atmospheres Regulations 2002
(DSEAR)

The detailed requirements identified in subsequent sections do not generally refer

specifically to the above documents but there are exceptions where either a choice
of standards exist, and Health & Safety requirements need to be emphasised or
where mention of a specific standard avoids the need for detailed description.

The detailed requirements identified in subsequent sections are, in all cases,

additional to the minimum requirements of the above standards.

1.6. Quality Assurance and Certification

All products and materials specified/installed shall have a Product Conformity

Certification (e.g. CE Mark, BSI Kitemark, BFI Safety Mark), or an EU mark or
Product Approval (e.g. British Board of Agreement Certificate).

1.7. Design Philosophy/Building Life

The overall design solution of the Mechanical and Electrical Building Services shall
satisfy the requirements of the design criteria whilst also being capable in all
respects of providing an environment, which is pleasant, environmentally friendly,
energy conserving with maintenance minimised.

Emphasis should be placed wherever possible on adopting durable low

maintenance sustainable materials and for avoiding over-complicated design
resource systems which are expensive to operate and maintain, and costly to
replace.

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The building and its services should be designed to operate effectively and
efficiently throughout its design life and the materials and components carefully
selected & specified with due consideration being given to their individual life
cycles relative to an overall design life of thirty years.

1.8. American Institute of Bakers (AIB)

Design solutions shall not conflict with the requirements of the AIB Global Matrix. A
copy of this document is available on request with specific reference to the
following sections:

Section 2 - Personnel requirements

Section 4 - Foreign object management
Section 5 - Microbes and allergens
Section 6 - Pest control
Section 7 - Sanitation
Section 8 - Maintenance requirements

1.9. Sustainability Aims

The general policy is to provide a facility (with its associated Mechanical and
Electrical Building Services installations) which is environmentally friendly from the
global, local external and internal aspects and which minimises the impact on any
local community and the environment.

1.9.1. Building Management (BMS) Systems

BMS systems shall be adopted to control all Building service utilities to regulate
energy demand depending on occupancy times. Application is to include lighting,
HVAC, refrigeration, domestic hot water and all other primary energy users.
Systems may be extended to control compressed air, steam raising systems, heat
recovery systems etc.

The design solutions adopted should therefore endeavor to ensure so far as is

reasonably possible that the building is designed to address the following:-

• Minimise any negative impact on the local environment and where possible
improve it
• Minimise the effect of ozone depletion
• Minimise the effect on global warming
• effluent
• Minimise water pollution
• Minimise water consumption
• Minimise non-renewable resource depletion
• Avoid radon contamination
• Minimise the risk of Legionnaires disease and the spread of Legionella
• Minimise the effects of ionising and electro-magnetic radiation
• Avoid the use of potential irritants and/or toxic substances
• Avoid design features associated with Sick Building Syndrome
• Maximize the opportunity for recycling
• Enable planned preventative maintenance regimes to be used to maintain
optimum performance.
• Maximize building/site energy efficiency
• Minimise solid waste production

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1.10. Existing Services

An overall design solution of the Mechanical and Electrical Building Services for a
particular PepsiCoInternational site/facility must take into account all the
associated existing services that maybe contained on the site/facility whether they
are to be retained as part of the design or disconnected and removed.

Details associated with any existing services on and around a site/facility, which
may be affected by any proposed development works, must be ascertained prior to
any works commencing.

Close liaison with the relevant statutory authorities to arrange for any respective
services to be isolated prior to disturbing or commencing any works on these
services must be considered accordingly.

All proposed works shall also be fully co-ordinated with any other respective
designers/contractors prior to arranging isolation or commencing works on these
services and to gain access to existing site services.

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ELECTRICAL ENGINEERING BUILDING SERVICES

2. ELECTRICAL ENGINEERING BUILDING SERVICES

2.1. Definitions

Extra Low voltage (ELV):

ELV is defined as a voltage not normally exceeding 50 V ac (RMS) or 120 V ripple
free dc, whether between conductors or to earth.

Low Voltage (LV):

LV is defined as a voltage normally exceeding extra low voltage but not exceeding
1000 Vac (RMS) or 1500 V dc between conductors, or 600 V ac (RMS) or 900 V dc
between conductors and earth.

Index of Protection (IP Rating):

All IP (Index of Protection) ratings shall be provided as defined BSEN 60529.

2.2. Electricity Supply Infrastructure

The Mechanical and Electrical Building Services and overall Building/Site electricity
supply loads shall be assessed with the local Regional Electricity Supply Company
(REC) to ensure that an adequate electricity supply capacity/infrastructure network
is available or can be made available for any proposed Services Installations
intended/proposed for a Building/Site whether they are intended as refurbishment
or new build.

The assessment shall encompass both High and Low Voltage (HV) and LV)
electrical distribution systems.

2.3. Electricity Supply Power Distribution HV & LV (General)

High voltage switchgear shall comply with all relevant Local Standards and Codes
of Practices

High voltage switchboards shall be of a composite floor-mounting metal clad,

extensible pattern suitable for outdoor use and protected to IP 54. Cable entries
shall be sealed following the installation of cables to exclude vermin.

All high voltage switchgear shall be suitable for operation on a 3-phase 3 wire 50
Hz supply at the voltage of the local supply and having a fault level of 250 MVA for
3 seconds.

2.3.1. Circuit Breakers

i. Circuit breakers shall be of the vertical isolation, horizontal withdrawal type

with single busbars.

ii. The operating mechanism of circuit breakers shall be hand charged, spring
assisted with a trip free over-riding feature arranged for padlocking. Each
unit shall have a direct driven mechanical ON/OFF indicator.

iii. Integral earthing facilities shall give ‘busbar earth’; ‘normal service’; and
‘circuit earth’ positions, with padlocking facilities in all positions and an
indication of positions.

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iv. Automatic safety shutters shall be fitted to cover the busbar and circuit
spouts as the circuit breaker is withdrawn. Shutters shall be lockable with a
padlock in the closed position. Busbar shutters shall be coloured ‘Red’,
shutters on outgoing circuits shall be coloured ‘Yellow’.

v. Full interlocking shall be provided to ensure that circuit breakers cannot

be:-

• Raised or lowered when in the ON position

• Raised only in ‘normal service’ or ‘earthed’ positions when inside
the enclosure
• ‘Closed’ unless fully raised or fully lowered

vi. Circuit breakers shall be vacuum or bulk oil insulated. Where oil is specified
this shall comply with the Local and insurers’ Standard and supplied with
the equipment in sealed drums.

vii. Circuit breakers shall be shunt tripped from a 30 volt DC trip supply unit.
Over current and earth fault IDMTL relays shall be installed with appropriate
plug setting ranges. Facilities shall be provided for inter-tripping low voltage
circuit breakers.

viii. Each circuit breaker shall be fitted with an ammeter and four position
selector switch. Incoming circuit breakers shall be fitted with a voltmeter
and selector switch.

Indication shall be provided for the following along with volt free contacts to enable
remote indication also:-

• circuit breaker open

• circuit breaker closed
• overload tripped
• earth leakage tripped
• bus section open
• bus section closed

Circuit breakers shall be supplied complete with all the necessary operating
handles, test plugs, padlocks, keys, cable boxed and compound.

A 30 volt DC supply shall be supplied suitable for use with the above equipment.
The unit shall include batteries, battery charger, charging ammeter in a wall
mounting enclosure and suitable for operation on a 230V 50Hz supply.

2.3.2. Sub Station Ringmain Units (RMU)

High voltage ringmain units shall comprise oil switches and oil fuse switches or oil
circuit breakers to insurers’ requirements.

All external steelwork shall be finished as per manufacturer’s recommendations

and be fit for purpose.

Cable sealing boxes shall be supplied complete with glands, armour clamps,
jointing material and lugs to suit 3 core armoured and served cables.
Arrangements shall be made to enable earth connections to be made between
cable glands with a 25mm x 3mm earth strip spanning all switches of the ringmain
unit.

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Switch mechanisms shall have independent, spring assisted, manual operating

facilities, and be arranged with ON/OFF/EARTH positions, with provision for
padlocking in each position.

Mechanical interlocks shall be incorporated to prevent direct movement from ON to

OFF and vice versa, and also to prevent access to fuse links unless the fuse switch
is OFF.

Fuse switches shall be arranged with a device to trip all phases, should any single
fuse blow.

Switch position indicators shall be positively driven in both directions to indicate all
positions.

Each switch and fuse switch of a ringmain unit shall be clearly labelled to indicate
the supply point or circuit controlled. Labels shall be engraved on
white/black/white Traffiolyte and fixed by stainless steel screws.

The ringmain units shall be supplied complete with locks, fuses, test plugs, oil and
compound.

2.3.3. Power Distribution Transformers

Oil filled transformers are considered the preference for use in the (UK).

Within the EU cast resin transformers should be considered along with any local
authority requirements applicable to that country.

Power transformers shall be ground mounting, outdoor pattern with double wound
core, fully insulated oil immersed windings cooled ONAN, complying with the
British Standard and ESI Standards, suitable for full load operation in the ambient
temperature applicable to its location.

Transformers shall generally be of vector group Dy 11, suitable for use on an 11

kV 3 phase 3 wire 50 Hz supply and having an open circuit secondary voltage of
433 volts.

Off-load lockable tap changing shall be provided on the HV winding to provide

secondary open circuit voltage variations of +/- 2.5% and +/- 5%.

The transformer shall be provided with the following fittings as a basic minimum:-

• Rating and connection plate

• Skids with bar holes and lifting lugs
• Drain and filter with sampling valve, plug and valve lock
• Oil filling cap and oil gauge
• Oil sealed silica gel breather with visual silica gel inspection window.
• Explosion vent
• Indicating dial type oil temperature indicator with “maximum” indicator.
• Earth terminal
• All necessary locks

The transformers shall be solidly earthed in accordance with the British Standard
or local Code of Practice to the earthing system.

Cable boxes shall be provided to accept the associated cables, compound filled on
the HV side, air insulated on the LV side.

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Transformer tanks shall be of welded steel with fixed radiators and bolted top
cover, grit blasted internally and oil pressure tested to a minimum of 0.4 bar.

Following successful pressure testing tanks shall be flood coated with oil resisting
primer and two finish coats.

Transformers shall be supplied complete with the first filling of insulating oil to the
relevant British Standard/local code of practice.

On transformers in excess of 1500kVA or where otherwise specified by PepsiCo

International, oil conservators shall be included and provided with Buchholz relay
protection, isolating valve, level gauge, filler cap and rain plug.

Where specific sites precludes the use of oil as the insulating medium, silicone
liquid or a synthetic ester based insulant shall be used.

Where low voltage cables and connections are not clearly visible, the transformer
shall feature an integral circuit breaker/switching facility.

2.3.4. Cast Resin Transformers

Cast resin distribution transformers shall be of the indoor naturally or forced

ventilation air cooled type, contained within a ventilated sheet steel case mounted
onto an adequate underbase with rollers.

The base of the case shall include expanded metal air inlets and the cover shall be
raised to provide a suitable air outlet facility.

The transformer shall be provided complete with the following features as a

minimum:-

• Off circuit tapping selection by use of links

• Lifting eyes
• Rating and diagram plates
• Bi-directional rollers
• Access covers and doors
• Earthing terminal
• Winding temperature indication
• Thermostat thermal protection system for alarm and trip Mechanical interlocks.

Operating Conditions:

These will normally be dictated by prevailing local ambient temperatures in the

country of the installation. Figures tabulated below are for guidance purposes only.

Maximum Daily Ambient Temperature 400 C

Average Daily Ambient Temperature 300 C Max

Average Yearly Ambient Temperature 200 C Max

No load losses, voltage ratios and impedance voltages shall comply with the
relevant British Standards and IEC Standards requirements.

Short circuit testing shall comply with British Standards.

Windings – the high voltage winding shall have Class B Insulation.

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The low voltage winding shall have Class F Insulation.

The ventilated tank shall be provided with an HV3-pole, single gland box and an LV
4-pole engraved cable termination boxes.

The transformer shall be painted finished suitable for use outside.

The ventilated case shall have a degree of protection of not less than IP23.

2.3.5. Substation and Switchgear Equipment

The following equipment shall be supplied and installed within all high voltage
switch rooms and all low voltage switch rooms as a minimum requirement:

• 1 No. Electrical Review Electric Shock Treatment poster mounted in plastic

frame
• 1 No. Rubber mat complying with British Standards to run the complete length
of the switchboard.
• 1 No. Copy of the Electricity at Work Regulations.
• 1 No. Schematic diagram of the main and sub-main supply system (in glazed
frame).

Within the high voltage switch room the following additional equipment shall be
provided:

• One first aid outfit

• One pair of rubber gloves
• One set of Danger labels
• Circuit breaker handle(s)
• Special maintenance tools
• Adequate access for maintenance to and around switchgear contained within
switchrooms shall be provided, with a minimum requirement of 2 metres on
all sides between switchgear/switchroom walls etc

2.3.6. Low Voltage Switchboards

LV Switchboard General Assembly:-

All switchboards shall be metal-clad, totally enclosed, extensible, unit or cubicle

type.

The assembly shall be a CE marked, ASTA certified, multi-cubicle, type-tested

assembly (TTA), with Form 4 segregation to BS EN 60439-1. A copy of the specific
certification and methods of operation and maintenance shall be contained within a
proprietary Health & Safety File.

The assembly shall be provided with arc-fault containment facilities to IEC 61641
or equivalent.

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The assembly shall be capable of supporting the weight of a person walking on the
enclosure without damage.

Doors shall be provided with neoprene gaskets and door mounted equipment shall
be restricted to instruments, control switches and switch operating handles. Door
handles shall have an integral cylinder lock and two keys shall be provided for each
lock. Keys shall be fully labelled.

Each section of the assembly shall be divided into individual compartments on a

modular basis, to ensure that future alteration and/or additions of equipment can
be accomplished without difficulty (i.e. bolted removable divisions, not welded).

The assembly shall be readily extensible at either end, with pre-drilled busbars and
removable busbar chamber end panels. The layout shall be selected to provide the
shortest practicable switchboard length.

This requirement shall also be considered as part of the switchroom design solution
with sufficient space allocated in the switchroom to accommodate any future
extension, typically a minimum of 25%.

Removable un-drilled gland plates, in removable sections to permit future drilling,

not less than 3 mm thick shall be provided. Gland plates for single core cables
shall be non-magnetic.

Connections from the busbars to the live side of functional units shall be shrouded
to IP 2X minimum, with warning labels.

Outgoing circuits shall be arranged and separated such that connections can be
made and maintenance carried out on any piece of equipment, without isolation or
disturbance to another.

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Removal of any covers for cabling outgoing circuits shall not expose any live parts.
An integral secondary barrier shall be provided.

Full segregation shall be maintained between circuits operating at different

voltages. All terminals shall have clear covers marked with the operating voltage.

The assembly shall include air circuit breakers, moulded case circuit breakers,
fuse-switch-disconnectors, switch-fuse-disconnectors or disconnectors, as the final
agreed design solution dictates. Unless otherwise stated, feeders shall be
triple-pole with removable bolted link neutral.

All feeder equipment shall be ASTA certified, independently operated, capable of

being locked in the OFF position and suitable for uninterrupted duty in the closed
position at rated loads.

Switchboards shall be ASTA certified at the fault rating indicated elsewhere in this
Specification.

Switchboards shall have a solidly continuous neutral.

LV Switchboard General Installation:-

The switchboards shall be floor standing or wall mounting (site specific), shall be
rigidly constructed, with smooth external surfaces, and have a minimum degree of
protection classification IP32 unless stated otherwise, cables access shall
preferably be via bottom cable entry.

Switchboards shall provide effective segregation between incoming

circuits/busbars/outgoing circuits/control circuits and equipment. Where
equipment is fitted above busbar chambers it shall not be possible for objects to
fall into the busbar chamber.

The segregation provided shall prevent the passage of ionised gas, resulting from
the making or breaking of any circuit under normal or fault conditions, to any
busbar or adjacent switch.

Switchboards shall have vermin-proof drainage and ventilation holes as necessary,

shall be typically 2100mm high but not exceed 2300 mm in height, unless stated
otherwise, and have operating handles and control devices located within the limit
of 450mm and 1950mm above finished floor level.

LV Switchboard Internal Busbar Chamber:-

Busbars shall be of air insulated copper of constant cross section throughout with
solid copper connections to outgoing switches etc. The connections shall be as
short and direct as possible and shall be air insulated except where insulated cable
connections are a necessary design feature.

Busbars shall be coloured in accordance with BS 7671 – 2001 (current edition).

This shall apply also to connections to outgoing switches etc.

The busbars shall be rigidly clamped and secured to prevent undue movement
under fault conditions or displacement as a result of the insulation of cabling and
be provided, where necessary, with insulated phase or circuit barriers.

Clamping and supporting bolts, screws, nuts, shall be of plated brass or steel.

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The assembly busbar and dropper/riser system shall be housed within a separate
earthed metal chamber, with the main busbar located generally at the top of the
switchboard wherever possible. Busbars and droppers shall be ASTA certified for
the fault rating and continuous rating stated previously.

The neutral busbar shall have the same rating as the phase busbars.

Where specified, the busbar system shall be arranged for the neutral earthing of
the supply transformer to be made within the switchboard. Removable links shall
be provided for testing purposes.

Busbars shall be manufactured from hard drawn, high conductivity copper to the
relevant British/European standard.

All busbar joint surfaces shall be tinned or plated and all joints shall be bolted with
vibration resistant fixings. Bolted connections of cables to busbars shall comply
with the relevant torque settings as per the manufacturers instructions & to the
relevant markings on the busbars themselves to assist in planned maintenance
regimes.

Busbar supports shall be non-hygroscopic, anti-track, and flame retardant. Busbar

supports shall be strong enough to withstand, without damage, the forces set up
by any thermal expansion and forces created by fault currents.

Means shall be provided to prevent arcs or arc products occurring on one busbar
from affecting the other busbar.

Access to busbars within switchboards and cable connections shall only be possible
by the use of a spanner or hexagon bolts and covers shall be fitted with engraved
laminated labels with the legends ‘DANGER’ and ‘ACCESS BUSBARS ONLY WHEN
ISOLATED’ in 10mm (min) black lettering with ‘lightning flash’ symbol.

2.3.7. Power Factor Correction

Each main switchboard shall incorporate either internally (space permitting and
preferred) or remote detuned Power Factor Correction (PFC) equipment.

Power factor correction shall be designed/provided to automatically maintain the

power factor of the plant loads at not less than 0.97 lagging when operating at
normal maximum load conditions.

PFC capacitors shall be of the non-toxic, static type with biodegradable

impregnated insulation and shall have an internal discharge device.

Suitably sized HRC fuses shall be included in the capacitor circuit for protection
purposes, capacitors shall be of the de-tuned typed to counteract the effects of
harmonics.

2.3.8. Cable Glands and Terminations

All necessary glands, spreader boxes etc. other than for mineral insulated metal
sheathed cables shall be provided as part of the switchboard or panel by the
manufacturer.

Removable gland plates shall be provided. For cubicle type switchboards and
panels sufficient gland plates shall be provided to cater for all future additions to
the switchboard or panel, up to the maximum design capacity. The gland plates

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shall be so sized and arranged as to facilitate their removal for drilling for future
additional cables.

Glands and terminals shall be so designed and constructed as to minimise the

bending of cable cores.

Means shall be provided as part of the switchboard or panel for securing these
cores by means of clamps, trunking etc. Cores shall not be run with the busbars.

Where current transformers are called for means shall be provided for properly
securing these to the switchboard or panel proper. It shall not be acceptable for
current transformers to be fitted and secured to cable cores.

Terminations shall be made by either bolted connection, sweated lugs, clamp

connections or compression lugs.

Auxiliary cables shall not be terminated in the same chamber as the main cables.

2.3.9. Earthing

A suitably rated copper earth bar in accordance with BS EN 60439-1 shall be

provided throughout the length of the switchboard. It shall be pre-drilled to each
end for future extension and removable end plates shall be provided.

The earth bar shall be drilled to accommodate all protective conductors and the
incoming supply cable earth.

All protective conductors shall be connected to the earth bar by brass nuts and
bolts, with flat and spring washers.

A main earth termination point shall be provided inside each incomer

compartment.

All equipment and metalwork, including gland plates, shall be effectively connected
to the switchboard earth bar. All hinged doors and removable covers shall be
bonded by separate flexible earth conductors.

An earth connection shall be made to each gland and/or armour clamp where
cables terminate at the assembly.

Proprietary traffolyte labels shall be provided to clearly identify each earthing

conductor installed, labels shall be applied fixed at the connection to earth bars,
label shall also identify the associated cable sizes.

Switchboards and panels shall have an earth bar to which all items of equipment
shall be effectively bonded. These earth bars shall be of copper construction and
be of the following minimum size.

• Equipment with 3 second rating 50 x 6mm

• Other equipment 25 x 3mm

The frames of draw-out circuit breakers shall be earthed by means of a plug type
contact sufficiently long to allow the shutters to close before contact is broken.

The star point of each group of current transformer secondary connections shall
have a separate earthing connection / conductor link provided in an accessible
position.

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Neutral busbars shall be insulated from earth and, where necessary, shall have a
cable gland and connection for an insulated single-core earthing conductor.

2.3.10.Current Transformers

Current and voltage transformers shall be mounted within separate chambers

within the switchboard. Transformers shall conform to BS EN 60044.

Current transformers shall be fitted to the fixed portion of the equipment and
suitable for the characteristics of the apparatus with which they are associated:

i. The transformers shall withstand safely and without damage the mechanical
and thermal stresses set up by a short circuit equal to the full short circuit
rating of the switchboard or panel and the effects of an open circuit in the
secondary circuit with full load in the primary for a period of one minute.

ii. Current transformers shall be secured in position using a method which

does not exert undue pressure on the winding and shall have all secondary
connections brought out to a terminal board by means of separate insulated
leads. The leads shall be so arranged as to avoid the possibility of contact
with any mains connection.

2.3.11.Harmonic Testing/Analysis

The switchboard design shall feature a simple connection for both voltage and
current analysis equipment to enable analysis of the Harmonics to be carried out.

The connection facility shall be accessible from the switchboard fascia.

2.3.12.Instruments

Each main switchboard shall incorporate a fully functional integral, multimeter for
measurement and recording of the total electricity load consumption of the
switchboard.

The meter shall feature LCD readout accessed from the front of the switchboard
and user controls to alter parameters of the monitoring i.e. to view voltage,
amperage etc and a pulsed output for providing remote connection if required.

In addition to the multimeter and as a minimum requirement, the switchboard

shall also feature analogue instrument meters to monitor full load (Amps) and total
supply voltage characteristics (TPN & SPN), each instrument meter shall be
provided with a phase selector switch.

The analogue instrument meters shall generally comprise the following;-

The instruments shall conform to BS 89, accuracy Class 1.5 (min) and to DIN
43700 style, minimum size 72mm square.

i. Labels shall show the polarity of primary and secondary windings and the
duty or function of each transformer.

Indicating instruments shall be “Industrial” grade to British Standards, of robust

construction, enclosed in dust-tight, flush mounting cases, shall have 240 degree
movement and maximum possible length of scale.

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The dimensions of any associated service terminations, current transformers,

metering equipment etc that may be supplied by the Regional Electricity Company
for incorporation into the switchboard shall be ascertained directly from the REC.

The Contractor shall supply and install all the necessary interconnecting cabling to
enable the REC to make the final connection to the service connection and
metering equipment.

2.3.13.Locking & Interlocks

Locking facilities shall be provided to suit the following:-

i. To enable all shutters to be locked in the closed position.

ii. To enable each fuse switch, isolator, etc. to be locked in the OFF position.
iii. To enable each changeover switch to be locked in all positions.
iv. Padlocks shall be non-ferrous and not smaller than 25mm overall.
v. One key only shall be provided with each lock or padlock.
vi. Access doors to cubicle switchboards and panels shall have a handle or
padlock facilities.
vii. Details of locks, keys, numbering etc. shall be confirmed with the Engineer
before ordering.

Interlocks shall be provided to ensure that:

i. The cover of any fuse switch, isolator etc. cannot be opened with the
switch closed.
ii. Any fuse switch, isolator, etc. cannot be operated with the cover opened.
iii. Cubicle doors cannot be opened with the main isolator closed.
iv. The main isolator for any cubicle cannot be operated with the door open.

Low Voltage Switchboard Internal Small Power Wiring shall:

i. Be not less than 1.0 mm, multi-stranded, as specified for Control Cables, to
the relevant Standard.
ii. Be grouped, as far as is practicable, according to the circuits involved.
iii. Be run in insulated cleats, plastic or steel conduit or trunking.
iv. Be terminated with clamp washers or crimped terminals.
v. Have a numbered ferrule or sleeve at each end of each wire. The
numbering shall be in accordance with the wiring diagram.
vi. Be run between terminal points, joints shall not be permitted.
vii. Be provided with fuses and links to enable all circuits to be isolated from
any bus wires.
viii. Be so designed and installed as to permit maintenance and test work to be
carried out without de-energising the whole switchboard or panel.
ix. Incorporate terminal boards having stud or clamp type connections.
x. Be connected at the front of the terminal boards.
xi. Be clearly identified and marked where it may be alive when the main
circuit isolator is open.
xii. Be segregated in accordance with the IEE Regulations where relevant.
xiii. Have a terminal for all spare wires and spare cores of multi-core cables.

2.3.14.Environmental Treatments

Generally equipment shall be ‘Fit for Purpose’. The supplier is to advise standard
finish for approval by PepsiCo International.

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The assembly shall be manufactured from high grade, machine folded/welded, zinc
coated, sheet steel of not less than 2mm thickness and be provided with a 50mm
high (minimum), removable rolled mild steel plinth.

Anti-corrosion treatment and suitable painting of the switchboard shall be

provided.

The switchboard sheet steel construction shall be zinc-coated, and rust-proofed.

Prior to despatch from the manufacturer’s works, all equipment shall be painted
with rust proof primer, filled and flattened, painted two undercoats and a minimum
of two finish coats of semi-gloss finishing paint to an approved colour.

Where a manufacturer proposes an alternative paint system to that specified,

approval from the PepsiCo International Engineering Staff shall be sought,
obtained in writing, prior to any works commencing.

2.3.15.General Requirements

Switchboards and Panels shall generally comply with this Specification for:

• Fuses
• Miniature Circuit Breakers
• Moulded Case Circuit Breakers
• Distribution Fuse boards
• Fused switches, Switch fuses and Isolators
• Labeling
• Contactors
• Transformers
• Motor Starter and Controllers

All outgoing circuits shall be sized in accordance with BS 7671 or as indicated on

single line diagrams (where these diagrams are not issued as supporting
documentation the requirements of BS 7671 shall take precedence) and shall be
housed in separate compartments such that no access can be gained to the fused
switch or MCCB or ACB by removal of another unit.

Local distribution boards and control sections within panels, MCB protective devices
are preffered.

The panel shall be suitable for cable access for all incoming and outgoing cables.
This access shall be so arranged that cables can be installed directly to their
respective terminations without having to be threaded through several
compartments before reaching that termination.

Suitably engraved traffiolyte labels, or other approved, of 150mm x 50mm

minimum size shall be provided on the front of each fuse switch to indicate its
designation, function, cables size information and rating of the associated
protective device. Labels shall be fixed by means of a minimum of 2 No cadmium-
plated round head self tapping screws.

The proposed label schedule shall be submitted to the PepsiCo International

Engineering Department for approval prior to manufacture/installation.

Outgoing circuits which supply Fire Alarm systems shall be labelled “FIRE ALARM
DO NOT SWITCH OFF” as required by BS 5839 2002, be lockable in the ON & OFF
positions and the compartment cover shall be to finished “Red”.

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Any tools necessary for the maintenance of the switchboard shall be supplied and
contained within a proprietary wall mounted cabinet located within the switchroom.

Spare fuses, MCCB’s and MCB’s shall be provided on the basis of 1 No of each size,
whichever is the greater. They shall be housed in the tool cabinet referred to
above. This consideration of equipping spare ways/cubicles on switchgear may
negate the need to provide protective devices.

All spares shall be handed to the Clients Representative and signed for, upon
practical completion of the works.

2.3.16.Installation Requirements of HV & LV Switchboards

Install LV Switchboards and enclosures, including electrical connections, in

accordance with the manufacturer’s written instructions, the applicable
requirements of IEE, the (NICEIC) National Inspection Council for Electrical
Installation Contracting, the (ECA) Electrical Contractors Association, and in
accordance with recognised industry practices to ensure that products serve the
intended function.

Co-ordinate installation of panelboards and enclosure with cable and other

associated installation work.

Anchor enclosures firmly to walls and structural surfaces, ensuring that they are
permanently and mechanically secured.

Fill out enclosure’s circuit directory card upon completion of work.

Information to be provided with the Tender:

i. Builders work requirements

ii. Brochures of proposed equipment
iii. Time/current characteristics of protective devices
iv. Variations or non-compliance with this Specification. If none is stated, it
shall be assumed the tenders comply fully with its requirements.

Information to be provided prior to manufacture:

i. Weight of switchboard
ii. ASTA Certification
iii. The list of tools that would be supplied for maintenance purposes. The list
and cost of recommended spares shown separately, other than those to be
supplied by the Sub-Contractor.
iv. 3 copies Certified General Arrangement drawings for approval.
v. 3 copies Certified Wiring Diagrams for approval.

Information to be provided following Manufacture:

• 3 copies Certified Test Certificates

Information to be provided immediately following Installation:

• 3 copies of ALL relevant drawings

• 3 copies Operating and Maintenance Instructions
• CD/ROM containing all associated drawings, schematic diagrams and the
entire Operating & Maintenance Manuals.

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2.3.17.Pre Delivery Inspection at Manufacturers Works

It shall be a requirement for the PepsiCo Engineering Department to carryout

inspections of the switchboard construction at the manufacturer’s works and
witnesses any works tests considered necessary.

Provide at least 14 days notice given to the Engineer of a suitable date for a visit,
in accordance with a pre-agreed schedule of visits.

Where the final agreed dates for a visit cannot be adhered to by any party at least
48 hours notice shall be given to all parties concerned so that rescheduling of the
visit can be arranged.

2.3.18.Site Commissioning

On site commissioning secondary injection tests etc. shall be carried out by the
Manufacturer/and or the manufacturers representative.

2.4. Standby Power Systems – UPS, Surge Protection and Generator

Standby Power systems shall be considered as part of the overall design solution
and will be based upon site requirements/specifics.

Both UPS (uninterruptible power supply) and standby generation shall be

considered.

Surge protection shall be provided to all main switchboard installations and to all
local distribution boards where they serve what is considered to be sensitive
equipment which may be susceptible to the effects of surges on electrical
distribution systems.

Connections of main circuit breakers to emergency distribution boards, low voltage

distribution boards and generator panels shall have mechanical and electrical
interlocking facilities. Automatic change-over systems shall be provided between
panels, low voltage distribution boards and back up generator panels. These shall
operate such that in the event of raw mains electricity failure, the power to the
emergency distribution boards shall be automatically energised/switched by the
changeover panel.

Any diesel generator sets shall be located near to transformer/low voltage

switchgear rooms or adequate space should be provided for equipment hired in
during any emergency.

The standby generator & emergency distribution equipment shall supply

emergency power for only emergency loads, as considered below:

a) Extruder loads,
b) Fryer loads,
c) Heat exchanger combustion air fan,
d) Emergency lighting,
e) Heating system of fuel oil and vegetable oil tanks,
f) Fire alarm, electric sprinkler pump and diesel sprinkler pump &
associated jockey pump
g) Safety system
h) Security system
i) Communications room back up unit

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j) Amenities block
k) Effluent plant
l) Electrical trace heating system for frying oil pipework.

NOTE: some sites may require 100% standby power this requirement shall be site
specific and agreed with PepsiCo International.

3. Small Power Services/Wiring Accessories

3.1. Factory Areas

This section shall also be read in conjunction with the Process Engineering Services
- Electrical Engineering Specification. Typically the installation standard shall be
cable tray installed vertically to minimize area for contamination build up.

All factory areas shall be provided with the necessary wiring devices (switches,
socket outlets, push-buttons etc) with protection class minimum IP44. All devices
shall be surface mounted.

Switch interlocked socket outlets, generally 2 per circuit to BS 4343, rated at 32A,
400V with neutral shall be provided for welding plant, portable pumps etc.

Switch interlocked socket outlets for small power, floor scrubbing machines etc,
shall be provided to BS 4343 rated at 16A. 230V.

For general power tool use, provide 16A 110V socket outlet derived from 3KVA
transformer.

Within dry plant areas, socket outlets shall be rated minimum IP44 and in
wet/washdown areas they shall be minimum IP55.

3.2. Plant Rooms

Surface fixed metal clad wiring accessories shall be utilised, with clear traffiolyte
engraved labels located adjacent to every outlet identifying their function. Where
wet/damp atmospheres may be present wiring accessories with a suitable IP rating
shall be utilised.

3.3. General Use/Cleaners Use

Flush & Surface fixed metal clad/white moulded plastic wiring accessories shall be
utilised for general use and cleaners use.

Outlets shall comprise 13A twin switched socket outlets.

3.4. General Office Accommodation & Ancillary Areas

The small power installation shall generally comprise 13 A socket outlets and 13 A
fused connections units to BS 1363, and various other isolators of varying types
and sizes to suit connected loads and the design solutions. All shall be switched.
Within office accommodation as a minimum provide 3 No. twin 13 Amp switched
socket outlets per workstation.
To meet the general ancillary power requirements and to avoid the use of
extension leads for photocopiers, facsimiles, water coolers etc provide a minimum
of 2 No. twin 13 Amp switched socket outlets per item of ancillary equipment.

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Generally and unless detailed otherwise flush fixed white moulded plastic wiring
accessories shall be utilised. Where wet/damp atmospheres may be present wiring
accessories with a suitable IP rating shall be utilised.

All socket outlets shall be 13A switched sockets.

Switched socket outlets within Office accommodation areas, which serve IT

equipment shall comply with Regulation 607 of BS 7671.

3.5. Warehouse/Distribution Areas

Within warehouse and general distribution areas provide the following power
outlets:
110V distribution – Provide typically 8 no. dedicated 110V outlets derived from
their own dedicated 110V transformers. Each transformer shall comprise integral
MCB, 3KVA transformer contained within a ventilated steel enclosure, all suitable
for wall mounting. The 110V socket outlet shall be suitably IP rated and conform
to BS 4343 industrial outlets.
Power Distribution Units (PDU) - Provide typically 6 no. PDU’s Each PDU shall
comprise integral MCB(s), controlling a 3KVA transformer for a 110V socket outlet
and a 32A 400V TPN socket Outlet. The PDU shall comprise ventilated sheet steel
enclosure and be suitable for wall mounting. The 110V & 400V socket outlets shall
be suitably IP rated and conform BS 4343.
General Use – Provide adequate single switched 13A socket outlets for general
use.
Work Stations – Within the warehouse areas provide a minimum 3 No. twin 230v
switched socket outlets for workstation areas.
As part of the overall design solution further electrical power supplies both 230v
and 400V shall be considered to generally serve:-

a) Battery Charge Equipment

b) Compactors
c) Loading Bay Doors
d) Smoke Ventilation Systems
e) Sprinkler Systems
f) Dock Levellers

Surface fixed metal clad wiring accessories shall be utilised, with clear traffiolyte
engraved labels located adjacent to every outlet identifying their function. Where
wet/damp atmospheres may be present wiring accessories with a suitable Index of
Protection rating shall be utilised.

3.6. Gatehouse

A dedicated sub distribution board should be provided in the Gatehouse.

Provide power to heating and ventilation equipment.

Provide lighting luminaires with local lighting controls illumination levels shall meet
the requirements detailed elsewhere in this document.

Adequate/suitable task lighting shall also be provided in order to provide desktop

illumination for night time use, to enable the security officer to see outside.

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Provide typically 4 No. twin 13A switched socket outlets for general use over and
above any workstation requirements as detailed previously.

3.7. Sprinkler Pump House

Provide power sub distribution board.

Provide power to unit heaters where applicable, jockey pump and an adequate
fluorescent lighting system.

Provide wiring to the associated pump controls, block heater and battery charger.

Provide power to 2 No well pumps normally furnished as a package with pump

motor starters and controllers.

Provide adequate (typically 2 No.) twin 13A switched socket outlets (metal clad)
and a 110V 3KVA power transformer/outlet for general use.

3.8. Wastewater Treatment Plant

Equip the Treatment room plant room with its own suitably sized non-essential and
essential low voltage distribution boards. The plantroom may also contain supplies
associated with HEATING, VENTILATING AND AIR CONDITIONING control panel,
Process Motor Control Centre (MCC) and Process MCC control panel.

Provide suitable fluorescent or HQI luminaires to meet the specified illumination

levels.

Switch interlocked socket outlets shall be provided for 110V portable tools, 230V
for small appliances and 400V for welding equipment.

3.9. Process/Packaging Areas

Please refer to the Process Engineering Services - Electrical Engineering

Specification for the associated power requirements to these areas.

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4. Lighting

4.1. General

Good illumination levels are considered to be a key factor for PepsiCo facilities in
particular food manufacture as it encourages good cleaning practices. Dirt, food
debris, insects or even mouse droppings can sometimes only be seen under good
lighting conditions.

Lighting schemes should form part of an integrated plant layout including all
services and process plant in position. Luminaires should be positioned where
practicable so that they may be accessed for maintenance from directly underneath
by standard ‘Flying Carpet’ type access platform.

Glass and hard plastics represent a serious potential contaminant to PepsiCo

International products and therefore exposed glass products shall be avoided or
they shall be protected at all times.

Lighting shall be provided generally fixed at ceiling level, and illumination level
readings (lux) shall be taken at the working plane. This shall normally be 1 metre
from finished floor or the working plane/level.

Exposed glass contained on luminaires and exposed glass lamps shall be avoided
at all times and are totally unacceptable. Non-glass fixture lenses i.e luminaire
diffusers and the like and proprietary exposed tube shatter shields shall be used in
all areas to comply with this requirement.

All luminaires shall be supplied with “unbreakable” polycarbonate or plastic cover

diffusers with lamps fitted with encapsulated tubes or proprietary lamp over
sleeves. All luminaire diffusers shall comply with the associated spread of flame
requirement i.e. Tpa, Tpb etc.

The above requirement shall extend to all designated emergency lighting system
luminaires and electric fly killers.

Each PepsiCo International facility shall be provided with the following lighting
design solutions;

a) General Lighting
b) Emergency Lighting
c) Evacuation Lighting

Light fittings/luminaires shall not be installed directly over equipment or plant

where access to the equipment/plant proves difficult for cleaning and maintenance
purposes. Final locations shall be agreed with all parties in relation to this
requirement

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Typical high bay style lighting installation using Holophane 400w multi vapour metal halide
luminaires

The final selection of all luminaires shall be agreed with PepsiCo International.

Within clean process areas, dust/watertight luminaires shall be provided with a

minimum Index of Protection of IP56 typically.

In all lighting applications natural daylight, in conjunction with a building

management system, shall be used as an essential part of the overall lighting
scheme. This should make use of solar tubes where appropriate.

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Typical lighting system using natural daylight in conjunction with high efficiency
fluorescent lighting.

Where there is a definite requirement for no natural daylight all or some of the
lighting systems shall be designed such that they operate on a 24 hours per day
basis dependant upon occupancy. Manual switching within these areas shall not be
a requirement unless this building is used for potato storage.

Switching shall generally be designed specific to each site and offer energy
conservation and flexibility.

Where lighting distribution boards are proposed as part of the design solution they
should be located at low level in process areas to suit ease of maintenance and be
contained within proprietary IP56 stainless steel lockable enclosures. Each
distribution board shall be equipped with suitably rated miniature circuit breakers
(MCB’s) designed to operate/control the lighting luminaires directly.

Where 400W metal halide lamps are proposed as part of the design solution these
shall normally be wired with 2 luminaires connected to 1 No. 20A rated MCB.

Additional, localised task lighting shall be provided to areas where the general
lighting solution does not provide sufficient illumination levels to areas within the
buildings. Fluorescent bulkhead &/or suitable linear fluorescent luminaires shall be
provided to the underside of equipment and under large equipment platforms, such
as potato peeler platforms and packaging.

Luminaires provided to the Peeler platforms shall have a minimum IP67 protection.
Packaging area luminaires shall have a minimum IP54 protection. Any raised
process platforms may also require emergency lighting. This shall be considered as
part of the process equipment supply contract.

4.1.1. Illumination Levels & Glare Indices

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Lighting design solutions shall be carried out in strict accordance with the relevant
design standards (where work is to be carried out outside of the UK) including the
Chartered Institute of Building Services Engineers Code for Interior Lighting (CIBSE
Lighting Guides) (where work is to be carried out within the UK) with respect to
illumination levels and glare control.

Generally the following table identifies typical areas associated with the PepsiCo
International operations and associated illumination levels, these are provided
purely as a guide to assist in the lighting design solution:-

Areas Illumination Level (Lux)

Employee Parking 20
Potato Storage 5
Emergency Lighting, & Egress Routes (to local codes)
Truck Parking 20
Building Entrances 50
Stairways 100
Corridors 100
Finished Goods Warehouse 300 (see note below)
Dock Areas 50
Toilets and Locker rooms 100
Marshalling Areas 300
Storage rooms 150
Plant & Equipment rooms 300
Replenishment Aisles 200
Lobbies 200
Cafeteria 200
Raw Materials Storage 150 (see note below)
Maintenance Areas 300
Ancillary Areas (Cleaners cupboards etc) 100
Finished Goods Warehouse Pick Faces 100
Gatehouse 200 plus task lighting
Kitchen Servery Areas 300
Kitchen Food Preparation Area 500
Food Stores 150
Computer rooms 400
Minor Treatment / First Aid rooms 300
Processing Areas 600
Packaging 600
Inspection & Sorting operations 750 general - 900 task
Quality Control (QC) Labs 500 general – 1000 task

Lighting of raw materials & finished goods warehouses shall also take into account
the effects of filled storage racks upon the lighting levels.

4.2. Warehouse Areas

Warehouse areas shall be illuminated with specialist luminaires. 2 No. solutions

shall be considered high/low bay discharge lighting and high output (T5)
fluorescent lamp luminaires.

Luminaires shall be fixed at high/ceiling level within the designated aisles, and not
above the racking areas. In transfer areas luminaires shall be installed to permit
ease of access for maintenance.

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Luminaire types within the warehouse areas shall feature lamps with a design life
of at least 8,000 hours.

All lighting design solutions shall be calculated using a maintained luminance.

Building designs shall comprise transparent roof lights. An automated occupancy

control system shall be part of the overall design solution. This shall comprise
typically of a PC based system that can monitor occupancy and automatically
switch on/off & dim or brighten luminaries according to both occupancy levels and
the amount of natural daylight being monitored/introduced into the space via the
roof lights.

4.3. External – Building & Yard Areas

Where possible, external lighting luminaires should not be fixed/attached to the

building, but should be positioned some 5-6m away, with light directed onto
doorways/walkways etc. With this design solution insects are less likely to be
attracted to the building.

High mast lighting should be considered for large open truck parking and vehicle-
manoeuvring areas, although glare to drivers and light pollution to surrounding
areas must also be carefully considered as part of the design solution.

Lamp columns with suitable lighting luminaires shall be used for illuminating roads
and parking areas, including the entrance roads to plant from main roads.

Exterior lighting shall be controlled by means of photoelectric cells, with manual

override facilities.

Luminaires with high-pressure sodium vapour lamps (SON) shall be used for
external flood and roadway lighting. All luminaires shall be vandal proof fitted with
secure fixings and polycarbonate or plastic covers.

The external lighting design solution shall provide sufficient light for night time
working purposes taking into account light pollution.

The external lighting design solution shall conform to relevant Emergency Lighting
Regulations/Standards.

Opportunities for the use of fully sustainable lighting, typically solar powered, shall
be explored.

4.4. Office/Administration Areas

Lighting design solutions shall be carried out in strict accordance with the relevant
design standards (where work is to be carried out outside of the UK) including the
CIBSE Lighting Guides (where work is to be carried out within the UK) with respect
to illumination levels and glare control.

Generally the following table identifies typical areas associated with the PepsiCo
International operations and associated illumination levels, these are provided
purely as a guide to assist in the lighting design solution:-

The levels of illumination shall be in accordance with the following:-

Areas Illumination Level (Lux)

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Office Areas (open Plan) 400 - 500

Reception Areas 300
Individual Offices 400 - 500
Kitchenettes 300
Lobbies 200
Meeting rooms/Boardrooms 300 - 500
Stores 100
Toilet/Wash rooms 100

Where appropriate, rows of luminaires shall be switched parallel to windows.

Within office areas lighting Control shall meet the requirements of Building
Regulations Part L (UK) or to local codes (outside of the UK).

Automated lighting controls for all office accommodation areas shall be considered
as part of the design solution. The automated lighting control system shall utilise
both occupancy controllers to control lighting luminaires dependant upon
monitored occupancy levels, the controls shall also be capable of monitoring
ambient daylight lighting levels in a space and automatically dim/brighten the
luminaires to maintain the desired lighting levels as detailed previously.

Two way & intermediate switching shall be provided as a minimum along notional
corridors.

All luminaires shall be selected such that they are robust, do not create a hazard to
staff or visitors and in any event be fit for purpose. They should be easily
maintainable and complement the environment in which they are to be installed.

The final positions of luminaires shall be agreed with PepsiCo International.

Where recessed luminaires are proposed that shall be connected using proprietary
plug in ceiling roses 3 & 4 pin (emergency luminaires) located within the ceiling
voids, no more than 500mm away from the luminaires that they control. Final
connection to luminaires shall be provided via 3 core heat resistant flexible cabling.

Where surface fixed luminaires are proposed final connections shall be via direct
connection.

Any small circular or square fittings fitted within suspended ceiling tiles shall be
provided with a wooden backing to ensure a secure fixing.

5. Emergency Lighting Systems

Emergency and standby lighting installations shall be provided to meet with the
requirements of BS 5266-1: 1999 and BS EN 1838: 1999 (also numbered BS
5266-7: 1999). The design shall be re-visited and reviewed after any process plant
is installed.

The design solution associated with the provision of emergency or standby lighting
shall be considered utilising the following methods, which shall be project specific.

• Central Battery/Central Section Low Power System

• Self Contained (inverter packs)
• Addressable PC based design solution for automated testing and
maintenance of emergency lighting systems

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Luminaires for use on emergency lighting systems shall comply fully with BS EN
60598-2-22. Self-contained luminaires shall be ICEL approved and suitable for 3-
hour operation.

All luminaires shall be purpose made manufacturers equipment, properly tested

and certified by the manufacturer. On-site conversion of mains luminaires with
emergency battery kits by other manufacturers shall not be acceptable.

Emergency lighting shall be provided in all areas necessary, including exits and
external escape and assembly areas.

Emergency lighting shall be designed taking into account any local codes &
practices and in strict accordance with local Building Control’s requirements (site
specific).

As a general guide, emergency lighting either by central battery or self-contained,

non-maintained shall be used as general escape lighting. Self-contained,
maintained shall be used above all fire exit doors. Working emergency lighting
shall be considered in essential utility areas such as electrical sub stations, switch
rooms and standby generator rooms.

All emergency lighting systems shall be provided with a complete computer based,
automated, self-testing & monitoring system designed to BS 5266. A proprietary
“PC” complete with licensed manufacturers software shall be included as part of
the design solution.

6. Methods of Wiring & Containment Systems (Non Process Areas)

Note: The following clauses are a duplication of the section contained within the
Process Engineering Services - Electrical Engineering Specification. Hospital saddles
shall be used for all conduit installations in process areas. No cabling is to installed
without suitable containment.

6.1. Cable Installations Underground

a) Cables shall not be installed underground without appropriate
ducting.
b) Ducting should be typically 100mm diameter as a minimum and
buried in the ground at a minimum depth of 750mm from finished
ground level. A 75mm bedding covering of sand and warning tape
shall be provided over each duct, prior to back-filling of the trench.
Spare ducting should be installed at the installation stage to allow for
any future requirements.
c) Unless specified otherwise, the excavation, provision of a sand-bed
and the back-filling of trenches for buried cables will be carried out by
others, but the installation contractor will be required to provide
details of the routes for plant records.
d) Where cable ducts enter a structure below ground level, they shall be
sealed by an appropriate sealing compound
e) Buried cables which rise from the ground or floor onto vertical
surfaces shall be protected from mechanical damage by provision of
a suitable metal sleeve that has a minimum length of 150mm.
f) Sufficient draw pit shall be provided and all ducting should be
provided with draw ropes.

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6.2. Cables Installed in Trenches

a) All cables installed in trenches are to be supported on cable tray or,
for large cables, on steel hangers fixed to the trench wall.
b) No cables are to be in contact with the trench floor.
c) Due regard is to be given for the minimum bending radius and
support centres for large cables when determining the route.

6.3. Cables Installed within the Building Structure

a) For raised floors and suspended ceilings, cables must not be loose
laid on floor slab or ceiling grids. Containment shall be installed with
the appropriate segregation for power, data and telecom cabling
along from a combination of conduit, trunking and basket with
suitable tee-offs to all component points on the network to form an
integrated installation. The containment under the floor shall all have
uni-strut type supports at 600mm centres securely fixed to the floor
slab. Cables installed in ceiling and floor voids shall be run parallel to,
or at right angles to, supporting beams or joists.
b) When cables are installed in standard wooden floors they shall be run
in such positions that they are not liable to be damaged by contact
with the floor or its fixings or fixings for carpets or other services.
Where a cable crosses a timber joist under the floorboard, the joist
shall be drilled so that the cable, when installed and securely fixed, is
at least 50mm from the top of the joist. Notching out the tops of the
joists is not acceptable.
c) Where cables are installed within solid floors, a duct or conduit shall
be installed to facilitate this and provide mechanical protection.
d) Cables buried within plaster shall be run only in vertical or horizontal
directions and shall be protected with a metal capping.

6.4. Conduits Concealed in the Building Structure (Incl. Partitions)

a) Concealed conduits shall be installed in wall chases and ceiling voids
in such a manner that inspection and draw-in boxes are at accessible
positions.
b) Boxes shall be erected so as to be recessed approximately 2mm
below the finished surface. To meet this requirement the Electrical
Contractor shall verify the thickness of all wall and ceiling finishes on
site.
c) Conduits that are buried in plaster shall be securely fixed and
installed at a depth that allows a minimum plaster depth of 5mm over
its entire length including fixings.
d) Extension rings shall be fitted to recessed conduit boxes to which
luminaries or wiring accessories are to be attached if the distance
between the conduit box and finished surface exceeds 10mm.
e) Where conduit boxes are installed flush, they shall be provided with
an overlapping cover lid.
f) Where barium plaster is to be applied, the conduit shall be covered
by cement and boxes shall be built up to the edges with cement
before plastering.
g) Steel conduit buried in the ground shall be wrapped with Denso tape
(or similar) and the tape shall extend for a distance of 150mm beyond
the point where the conduit emerges from the ground.
h) Conduits shall be installed in wall chases and ceiling voids in such a
manner that inspection and draw-in boxes such that access can be

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maintained after completion of the installation. Draw-in boxes shall

not be fixed in plastered walls. In order to complement this,
inspection pattern bends, tees and elbows shall be used at
appropriate positions with the provision of draw-in boxes at intervals
of 8m maximum on a straight run. No more than two right angle
bends shall be permitted between any two access points or outlet
boxes.

6.5. Fixing of Cables

a) Cables shall be in accordance with the regulations and the Amtech
calculation or similar and approved.
b) All tie wraps will be coloured black except those used in the product
zone.
c) Where tie wraps are used in the PRODUCT ZONE as described in
this document, they shall be coloured blue and be of the METAL
DETECTABLE type.
d) Where tie wraps are used, they should be correctly sized for the duty
spacing between them should be in accordance with manufacturer’s
recommendations.
e) The use of small cable ties at a single point on a large cable is not
acceptable.
f) All cables are to be secured using adequate sized tie wraps having
interval spacing to ensure that all cables are secured correctly
without any sagging.
g) For PVC armoured multicore cables up to 25mm2 the tie wrap width
shall be a minimum of 8mm on an interval spacing of 400mm max.
h) For PVC armoured multicore cables up to 35mm2 to 95mm2 the tie
wrap width shall be a minimum of 12mm on an interval spacing of
300mm max.
i) For PVC armoured multicore cables up to 125mm2 the tie wrap width
shall be a minimum of 14mm on an interval spacing of 200mm max.
j) Individual cleats designed for the type of cable would also be
acceptable for the above situations.
k) For bunches of PVC Armoured cables on vertically mounted trays,
the total weight of cables can be considerable. In order to ensure that
they never become detached, a “Beta Strip” band or similar should be
fixed at 3mm intervals in addition to the other fixings.

6.6. Underfloor Cable Trunking and Accessories

a) Underfloor cable trunking shall be medium duty zinc coated sheet
steel, complete with a 'top hat' fixing section on the base plate with
internal divisions where specified.
b) The trunking body shall be provided with a return flange to facilitate
fixings and 'key' the trunking into the screed. Trunking joints shall be
provided with a saddle type coupler to prevent the ingress of screed,
which shall screw fix to the base flange each side of the joint.
Trunking lengths and accessories shall be provided complete with
coupling pieces and tinned copper earth links. At trunking ends a
suitable end cap shall be provided.
c) All bends, tees, intersections and service outlet boxes shall be the
accessible screw fixed type and the same design and construction as
the main trunking.
d) The boxes shall be of suitable depth to suit the minimum screed
depth and shall be provided with an adjustable carpet frame and

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carpet recessed lid. Lids shall be hinged and comprise a pan plate
forming the carpet recess with a welded reinforcing plate. Boxes,
frames and lids shall be supplied separately and all boxes shall be
fitted with a blank plate to prevent ingress of screed during
installation.
e) Trunkings shall be run in line or at right angles to walls, consequently
only 90O bends can be used.
f) For raised floors, trunkings shall be run in line and in the centre of the
pillars that support the floor sections.
g) Trunking shall be laid direct onto the slab and fixed into place with
size 5.5mm x 50mm screws on either side, at regular intervals. If
there is any unevenness in the floor, suitable spacers and wedges
shall be used to prevent any twisting of the trunking.
h) Prior to screening, trunking boxes shall be fitted with blanking plates
and joints shall be sealed by a suitable tape. On completion of the
screening, the blank plates shall be removed and the carpet frames
and lids fitted.
i) Trunkings shall be thoroughly cleaned of particles prior to the
installation of cables.

6.7. PVC Conduits and Accessories

a) PVC conduits shall be the rigid high impact type and shall not be
used where the ambient temperature is below -5oC or above 60oC.
b) PVC Conduit boxes shall be of the standard circular pattern complete
with circular cover lid and these shall be fixed by the requisite number
of screws.
c) All conduit boxes, couplers, etc. shall be provided with slip type
couplings with socket ends and be of the same manufacture and
colour throughout.
d) All conduit boxes shall be fitted with brass earthing terminals.
e) Where boxes form part of an external installation, circular rubber
gaskets shall be provided between the cover lid and box.

6.8. Steel Cable Trunking

a) In view of the application of food safety standards, it is most unlikely
that trunking would be acceptable in production areas although it
would be acceptable in other areas.
b) The size of trunking used shall take into account the requirement for
a minimum allowance of 25% for future development. The minimum
size of trunking used shall be 50mm x 50mm.
c) Cable trunking for non-production areas shall be medium duty
galvanised steel.
d) All bends, tees, intersections and other accessories shall be of the
same finish and manufacture as the main trunking and where
possible, be provided with gussets.
e) Lengths of trunking shall be connected with the proprietary coupling
units and these shall be of sufficient length and rigidity to prevent any
sagging. The length of the lids shall be so arranged that the joints
always coincide with the centre of the coupling unit.
f) An earth bonding link shall be fitted between all adjacent lengths of
trunking, including bends and intersections, to provide continuity for
earth bonding.
g) Trunking runs shall be so arranged that the lid or cover plate is
always on the top or side and not underneath.

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h) Where trunking is installed on its side, the lids shall be provided with
cable retaining straps at intervals of not more than 1000mm.
i) Trunking shall be supported by heavy duty brackets where required
or direct to the structure at suitable intervals. No suspensions or
fixings shall intrude into the internal space.
j) Trunkings shall terminate with end flanges which shall be bolted
direct to equipment.
k) Where trunking does not terminate into equipment, the otherwise
open end shall be provided with an end cap suitably fixed in position.
l) Where conduits connect to multi-compartment trunkings and their
appropriate compartment is not accessible from the side, they shall
be provided with proprietary ‘crossovers’ to ensure that direct wiring
is possible.
m) Trunkings shall be provided with internal fire barriers where
appropriate.
n) Where trunking passes through walls, ceilings, partitions or slabs, the
lid shall terminate 80mm at either side of the structure. Between the
removable sections of lid, a fixed section of lid shall be installed
through the structure.
o) At building expansion joints, the trunking shall be provided with a
sliding coupling complete with flexible earth continuity braid.
p) Care must be taken to ensure that all steel and brass particles, etc.
are removed from the trunking prior to installation of the cables.

6.9. PVC Cable Trunking (including Dado/Skirting Trunking)

a) PVC trunking and mini trunking shall be manufactured from high
impact PVC shall be installed in accordance with the manufacturer's
recommendations.
b) PVC mini trunking (sizes below 50mm x 50mm) shall only be used for
concealing PVC / PVC cables run surface unless specified otherwise.
c) Trunking lids shall be of the internal 'snap-on' type.
d) Straight lengths of trunking backbone shall be connected by the
appropriate internal couplers.
e) Joints in trunking lids shall be arranged not to coincide with joints in
trunking backbone.
f) At building expansion joints, trunking shall be provided with couplers.
g) All PVC trunking shall be provided with suitable protective conductors
which originate from the earth bar of the local distribution board.
h) Within office accommodation skirting and/or dado multi compartment
trunking systems shall be considered as part of the design solution to
provide flexibility for the wiring accessory installations.
i) All skirting/dado trunking shall be finished ‘white’.
j) Dado trunking systems shall be located generally above
worktop/desking level. Skirting trunking shall be located at skirting
level.
k) All trunking installations shall utilise manufacturers fittings i.e bends,
lids, metallic screening between power and the structured cabling
compartments etc.
l) Accessory box outlets shall be mounted into the trunking lids using
the proprietary manufacturers back boxes such that all outlets are
flush fixed generally.
m) When skirting/dado trunking outlets are cabled, one meter of spare
(slack) cable shall be incorporated into each run to allow for future
connections/alterations to be made to the wiring system.

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n) Live feeds, telephone and computer cabling shall be routed within the
respective compartment of the multi compartment skirting/dado
trunking.
o) The trunking system installations shall have surface fixed vertical
rising sections using proprietary manufacturers T sections or bends
etc routed into the ceiling voids to enable cabling back of the main
containment systems.
p) At all designated telephone and computer point’s white, moulded,
back boxes 35mm deep shall be provided.
q) Continuous conduits shall be provided linking the skirting/dado
trunkings system installations to the respective main containment
systems. At the main containment system the conduits shall be fixed
using proprietary conduit adapters.

6.10. Cable Ladders

a) Cable ladder cannot be used in production environments and would
normally confined to switch rooms and plant rooms.
b) Cable ladder and its support brackets shall be heavy-duty galvanised
steel.
c) Cable ladder shall normally be fixed overhead in the vertical plane so
that the weight of the cables can be carried without sagging or
distortion.
d) The heavy-duty support brackets shall be fixed using ‘rawl-bolts’ or
similar fixings, correctly sized for the duty.
e) If it has to be cut, the bare metal shall be cleaned and painted with a
galvanising paint.
f) Cable ladder shall be of sufficient size to accommodate all the cables
in double tier formation, leaving at least 30% spare capacity for future
requirements.

6.11. Cable Trays

a) Cable tray shall only be used in non-production environments
b) Cable tray and it support brackets shall be heavy-duty galvanised
steel.
c) Cable tray shall be firmly fixed in the vertical plane so that the weight
of the cables can be carried on the tray without sagging or distortion.
d) The heavy-duty support brackets shall be fixed using ‘rawl-bolts’ or
similar fixings, correctly sized for the duty.
e) When traywork is cut for bending or termination, the bare metal shall
be cleaned and painted with a galvanising paint.
f) Cable tray shall be of sufficient size to accommodate all the cables in
double tier formation, leaving at least 30% spare capacity for future
requirements.

6.12. Cable Trays and Ladders Installed Within Process Areas

Where containment systems for the Building Services Engineering design solution
are to be routed within Process and packaging areas, the following clauses shall be
adhered to:-
Large main supply cables should be supported on cable ladder, which shall be of
hot dipped galvanised steel construction. The system shall have a maximum rung
spacing of 300mm.

Unistrut or open channel brackets for support shall not be permitted.

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Unpainted mild steel shall not be acceptable. Cable ladders shall have a continuous
connection to the main earthing system of the building.
Cable trays shall be sized to contain all cables specified with 50% additional
capacity for associated control cables and 30% capacity for future expansion.

A 50mm gap, bonded with flexible copper jumpers, shall be provided in cable tray
runs across building expansion joints.

Maximum spacing between cable tray supports shall be 1000mm.

All metallic conduit installations shall be of the hot dipped galvanised steel and / or
black enamel steel construction as applicable for the intended area of installation.

All conduit supports and cable trays should be positioned away from the walls to
facilitate cleaning. This shall be a minimum of 100mm. Cable trays must be hung
vertically, not horizontally.

‘Cablofil’ steel wire basket type cable trays shall be used for installation of open
cabling.

Joints, sets, bends, etc must be welded and not bolted. The cable tray system shall
be fixed to stand off steel bracket arrangements by the use of welding.

All conduit connections to motors shall be carried out in flexible conduit, moisture
and oil proof with suitable fittings. Flexible conduits as specified in Frito Lay
Engineering Specifications shall be used between steel conduit and final site
electrical equipment.

Any penetrations of fire compartment walls should be provided with fire barriers.
PVC rigid and flexible conduit is acceptable in dry wall office areas only.

All conduits in outside areas are to be screwed galvanised rigid, metallic, thick-wall
type, 20mm minimum.

PVC conduit or pipe shall be used for all underground installations except where
noted otherwise.

All associated trays cables & conduits shall be kept a minimum of 150mm from
steam and hot water pipes.

Expansion fittings shall be used across building expansion joints.

6.13. Cable Ties and Cable Identification

Identification labels shall not be positioned in or over any product zones and never
directly over open product areas. They shall be well off line and preferably within
an electrical cabinet.

All cables shall be held in place with blue metallic metal detectable cable ties
(Thomas & Betts nylon Tie-wraps). The use of plastic or PVC cable ties is not be
permitted.

7. Lightning Protection System

Lightning protection systems shall be designed and installed in accordance with the
requirements of BS 6651.

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The system shall generally comprise of air terminations, down conductors, testing
joints, earth terminations and earth electrodes. Steel reinforcing contained within
structural columns shall not be used as a down conductor unless their continuity
and current carrying capacity is verified and the reinforced connections are welded
and independently verified to ensure compliance with BS 6651: 1999.

The materials for the component parts of the lightning protective system shall be
those detailed in Tables 2 & 4 of BS 6651. Care shall be taken in the selection of
bonding clamps to prevent corrosion from the action of dissimilar metals.

Metallic roofing and cladding shall be verified as being electrically continuous and
bonded to the lightning protection system. All metallic projections onto or above
the main surface of a roof structure shall be bonded to the lightning protection
system. All bonding connections shall be covered with a suitable “grease”
compound to prevent corrosion.

Any extended metal routed/running vertically through a structure shall be bonded

to the lightning conductor at the top and bottom, unless the clearances are in
accordance with BS 6651.

Where the foundations or piles, etc. are being used as the earth termination
network for the lightning protection scheme, reference electrodes shall be installed
for periodic monitoring of the condition of the network.

All underground joints shall be carried out using exothermic processes and
protected against the effects of corrosion. Above ground joints shall be made
using gunmetal or phosphor bronze fittings and fixtures. All above ground joints
shall be accessible for inspection.

The installation of the lightning protection system shall take full account of the
environmental conditions at the site (which may be site specific) and the materials
used in the building construction to ensure that the lightning protection system will
provide trouble-free life for a minimum of 30 years.

Any building weatherproofing shall not be impaired or effected by the lightning

protection system.

Proprietary testing joints shall be provided located in convenient accessible

positions to provide adequate means of access for testing, these shall all be located
approximately 1 metre above ground level.

Earthing electrodes shall consist of metal rods or tapes or a combination of both to

suit the proposed design solutions.

On completion, the whole system shall be fully tested in accordance with BS 6651
and copies of the associated test results contained within the Health & Safety File.

Facilities are to be provided with a lightning protection system in accordance with

local codes.

Lightning protection is to be provided for all process and utility vent stacks.

All metal equipment mounted on the roof shall be bonded to roof lightning
protection system.

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8. Site Security

8.1.1. Security

There are three levels of security systems which are adopted by PepsiCo
International;-

a) CCTV
b) Card Access and Door contacts to all perimeter or security doors,
movement detectors to be positioned at all vulnerable locations, and
manual key locking systems throughout.
c) Lighting to internal and external areas.

8.1.2. CCTV system

The factory shall be equipped with CCTV security system located in the security
room with cameras around the building, and to be connected to monitors and
recording facilities. The security system cameras shall be located in the following
areas:-

a) At the corners and entrance of the office and process buildings.

b) At main gate entrance and around the perimeter fence
c) At waste water treatment.
d) Truck and car parking

The system shall include the following equipment:

a) Motorised colour type cameras

b) Moving 360 degrees (PTZ)
c) Full matrix switching equipment
d) Monitor 17 inch colour
e) 24 hour digital video recording equipment

All this equipment except the cameras shall be located in the security room near
the main entrance to the site office building.

8.1.3. Card access system

Each building/facility shall be provided with a site wide electronic card access
control system. There shall be two (2) different types of card access system
adopted.

• To give access permission for staff personnel to all office and security areas.
• To give the access permission for workers to go into the process/warehouse
areas.

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9. Building Management System (BMS)

A BMS shall be considered for all sites as part of the Building Services Design
Solutions, the system design shall be site specific and agreed with PepsiCo
International.

The BMS shall be designed according to the mechanical building services design
solution.

Important status information and fault alarms shall be displayed on the PC based
computer system of the BMS.

The system design shall enable operators to easily adjust system

settings/parameters of the BMS.

The system shall generally consist of the following equipment:-

• MCC panels (With contacts for the HEATING, VENTILATING AND AIR
CONDITIONING equipment inside),
• Control panel (With BAS microprocessor field controller such as DX. XT
inside),
• Field equipment may also comprise:

• Air handling units

• Valve actuators
• Damper actuators
• Temperature and pressure sensors
• Differential pressure switches
• Duct and site type thermostats
• Circulation pumps
• Exhaust fans
• Other equipment

The main BMS station shall include a computer and alarm printer facility.

The BMS shall be designed to monitor and record all internal air space
temperatures.

10. Fire Detection and Alarm System

All site buildings shall be provided with either a new and/or extension to an
existing fire detection and alarm system.

The design of the fire alarm system shall be carried out in accordance with the
sites fire strategy/risk assessment which shall be carried out on a site specific basis
in close liaison with PepsiCo International.

The fire alarm system shall consist of an analogue addressable fire alarm control
panel with battery back up, connecting automatic detectors, sirens, emergency
manual break glass call points and shall be designed according to Local Regulations
(in the UK BS 5839: 2002).

The fire alarm system shall be designed to show the signals on the main Fire Alarm
Panel, which should be located local to a main Office Building/accommodation area.

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The following buildings shall be provided with their own separate fire alarm and
detection systems but shall be linked to the main system panel for
annunciation/control purposes.

• Process building
• Office building
• Waste Water Treatment

A connection from the main fire alarm panel to the site security room shall also be
provided. The security room shall comprise of a fully functional fire alarm system
repeater panel, which shall be capable of receiving data signals from the various
other site wide separate systems. The repeater panel shall indicate all fire and fault
alarm conditions.

The fire alarm related control functions shall mainly consist of:

• Activating pre-action sprinkler valves in case of fire alarm.

• Activating the alarm system.
• In case of fire stopping of ventilation and air conditioning equipment of the
whole building involved.
• Starting of diesel fire pump.
• Activating fire door magnets

An automatic fire detection panel shall control all the above functions for each
building, with alarm identification per detector. Every detector shall be identified at
the central control panel with its own unique address.

The software of the fire alarm system shall become the property of PepsiCo
International on completion of any system installation.

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11. Electrical Building Services Located within Process Areas

Where Electrical Building Services are to be routed through the designated

Factory/Process areas of a PepsiCo International building/facility – the installation
of the building services shall be completed in strict accordance with PepsiCo
International Electrical Engineering Specifications.

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12. IT & Data Equipment

Please refer to the Process Engineering Services - Electrical Engineering

Specification for the associated requirements.

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13. MECHANICAL ENGINEERING BUILDING SERVICES

Where mechanical services are to be routed through the designated factory/process

areas of a PepsiCo International building/facility, the installation of the building
services shall be completed in strict accordance with PepsiCo International Mechanical
Engineering Specifications.
Piped services shall be supported on suitably designed gantries supported from the
floor and not from the building fabric unless this has been specifically designed for
this purpose.

Energy efficiency and whole life costs are to be considered for all mechanical building
services.

13.1. Definitions
Mains Cold Water
High pressure cold water supplied from the water authority mains supply for
drinking, culinary and storage purposes (including safety shower, eye wash, etc.)
or from an on site boosted system.

Domestic Hot and Cold Water

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A system normally open to atmosphere, supplying hot water at temperatures up to

60 degrees centigrade for washing and culinary purposes (e.g. in canteen, toilet,
etc.).

Process Water
Cold water from storage tanks used for general washing in Production and
Research areas. This will normally be provided in 2 systems operating at 1bar and
4bar respectively.

Hot Water
A system open to atmosphere or a sealed system which operates at temperature
up to a maximum 90 degrees centigrade.

Food (Process)
A wide range of solutions used for finished products or liquid ingredients.

Trade Effluent
Any liquid waste from Production activities.

Steam
Either for service duties such as heating or for process applications such as steam
injection into product mixers.

Chemical
Either for service or process duties

13.2. Fuel Supplies

The Mechanical Services and overall Building/Site Gas, Water and Fuel Oil supply
loads shall be assessed with the local regional supply companies to ensure that
adequate existing supply capacities/infrastructure networks are available or can be
made available for any proposed Services Installations intended/proposed for a
Building/Site, whether they are intended as refurbishment or new build. All fuel
supplies shall be provided with the means to record the quantity of fuel consumed
at the point of use.

13.2.1.Natural Gas

Natural gas shall be derived from the local mains natural gas distribution network
complete with above and below ground pipework, metering, isolation valves,
pressure reducing valve stations and all the necessary safety devices for safe
installation and operation. All design and installation works associated shall be
carried out in strict accordance with The Gas Safety (Installation and Use)
Regulations 1998. The use of ‘Firm’ and ‘Interruptible’ supplies should be
considered from the gas supplier. In the event of an interruptible supply,
alternative fuels such as gas oil or LPG will be required.

Capacity of the supply shall be agreed with PepsiCo International. The provision
shall include agreed spare capacity for future expansion. The outside plant network
capacity should be investigated to ascertain any future requirements.

NOTE: where electrical services installations are contained within an enclosed room
which also contain natural gas equipment, they shall be completed using
“flameproof” wiring and accessories of the suitable zonal rating.

All gas equipment rooms shall be designed / ventilated in accordance with local
authority requirements.

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13.2.2.Fuel Oil

Fuel oil tanks (if required) shall be installed underground and to local codes. Any
tanks installed above ground shall be provide with bunded areas to local authority
requirements.

Capacity of the tanks & fuel oil systems shall be discussed with PepsiCo
International and provision made for a future expansion of 25%.

Trace heating/heating systems may be required for fuel oil tanks where they are
located in cold climates or where heavy fuel oil is proposed/utilised.

All systems shall be designed to include the necessary pipework, isolation valves
and devices for safe operation.

The installations and locations of oil storage tanks shall meet the requirements of
the current fuel storage regulations, OFTEC and the Environment Agency (UK) and
local codes of practice (outside of the UK).

Regulations specify minimum distances between oil storage tanks and adjacent
buildings, boundaries and sources of ignition, this shall be taken into account when
siting tanks and the like.

Due consideration shall also be given to tank locations in respect of providing

adequate access for the delivery of fuel oil.

All installation works shall be carried out by a contractor who is OFTEC registered
(UK).

Lists of registered contractors can be obtained from: -

OFTEC
Oil Firing Technical Association
Foxwood House
Dobbs Lane
Kesgrave
Ipswich
IP5 2QQ

Tel: - 0845 6585080

Fax: - 0845 6585181

The oil distribution system shall comprise of the following components as a

minimum.

a) Isolating valves
b) Distribution pipework
c) Filters
d) Oil solenoid shut off valves located above boilers, gas/oil fired water
heaters. The solenoid valve shall be controlled via a wall mounted
emergency stop button and electro thermal links positioned above the
appliance burners or in the position deemed most suitable.

13.2.3.Liquid Petroleum Gas (LPG)

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Where LPG fuel is proposed as part of the design solution, the locations of LPG
tanks shall be installed to local codes either under or above ground.

Suitable pressure reducing equipment shall be installed as necessary where the

supply pipework enters a building/facility.

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14. Heating

14.1. General

As part of the overall Building Services heating system design solutions, various
options shall be considered and offered for consideration by PepsiCo International;-
The use of reclaimed heat from processes where practicable
Ground source heating
Solar energy
Direct Expansion (DX) Spilt System Heat Pumps/VRV 3 pipe DX heat
pump with heat recovery
Absorption cooling using process waste heat
Low Temperature Hot Water (LTHW)
Medium Temperature Hot Water (MTHW)
High Temperature Hot Water (HTHW)
Electric Heating
Gas Fired Radiant Strip Heating (Warehouse/Marshalling Areas typically)
Warm Air Blowers (Gas Fired)
Steam Generation (Process Engineering)

14.2. Heat Pumps

Consideration shall be given for the use of heat pumps where the opportunity
arises to exploit different sources of low-grade heat.

The use of reversible air to air heat pump units shall be considered primarily where
there is a significant demand for cooling, in the form of typically DX single/multi
split or variable refrigerant volume (VRV) systems. The use of a heat recovery
(typically 3 pipe system) VRV systems shall also be considered where different
areas of a building/facility requires simultaneous heating and cooling dependant
upon building/facility orientation (i.e solar gains) and to provide general
heating/cooling requirements.

When considering the use of heat pumps the following shall also be reviewed:

• Heat pump Coefficient of performance (COP) at varying external ambient

conditions.
• Potential problems with ice formation of the heat exchanger (at high
humidity levels) requiring the system to have a defrost cycle.
• Carbon emissions of the fuel used to power the heat pumps.
• Refrigerant type.

14.3. Hot Water Heating Systems LTHW, MTHW & HTHW

A number of factors shall be considered prior to the selection of the type of heating
most suitable for the particular application in a building/facility.

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Medium/high temperature hot water heating systems shall only be considered for
large sites where minimising the size of the distribution systems would be of
significant economic benefit. An example of this could be where a centralised boiler
plant is provided to serve a district-heating scheme.

Systems to recover waste heat from process plant, air compressors etc should be
considered as part of the overall design of water heating systems.

14.3.1.Boilers

Where hot water boilers form part of the overall design solution a number of
factors shall be considered prior to the design, specification and selection:-

• System Design Criteria (ie. LPHW, MTHW, HTHW)

• Heating and hot water loads (kW)
• Efficiency
• Capital costs
• Size and weights of proposed plant
• Potential for on site assembly
• Future site expansion
• Available fuels ie. gas, solid fuel, oil, dual fuel in the case of interruptible
gas supplies.
• Compliance with the Building Regulations applicable to building control
(UK) or local standards outside the UK.

Due consideration shall also be given to the use of different types of boilerplant
that are readily available (dependant upon the factors listed above).

• Cast iron sectional boilers

• Welded steel and reverse flow boilers
• Steel shell and fire tube boilers
• Multiple or modular boilers
• Condensing boilers

When sizing the total output of the plant consideration shall be given to the degree
of standby that may be required, which shall meet the operational requirements of
the site.

Boiler plant shall be located generally on a level fireproof base and positioned such
to meet with the recommended spatial requirements for ease of plant access for
maintenance purposes.

All boilers shall be installed strictly in accordance with the manufacturers

recommendations and instructions so as not to infringe or curtail the
manufacturers guarantee. Boiler combustion unit shall be positioned to be easily
maintained and tuned for maximum efficiency. The pre-heating of combustion air
using any process waste heat shall be considered for all designs.

Where boilers are of sectional construction requiring on site erection, such erection
works shall be carried out to the manufacturers instructions by Specialist Engineers
approved by the manufacturers and shall include hydraulic pressure testing and
flushing of the erected boiler before final pipework connections are completed.

Each boiler shall be fitted with the following mountings as a minimum:

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• Safety valve fitted with padlock and a copper discharge run clear of
any insulation to terminate 150mm above finished floor level with birds
beak.
• Thermometer
• Altitude gauge with cock
• Drain cock

14.3.2.Flues and Flue Pipework

Boiler flue outlets shall be connected to vertical chimneys by means of purpose

made flue pipework and fittings. In all cases, supports shall be arranged such that
no flue weight is taken on the appliance.

Flue pipework shall generally be designed to meet current regulations, using

typically 304 grade stainless steel with insulated annulus and socket/spigot liner
joints and clamp band casing joints.

Clean out doors shall be provided at the necessary locations to enable efficient
maintenance and inspection of the plant to be carried out.

Care shall be taken during installation and grading the flue pipework to ensure the
removal of internal moisture. The flue installations shall incorporate a drain tee
with trapped UPVC drain routed to a convenient discharge position.

Flue pipework bracketing shall generally conform to the relevant manufacturer’s

recommendations. In all cases allowances shall be made for expansion/movement.

Brackets fitted in internal locations shall be painted, external bracketing shall be

either stainless steel or galvanised finish.

All flues passing through any fire compartment division shall be fitted with the
manufacturer’s purpose made fire stop closure plates.

At all roof penetrations soaker sheets, weather aprons etc shall be provided.

14.3.3.Circulating Pumps

Circulating pumps shall be provided to meet with the requirements of the various
heating circuits. The degree of standby shall be considered and
duty/assist/standby pumps (twin-head) installed if deemed necessary. An auto-
changer facility shall be provided for this.

All circulating pumps shall be installed such that they do not impart any
mechanical vibration to either the fabric of the building or to the relevant pipework
system.

Pipeline mounting pumps shall be supported on purpose made steel platforms

incorporating suitable anti-vibration material or mountings.

Purpose made flanged or screwed anti-vibration bellows shall be fitted on the

suction and discharge side of each individual pump set.

Anti-vibration bellows shall be flexible reinforced rubber type suitable for reducing
noise and vibration. The said bellows shall have a maximum working pressure of
16 bar.

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Where pump connections differ from the specified pipework sizes, purpose made
taper pieces shall be provided at the pump connection. All surrounding valves,
strainers etc. shall be to pipeline, not connections size.

All individual pumps shall be fitted with either flanged or union joints to enable
individual removal and replacement. Drain valves shall be provided between pump
isolation valves to enable pump replacement without system draining.

The suction and discharge connections to each pumpset shall each be provided
with a pressure gauge with loose red pointer and gauge cock.

Care shall be taken to ensure that the shaft orientation of glandless pumps
conforms to the relevant manufacturer’s recommendations.

14.3.4.Pressurisation Units

Where unvented or sealed hot water systems are to be installed pressurisation and
expansion equipment shall be installed to provide for automatic system make up
and provide for adequate expansion of the hot water system.

Prior to final selection of the equipment the following design information shall be
considered: -

• Output of boilerplant (Kw).

• System water content.
• System cold fill pressure.
• System design operating pressure.
• Maximum system operating pressure.

The pressurisation units shall be typically of a packaged design including a cold

water break tank with float controlled mains cold water feed inlet valve
incorporating a Class A air gap. Break tank, pump and control equipment shall be
mounted on a base frame, together with a remote expansion vessel with
diaphragm separation of system water and fixed volume air cushion.

The controls package shall include as a minimum, pressure sensors for pump
on/off control and no volt contacts for a common high and low pressure alarm (for
signalling to the building/facility BMS).

The link line from the pumpset to the system shall include a non-return valve at
the pump discharge, a tee connection to the expansion vessel and typically a 2
metre high anti-gravity loop with auto air vent at the high point and isolating stop
valve at the system connection.

The LTHW system served by the pressurisation unit shall incorporate the
following:-

• Full bore air purger with auto air vent, fitted into main system flow
pipe.
• Quick-fill tee connection into system return incorporating a stop valve
with loose flexible hose and union connectors. A corresponding
stopcock with double check valve shall be provided from the mains cold
water system adjacent to the quick-fill point. The size of the quick-fill
facility shall be not less than 20mm.

14.3.5.Radiators

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Where radiators form part of the overall design solution, radiators shall generally
be provided to meet with the heat requirements of the internal space.

Radiators shall be positioned generally below windows and in positions deemed to

provide adequate distribution of heat.

Radiators may be used in conjunction with other forms of heating, i.e warm air,
heat pumps etc however suitable control systems shall be installed to prevent
overheating and heating/cooling systems operating simultaneously.

Prior to the final selection of radiators the following criteria shall be considered:-

• Model/styles of radiators.
• Aesthetics to be considered in accordance with any Clients/Architects
requirements.
• Maximum surface temperature of heating surfaces, i.e. are low surface
temperature radiators necessary to comply with local standards.
• Physical constraints imposed by the building.

All radiators shall be generally factory self finished in a gloss white paint finish with
protective wrap.

Radiators shall be generally fitted with a thermostatic radiator valve and matching
lockshield valve on the flow and return connection respectively.

The locations of internal sensors and thermostats shall be considered to ensure

proper and efficient operation, where radiators are installed.

14.4. Gas Fired Radiant Strip Heating

Should Gas Fired Radiant strip heating form part of the design solution the
following points shall be considered:

Radiant strip heating is normally considered for use in high volume spaces, such as
warehousing, storage areas where lower ambient air temperatures would be
acceptable.

The radiant strip heating should be positioned to meet with the thermal comfort
conditions of the personnel only i.e work stations/aisles between storage systems
etc, as no direct heating of the air, is provided by this method of heating.

It is important however to consider the following criteria prior to selecting direct

gas fired radiant heating:-

a) Mounting heights requirements of the heating elements.

b) Proximity of the heating elements to potentially combustible materials.
c) Ambient air temperature requirements of stored products and associated
packaging.
d) Heater fluing requirements/restrictions.
e) Suitability of internal environment to house direct gas firing equipment (i.e
not suitable for use with potentially explosive atmospheres).
f) Thermal comfort levels pf personnel/occupants.
g) Structural implications (i.e. suspending the units from a roof structure).

14.5. Gas Fired Unit Heaters

Should Gas Fired Unit Heaters form part of the design solution the following points
shall be considered:-

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Gas fired unit heaters are normally be used in high volume spaces such as
warehousing/storage areas and where noise and excessive air movement/velocity
would not normally be restrictive.

Unlike radiant strip heating, the gas fired unit heaters would provide convective
heat, thereby heating the air within the volume of the space.

It is important however to consider the following criteria prior to selecting gas fired
unit heaters:-

a) Mounting height requirements of the unit heaters in respect of throw of air.

b) Positioning of the unit heaters in respect of heat distribution.
c) Positioning of unit heaters in respect of air distribution and proximity to
storage systems, i.e the heaters need to be positioned such that the design air
throw can be achieved.
d) Heater fluing requirements / restrictions.
e) Ambient air requirements of stored products and associated packaging.
f) Restrictions in respect of air movement/velocity.
g) Structural implications (i.e suspending the units from a roof structure).
h) Positions of lighting and sprinkler system heads.

14.6. Steam Systems

Where steam systems form part of the design solution, the system shall generally
be installed to meet with the requirements of any process engineering and
sterilisation systems that may be required at a building/facility/site.

Where steam systems are considered necessary to meet with the process
engineering requirements, due consideration shall also be given to the utilisation of
the steam systems to meet the requirements of both space heating and domestic
hot water generation for the building/facility/site.

The following criteria shall be considered;-

• Calculation and sizing of system loads.

• Calculation and sizing of system working pressures.
• Pipework sizing.
• Selection of pressure reducing equipment.
• Steam trapping and air venting.
• Condensate handling/condensate pumping
• Water treatment
• Health and Safety

15. Building Mechanical Services

This section is based on the following external design temperatures:

-3OC Dry Bulb Saturated (winter)

28°C Dry Bulb/23°C Wet Bulb (summer)
The figures detailed above are based upon UK climates and should be
altered/adjusted accordingly to suit temperatures in other parts of the World
generally to suit the building/facility location.

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15.1.1.Internal Design Temperatures

Areas Design Temperature OC

Offices 21°C Winter/23°C Summer

Canteens 21°C Winter/23°C Summer

Meeting Rooms 21°C Winter/23°C Summer

First Aid Room 21°C Winter

Main Entrance/Circulation area 21°C Winter
Stairwells 18°C Winter

Toilets 18°C Winter

Locker Rooms 21°C Winter

Shower Rooms 22°C Winter

Store Rooms 16°C Winter

Fork Truck Workshops 16°C Winter

Warehouse Areas 5°C Winter (frost protection)

Process Areas Minimum 16°C ± 2°C - to a maximum of 2°C

above outside ambient. The system design
temperature shall be achieved using purely
mechanical ventilation and shall provide a
positive pressure to the process areas.
Cooling shall be considered on a country/
location basis as part of the Process Area
ventilation design solution/study. The systems
design shall be site specific and agreed with
PepsiCo International on a site-specific basis
Packaging areas 21°C ± 2°C at a maximum outside
temperature of 27°C. The system shall be
designed to suit the local environmental
conditions of the site, which will dictate the
ambient conditions accordingly. The system
design shall be site specific and agreed with
PepsiCo International on a site specific basis.

All specified internal temperatures are to be controlled on a ±2°C tolerance.

15.1.2.Natural Infiltration Rates

Areas Infiltration Air Change

Offices 1 air changes/hr
Canteens 1 air changes/hr
Meeting rooms 1 air changes/hr
Main entrance/circulation area 2 air changes/hr
Stairwells 1 air changes/hr
Toilets 2 air changes/hr
Lockers 1 air changes/hr
Fork Lift Truck Workshop 2 air changes/hr
Warehouse Area 1 air changes/hr

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15.1.3. Mechanical Supply/Extract Ventilation Rates

Areas Mechanical Air Change

Toilets/Locker Rooms 10 air changes/hr (supply & extract)
Shower Areas 12 air changes/hr (supply & extract)
Offices/meeting rooms Fresh air to suit occupancy level at a
minimum of 12 l/s per person for general
ventilation extract at a balanced rate.
Canteens 10-12 air changes/hr (supply & extract)
Drivers Lobbies 6 air changes/hr (supply & extract)
First aid rooms 6 air changes/hr (supply & extract)
Warehouses Naturally or/by means of a smoke ventilation
system.
Fork Lift Truck Workshops Mechanical extract ventilation in accordance
with battery charging equipment
manufacturers recommendations, air make up
via external louvres.
Process Areas 6 to 8 air changes/hr supply & extract
complete with high efficiency particulate
absorption (HEPA) filtration equipment and
sock type diffusers
Packaging Areas 3 to 4 air changes/hr supply & extract
complete with high efficiency particulate
absorption (HEPA) filtration equipment and
sock type diffusers
Warehouse Pick Tunnels Mechanical ventilation air movers along tunnel
route at the mesh ceiling height for transfer of
heat generated from the tunnels to the
general warehouse areas or tempered make
up system.

15.1.4.Thermal Transmittance

All ‘U’-values for heat loss purposes shall be in accordance with the specified
building construction and materials and fully in accordance with the current
Building Regulations or to local standards (outside of the UK).

Heat loss/gain calculations shall be carried out fully in accordance with the
recommended CIBSE Guides.

Pipework velocity

Areas Velocity

Low Pressure Hot Water Heating Maximum 1.5 m/s (steel pipework) Maximum
1.0 m/s (copper pipework)
Hot and cold water services Maximum 1.0 m/s
pipework
Minimum pipework size 15mm nominal bore

Pipework Pressure drops

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Hot and cold water services To suit the system static head design and
pipework the available/designed mains water pressure
(site specific)

Ductwork Velocity- Offices/Ancillary areas

Areas Velocity

General (main sections) 3-5 m/s

Branches 2-3 m/s
Connections to grilles 2-5 m/s

The above velocities shall be considered as a maximum and the systems shall be
designed using appropriate velocities to achieve the specified noise criteria as
detailed below which may be site specific.

15.1.5.System Temperatures

Low surface temperature in 43°C

disabled person’s toilets

HWS flow/return distribution 60°C/50°C minimum

temperatures

Blended water to wash 43°C

hand basins/troughs

15.1.6.Noise Levels

External noise criteria shall be agreed with PepsiCo International on a site specific
basis.

Internal Noise Criteria:

Offices/meeting rooms NR 35
Toilets/lockers/showers NR 40
Warehouse NR 50
At displacements and Sock 50DB(A) at 1 Metre
Diffusers

15.1.7.Heat Gains
Occupants 90 W Sensible 50 W Latent

Lighting 15 W/M2
Equipment Loads 1 PC per occupant @ 350W
1 Printer per 4 PC’s @ 500W
1 Photocopier @ 1000W
1 fax machine @ 200W

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Where specific equipment loads are unknown 25-30w/m2 power may be used as an
alternative to those stated above, final equipment loads shall be agreed with
PepsiCo International on a site specific basis.

Fresh Air As rates specified previously and temperature

differences stated
Packaging Area 145 kW
Process Area 450 kW

NOTE: The figures denoted above for Packaging and Process plant heat gains are
provided purely as a guide for reference purposes to assist in the design process
and must be discussed/agreed with PepsiCo International on a site-specific basis.

15.1.8.Building Occupancy Levels

For the purpose of design solution/calculations occupancy levels shall be taken in

accordance with all associated proposed furniture drawing layouts with allowances
made for general circulation and visiting occupants. No diversity of occupancy
levels shall be permitted.

Packaging Areas 35 people per shift

Process Area 5 People per shift

NOTE: These figures must be discussed and agreed with PepsiCo International on a
site specific basis.

16. Ventilation Systems

16.1. General

As part of the overall Building Services ventilation system design solutions, various
options shall be considered and offered for consideration by PepsiCo International;-
Ducted Systems fed via centralised Air Handling Units (AHUs) plant or
localised heat recovery void mounted type units
Via the Wall localised Ventilation units
Ducted Dedicated air handling units to serve Process and Packaging
areas

All ventilation systems shall meet fully with the specified design criteria and all
requirements of local building control (UK) or to local standards (outside of UK).

Ventilation fans/air handling units shall be mounted in positions suitable for ease of
servicing and maintenance and agreed with PepsiCo International.

The general principles for the ventilation strategies shall be as follows;-

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e) All toilets and washrooms shall have mechanical extract ventilation,

comprising common twin duct mounted fan system with automatic
changeover panel. The panel shall feature a duty share facility. The
controller shall be mounted in an accessible location and suitably
labelled. The system shall incorporate a remote fan fail indicator
mounted in an area to be agreed, and be clearly labelled indicating its
use. The systems shall be controlled via automatic occupancy
sensors i.e. PIR’s with run-on timers. If a common system is provided
to serve several areas, the control system shall be operated via a
time switch facility. Ductwork systems shall include attenuators to
satisfy noise design criteria and ensure that cross talk does not
occur. Discharge points shall be via external louvres installed within
agreed locations and with a paint finish to a RAL colour as agreed
with PepsiCo International.
f) Make-up air shall be provided via centralised air handling unit
systems, ducted or via door transfer grilles, both options shall be
considered as part of the design solution and offered to PepsiCo
International for comment.
g) All areas receiving fresh air on a balanced supply and extract basis
as detailed within the specified design criteria shall be served by
plant comprising of centralised air handling equipment or localised
void mounted heat recovery units located in agreed positions
h) Fresh air intake to agreed filtration specification shall be derived via
external weather louvres designed to a RAL Colour as agreed with
PepsiCo International, complete with bird guards.
i) Where air intake/extract locations are similar the design solution shall
ensure that adequate separation is given between the intake/exhaust
louvres in order to prevent any potential cross flow contamination.
j) Supply/extract ductwork shall be complete with the necessary fire
dampers (conventional type or with remote indication of operation)
built in where passing through plant room walls and in all other
instances of breaching fire protection walls and fitted with local
access panels within the ductwork in accordance with current (UK)
standards or to local codes (where outside of the UK).
k) Make-up air to toilet extract systems shall incorporate ductwork
terminating at ceiling mounted louvre face diffusers.
l) Door transfer grilles for air make-up purposes shall be provided
where the supply system make-up via ceiling grilles is not deemed
suitable, where/if fitted within fire doors they shall be complete with
intumescing fire blocks/automatic smoke dampers/controls as
required to meet with requirements of the and approved by building
control.
m) The Contractor shall include for all volume control dampers to enable
satisfactory balancing and commissioning of the ventilation ductwork
systems.
n) There shall be 2 stages of commissioning, summer and winter

16.2. Process Area Ventilation

The following represents a typical building services ventilation system solution for
Process Areas. NOTE, this solution is by no means a preferred or fixed
solution and the final scheme proposed shall be agreed in strict
consultation with PepsiCo International on a site-specific basis.

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The ventilation system design associated with the Building Services requirements
of a facility may also be implemented/considered for use by the Process
Engineering Plant and equipment designers i.e. the combustion air requirements of
a gas fired fryer. The designer/installer of the building services systems shall liaise
closely with the process engineering designers/installers to affect a fully
coordinated combined system design and installation to suit both requirements.
These combined system solutions shall be agreed with PepsiCo International on a
site specific basis.

A weather tight double deck, air handling unit where necessary, located externally
at ground or roof level shall be used to serve the process area.

Fresh air shall be preheated, filtered, and tempered as necessary using heat
recovery/re-heater and delivered via external roof mounted ductwork with
branches dropping down to serve displacement air terminal units which shall be
carefully located, floor mounted, within the Process Area to ensure good air
circulation and distribution.

The exhaust air from the Process Area shall be extracted at high level via stainless
baffle type grease filters, then ducted across the roof of the building/structure to
the AHU where it shall be filtered and passed through an air to air recuperator
where it shall be finally discharged to atmosphere. The recuperator shall be
complete with motorised bypass and shut off dampers and stainless steel drain
trays suitably trapped.

Inverter speed control drives shall be provided on both supply and extract fans to
vary proportionally the supply and extract air volumes should process loads
fluctuate.

Supply air volume shall be not less than 24m3/s.

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Any high level platforms where operators are stationed shall be provided with a
dedicated supply air branch duct fitted with a DX cooling coil and an air cooled
condensing unit mounted on the roof to supply local food safe grade textile sock
diffusers to afford spot cooling.

16.3. Packaging Area Ventilation

A dedicated air handling unit complete with associated distribution ductwork shall
be provided to serve the Packaging Area designed in a similar manner to that
detailed previously for the Process Area, but with the addition of chilled water
cooling coil(s) facility.

The cooling coil shall be off copper tubes and fins with electro tinned finish. Space
shall be provided to allow the future installation of actuated carbon filters on the
exhaust air side should this be a future requirement.

Sock supply air diffusers shall be provided at high level, with high level extract
points provided, fitted with baffle grease and moisture filters.

The air handling unit and distribution system shall be capable of a supply air
volume of 20 m3/s.

Supply and extract fan volumes shall be set to maintain a 10% differential to
enable space pressurisation and air flow to be achieved.

16.4. Ductwork

All sheet metal ductwork shall be manufactured and installed in accordance with
the current Heating and Ventilating Contractors Association (HVCA) Specification
requirements with exceptions where identified below. All ductwork shall be leakage
tested in accordance with the current standards.

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• Ductwork shall be manufactured using hot dipped galvanised sheeting to

current British Standards (UK) and to local codes outside of the (UK), the
ductworks shall have 275 mass coating, M finish, B surface with C surface
treatment, to the nominal cross sectional sizes as required to meet the design
criteria. The ductwork designed sizes shall be based on standard sizes and
thickness as described in the Heating and Ventilating Contractors Association
(HVCA) current specifications, no gauge less than 0.8mm shall be used for
indoor applications or less than 1.0mm for outdoor applications.

• Longitudinal seams shall be made using the ‘Grooved Seam’ method with
continuous sealant injected during the seam forming process.

• Cross joints in rectangular ducts shall be by slide-on flanges with bolted corner
joints and knock-on clamps. Slip joints may be used for adjustable sections
only when they shall be angle reinforced for their full girth, integrally sealed
and fixed using mechanical rivets at 50mm centres.

• Rectangular ductwork shall be provided with additional stiffening as necessary

to obviate vibration and drumming by either cross bracing or beading or closer
spacing of cross joints.

• Cross-joints in circular ductwork shall be plain socket and spigot, with or

without connectors, with integral sealant and mechanical rivet fixings. Flanged
joints, with gaskets, shall be used in strategic positions to facilitate future
removal.

• Changes in direction in rectangular ductwork shall be by square pattern fittings

with integral air turns. Air turning vanes shall be of the correct profile to
ensure complete changes of direction of the air flow, with extended leading
and trailing edges and with the radius and spacing selected to achieve uniform
velocity through the bend. Air turns shall be fixed to the ductwork fitting with
mechanical rivets and stiffened to obviate vibration or blade oscillation.

• Bends in circular ductwork shall be 0.5D throat radius on sizes up to 400mm

and segmented thereafter.

• Branches off main ducts shall be by 45° shoes.

• Shape changes shall be long taper with the total included angle not exceeding
30°.
• Offsets shall be at a maximum angle of 30°.

• Flexible ductwork (acoustic where deemed appropriate) shall be installed at

final connection points to equipment and grilles etc. The maximum length
permissible shall be 200mm.

• Access points shall be provided local to all volume control dampers and within
ductwork systems to enable the satisfactory cleaning of the systems installed
in accordance with the requirements of the current Heating and Ventilating
Contractors Association (HVCA) Specification.

• Full calculations shall be provided for the roof loading of ventilation equipment
whether internally or externally mounted. These should take into account static
& dynamic loads, wind load, uplift, and snow load.

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16.5. Air Handling Units

Where air handling units form part of the overall design solution, suitably heated
air supply/extract air handling units shall be provided (located in agreed locations),
to deliver tempered and filtered fresh air supply air to the areas necessary to
receive supply/extract ventilation. Systems with heat recovery shall also be
considered as part of the final design solution. All system design solutions shall be
agreed with PepsiCo International on a site specific basis.

Air handling units shall be of the double stacked configuration (where practical and
space permitting) and shall generally comprise the following components in
direction of airflow.

Supply:

• Motorised inlet damper

• Frost coil (LPHW or other suitable means)
• Pleated bag filter EU5
• Heating coil (LPHW or other suitable means)
• Supply fan

Extract:

• Motorised exhaust damper

• Extract fan

The units shall be designed in accordance with the following typical installation
details:

Unit Frame

The unit framework shall be constructed using hot dipped galvanised steel box
section. `

The frame shall be assembled using pre-formed corner sections and seam welded
internally. Intermediate post work shall be fitted where necessary to provide a
structure of strength and rigidity. The frame shall be capable of supporting the
components and fittings forming the air handling unit and withstanding the
pressure within the air system under operating conditions.

Paint Application

The final assembly shall be pre-etched and treated as follows to provide a tough
uniform finish:

• clean down and degrease

• welded areas treated with a zinc, lead or aluminium based protective coating
• high gloss alkyl enamel finish

Enclosure and Access Panels

All enclosure panels and access doors shall be typically insulated and double
skinned.

The outer skin shall be manufactured from BSC colour coat plastisol (plastic coated
steel). The inner shall be manufactured from, hot dipped, galvanised steel. The

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cavity shall be packed with blanket fibre insulation compressed between the inner
and outer skin, to form a panel with excellent thermal and acoustic properties.

All panels shall be flush-mounted into the unit frame and be fully removable.

Access doors shall be provided to areas of regular maintenance and shall be hinged
or lifted off. They shall be internally strengthened and fitted with the following
furniture:

• Door catches: quick release, variable pressure bridge bar.

• Hinges: floating, lift off, double axle with variable pressure facility.

• Handles: grab type.

All panels shall be located on closed cell neoprene acoustic gaskets, about their
perimeter.

Unit Base Skid

All air handling units shall be fitted with a steel base skid designed to support the
unit at the relevant structural points.

The units shall also include the following:

Standard Features

1. Unit constructed to meet the leakage requirements of the HVCA current

Specification.

2. Frame to be vapour sealed.

3. Fan motors wired to local isolators complete with auxiliary contacts.

4. Fan assemblies mounted on vibration isolators.

5. Fan assemblies earth bonded.

6. Fan discharges fitted with internal flexible duct connectors.

7. Coils installed on slide rails.

8. Filter sections fitted with manometers to indicate filter state.

9. Bag filters installed in manufacturer’s frames.

10. Spigot connections flanged.

11. All units fitted with flush base skids.

12. All sections fitted with permanent lifting facility.

13. Access doors adjustable to allow for seal deterioration.

14. All non-access panels removable.

15. Finish: Framework: high gloss enamel paint or hot dip galvanised

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Panels: plastisol coated to RAL No.

Air Filters

Filters to be mounted in flat bank formation and arranged for front withdrawal on
bags using manufacturer’s frames and side withdrawal on panels.

Each filter bank to be fitted with a manometer to allow the maximum operating life
to be obtained from the filters and this manometer is to be connected at works by
the manufacturer. Clean and dirty indication labels to be fitted to each manometer.

Provide one complete set of spare filters for each air handling unit and hand them
over to the Employer’s representative immediately prior to practical completion.

Special HEPA filters shall be utilised in all air handling plant & equipment where
they are located within and serve all Process and Packaging areas of PepsiCo sites.
Filters selected should be compatible with spares held at the plant.

Hot Water Coils

Heating coils shall be constructed from 16mm OD seamless drawn copper tube,
mechanically bonded onto hard temper aluminium plate fins and mounted in a
flanged and bolted galvanised mild steel casing. Return bends to be copper and the
coil headers to be mild steel, with screwed or flanged connections as indicated and
tappings for venting and drainage.

The coil casing to be bolted onto a full width diaphragm mounting plate to reduce
air bypass leakage and supported on slide raise for ease of removal. Heating coils
to be sized so that the air velocity does not exceed 3.0 m/sec.

Electric heater batteries may also be deemed acceptable.

Legionella inspection housing shall be provided where necessary.

Fan Section

Unless otherwise stipulated the supply and extract fans to be of the double inlet,
double width type, fabricated from galvanised mild steel sheet with press formed
side plates and aerodynamically shaped inlet cones to give even distribution of air
over the full width of the impeller. Impellers to be either forward or backward
curved as stated and statically and dynamically balanced and mounted on
accurately trued and ground steel shafts, grooved and fitted with parallel key to
take driving pulleys. Bearings to be of the pre-greased, sealed for life type.

Fans to be mounted with their respective electric drive motors on a rolled steel
channel frame which is to be isolated from the unit structure by means of spring
type anti-vibration mountings. The fan outlet is to be connected to the unit casing
by a flanged, removable, incombustible flexible connection.

In order to reduce mechanical start up loads on larger fans, all fan motors of
5.5kW rating and over are to be arranged for soft start, star delta starting, or
inverter control where required and not direct on-line starting. This does not apply
to multi-speed motors or motors controlled by inverter drives.

16.6. Grilles/Diffusers/Louvres

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Provide sufficient input and extract diffusers/grilles/louvres to meet the design

requirements.

The design solution shall also consider the aerodynamic or thermodynamic effects
of handling air to avoid draughts or low temperature areas at working levels
particularly in reception areas, office and office/seminar accommodation.

Each supply and extract grille/diffuser is to be fitted complete with an integral key
operated volume control damper.

All supply air grilles shall typically be of the 4 way throw diffuser type complete
with manufacturers plenum box incorporating integral diffuser plates, with
matching diffusers utilised for the extract points with the exception of the toilet
areas all finished in white RAL 9010.

Extract grilles to toilet areas shall be of the egg crate type or circular air valve type
to suit volume flow and noise restriction characteristics, all grilles shall be typically
RAL 9010 complete with plenum boxes (eggcrate only).

Door transfer grilles shall be of the non-vision framed type to a RAL colour
approved by the PepsiCo International complete with fire/smoke
dampers/blocks/controls if installed within fire doors.

External louvres shall be finished in a RAL colour as agreed with the Architect and
incorporate bird guards. Maximum velocities shall be designed in accordance with
the noise criteria specified and with attention also to noise generation externally
(maximum velocity to be 2.0 - 2.5m/s).

As detailed previously sock type diffusers shall be considered as part of the design
solution for use in Process and packaging areas.

16.7. Attenuators

Provide where deemed appropriate suitable duct mounted attenuators and cross
talk attenuators in order to meet the requirements of the noise design criteria.

Silencer casings shall typically be fabricated from pre-galvanised steel sheet,

utilising grooved seamed joints as appropriate.

Each joint shall be filled with high velocity duct sealant conforming to the current
standard, irrespective of any leakage class specified.

The attenuator flanges shall be secured to the casing via mechanically closed,
sealed blind rivets having a shear strength of typically 2260N/m, at maximum
pitches of 225mm. Rolled steel flanges shall have the casing end returned over its
face regardless of the specified leakage class.

All attenuators are to be manufactured using proprietary flanges, which are to

have additional sealant applied between corner pieces irrespective of the specified
Leakage Class.

Attenuators shall have internal sideliner and splitter elements which are to be
constructed from Grade Z2 pre-galvanised perforated steel sheet, having a free
area of not less than 37% which is to be formed into trays. These trays shall be
linked together using pre-fabricated angles to form a self-contained unit.

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The attenuators media utilised shall be 32kg/m3 density “Super Glass”, which shall
be additionally faced with a woven glass fibre scrim to prevent fibre erosion into
the air stream. “Super Glass” to be completely inert and not harbour
bacteriological growth and shall be tested in accordance with BS476 parts 4, 6 and
7 (UK) and to other local codes (outside of the UK). The contractor is to advise of
any other ‘Fit For Purpose’ alternatives.

All silencer sideliner and splitter elements shall be fitted with leading and trailing
radius fairings which are to be formed from pre-galvanised steel. Splitter elements
shall be secured into the silencer casing via two parallel rows of sealed rivets at a
maximum pitch of 250mm.

High pressure sealant shall be universally applied to all joints between internal
sideliner and splitter elements and the casing.

Attenuators shall be melamine lined where they are proposed in areas where
moisture/grease is likely to be present i.e. showers, kitchens and process
engineering plant areas.

16.8. Fire Dampers

Provide duct mounted Fire dampers shall be provided where ductwork penetrates
any fire compartmentation barrier fully in accordance with the requirements of the
fire strategy for the site/facility to be agreed on a site specific basis.

Installation frames shall be provided where appropriate and built into building
construction. Dampers shall have blades out of the air stream and also include
open/closed status indication (to be agreed with PepsiCo International), with
remote connection facility to the BMS and fire detection systems.

Ductwork access points shall be installed local to all damper positions for re-
setting/maintenance where fusible links are proposed, on both sides of the
damper.

All dampers shall be inter-linked to the Building Management System to show

status of the damper i.e open/closed. Where no Building Management System is
provided (site specific) a “self contained” remote damper status indication panel
shall be provided to a manned location i.e. Gatehouse/Security lodge or similar
(final locations shall be agreed).

16.9. Testing and Commissioning

The systems shall be tested and commissioned fully in accordance with the CIBSE
Commissioning Code A for Air Distribution Systems (UK) and to local codes
(where sites are located outside of the UK).

The system shall meet fully with the specified design/operational requirements.

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17. Air Conditioning/Direct Expansion (DX) Comfort Cooling Systems

17.1. General
As part of the overall Building Services ventilation system design solutions, various
options shall be considered and offered for consideration by PepsiCo International;-
Full Air Conditioning Systems (Chilled Water/DX)
Localised cassette/condenser arrangements (VRF), (VRV) etc
Single/Multi Split Systems

17.2. Chilled Water Systems

Chilled water systems shall generally be provided to meet with the requirements of
central plant air conditioning systems (including de-humidification) and comfort
cooling equipment (fan coil units etc).

Chilled water systems shall generally comprise the following: -

• Packaged air or water-cooled chillers.

Note:- should water cooled chillers be utilised then adequate measures shall be
taken for the control of legionellosis.
• Pressurisation/expansion equipment.
• Buffer vessels.
• Circulating pumps.
• Distribution system.
• Chilled water batteries located within air handling units and fan coil units.
• Automatic controls equipment.

The following criteria shall be considered for chilled water systems: -

• Total building chilled water loads.

• System flow/return temperatures.
• Locations of chillers
Note: - Location of the plant may have implications in respect of Structural
supports, Planning/Aesthetic issues and Noise Pollution. In addition the chilled
water plant shall be positioned to meet with the recommended requirements
for access/maintenance.
• Size and weights of chillers.
• Future site expansion.
• Available fuel (Gas or Electricity).
• Health and Safety issues, to include site access for planned/routine
maintenance.

When establishing the total outputs of the chilled water plant due consideration
shall be given to the degree of standby capacity required, which shall be discussed
and agreed with PepsiCo International.

17.3. Comfort Cooling/Heat Pump Installations

Where as part of the design solution Comfort Cooling/Heat Pump systems are
proposed the following shall be considered;-

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Note: As an alternative to ceiling/wall mounted comfort cooling/heat pump systems,

consideration shall also be given to utilising above ceiling ducted type fan coil units,
with high external pressure and associated discharge plenums/spigots where
necessary.

The system shall utilise units with acoustic insulation fitted and be suitably vapour
proofed with all louvre faced ceiling mounted diffusers/insulated and vapour proofed
plenum boxes.

The general areas that are to receive comfort cooling/heat pump system installations
shall be agreed and be based upon site specifics. Typical areas shall be as follows;-

• Office areas
• Reception
• Training Rooms
• Meeting and Board Rooms
• IT Computer Room

All other ancillary areas shall be served by other means of heating i.e. LTHW etc as
detailed elsewhere in this specification.

The control system shall be capable of providing a 7 day/24 hour timed function for
each system with day omit facility via a connection to a BMS system.

The BMS connection shall also be capable of receiving enable/fault indication from
the control system.

In addition to the above, each plant/system shall be capable of operating

automatically should a frost condition occur, in order to protect the building fabric
and internal services at a nominal set back condition.

Note:

Consideration shall also be given to the installation of a proprietary manufacturers

centralised controller facility to provide full function control of all systems from a
central area such as a reception desk in lieu of localised individual controllers.

The design/selection of the systems shall be made with due consideration in order to
maximise on the system efficiencies and controllability.

17.3.1. Refrigeration Pipework (direct expansion)

Refrigerant pipework shall be soft copper designed, sized and installed to meet the
requisite current Standards.

All refrigerant pipework shall be dehydrated for refrigerant use and shall be marked
as such. Fittings shall be manufactured from copper or a suitable corrosion resisting
alloy for copper.

All tubing shall be supplied and stored in clean conditions with the ends sealed.

Cleanliness shall be maintained throughout the installation phases by purpose made

plugs, caps and blanking flanges fitted to all open ends.

Pipework shall be designed and arranged to maintain refrigerant velocities and

gradients to prevent trapping oil and sludging and to ensure that oil is returned to
the compressor under all conditions, including lowest stage of capacity unloading. All

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horizontal discharge lines shall be sloped away from the compressor to prevent
gravity oil return to the discharge ports.

Dry nitrogen shall be fed through the pipework whenever a brazing operation is
being carried out to prevent any formation of oxides within the pipework. When
brazing adjacent to valves etc., precautions shall be taken to prevent the heat
distorting valve seats or similar by wrapping components with a damp rag to absorb
the heat.

Pipework routes shall be such as to minimise the length of runs and the number of
directional changes. Pipework joints shall also be minimised to reduce the risk of
leakage and hence refrigerant emissions to atmosphere.

Brackets for refrigeration pipework fixed to walls shall generally be of the

“Hydrazord” type. Where direct wall fixings are not practicable, then refrigerant
pipework shall be supported on suitably sized cable trays along its entire length. The
cable tray shall be hot dipped galvanised, heavy duty with return flanging.

All bends, tee sections etc., shall be made using the proprietary manufacturers
fittings, no site made fittings will be allowed. The cable tray shall be supported at
regular intervals in accordance with the manufacturers recommendations and the
spacing of supports shall be such that no “sag” is apparent when the tray is fully
loaded.

Pipework shall have flexible couplings to prevent vibration transmission where it is

connected to compressors and air cooled condensers. Gas pulsation dampers shall
be fitted where appropriate to minimise noise and vibration transmission.
Upon completion of the pipework installation, the system shall be pressure tested.
After the pressure testing and dehydration, the system shall be charged with the
required amount of refrigerant.

All pipework upon completion shall be labelled to indicate the system reference
installed at 3 metre intervals. In addition, the external condensing units shall be
fitted with suitable engraved labels indicating the system reference and details of the
area served.

The refrigerant pipework shall be thermally insulated with Armaflex Class “O” with a
minimum wall thickness of 13mm. The insulation shall have a thermal conductivity
of 0.037W/m2K to DIN 52613.

17.3.2. Condensate Pipework

For each fan coil unit a PVC condensate gravity drain pipework or pumped drainage
system shall be provided, including all necessary running traps, tundish air breaks,
disconnection traps etc.

Condensate lift pumps shall be provided as necessary.

All condensate pipework immediately off the fan coil units (first 2 metres) shall be
thermally insulated with 13mm Armaflex with Class O rating insulation within any
high risk areas such as document rooms or IT/Communication rooms they shall be
suitably vapour sealed.

All gravity condensate pipework shall be trapped prior to connection to any drain
pipework and shall be installed to falls.
All PVC pipework shall incorporate solvent welded fittings/accessories.

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17.3.3. External Condensing Units

The outdoor condensing units shall be sited externally in an agreed location to be

agreed on a site-specific basis. A designated condensing unit compound shall be
the preferred solution.

All allowances for unit separation for correct airflow and access for future
maintenance shall also be considered.

The final condenser unit arrangement shall be determined to suit the site layouts,
refrigeration pipework routes, having paid particular attention to the permitted
maximum lengths of run for the refrigeration pipework.

The condensing units shall be sited on purpose made anti-vibration strips on

(common or single) concrete bases.

Adequate drainage shall be considered within any designated compound where

heat pumps are proposed.

17.3.4. Commissioning

The Contractor shall include for setting to work and commissioning each and every
system to the satisfaction of PepsiCo International or the Employers
representative.

Following completion of the above the installer shall demonstrate the system
operation to the Employer.

The system shall meet fully with the specified design/operational requirements.

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18. Domestic Water Services

18.1. General

The complete hot and cold water services installation shall be provided to serve all
the various sanitary appliances/outlets etc which shall be agreed on a site specific
basis.

18.2. Direct off Mains Electric Water heaters

As part of the design solution, direct off mains electric water heaters shall be
considered to provide for point of use hot water.

The utilisation of electric water heaters shall only be considered when there is no
adequately sized hot water secondary distribution system in the vicinity that may
be adequate for connecting into.

Electric water heaters shall only be considered when the hot water outlets are
localised and the hot water demand is considered low.

The water heaters shall be installed complete with all the necessary safety devices
as required by Building Regulations (UK) and to local codes (outside of the UK). In
addition the mains water pressure shall be reviewed and the water heaters
supplied c/w the necessary pressure reducing/expansion kits as deemed
appropriate.

Where appropriate electric water heaters fitted with integral blending valves shall
be considered to serve outlets which require a maximum outlet temperature of
430C. The location of the water heaters in respect of the outlets shall also be
considered as pipework dead legs on the hot water distribution shall be kept within
the recommended minimum. Electric trace heating of the hot water distribution
pipe shall be considered if the distances between the water heater and outlet is
considered to be excessive/exceeds the minimum recommended.

The electrical services infrastructure shall be reviewed prior to the selection of the
water heaters to ensure that adequate spare capacity is available.

18.3. Indirect Hot Water Calorifiers

As part of the design solution, indirect hot water calorifiers shall be considered to
meet with the hot water demand of the building.

Consideration shall be given to the following design criteria prior to the selection of
a equipment: -

• Anticipated hourly demand (litres/hour).

• Anticipated peak demand (10-20 minute period).
• System static head (meters).
• Primary heat source available (kW).
• Electric immersion heaters for standby purposes.

Should the unit selected be of the unvented type then the unit shall be supplied
c/w all the necessary safety devices as required by current building regulations (ie.
non-vented kit - UK) or to local codes (outside the UK).

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Due consideration shall be given to the routing and termination of the safety
device discharge pipework. Should a boosted hot water scheme be adopted the
pressure rating of the calorifier shell shall be considered to suit the working
pressures of the system.

The calorifier shall be installed c/w all the necessary controls to provide for control
of the hot water storage temperature to include, control thermostat, high limit
thermostat and pipe mounted control valve to be installed within the hot water
primary pipework.

18.4. Pipework

The internal hot and cold water services installation shall be carried out in copper
tube to BS EN 1057-R250 (UK) and to local standards (outside of UK). Soldering to
all fittings used shall be lead free soldered to current standards (UK) and to local
standards (outside of UK). End feed fittings will not be accepted.

Under no circumstances shall cold water service pipework be routed within heating
or hot water pipework boxings/voids etc. in accordance with recommendations to
prevent the growth of Legionella Bacteria.

Only metal pipe clips will be accepted and under no circumstances shall plastic
clips be used for the support of pipework services. Drain cocks shall be fitted to all
system low points.

Where pipework is exposed, typically within fully tiled toilet areas, the pipework
shall have a chrome plated finish with matching fittings and brackets.

18.5. Valves

Valves shall be fitted in pipework lines, within main runs, branches from mains and
to each range of fittings to provide suitable isolation and regulation. The valves
shall be fully Water Supply Regulations (WSR) approved and installed in
accordance with the water regulations (UK) and to local codes (outside UK).

Service valves shall be fitted on all draw-offs.

Double regulating valves shall be provided on any secondary return sub-circuits to

maintain suitable balancing to meet the circulation temperature specified within
the periods recommended.

18.6. Insulation

All domestic hot and cold water services pipework shall be thermally insulated
using proprietary insulation methods such as “Rockwool Rocklap” sections or
similar, the insulation shall have a nominal density not less than 120 kg/m3 with a
factory applied facing which is a laminate of close mesh reinforcement between
two layers of foil including integral lap for fixing.

The insulation shall comply with current standards BS5422 (Table 1) and BS5970
water vapour permeance and Building Regulations Class O definition (UK) and to
local codes (outside of UK).

Thermal conductivity at 50°C mean temperature shall be at least 0.037w/mK.

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Thermal insulation shall be installed in strict accordance with the manufacturer’s

recommendations.

Thermal Insulation shall be applied to all Hot and cold water services unless agreed
with the PepsiCo International.

18.7. Mains Cold Water Supply

A mains cold water service shall be provided to all buildings/facilities designed to

meet the use of the building. Capacity of the supply shall be agreed with PepsiCo
International. The provision shall include agreed spare capacity for future
expansion. The outside plant network capacity should be investigated to ascertain
any future requirements.

Generally the mains pipework services shall be extended from a typical external
meter position to be located at typically a site boundary and generally routed
underground in Blue MDPE to the agreed intake point of the building/facility, all to
be agreed with PepsiCo International. Marker tape shall be installed above all
underground external services. All fittings, valves, plant/equipment utilised on the
water services systems shall meet the requirements of both be WSR (Water Supply
Regulations) and the WRC (Water Research Commission) (UK) or to local codes
(outside the UK).

The copper pipework shall be connected to the MDPE internally and be routed to
serve typically a suitable cold water storage tank & booster pumpset. NOTE: Water
storage facilities within buildings/site facilities shall be agreed on as site specific
basis with PepsiCo international.

The cold water storage tank shall be fully compliant to Water Supply Regulations
(WSR) (UK) or to local standards (outside of the UK).

At building entry points provide a stop valve, double check valve and drain facility.

Consideration shall also be given to any external irrigation watering points, which
shall be provided in strict compliance with the local water authority including all
necessary anti-syphonage devices and insulation etc.

18.8. Boosted Cold and Domestic Hot Water Service

A complete boosted cold water system shall be provided to all PepsiCo

International facilities designed to suit site specific conditions.

The drives for the booster pumps shall be inverter driven with the booster pumps
fed directly from a suitably insulated, sectional, storage/break tank.

The tank shall be sized in order to provide an 8-hour standby supply to the
site/building. The level of standby shall be agreed with PepsiCo International on a
site specific basis.

Tank support systems shall be suitably sized so as to accept additional tank

sections should they be required for future expansion.

The tank shall be positioned above the location of the booster set, within a the
site/building plant room, on a purpose made tank stand, designed, engineered and
installed by with special allowances made for access and maintenance purposes.

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From the delivery side of the booster the boosted cold water shall serve all cold
water outlets other than those tap outlets designated as “Drinking Water“ points,
which shall be served direct off mains.

The cold water booster set shall also supply a packaged plate heat exchanger unit
to provide a boosted domestic hot water service to all hot water tap outlets. This
option shall be agreed on a site specific basis with PepsiCo International.

An electromagnetic water conditioner shall also be provided installed inline

between the booster set and the packaged plate heat exchanger set.

18.9. Packaged Cold Water Booster Set

The booster set shall be of a typical packaged design incorporating the following
features as a minimum:

• Base Frame. The base frame shall be manufactured from mild steel box
section shall of welded construction. The rigid frame shall extend beyond
the booster set pipework to provide strength and protection to the unit.
The complete base frame shall be hot dip galvanised finish. For installation
in process areas see PepsiCo Mechanical Engineering Standards.

• Pumps. The packaged unit shall be complete with 2 No stainless steel

vertical multi-stage pumps. Motors to be T.E.F.C. construction with class IP
54 protection, suitable for operation on 400v/3ph/50Hz. Insulation to class
“F”. Both motors shall be fitted with individual inverter drive control units.

• Pipework. Suction and discharge manifolds shall be completed in stainless

steel, complete with isolating valves to each pump suction. Isolating and
non-return valves shall be fitted to each pump discharge, terminating in
suitably sized manifold valves.

• Hydraulic Accumulator. The packaged unit shall be complete with a vessel

constructed of a mild steel, powder coated for protection. The vessel shall
be complete with a replaceable rubber bladder and stainless steel flange.

• Gauges. The unit shall be complete with a system pressure gauge.

• Control Panel. The unit shall be complete with an integral control panel,
containing the following features and control functions as a minimum.

Class IP 55 enclosure mounted at minimum 300mm from floor

level
Class IP2X
Earthing to IEE Wiring Regulations
Main and control circuit protective devices
Contactors
Power on lamps
Inverter controls
On / off / auto switches
Pump duty alternating
Auto changeover

The panel shall also contain terminal arrangements for:-

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Water Storage/Break Tank Low level cut out

Remote stop/start
Volt free contacts for inverter trip and link to BMS system

The controls package shall also include for pressure sensors for pump
inverter control and volt free contacts for a common high and low pressure
alarm with facility to link these to a BMS connection.

A safety relief valve shall be incorporated within the discharge pipework to

prevent any system damage in the event of control failure.

18.10. Plate Heat Exchanger

As part of the design solution an option for the use of a plate heat exchanger
system shall be considered, designed to operate on a run/standby basis to meet
with the hot water requirements of a particular building/facility. Note: Secondary
hot water circulation must circulate both duty and standby units simultaneously so
as to minimise stagnation/proliferation of Legionella bacteria. The use of plate heat
exchangers shall be agreed on a site specific basis with PepsiCo International.

(As an alternative to the plate heat exchanger typically a calorifier/cylinder with a

high recovery facility & localised water heaters shall also be considered).

The plate heat exchanger unit shall be served on the primary side by the LTHW
heating system via a constant temperature circuit.

The plate heat exchanger unit shall incorporate all integral twin primary circulation
pump sets and associated controls/auto-changeover etc linked to the Mechanical
Services Automatic control system with BMS connection facility.

A nominal buffer vessel shall be provided linked with the plate heat exchanger to
level out load demands and provide some storage for peak demands.

Design of the storage facility shall be selected when determining the plate heat
exchanger maximum peak flow rate, thus ensuring the optimum boiler plant
provision is made.

18.11. Electromagnetic Water Conditioner

An in-line electromagnetic water conditioner shall be provided connected on the

discharge side of the cold water booster set.

The electromagnetic conditioner shall be located prior to the packaged plate heat
exchanger/calorifier/cylinder but after the branch connection to the boosted cold
water service take off.

The electromagnetic water conditioner shall be suitable for mains electricity

operation (typically 230v/ 1ph/50Hz) and shall be sized to accommodate the
maximum flow rate of the DHWS system for all options considered as part of the
design solution.

The water conditioner shall be complete with isolation valves and a full bore by-
pass facility.

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18.12. Urinal Flush Controllers

Urinal flush controllers shall be provided to serve all the urinals installed within the
male toilet facilities of a facility.

The systems shall be of the automatic PIR occupancy sensing type integral with
mains 230v electric power supply. Battery operated types shall not be permitted

18.13. Thermostatic Blending Valves

Thermostatic blending valves shall be provided to all outlets within the building
areas requiring a blended hot water temperature of 43°C generally as scheduled
below as a minimum but shall be agreed on a site specific basis:

• wash hand basins within public toilet areas.

• wash hand basins within disabled toilets.
• hand washing troughs in factory/process changing rooms/areas

The valves shall be selected to suit the available pressure to provide failsafe shut-
off to prevent scalding, be tamper proof.

The valves shall be Water Supply Regulations (WSR) approved (UK) or to local
standards (outside of the UK).

All valves shall be fitted with isolation valves and in-line strainers. Balanced
pressure supplies shall be provided to all mixer valves and associated mixer taps.

18.14. Showers

Recessed thermostatic showers shall be provided to all areas where necessary on a

sites specific basis, including approved disabled showers (where necessary)
including all associated accessories.

The showers shall be selected to suit the available pressure to provide ‘failsafe’
shut-off to prevent scalding, be tamper proof and fully comply with the TMV3
scheme. The valves shall be Water Regulation approved.

Strainers shall be provided on each of the hot and cold water supplies to each
shower c/w with isolation valves.

Exposed pipework in the shower areas shall be chrome-plated copper.

As an alternative thermostatic electric showers shall also be considered.

18.15. Secondary Return Circulating Pump

Within the common secondary return pipework local to the heat exchanger units a
bronze secondary return circulating pump, shall be provided as part of the design
proposal to minimise the risks associated with dead legs in pipework/Legionella
growth.

Alternatively and should a common pumped secondary not be provided, electrically

operated trace heating of the distribution pipework shall be considered.

The pumps shall be a variable speed, glandless circulator.

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The pumps shall be fitted with isolating and non-return valves and temperature
gauge on the return pipework.

Upon completion of the installation the secondary circulation systems shall be

balanced to ensure a minimum temperature of 50°C is maintained throughout.

Under no circumstances should the pumps be installed in such a manner that the
shaft is in the vertical plane.

18.16. Chlorination

The chlorination of the domestic water systems shall be carried in accordance with
HS G (70) and BS6700 (UK) and to local standards (outside of UK).

Under no circumstances shall a PepsiCo facility be handed over to the Client for
occupation without Chlorination Certifications having previously been issued stating
that the domestic water services are safe to use.

Inhibiting chemicals shall be of proprietary manufacture and used in accordance

with the manufacturer’s safety instructions.

The sterilisation process shall be carried out by specialists in this field of work who
shall submit signed certificates to warrant that the systems have been properly
disinfected in accordance with the stated standards.

On completion of sterilisation of the systems, all shall be thoroughly and totally

flushed out at least twice with clean water prior to any water being used for
domestic purposes.

Two sets of water samples from the sterilised system, one set immediately after
sterilisation and one set immediately prior to handover shall be tested. The method
of obtaining samples, sampling point etc shall be recorded, witnessed and certified
by PepsiCo International. The samples shall have tests carried out by the Water
Authority to confirm that water from the installation is suitable for human
consumption and free from harmful bacteria/chemicals.

Two copies of the test reports shall be forwarded to PepsiCo International.

The methods used to test the samples shall be in accordance with those laid down
in ‘Analysis of raw, potable and waste waters’ published by the Department of the
Environment, HMSO 1972 (UK) or any method approved and employed by the
Environmental Health Department at the time of the tests.

A clean water certificate is to be issued prior to Practical Completion.

18.17. Testing and Commissioning

Testing and commissioning of the whole domestic water services installation shall
be carried out fully in accordance with the CIBSE Commissioning Code W for Water
Distribution Systems (UK) and to local standards (outside of UK).

The system shall meet fully with the specified design/operational requirements.

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18.18. Hot Water Washdown System

Hot water washdown (HWW) systems for process areas are normally provided by
Diversey Lever. The contractor may be required to install any high pressure pump
set and necessary pipework.

HWW stations shall be located on columns and on the perimeter walls in agreed
locations.

One HWW station shall be located in the Boiler plant room and in the Compressed
Air Room.

18.19. Safety Showers & Eye Wash Facilities

The processing and Battery Charging Stations shall be provided with a hot and cold
water sink, and drinking fountain.

The Finish Goods Distribution stations shall include a hot and cold water sink and
drinking fountain.

The following areas shall normally be provided with a proprietary eyewash station
and safety shower facility

Battery charging area

Fryers
Chemical stations
Other areas by local risk assessment

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19. Compressed Air Facility

A compressed air facility shall be provided to all process/factory areas, agreed on a

site-specific basis with PepsiCo International.

The compressor shall be of the enclosed type for noise control.

The compressor(s) shall have energy efficient unloaded modes of operation and vibration
shutdown sensors. Temperature and pressure indicators shall be included at all stages of
the unit and at the exit. For multiple compressor installations the use of inverter control
and air management systems shall be considered.

Baseline compressors shall be operated continuously at full load while using a

smaller trim compressor to handle variable loads. Install multiple baseline
compressors so that units shut off as the system demand decreases. For heavy
baseline loads turbo compressors should be considered, with a rotary screw as a
secondary option, this should be fitted with a variable speed drive.

Food grade, code approved, lubricant shall be utilised. The compressor shall be
sequenced for operation.

Air dryers shall normally be of the refrigerant type and shall be sized to handle the
entire plant load via a single unit. The dryer shall be equipped with hot gas by-pass
for low load control. The dryer shall be of the enclosed type for noise control. The
dryer shall be equipped with a manual and an automatic blow-down system
facility.

Desiccant dryers shall only be used in isolated cases where conditions demand
drier air such as instrumentation etc.

Airreceivers shall be provided to handle large volume users and absorb fluctuation
in system loads. They shall be designed in accordance with current local standards
& specifications and shall be equipped with a manual and an automatic blow-down
system facility.

Filtration of the air shall be required to provide 99.9% oil free air to the process
plant. The first two No. filters shall be coalescing filters located after the surge
tank, but before the dryer. The last filter section shall be a charcoal filter located
after the dryer.

Each filter shall be equipped with a differential pressure gauge. The objective is to
provide clean, dry, oil free, instrument air. Each filter shall have a manual and
automatic blow-down and an independent, differential pressure gauge to monitor
operation.

The compressor and dryer shall be of the air-cooled type.

The compressed air system shall be provided with an Air Marshalling/Managements

System as part of the design solution.This shall include power monitoring equipment,
a
power meter for the entire compressed air system and an air flow meter for the main
air header.

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The system control system and electrical services shall feature connection to the
site BMS facility.

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20. Automatic Controls For Mechanical Building Services Plant and Equipment

20.1. General

As part of the design solution an automatic control system shall be provided for
the complete operation of the proposed Mechanical Building Services plant and
equipment, in accordance with the specified design criteria. The control system
design shall meet the full requirements of Part L of the building regulations (in the
UK) and to suit the building/facility operation and usage patterns proposed for the
building/facility.

The Heating, Ventilating and Air Conditioning systems automatic controls shall be
linked to the site fire alarm system and the BMS system (where applicable to be
agreed on a site specific basis as agreed with PepsiCo).

NOTE: the controls/fire alarm link shall be configured such that the main gas
valve does not operate to the closed position during routine testing of the fire
alarm system.

20.2. Installation

The control system shall feature dedicated electrical control panel(s) from which all
plant & wiring and associated field devices shall be controlled.

The control panel shall be located within the building/facility main plant room or as
agreed on a site specific basis with PepsiCo International.

Provide suitable containment as detailed previously. Systems for all LV and ELV
wiring from the control panels shall be provided with adequate segregation
between power and control circuits and to avoid mixed voltages and effects of
interference.

The controls shall be installed complying with the PepsiCo International Electrical
Specification Manufacturing & Logistics, which is issued as a separate document to
this Specification.

No joints shall be permitted in cables, where these are unavoidable, the cables
shall be joined using an approved housing, securely fixed and having cable
securing clamps.

Where cables are connected to sensors measuring extreme heat, the necessary
thermal breaks in local connecting cables are to be supplied. No data cable shall be
installed in the same conduit as any power cable nor be parallel affixed within
25mm if surface/tray mounted.

Each field device shall be identified (internally on space detectors) with a common
code by affixing sleeves at the controller and field device terminations. The codes
shall be used in the control panels and on the installation diagrams/drawings. Any
outstation shall be provided with a schedule identifying the points connected to the
I/O terminals inside the panel door.

Sensors, actuators, switches and all field devices shall be mounted according to the
manufacture’s instructions. All shall be installed with clearance to allow the
servicing and the conduit connected by methods to allow easy replacement.

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Special care shall be taken to ensure that the manufacture’s recommendations with
respect to earthing data cables and controllers are followed.

Wiring within the controllers/control panels shall be completed in a neat and

professional manner with lacing/cable ties and cables cut to correct length to assist
maintenance. Earthing braids/wires shall be neatly terminated. Prior to
commissioning each controller enclosure/control panels shall be cleaned of all cable
waste.

20.3. Control System Panel Types

The control panel shall be a “wardrobe type” constructed from formed sheet steel,
as necessary.

The panel shall be divided into two separate sections: power and controls.

The controls door and power section door shall be interlocked with the mains
electrical supply.

All starters, contactors and associated equipment shall be based within a common
power section of the control panel. This section shall be fitted with an interlocked
main isolator.

Each item of equipment shall be supplied from a hand/off/auto switch with auto-
position monitored by common plant input controllers. Indicator lamps shall be
provided to give local indication of plant status.

All panel equipment shall be protected to a minimum IP31 and any items not IP31
shall be fully shrouded.

Internally the panel shall be shrouded to IP2X.

All panel fascia indicator lights shall be of LED type.

Earthing and Bonding shall meet with the requirements of the IEE Wiring
Regulations.

20.4. Commissioning and Testing

The controls system shall be completed prior to final commissioning of the

mechanical plant. Where final commissioning and witness testing of the controls is
dependent on operation of the plant, this shall be identified during the
programming stages and a commissioning plan agreed.

All the necessary test equipment and materials used in commissioning shall be
supplied by a controls system specialist and shall have current test and calibration
certificates.

All safety interlocks, overrides and fail-safe conditions are to be operational prior to
starting the plant and demonstrated to the satisfaction of the PepsiCo International
prior to placing plant in auto mode.

Fault conditions for all critical alarms, safety devices and controls interlocks shall
be simulated and proved effective as soon as practical.

Commissioning documentation and schedules shall be submitted for approval

during the design phase showing each plant, point, interlock and control algorithms

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and the stages of checks and commissioning required. A complete set of the
commissioning documentation shall form part of the system documentation.

Provide seven days notice to the PepsiCo International of the intention to provide
the acceptance demonstrations following the commissioning period of a
building/facility;-

20.5. Documentation

System manuals shall comprise the following information as a minimum:

• Details of site name, date, controls specialist details, telephone numbers,

contacts, controller addresses etc.
• Diagrams showing the full schematic and physical layout of the system and
components.
• Equipment schedules identifying manufacturers, suppliers, recommended
spares, part references, contact numbers/addresses.
• Motor control Panel wiring diagrams, showing the connection to each item of
field device or equipment.
• Data sheets and maintenance instructions shall be provided for each item of
equipment. Copies will not be acceptable.
• Record drawings of the installation on marked up mechanical/architectural
layout drawings.
• Safety requirements.
• Health & Safety documentation.

All drawings relating to the controls shall be supplied on A3/A4 sized bound into A4
binders.

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21. Mechanical Building Services Located within Process Areas

Where Mechanical Building Services are to be routed through the designated

Factory/Process areas of a PepsiCo International building/facility – the installation
of the building services shall be completed in strict accordance with the following
specification issued as a separate document to this specification:-

Mechanical Engineering Standards for Snackfood Manufactu

Material Schedule for Mechanical Installations

Item Potato Process Area Packaging Room Waste

Preparation Room
Unit Heaters Not stainless Not applicable Not stainless steel Not Stainless
steel Steel

Unit Heaters pipes Stainless steel Not applicable Not stainless steel Stainless steel
below line of 5.1 m
above FFL of
ground floor slab
Diffusers Stainless steel Stainless steel Not stainless steel Stainless Steel

Ductwork Stainless steel Stainless steel Not stainless steel Stainless steel
below line of 5.1 m
above FFL of
ground floor slab

Floor Drain As stated in As stated in As stated in As stated in

Gratings mechanical mechanical mechanical scope mechanical scope
scope of work scope of work of work of work
Rain Pipes Stainless steel Stainless steel PVC Stainless steel
covering covering below line of 5.1 m
above FFL of
ground floor slab
F/H Cabinets Stainless steel Stainless steel Not stainless steel Stainless steel

F/H Cabinets Piping Stainless steel Stainless steel Not stainless steel Stainless steel
below line of 5.1 m
above FFL of
ground floor slab
Smoke Hatches Not stainless Not stainless Not stainless steel Not stainless steel
steel steel

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