STANDARD SPECIFICATIONS TECHNICAL TERMS Pipeline... · STANDARD SPECIFICATIONS ... 4.1...

WAM

client: FEDERAL ELECTRICITY AND WATER AUTHORITY (FEWA) project: STANDARD SPECIFICATIONS FOR WATER WORKS

Engineer WATER DIRECTORATE - ASSET MANAGEMENT DEPARTMENT

title: Technical Terms / Chapter 4/ Engineering Specifications / Pipeline Works Specifications

PS04-HDPE PIPES- MATERIAL & INSTALLATION

office: DUBAI order: Document:: MWA_PRO_07/WAM-04-PS04 Rev: DEC/2014 SHEET: 1 of: 55

Federal Electricity & Water Authority

Water Directorate

Asset Management Department

STANDARD SPECIFICATIONS

FOR WATER WORKS

TECHNICAL TERMS

Chapter – 4

Engineering Specifications

E – Pipeline works Specifications

PS 04

HDPE PIPES – MATERIAL & INSTALLATION

WAM





office: DUBAI order: Document:: - MWA_PRO_07/WAM-04-PS04 rev: DEC/2014 SHEET:

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SPECIFICATIONS FOR HDPE PIPE MATERIAL & INSTALLATION

TABLE OF CONTENT

A. SPECIFICATIONS FOR (HDPE) PIPES, FITTINGS AND ACCESSORIES - MATERIAL

1. SCOPE

2. APPLICABLE STANDARDS

3. MATERIAL

3.1 General Requirements

3.2 Colour

3.3 Carbon Content

3.4 Dispersion of Carbon Black

3.5 Thermal Stability

3.6 Effects on Water Quality

3.7 Physical Properties

3.8 Dimensions of Pipes

3.9 Pressure Reduction Factor for HDPE Pipeline for use at Temp. above 20 º C

3.10 Fittings

3.11 Hydrostatic Strength

4. INSPECTION AND TESTING

4.1 Certification and Documentation

4.2 Test and Frequencies

4.2.1 Fusion Compatibility

4.2.1 Thermal Stability

4.3 Inspection and Audit Requirements

4.4 Acceptance Criteria

4.5 Defects

5. QUALITY ASSURANCE/QUALITY CONTROL

6. PACKING, MARKING AND VENDOR DOCUMENTATION

6.1 Marking and Packing

6.2 Shipping

6.2.1 Delivery

6.2.2 UV Protection

6.2.3 Tie-Downs

6.2.4 Pallets

6.2.5 Overhang

6.2.6 Stacking

6.2.7 Trucking

6.2.8 End Caps

6.2.9 Banding

6.2.10 Silo's

6.2.11 Banding

6.2.12 weathering

6.2.13 Vendor Documentation

7. WARRANTY

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B. SPECIFICATIONS FOR HDPE PIPES INSTALLATION WORKS

1. GENERAL

2. APPLICABLE STANDARDS AND CODES

3. TECHNICAL REQUIREMENTS

3.1 General

3.2 Pre-Construction Survey

3.3 Right-of-Way (ROW)

3.3.1 ROW in Rough and Rocky Terrain

3.3.2 ROW in Sand Dune and Sandy Areas

3.3.3 ROW in Sabkha Area

3.3.4 Gatch Material for ROW

3.3.5 Clearing, Grading and Backfilling of ROW

3.4 Crossings and Detours

3.5 Fences and Barriers

3.6 Pipes Handling, Hauling, Stringing and Storage

3.6.1 Pipe Material

3.6.2 Handling of Pipe

3.6.3 Hauling and Stringing of Pipe

3.6.4 Pipe Storage

3.7 Trenching

3.7.1 Excavation and Cover

3.7.2 Protection of Other Utilities

3.7.3 Grading and Padding

3.7.4 Trench Crossings

3.7.5 Protection of Trench

3.8 Pipe Installation and Jointing

3.8.1 Pipe Installation

3.8.2 Required Equipment

3.8.3 Mechanical Joints (MJ) Adaptors and Couplings

3.8.4 Minimum Allowable Elastic Bending Radius

3.8.5 PE Pipe Jointing

3.8.5.1 Butt Fusion Welding

3.8.5.2 Electro fusion Welding

4. TESTING AND (PRE)COMMISSIONING

4.1 Hydrostatic Testing

4.2 HDPE Pipe Testing Method Statement & Recommendations

4.3 Disinfection and Flushing of Water Pipeline

4.3.1 Disinfection and Flushing

4.3.2 Acceptance Criteria for Disinfection

4.4 Connection to Existing Water Pipelines and Commissioning

4.5 Pipeline Commissioning

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5.1 Documentation and Records

5.2 As Built Drawings and Pipe Book

6. APPENDICES

6.1 Welders Identification Badge

6.2 Recommended Shelters for protection of welding areas during fusion

6.3 Generator Recommendation for Butt and Electro fusion Machines

6.4 Specification for PE100 Fittings and Electro fusion Machines

6.5 Specification for Butt Fusion Machines

6.6 Specification for Large Tolerance Mechanical Fittings <_ DN300

6.7 Specification for Large Tolerance Mechanical Fittings DN300 to 5 DN600

6.8 Specification for Stepped Coupling Mechanical Fittings >_DN300 to 5 DN600

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A. SPECIFICATIONS FOR HIGH DENSITY POLYETHYLENE (HDPE) PIPES, FITTINGS AND

ACCESSORIES MATERIALS 1. SCOPE

The scope of this specification is to specify the details the minimum required properties for the design, manufacture, testing, inspection and supply of High Density Polyethylene (HDPE) or High Performance Polyethylene (HPPE) pipe material and fittings to be used for transport and distribution of potable water.

2. APPLICABLE STANDARDS The following codes and standards, to the extent specified herein form a part of this specification. The latest edition of these codes shall govern the work.

ISO 4427 Polyethylene (PE) pipes for water supply specification or equivalent

International Standard. ISO-161-1 Thermoplastic pipes for the conveyance of fluids – Nominal outside

diameters and nominal pressures – Part 1: Metric Series. ISO-1167 Thermoplastic pipes for the conveyance of fluids – Resistance to

internal pressure – Test Method. ISO-3126 Plastic Pipes – Measurement of dimensions. !SO-4065 Thermoplastic pipes – Universal wall thickness table. ISO 6964 Polyolefin pipes and fittings – Determination of carbon black content by

calcination and pyrolysis – Test method and basic specification. ISO 9080 Thermoplastic pipes for the transport of fluids – Method of

extrapolation of hydrostatic stress rupture data to determine the longterm hydrostatic strength of thermoplastic pipe materials.

ISO 11922-1 Thermoplastic pipes for the conveyance of fluids – Dimensions and tolerances Part: 1: Metric series.

ISO 12162 Thermoplastic materials for pipes and fittings for pressure applications – Classification and designation – overall service (design) coefficient.

ISO-13761 Plastic pipes and fittings – Pressure reduction factors for polyethylene pipeline systems for use at temperatures above 20ºC.

ISO- 7005-3 Metallic flanges – Part 3, copper alloy and composite flanges. BS EN 12201 Plastic piping systems for water supply – polyethylene ISO 6259 Determination of tensile properties

ISO11357-6 Diternination of Oxidation Indecation Time (OIT) and Oxidation Indication tempreture ( dynamic OIT).

ISO 1133 Plastic – Determination of melt mas fear rate (MFR) and melt vacume fear rate (MVR) of thermo plastic.

ISO 7005-3 Copper alloy and Composite Flanges – Part - 3 2. MATERIAL

3.1 General Requirements

The Contractor shall identify the manufacturer of the resin, the resin type and classification. In addition, the Contractor shall provide evidence that the resin proposed is suitable for use at

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the design temperature and under the design pressures indicated.The material shall be certified as meeting the requirements of the PE100+ Association. Any change in the material, the material specification, or the manufacturer's location shall be subject to prior approval of the FEWA.Pipes and fittings shall be homogenous throughout and free from visible cracks, holes, foreign inclusions, blisters, dents, scoring, cavities and other damaging defects. Joints are not acceptable.

Material shall be uniform in opacity, density, interior smoothness, and other physical properties. It shall have adequate resistance to weathering and other ageing from storage for a minimum of two years after manufacture.he pipes shall be manufactured from polyethylene containing only those anti-oxidants,UV stabilizers and pigments necessary for the manufacture of pipes conforming to the requirments of FEWA and specification.

The material of the polyethylene pipes and fittings which is in contact with or likely to come in contact with driking water shall not constitute a toxic hazard, shall not support microbial growth and shall not give rise to unpleasant taste or odour, cloudiness or discoloration of the water. The concentration of substances, chemical and biological agents reached from materials in contact with drinking water, and measurements of the relevant organoleptic/physical parameters, shall not exceed the maximum values recommended by the World Health Organization in its "Guidelines for Drinking Water Quality" or the EEC Council Directive on the "Quality of Water Intended for Human Consumption", whichever is more stringent in each case.

For the manufacturing of pipes & fittings new materials to be used only (Rework material is not acceptable).

Pipe manufacturer shall confirm that all fittings to be provided for the pipe systems shall meet the same quality requirements as for the pipes to ensure the same performance for design life cycle.

Fittings shall be manufactured for design pressure of 16 Bar/as required by contract.

Nominal diameter of the pipe shall be the outer diameter of pipe.

Standard dimension ratio (SDR) it is ratio between outer diameter of pipe and its wall thickness.

All pipes and fittings shall be suitable for butt fusion or electro fusion techniques.

Contractor shall provide PE manufacturers guideline for the applicability of the material used. If required PE manufacturers shall provide assistance and training.

Contractors shall have fully trained and capable skilled techicians for laying and jointing of the pipes. Certificates to that effect shall be produced prior to start of the construction works.

Pipes & Fittings shall have a reference of supply & installation for minimum three years of performance history in Government utilities in UAE/GCC Countries.

3.2 Colour

The pipe shall be black with blue coloured strip marking. 3.3 Carbon Content The carbon black content in the compound for black pipes shall be 2.25 + 0.25% by mass,

when measured in accordance with ISO 6964.

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3.4 Dispersion of Carbon Black When determined in accordance with ISO 18553 the dispersion of the carbon black shall be equal to or less than grade 3.

3.5 Thermal Stability

When determined in accordance with ISO 11357-6 the induction time shall be at least 20 min. when tested at 200º C.

3.6 Effects on Water Quality

Materials in contact with drinking water shall be certified from an internationally recognized authority such as WRAS Certification conforming its suitability to permanent contact with potable water.

3.7 Physical Properties

Polyethylene pipes and fittings shall be high density polyethylene pipes (HDPE), and shall comply with the requirements of ISO 4427 type PE 100, PN16 SDR11. The material used for the manufacturer of pipes and fittings shall be in accordance with Table 1 and Table 2 of clause 4.4 of ISO 4427-1 The minimum required strength (MRS) of the material compound shall be 10 Mpa at 20ºC and 50 years life time. The design stress shall be 8 Mpa. The design temperature shall be 40º C. The polyethylene pipes and fittings shall meet the following specification:

Minimum density measured according to ISO 1872 > 959 kg/m3

Melt flow rate measured according to ISO 1133: - At 2.16 kg load < 0.15 g/10 min. - At 5.0 kg load < 0.5 g/10 min.

Tensile strength at yield = 23 Mpa

Elongation at break > 600%

Thermal conductivity at : 0.4 W/mo k

Vicat softening point at 1 kg load = 124ºC

The thermal stability of polyethylene material shall meet the requirement of ISO 4427.

3.8 Dimensions of Pipes The pipe dimensions shall be based on standard dimensions according to ISO 4427 and measured in accordance with ISO 3126.The pipe dimensions, which are based on standard dimensions ratio 11 (SDR 11) are specified in Table 1.

Table 1: Pipe Dimensions

Nominal Outside Diameter (mm)

Mean Outside Diameter (mm)

Wall Thickness (mm)

Minimum Maximum Minimum Maximum

90 90.0 90.6 8.2 9.2

110 110.0 110.7 10.0 11.1

180 180.0 181.2 16.4 18.2

250 250.0 251.5 22.7 25.1

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315 315.0 316.9 28.6 31.16

355 355.0 357.2 32.2 35.16

500 500.0 503.0 45.4 50.1

630 630.0 633.8 57.2 63.1

Straight pipes shall be supplied in standard of 12m (-0 + 50 mm) measured at 23ºC ± 2º C. Unless otherwise specified, coil lengths shall not exceed 100 m. the coils shall be wrapped and shall not be exposed to direct sunlight.

3.9 Pressure Reduction Factor for HDPE Pipeline Systems for use at Temperatures above 20 º C

Reduction factors to be applied to obtain the maximum allowable operating pressure for elevated – temperature operation of HDPE pipes and fittings shall be comply to the Table 7 of ISO 4427.

3.10 Fittings

The fittings shall be injection moulded or formed from material compatible to that of the pipe. At locations where HDPE to metal/GRP connections are specified, stub flanges with PPV backing rings shall be used or special restrained transition fittings approved by FEWA. The flanges shall be drilled to BS 4504 ( or ISO 7005 – 2), PN16 as per the design requirments. The dimensions of the fittings shall be measured in accordance with ISO 3126. The wall thickness of the body of the fitting at any point shall be equal to or greater than the minimum wall thickness of the corresponding pipe.

3.11 Hydrostatic Strength

Hydrostatic strength of pipes and fittings shall comply to ISO 4427 when tested in accordance with ISO 1167.

4. INSPECTION AND TESTING 4.1 Certification and Documentation

The Manufacturer shall document and certify all products required tests and Contractor shall supply FEWA with copies of these certifications and test documents. Such documentation shall be subject to FEWA’s approval prior to shipping. All items shall comply with the requirements of ISO 4427 and any additional requirements listed in this specification.

4.2 Test and Frequencies

The Manufacturer shall establish and maintain a current record of test results according to the requirements of the applicable standards and this specification. The Manufacturer shall perform all the tests required by ISO 4427 to demonstrate the characteristics and quality of the resin material and the dimensional tolerances of the pipe.

The Manufacturer shall document all the tests, with frequencies and results as indicated in ISO 4427. Notes: For establishing test frequencies:

Coil and straight lengths are as noted in clause 3.2;

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Straight length pipe shall be tested at the same frequency as coiled pipe;

A continuous production run is the manufacture of pipe of one resin type, size, and wall

thickness, for one purchase, with no interruption or change in the manufacturing process.

The Contractor/ Manufacturer shall supply the FEWA, with copies of all material certificates and inspection and test results obtained in the course of quality verification. When requested, the manufacturer shall also provide access to and copies of all production record, process control charts, and other records compiled during manufacture.

4.2.1 Fusion Compatibility

Pipes and fittings shall be joined by butt fusion or using electro-fusion fittings and the joints shall conform to the requirements specified in Table 8 of the ISO 4427.

4.2.1 Thermal Stability

The iduction time for test specimens taken from pipes shall be at least 20min. when tested at 200ºC in accordance with ISO 11357-6. The specimens shall be taken from inside the pipe.

4.3 Inspection and Audit Requirements

Pipe shall comply fully with ISO 4427 and all the additional requirements of this specification. To verify compliance with this specification, FEWA/Engineer shall reserve the right to appoint an independent third party inspector to witness the applicable qualification tests, review production records, and inspect general handling and shipping procedures.

4.4 Acceptance Criteria

The order shall meet the following criteria: Copy of the raw material Manufacturer's "Certificate of Quality Control Testing" covering each batch of raw material used for pipes purchased under this specification, shall be available for inspection by FEWA on request. Pipe wall thickness shall be controlled by continuous scanning using gamma ray or other qualified devices. These devices shall be regularly calibrated for accuracy.Successful test performance and acceptable results for the testing program outlined in this specification.An acceptable inspection report from a third party inspection company (at the option of FEWA).

When performed, acceptable results from an independent test audit of any portion of the tests noted in ISO 4427 and this specification.FEWA may reject any item that does not fully comply with the requirements of this specification.

4.5 Defects

When the rejected item is a length or coil of pipe, the lengths or coils manufactured immediately before and after the defective lengths or coils shall be carefully examined. If further defects are found, this is sufficient cause for rejecting the entire batch. This will not apply to local damage that did not occur during manufacture, such as gouges or cuts during handling or transit.

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A copy of the Manufacturer's QA/QC plan shall be submitted to FEWA/Engineer with its quotation for review and concurrence prior to award.If Manufacturer's facility is ISO certified, QA audit requirements shall be waived in favour of ISO 9001 registrar audits, unless FEWA/Engineer’s trend analysis program indicates areas of concern.

6. PACKING, MARKING AND VENDOR DOCUMENTATION 6.1 Marking and Packing

a) The marking information and sequence shall comply with ISO 4427 and this specification. All pipes and fittings, including test samples shall be clearly and permanently marked using indent printing in a colour that contrasts with the pipe. All pipes shall be indelibly marked at maximum interval of 1m and shall be displayed on the outside of the coil/length together with the following information:

Manufacturer’s Name or trade mark

Client “FEWA”

Contract Number

Nominal outside diameter (NOD) in millimeters (mm)

Designation of the pipe material - Resin name or type (to be proposed and subject to prior FEWA's approval)

The letters "PE" followed by the PE grade (e.g. PE100)

The service, i.e. the word "Water" for water pipelines (blue marked)

Nominal wall thickness

Standard dimension ration

Coil/length number

plant location and date of manufacture, e.g. X 29 08 00, where X designates the plant .

The letter "R" if regrind material was used

Nominal pressure

Production information, e.g. 251Y, where 2 indicates shift, 5 indicates operator,

1 indicates extruder, and Y indicates compound supplier

Number of the international standard

b) Fittings shall be marked as follows: Butt-Fusion Fittings:

1. Manufacturer’s name and logo 2. Standard 3. Size in mm 4. Type of fittings 5. SDR 6. Month and year of manufacture.

Electrofussion Fittings:

1. Manufacturer’s name and logo 2. Standard 3. Size in mm. 4. Type of fittings

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5. SDR 6. Weld time in seconds 7. Cool time in minutes 8. Month and year of manufacture

The maximum quantity of pipe to have the same coil/length number is one silo (coiled pipe) or one bundle (straight lengths). The maximum combined length of pipe in the silo or bundle with the same coil/length number shall not exceed the maximum allowable coil length specified in clause 3.2.

When pipe material is boxed, the coil number shall be clearly marked on the outside edge of the box or silo. Invoices and packing lists shall include the date of manufacture and coil/length numbers for all material in the shipment.

The fittings shall be packaged in bulk or individually protected were necessary in order to prevent deterioration and contamination. The package shall have at least one label with manufacturer name, type and dimension of the fittings and number of units.

6.2 Shipping The Contractor/supplier shall provide packing and shipping procedures for approval by FEWA and shall comply with the following requirements.

6.2.1 Delivery Delivery of the plastic pipes and fittings to site, shall be not later than six months after the stamped manufacturer date, for it to be acceptable. Pipes boxed immediately after extrusion and stored indoors, as well as pipes protected from UV light immediately after manufacture as per the requirements of clause 6.2.2, are - at the ENGINEER's discretion - exempt from this requirement and are acceptable up to one year after manufacture.

6.2.2 UV Protection To obtain this exemption (from clause 7.1) the manufacturer shall inform FEWA one month prior to manufacture for inspection and approval of the protective method. All silos of coiled pipe shall be shrink-wrapped in UV-blocking black plastic. The black plastic shall be thick enough to prevent accidental tearing and passages of visible light. The UV-blocking plastic wrap shall filter out 100% of the UV radiation from reaching any portion of the pipe.IF the plastic is not black, the MANUFACTURER shall receive prior approval from the FEWA before the wrap is used. Approval of non-black shrink wrap plastic may involve testing. The cost of this testing shall be to the account of the CONTRACTOR/MANUFACTURER.

6.2.3 Tie-Downs

Tie-downs shall be at least 100 mm wide and be clean and free from sand, gravel and other such materials. For straight length pipe a minimum 6 tie-downs are required.

6.2.4 Pallets

The pallets shall be suitable for transporting the materials from the place of manufacture to the designated receiving location without causing any damage to the pipe.The pallets shall not contain any broken planks or extremities that may damage the coiled pipe or straight lengths.They shall be durable enough to prevent loose pallet nails from gouging the bottomcoil/straight length. Pallet construction shall be subject to approval by the FEWA.

6.2.5 Overhang

Pipes shall not over hang at either end of the trailer.

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6.2.6 Stacking

The manufacturer shall not ship small coils stacked inside silos of larger coils of larger coils. Frames manufactured for the containment of straight lengths of polyethylene pipe during transport and storage shall not contain nails or other fastening devices that may damage the pipe.

6.2.7 Trucking

Where pipes are transported by vehicles, the vehicles should have a flat bed and free from sharp edges or projections. During transport, polyethylene pipes shall be protected from diesel fumes and be continuously supported to prevent movement between the material and its support.

6.2.8 End Caps Straight lengths and coils of pipe shall have internally fitted end caps that prevent direct and debris from entering the pipe during handling, storage and transport. Caps shall be attached by an approved method to prevent the accidental loss of the cap. All end caps shall have an outer lip, which prevents the accidental insertion of the cap into the pipe. A method to permit venting shall be provided in order to allow expansion of air due to temperature changes during storage.

6.2.9 Banding

All coils shall be banded at intermediate stages of coiling and upon completion of the specified length. Al least 8 intermediate bands shall be provided on 150 m coils.

6.2.10 Silo's Silo packs of coiled pipes shall be squarely stacked and well supported on pallets. Coils shall not overhang the pallets and, unless aproved by FEWA, shall not be stacked higher than 2.3 m.

6.2.11 Banding

All coils shall be banded at intermediate stages of coiling and upon completion of the specified length. Al least 8 intermediate bands shall be provided on 150 m coils.

6.2.12 Weathering A certificate from the pipe/fitting manufacturers shall be provided, confirming that the products may be stored in the open for minimum of 2 years without any adverse effect.

6.2.13 Vendor Documentation

The Contructor shall furnish, the following vendor data as a minimum, with the bid:

Manufacturer pre qualification documents.

Quality Management system Certificate

Type Tests Certificate for Pipes, Fittings full “Third Party Type Tests Certificate”.

Catalogues/ Brochures

Dimensional details of pipes and fittings.

Detailed material specifications

Manufacturer's drawings

Complete details of testing facilities at manufacturer works

Local (UAE) agent name and address.

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Materials Non Toxic to water Certificate “WRAS”

Technical Data Sheet.

Compliance Statement to FEWA specifications.

Any other Certificate required as per Standard

Reference list showing experience details of supply & installation for minimum three years of performance history in Government utilities in UAE/GCC Countries.

Bids not accompanied by any of above mentioned information/data shall be considered incomplete, and liable to be rejected.

7. WARRANTY The manufacturer must give warranty for 5 years for all HDPE Pipes & Fittings from the date of the issue of the Provisional Taking-Over Certificate (PTOC).

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B- SPECIFICATIONS FOR HIGH DENSITY POLYETHYLENE (HDPE)

PIPES INSTALLATION WORKS

1. GENERAL

This specification covers minimum requirements for the installation and testing of High Density Polyethylene (HDPE) pipes works for potable water distribution system and fittings including route survey, row, excavation, stringing, joint fusion, laying, backfilling, etc.

2. APPLICABLE STANDARDS AND CODES

Unless otherwise specified the works shall conform to the following standards and other standards noted elsewhere in this specification.

ISO 4427 Polyethylene (PE) Pipes for Water Supply – Specifications BS EN 12201 Plastic Piping Systems for Water Supply Polyethylene (PE) BS 8010 : Part 1 Pipelines on land. BS 8010 : Part 2 Pipelines on land design, construction and installation. AWWA C651 Disinfecting water mains.

3 TECHNICAL REQUIREMENTS

3.1 General

Contractor shall prepare and submit a detailed Method Statements i.e. Construction Procedures, for all described activities to FEWA/Engineer for approval to ensure compliance with the requirements as set forward in this Specification.Contractor shall take full responsibility for the stability and safety of design, all operations carried out and of all existing facilities/utilities/roads/etc.

Contractor shall be deemed to have inspected the work area(s) and their surroundings and to have satisfied himself as to the form and nature thereof, including sub-surface conditions, hydrological and climatic conditions, the extent and nature of the work, the materials necessary for the completion of the work and the means of access to all the work area(s).Contractor shall be deemed to have obtained all necessary information as above mentioned as to risks, contingencies and all other circumstances, which may influence the work.

3.2 Pre-Construction Survey

Prior to any construction activities, the Contractor shall carry out a pre-construction survey to stake the pipeline centreline and define the Right-of-Way (ROW) by stakes placed at a distance of 100 meters maximum from each other and they shall not be disturbed and where the boundary of the ROW can be determined. Contractor shall stake the entire pipeline route(s) as per the data available on the alignment drawing(s) (typical and detail), in compliance with a Procedure/Method Statement, to be submitted for FEWA/Engineer approval.The staking shall be based on the markers set along the pipeline route and construction drawings.

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The Contractor shall establish a reference point 25 meters offset from pipeline centreline.The final pipeline alignment shall be subject to approval of FEWA/Engineer.

3.3 Right-of-Way (ROW)

The pipeline shall be located at the centre of the ROW, unless indicated otherwise.Contractor shall co-ordinate with all local Authorities and utility owners to obtain the approval for the ROW. Prior to the commencement of any construction activities in an area, the Contractor shall locate and identify all existing buried facilities, such as cables, pipelines, water mains, sewers, etc., including those not shown on the drawings, crossed or at close proximity with the pipeline, by contact with relevant Authorities, carrying out appropriate surveys and exposing them by hand excavation, unless exempted in writing by FEWA/Engineer and shall be clearly marked.

Contractor shall submit for approval a detailed proposal for precautions to be taken for avoiding or preventing damage to existing facilities above or below ground.The Contractor shall not be entitled to extra compensation for any hardship and/or increased costs caused by the construction areas being adjacent to or in sand dunes or other difficult terrain or across roads, berms, flooded areas, communication structures, wires, cables, other pipelines, power poles, plantations, farms or other obstacles, which may physically restrict or limit the use of the ROW provided.

3.3.1 ROW in Rough and Rocky Terrain

ROW in rough and rocky terrain that occurs at certain locations shall be prepared by Contractor, with the use of special equipment as necessary.Wherever rocky terrain is encountered, grading and excavation to prepare ROW shall be carried out by ripping, drilling, wedging, chiseling using jack hammers or rock breakers, or by other recognised approved methods . Blasting will not be allowed.

3.3.2 ROW in Sand Dune and Sandy Areas

The ROW in sand dune and sandy areas shall be graded by the Contractor in compliance with the relevant drawings and shall be approved by FEWA/Engineer.The profile of the graded ROW shall generally follow the profile of the natural terrain with some minor alterations to enable proper construction of the pipeline and ensure safe bending and laying of the pipeline. While grading, any necessary cutting of high dunes shall be performed. The cut material shall be generally spread on the sides of the ROW and filling of low areas shall be minimised. Trenching will follow the general profile of the ROW as per the cover requirements. Localised sand dunes along the pipeline alignment shall be removed by Contractor as a part of his scope of work while preparing ROW.

3.3.3 ROW in Sabkha Area The ROW in Sabkha areas shall be constructed with gatch material, which shall be consolidated by compaction. The type of fill material to be used by Contractor shall be approved by FEWA/Engineer.

3.3.4 Gatch Material for ROW

Gatch material to be used for preparing ROW, or for stabilisation of shall be granular dry soil material with high level of cementation content, such as gypsum or clay which when watered, mixed and compacted, gives a firm and solid mass of material. The compacted gatch shall not

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contain loose patches of soil and shall not break nor erode during normal use and environmental conditions.

Contractor shall arrange to locate the source of gatch material and obtain FEWA/Engineer approval for the use of the gatch material. Gatch, at the optimum moisture content, placed in the ROW, shall be consolidated by compaction. The gatch material shall be wetted, rammed and compacted.

The required density, not less than 95 percent standard proctor density, shall be obtained by compaction in layers of 200 millimetres by suitable means. Moreover water shall be sprayed on the placed material as required prior to compaction to maintain the optimum moisture content. Note that the required density of the compacted bund shall not be less than 82 percent standard proctor density.

3.3.5 Clearing, Grading and Backfilling of ROW

During the preparation of the ROW , the Contractor shall grade the ROW to provide access to the pipeline during construction.Contractor shall grade the ROW to remove sharp, high points, to minimise bending and to maximise laying within the limits permissible for elastic bending.Where the construction ROW passes through or along roads, tracks, pole lines, plantations or any other improved or confined areas, Contractor shall grade only the width of the ROW necessary for digging the pipeline trench. Contractor shall establish Bench Marksand Intersection/Turning Points until the construction is completed. Contactor shall carry out all survey and leveling of line and grades including as-built survey necessary to complete the work and shall be responsible for the accuracy of such survey and grades.The ROW for all the pipelines shall be staked by the Contactor so as to be able to define ROW boundary for purposes of clearing, grading and backfilling and shall be maintained throughout construction. Contactor shall install distinct markers locating and indicating special points, such as but not limited to contract limits, warning notices, presence of buried structures, obstacle crossings, change of wall thickness including corresponding chainage, etc.The Contractor shall grade and construct the ROW so that the trench is excavated in undisturbed ground.Contractor shall have to grade sand dunes to allow vehicle access, safe laying of the pipeline within its elastic limit, and excavation of rock wherever encountered.Fill material shall be installed on the ROW as needed for vehicle access and make necessary arrangements such as ramps, temporary bridges, etc.

3.4 Crossings and Detours It shall be Contractor’s responsibility to acquaint himself with all relevant requirements and regulations of authorities and governmental bodies having jurisdiction over highways,roads, pipelines, cables and other services on the Right-of-Way or crossing the Right-of-Way and to obtain their approval in writing and all necessary permits before commencing work.Highways, Main-Roads and their verges shall not be used for loading, unloading or stacking of materials and/or equipment. For secondary roads, such loading/unloading is permitted only after prior approval from the concerned authorities. Contractor shall not close or divert roads without prior approval from FEWA/Engineer and the concerned authorities. Contractor’s shall never unnecessarily hamper the users of the roads.At locations where any part of the work is routed along, over, under or across tracks, roads or highways, the Contractor shall, with no extra compensation, provide and maintain

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detours, temporary bridges and road controls including warning lights as may be required by the concerned Authorities.Contractor shall carry out, as part of his scope of work, any local realignment of pipelineroute/profile and/or design modification as required necessitated by the presence of any underground structure, service or utility found during excavation.

3.5 Fences and Barriers

On completion of construction the Contractor shall reinstate any damaged or relocated fencing on camel compounds, pipeline corridors, and property boundaries to their original condition. Contractor shall install suitable warning trench mesh on either side of ROW where it is essential to ensure safety and non-interference, especially in industrial or in inhabited areas., etc. by suitable approved steel supports.

The Contractor shall provide and install heavy grade concrete barriers at any location where traffic might accidentally encroach on the construction.Fencing and barriers shall be continuously maintained.The Contractor shall note that motor trucks cross a number of the tracks that pass over (and obstruct) the ROW and that provision (detours) shall be provided for these activities to continue without interruption.

3.6 Pipes Handling, Hauling, Stringing and Storage 3.6.1 Pipe Material Receipt of Pipe Material

Contractor shall supply pipe materials as specified in the relevant Project Material Specification(s) at a designated area, subject to FEWA/Engineer's approval.Prior to taking delivery from Supplier, Contractor shall examine the pipes and satisfy himself about the condition of the pipe. After taking delivery of the pipes, Contractor shall be responsible for their care and custody and for any repairs to any damage.Transportation of pipe to the construction site is the Contractor's responsibility.

Any defective pipes shall be rectified or rejected as directed by FEWA/Engineer, the Contractor shall supply new pipes as per applicable specification.Contractor shall be fully responsible for arranging and paying for storage areas and method of storage shall be as approved FEWA/Engineer.

3.6.2 Handling of Pipe

The Contractor shall be responsible for handling, hauling, stockpiling, storage and stringing the pipe materials. Pipes shall be supplied fitted with end caps, which shall remain in place until the pipes will be joined together.

The Contractor shall be responsible for providing suitable trucks and equipment in sufficient quantity to transport the line pipe in such a manner that prevents damage. Pipe, bends and other fittings shall be stocked, chocked and padded, and secured in position during transportation and during storage at pipe dumps or stringing in an approved manner. If pipes are supplied in bundles or on pallets, they shall remain so packaged until they are delivered to the location of installation on site. There are occasions where pipes may already be bundled in frames, in this case proper lifting equipment shall be used. Pipes shall never be dropped onto hard or uneven surfaces. Pipes shall never be thrown from vehicles or be dragged or rolled along the ground. Rope or web slings shall be used with mechanical lifting equipment. Metal chains, hooks or cables shall never be used. Pipes shall

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generally be supported over their full length and not overhang by more than one metre.The Contractor shall lay out and measure the pipe so that the number of cut off pieces, less than 1.5 meters long, is held to a minimum.

3.6.3 Hauling and Stringing of Pipe

Pipe shall be unloaded from the stringing trucks and lowered by hand, or by means of suitable approved equipment onto pipe supports, placed on the ground. Chains, cables or hooks inserted into the pipe ends shall not be used.

Pipes shall be strung alongside the trench on supports properly spaced with the pipe at least 100 mm clear of the ground. The trench is to be completely excavated, the area cleared of all debris, and the requisite bedding and base padding stockpiled, before stringing of the pipes.

However the Contractor shall note and make allowance for sand drift into the trench in sandy areas, especially where sand dunes exist. The pipes shall be strung parallel to the ditch at a suitable and constant distance from the centre line of the ditch. The stringing of the ROW shall not put the pipe at risk and so as to cause the least interference with the normal use of access by trucks, etc. Gaps shall be left at intervals to permit the passage for traffic or equipment across the ROW or along public roads or highways.

All pipe strung on the ROW shall be supported to be free from contact with the ground at all times. Pipe ends shall be protected with plastic end covers to prevent sand from entering the pipe while the pipes are strung along the ROW.

3.6.4 Pipe Storage

Pipes shall be stored in a secure and sheltered place and such material shall not be strung on the ROW but shall be transported along the line in covered conveyances for use when needed. Pipes shall be stored on a flat even surface able to withstand the weight of both pipes and lifting equipment. Different sizes of HDPE pipes should be stored and/or transported separately. Where this is not possible, the larger diameter and/or thicker wall pipe shall be loaded first having side supports at no more than 1.5 m intervals. All supports shall be free from sharp edges. HDPE pipe materials shall be stored under cover, protected from direct sunlight and ensuring good ventilation. This will reduce exposure to UV light which over time can cause aging of the pipe surface. Any pipes stored/stacked at site shall be covered by tarpaulin. Storage in containers is not recommended.

3.7 Trenching 3.7.1 Excavation and Cover

Contractor shall excavate the pipeline trench on the surveyed route as staked and to the design profile. Contractor shall not start the ditching operations until the pipeline centreline has been approved by FEWA/Engineer. Contractor shall excavate the pipeline trench within the cleared and graded ROW using any method approved FEWA/Engineer. Care shall be exercised to see that fresh material recovered from trenching operations, intended to be used for backfilling over the pipe in the trench or at the berms, is not mixed with loose debris or with foreign or rejected material, required to be removed from site.

the trench shall be excavated to a minimum width so as to provide, on both sides of the installed pipeline, a clearance as specified in the typical drawings and to a depth sufficient

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to provide the minimum covers specified below. The cover shall be measured from the top of the pipe, after it has been laid in the trench or placed on the formation level, to the level of the original ground or graded surface where such surface is lower than the original ground level. Minimum Cover Requirements for Pipe Normal Terrain and Sand Dunes 1.0 m (min) Sabkha Area (On Prepared ROW) 1.5 m (min.) Track Crossings 2.0 m (min.) City/Town/Inhabited Area 1.0 m (min.) Metalled, Paved and Rig Road Crossings 2.0 m (min.) Wadi areas 3.0 m (min.)

Contractor shall excavate to additional depth where the pipeline approaches and crosses other pipelines, sewers, drain pipes, water mains, telephone conduits, and other underground structures to facilitate the use of elastic bends.

The pipeline shall be laid with at least 1 meter free clearance under the obstacle or as specified on the drawings. If greater minimum distances are required by Authorities having jurisdiction, those distances shall be maintained. Where the pipeline crosses areas whose easements specifically require greater than normal depths of cover, the trench shall be excavated to extra depth as required, including any necessary "lead in" and "lead out".

3.7.2 Protection of Other Utilities

Contractor shall provide all permenant protection and support for crossed structures/utilities above and/or below ground. Contractor shall be responsible for locating and protecting all underground lines and structures, whether shown on the drawings or not. The Contractor shall use pipeline locators and any other necessary means including manual excavation for locating all lines, utilities and substructures as part of his Scope of Work. Contractor shall only excavate the trench within 1.5m of such structures manually at no extra cost in compliance with FEWA/Engineer Procedures.any damage should occur to any structures/utilities, etc., the Owner/Authority concerned shall immediately be contacted by the Contractor and repairs shall be completed at the Contrac tor's expense.

3.7.3 Grading and Padding

The trench or formation shall be cut or made to a grade that shall provide a firm, uniform and continuous support for the pipe, allowing for any necessary bedding and padding. Bends shall be made in the pipe at significant changes in grade of the trench.

Contractor shall excavate at no extra cost the trench so that changes of grade will be by elastic bends, or bend the pipe to achieve changes of grade or when it is desired to reduce the required number of bends to a minimum to lay the pipe to conform to the general contour of the ground and maintain the minimum cover. This can be accomplished by cutting the trench slightly deeper at the crest of ridges and by gradually deepening the trench in approaches to road crossings and small water courses, if any.

The thickness of the compacted bedding shall not be less than 200 mm. In those areas that are to be bedded, the trench shall be at least 200 mm deeper than otherwise required, and evenly and sufficiently bedded to keep the pipe, when in place, at least 200 mm above bottom of excavated trench.

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Acceptable bedding shall be placed under the pipeline before its installation, and padding around it after installation to establish at both sides and on top of the pipe a permanent layer of bedding. The thickness of compacted bedding around the pipe corrosion coating shall be at least 200 mm. Bedding and padding materials that are approved by shall be sand containing no gravel, rock or lumps of hard material or any other material that may be deleterious to the pipe coating. On slopes, trench breakers shall be installed to prevent the migration of bedding and padding.Where the pipeline is to be laid in sand dunes, the trench shall be cut so that adequate trench bottom width is obtained in compliance with the applicable drawings.

3.7.4 Trench Crossings

Contractor shall, in all cases where the trench has been cut across access roads/tracks etc., install a by-pass track or substantial temporary bridge work to the full width of the roads/tracks, of adequate strength, properly constructed to ensure the safety of the public and to allow passage of normal traffic with minimum inconvenience and interruption.

The Contractor shall arrange to complete the trenching, laying and backfilling of such crossings and to remove the temporary bridging before the end of the regular work day in order to minimise the hazard to night traffic. The Contractor shall obtain the written permission of the appropriate authorities, before commencing work and shall ensure that all regulations and requirements of the authority having jurisdiction over such tracks are complied with. Proper warning signs shall be placed and maintained while such crossings are open.

3.7.5 Protection of Trench

Contractor shall keep the trench/pits in good condition until the pipe is laid and until backfill takes place. No claim is to be made by the Contractor for reason of the trenches collapse either before or after the pipe is laid. All materials necessary to shore the trenches and pits in order to prevent collapse and for safety are to be furnished, installed and subsequently removed by Contractor without any additional compensation.

In the circumstance of ground water being encountered, the Contractot shall provide adequately-sized dewatering equipment, shoring and any other equipment and materials required to excavate the trenches and pits. All trenches and pits shall be excavated in dry conditions and kept dry during all phases of work until completion of backfilling.

3.8 Pipe Installation and Jointing 3.8.1 Pipe Installation

Prior to installation of piping, the trench preparation shall be checked for the required elevation, slope and freedom from rock, stones and other deleterious materials. The bottom of the trench shall be cushioned with well compacted soft bedding material to a minimum thickness of 150mm below the barrel of the pipes and extending for the full width of the trench for pipes of diameter up to d315, thickness of 200mm for pipes of diameter d400 to d630 and thickness of 250mm for pipes of diameter d800 to d1200. Any soft spots shall be excavated and refilled with lean mix concrete or selected fill materials as directed by FEWA. The same above respective thickness shall be installed for filling too. Installation shall not be started until unsatisfactory conditions have been corrected.

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The polyethylene pipes, fittings, etc. shall be inspected for the sizes required as per drawing and also for distortion, bending, damages, etc. Each section of pipe and each fitting shall be thoroughly cleaned before it is installed.

The PE Pipe itself may be partially or completely surrounded by concrete but should be protected by a heavy duty polyethylene membrane to a minimum thickness of 3mm. If the pipe is laid in a sleeve, ensure that the sleeve ends are fitted in such way that no stress or cutting effect can be transmitted to the PE carrier pipe. The induction of stresses in the pipe or in joints during installation shall be avoided.

(Note: Electrofusion and butt fusion fittings should remain in original packaging until final installation). The pipes shall be laid in the trench straight and with spacing required as per specification/drawing. Ensure that the pipe is uniformly supported. Comply with the minimum allowable bending radii specified in this specification. Whenever pipe laying is discontinued for short periods, or when work is stopped at the end of the day, the open ends of all mains shall be closed with water-tight plugs.

Installation (i.e. welding) of piping shall be in accordance with Manufacturer's recommendation and FEWA's requirements. All necessary precautions shall be taken to ensure a safe working environment in accordance with local Safe Working Practices. When lifting pipe with slings, only wide fabric choker slings capable of safely carrying the load to lift, move, or lower pipe and fittings shall be used. Wire rope and chain shall not be used. Joints between pipes and fittings shall be by butt fusion or electro fusion. Refer section 3.8.5.1 for Butt Fusion procedure, and section 3.8.5.2 for Electro fusion procedure and section 4.1 Hydro testing. Persons making heat fusion joints shall be trained and certified in the manufacturer's recommended procedures. All certified personnel will also carry a welders ID badge.

Mechanical Joints (MJ) couplings and flanges shall be entered and aligned to the mating component before assembling and tightening bolts. MJ gland or flange bolts shall not be used to draw the connection into alignment. Bolt threads shall be lubricated and flat washers shall be used under the nuts. Tightening of bolts shall be even according to the tightening pattern and torque steps recommendations of the Manufacturer. At least 1 hour after initial assembly, flange connections shall be re-tightened following the tightening pattern and torque steps recommendations of the Manufacturer. The final tightening torque shall be as recommended by the Manufacturer.

3.8.2 Required Equipment

The following types and quantity of equipment shall be employed for activities associated with the PE pipe works. The equipment shall be operated only by Operators possessing necessary Site operation licenses.

1 Electro fusion Machine As required Electro fusion Welding of Fittings

2

Butt Fusion Machine As required Butt Fusion Welding of Fittings

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3 Hand Peeling Tools As required For PE pipe preparation

4

Clamps As required For clamping of PE pipes

5 Isopropyl Cleaning

Tissues / Fluid

As required For cleaning of pipe surfaces prior to welding

6

Tent / cover for welding area

As required For protection of weld area during welding.

3.8.3 Mechanical Joints (MJ) Adaptors and Couplings

DN65 and larger must be used with stainless steel insert stiffeners when connected to plastic pipes. Mechanical Joints will be restraint version from DN65 to DN300

3.8.4 Minimum Allowable Elastic Bending Radius

Where bending of PE pipes is unavoidable, pipes may be curved elastically to a minimumradius as recommended by the manufacturer. In general, a smaller radius shall require a formed bend or elbow. In the event of the manufacturer providing no recommendation the minimum bend radius shall not be less than 20 times the pipe OD. No electrofusion or mechanical joints should be incorporated in the sections of pipework which are to be bent.Instead a formed bend or elbow should be welded in the pipeline in order to prevent excessive stress.

3.8.5 PE Pipe Jointing General

The Contractor shall employ skilled labour who shall be subjectede to FEWA/Engineer's approval to perform all of the following jointing techniques to create PE pressure pipe systems. • To joint lengths of straight pipe and incorporate fittings such as bends, equal tees and

reducers; automatic butt fusion joining procedure shall be used. • To joint PE pipes to metal pipes and to valves; restrained transition fittings and stub

flanges shall be used. • To install off-takes or connections to existing lines, and on locations indicated and

approved by FEWA/Engineer; electrofusion fittings may be used. Method Statement

A detailed Method Statement for PE pipe jointing shall be prepared by the Contractor, and submitted to FEWA/Engineer for approval. This MS shall include details of how the work will be performed to ensure compliance with all requirements and recommendations of the Manufacturer or Supplier of the PE pipe material and of this Specification. This MS shall ensure that all fusion joints are of high integrity and shall include, but not by limitation : • Procedures for the operation, maintenance, periodic inspection and testing of fusion tools

and equipment. • A programme of update training for PE jointers, including certification and re-certification of

personnel to ensure competence. • Procedures for joint preparation, indicating method and degree of cutting, cleaning,

drying, scraping, alignment, support, etc. of the pipe ends to be joined.

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• Jointing procedures, specifying the equipment and tools as well as all relevant parameters (temperatures, pressures, heating time, cooling down time, joint fusion, etc.) and control of the jointing operations.

• Inspection and testing procedures and acceptance criteria together with proposals for independent inspection and testing on welds on a regular basis. As a minimum, 1 % of

all welds shall be tested on a regular basis and approved by a third party testing body. The testing shall involve both testing of random welded joints and material

characteristics performed by an independent test laboratory All costs associated with the testing, together with any consequent rectification of faults and retesting shall be borne by the contractor.

• QA/QC procedures • All safety precautions and procedures.

3.8.5.1 Butt Fusion Welding Butt Fusion is a common technique for producing fusion welds in HDPE piping. The equipment employed shall be fully automatic and shall provide fusion data specific to each joint, which shall include each joint's unique joint number to form part of the as laid records. All external beads shall be removed with an approved tool and inspected for defects.Each bead shall be numbered with its corresponding joint number clearly displayed.Removed beads shall be retained for inspection by FEWA/Engineer.The Method Statement for butt fusion systems, submitted FEWA/Engineer for approval, shall include the following :

Only pipes and fittings of the same size, SDR and material are to be butt fusion welded.

A dummy joint shall be made at the start of each welding session using pipe off cuts ofthe same size, material and SDR as the pipe being installed. The normal trimming, beadup and full heat soak cycles will be adhered to. For pipe sizes greater than 180mm two dummy welds will be made. If the pipe size is changed during the day, if the heater plate is allowed to cool below 180°C or if maintenance of the butt fusion equipment is carried out then a new dummy weld/s shall be performed.

Before the first joint of the day, or any change of pipe size and after cleaning or maintenance of the butt fusion equipment, the hotplate shall be placed into the machine and the pipe brought up to form a weld bead. This joint shall not be fused. The hotplate shall be removed and the melt allowed to cool for at least 10 minutes and the pipe trimmed back to remove the bead and the heat zone. Normal jointing will then continue.

Butt Fusion Inspection

All butt fusions shall be inspected and approved in accordance with the following criteria :

The gap between the two single beads shall not be below the fusion surface.

The displacement between the fused pipes must not exceed 10% of the pipe wall thickness.

The difference between two single beads shall not exceed 10% of the double bead width.

No signs of damage (such as scratches or deep impressions caused by clamps) shall be visible on either side of the fusion.

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A bead gauge shall be used to assess the bead width. Bead widths shall be within the ranges specified in the below table and shall be of uniform appearance.

The underside of the bead shall be examined and the bead inspected for lack of fusion, contamination, holes, offsets and melt damage.

Beads should be solid and rounded with a broad root. Hollow beads with thin root and curled appearance may have been formed with excessive pressure or no heat soak.

A bead bend back test, shall be conducted where the bead is bent, around the finger, every few inches and the bead inspected for slit defects. This test will highlight fine contamination from the heating plate. Any joints found to be contaminated shall be cut out and a new joint made; the failed joint shall be delivered to .

Records of all tests and inspections shall be maintained by the Contractor and made available for review and approval by FEWA/Engineer.

Table of Bead Width

Min Wall Thickness mm

Width of Bead mm

10 10 - 17

16 11 - 18

22 15 - 24

28 17 - 26

32 18 - 27

45 20 - 29

57 23 – 32

Note: Intermediate wall thickness shall be taken as the nearest lower wall thickness

Supervision & Skilled Labour

All work shall be carried out under the supervision of a supervisor experienced in carrying out of installing polyethylene pipe work. He should have sufficient experience in all aspects of the work including the fusion and back filling and pressure testing.The lead personnel involved in the carrying out of the fusion work will have been certified by the manufacturer of the welding machines used.

Pre-Joint Checks

1. Correct jointing parameters for the machine & pipe being welded shall be checked. 2. The generator shall be checked for sufficient fuel to complete the operation. Ensure

that the generator is positioned away the welding area to avoid fumes. Generator used must be in accordance with butt fusion machine manufacturers instructions.

3. A voltage stabilizer must be used between the generator and the welding machine to protect machine from voltage peaks.

4. Maximum cable length between fusion machine and generator is 50 metres (Cable diameter min 2.5mm2).

5. The calibration certificate of the generator, voltage stabilizer and welding machine should be valid.

6. The welding equipment shall be checked for:

Correct plugs and sockets are being used

The clamps must be effective in holding pipe square.

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The trimmer blades must be clean and sharp and the trimmer must be square.

The heater plate must have a control system capable of maintaining a uniform temperature over the area in contact with the pipe.

The heater plate surface must be in a good clean condition with no damage to the PTFE coated surface.

7. Pipe to be welded shall be supported on pipe rollers or PE skids. 8. Pipe to be welded is on good condition free from surface contamination and

deep scratches (scratched <10% of wall thickness are permissible). 9. Equipment shall be cleaned to ensure that oil and grease do not contact p ipe

surfaces. 10. To control dust contamination, welding shall be carried out in a protective

shelter as per manufacturer's recommendations. The floor should be covered by tarpaulin (or similar material).

11. To ensure that heater plate is fully clean it shall be washed when cold with a mild detergent and then rinsed with cold water. A dummy weld will be completed every time the plate has been allowed to cool.

Dummy Welding

To ensure that contamination does not affect welds in installed pipes, a dummy weld shall be made at the start of any welding session after the plate has been allowed to cool. The welding cycle shall be followed up to the point where the pipe is removed from the heater plate. Following cooling of the pipe, the surfaces may be re-trimmed to allow production welding to begin. Alternatively a scrap piece of pipe may be used and then discarded.

Welding Procedure

1. Connect frame, hydraulic unit, heater plate, planning machine and data logger or CNC unit together using the cables provided.

2. Ensure that hydraulic connections are clean, then connect to the hydraulic cables to the hydraulic unit and the machine frame.

3. Connect the power supply cable to the voltage stabilizer. 4. Start the generator then connect the voltage stabilizer to the generator. 5. Select the pipe material, size and wall thickness to be joined. 6. Place pipes to be joined on rollers each side of machine. 7. Clamp pipes into welding machine 8. Follow instructions given by CNC control unit or data logger (i.e. measure

dragging force of pipe). 9. Load planning device into the welding machine frame. Commence planning

operation. 10. When planning cycle is completed and carriage has opened, remove planer and

swarf. Do not touch pipe ends. Do not pull swarf up through trimmed pipe ends. 11. Perform visual misalignment check on pipe ends. (max 10% of wall thickness

misalignment allowed, max 0.5mm gap at pipe ends allowed). If misalignment >10% or gap >0.5mm found release pipes, re-align them and

return to step 7 before continuing).

12. Close pipe ends to prevent draughts that can cause tunnelling effect inside of pipe which can cool the heater plate.

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13. Clean faces of pipe ends and inside and outside with a soft clean cotton cloth using isopropyl alcohol (min. 70% alcohol).

14. Secure heater plate on to welding machine frame. 15. Close machine to press clamped pipes onto the heater plate to carry out initial

melting and heat soak cycle. 16. After heat soak cycle and upon prompting by machine remove heater plate and

rapidly bring ends of pipe together to complete fusion weld. 17. Allow pipe to cool using a timer to show the required time before removing from

the welding machine clamps. 18. Mark onto pipe near to joint with a silver indelible marker pen the following

information for QA/ Traceability purposes:-

Date

Welders ID

Joint Number

Machine Number

Cooling time (i.e. time at weld completion + cooling time)

19. Mark Fusion joint number on as-built drawing for future cross reference of welding records.

20. Check for cleanliness around the joint area.

Optional Extra QA Procedure 21. Remove the external weld bead and visually check the underside of the

removed bead for contamination. Bend the weld bead back at several positions and inspect for slit defects. If defective, cut out and redo joint.

22. Bag and tag the weld bead with identical details for supply to FEWA.

3.8.5.2 Electro fusion Welding Electro fusion is a common technique for producing fusion welds in HDPE piping. Barcode labelled or auto recognition electrofusion jointing shall be used and only fittings incorporating fusion indicators shall be acceptable.Positioning tools including suitable mains alignment clamps shall be used for all types of electrofusion systems to minimise misalignment and prevent movement during the fusion and cooling cycle of the joint. A suitable shelter and mechanical scraper will be used for all jointing operations. All pipework to be washed prior to commencement to remove any contamination. After which, a uniform and efficient scrape shall then be performed to remove the oxidized surface to a depth between 0.2 and 0.4mm. This shall be achieved using a mechanical scraper which is capable of cutting a continuous strip of swarf over more than the insertion length of the coupler and round the pipe. Only after preparation and scraping of the pipe end should the fitting shall be removed from its packaging and immediately inserted over the pipe end.

Electro Fusion Inspection A dot or line shall be initially marked on the pipe or spigot end to determine/confirm the depth of penetration. If a clamping/scraping tool is used which indicates the depth of penetration, then the marking requirement no longer applies. Each pipe or spigot end shall penetrate completely its relevant part of the electro-socket. Melt from the fusion process shall not exude outside the confines of the fitting. If this occurs the joint shall be removed immediately. If the

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fitting is designed with fusion indicators, after the fusion they shall be in a position complying with the fitting Manufacturer's instructions. Alignment clamps shall not be removed before the appropriate cooling time has elapsed. Abnormal displacement of the electric wire coils shall not occur. This shall be checked prior to commencement of fusion.

Equipment Specifications

All electro fusion equipment used will be suitable for use with electro fusion fittings having a bar code 2/5 interleaved to ANSO HM10.8M — 1938 and ISO CD 13950/0.8.94 rev.

Applicable Standards

Standards applicable to the use and operation of the electro fusion equipment include the guidelines from the DVGW Code of Practice, the DVS, and the appropriate national and local regulations.

Joint Identification and Data Retrieval / Reporting

Each electro fusion operator will be furnished with a personal identification card / start pass. Each joint will be numbered and data entered and stored in the control box.The equipment will be capable of recording all pertinent digital joint fusion data for download to a PC based record system and as required, immediate printer read out.

Cleanliness

Under no circumstances will heat fusion be carried out in conditions that are unsuitable for successful jointing. Trench side & trench conditions must be clean and dry and kept clear of ground water and mud. When necessary an enclosed habitat will be utilized to alleviate conditions of blowing sand. See appendix 3.2 for type of shelters permitted / required.

Supervision & Skilled Labour

All work shall be carried out under the supervision of a supervisor experienced in carrying out of installing polyethylene pipe work. He should have sufficient experience in all aspects of the work including the fusion and back filling and pressure testing.The lead personnel involved in the carrying out of the fusion work will have been certified by the manufacturer of the electro fusion machines or fittings being installed.

Pre-Joint Checks

Correct jointing parameters for the machine & pipe being welded shall be checked.

The generator shall be checked for sufficient fuel to complete the operation. Ensure that the generator is positioned away the welding area to avoid fumes. Generator used must be in accordance with butt fusion machine manufacturer's instructions.

A voltage stabilizer must be used between the generator and the welding machine to protect machine from voltage peaks.

Maximum cable length between fusion machine and generator is 50 metres (Cable diameter min 2.5mm2).

The calibration certificate of the generator, voltage stabilizer and welding machine should be valid.

The welding equipment shall be checked for:

Display screen working.

Bar code reader working.

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Connection plugs are clean, free from sand and make a secure fit on the fitting terminal.

Correct plugs and sockets are being used.

Pipe to be welded shall be supported on pipe rollers or PE skids.

Pipe clamps are available and in good working order.

Peeling tools are available and in good working order.

Fittings to be welded are still in their original un-opened or damaged packaging.

Pipe to be welded is on good condition free from surface contamination and deep scratches (scratched <10% of wall thickness are permissible).

To control dust contamination, welding shall be carried out in a protective shelter as per manufacturer's recommendations. The floor should be covered by tarpaulin (or similar material).

Welding Procedure

1. Check surface of pipes to be welded to ensure that there are no stones embedded in the surface.

2. Mark the insertion depths +10mm on the surface of the pipe to be welded with an indelible marker.

3. Remove the external oxidized layer of the PE pipe with an mechanical scraper up to the marked insertion depth +10mm. Hand scrapers are not recommended.

4. Remove all swarf from the pipe after peeling operation is completed. 5. Where necessary ends of pipes shall may be re-sized and re-rounded with a

mechanical or hydraulic pipe re-rounder. 6. Clean the peeled pipe surface and the inside of the pipe with a lint free cloth

impregnated with Isopropyl Alcohol (min 70%). Alternatively ready made cleaning tissues containing Isopropyl Alcohol may be used.

7. Remove fitting from bag (place magnetic card in pocket) and insert the ends of the pipe or spigot end of another fitting up to the pipe stop on the straight couplers or to the marked insertion depths on the pipe.

8. Alignment clamps will be used to clamp the fittings/pipe secure for the fusion cycle in order to remove misalignment and stresses from the joint area during and after the fusion process. Clamps must remain in position until the entire fusion cycle including cooling has elapsed. On some fittings integrated clamps may be present in the form of fixation screws. In this case external alignment clamps are not required.

9. Connect the power supply cable from the electro fusion machine to the voltage stabilizer.

10. Start the generator then connect the voltage stabilizer to the generator. 11. Once machine starts enter welder ID card details via bar code on welders ID badge. 12. The electro fusion machine leads will be connected to the fitting to be welded, the bar

code on the magnetic card or fitting should then be read into the electro fusion machine using the bar code scanner or 'pen' supplied with the electro fusion box..

13. Press the weld button on welding machine and allow fusion cycle to fully complete. 14. Allow pipe to cool using a timer to show the required time before removing from the

welding machine clamps. 15. Mark onto pipe near to fitting joint with a silver indelible marker pen the following

information for QA/ Traceability purposes:-

Date

Welders ID

Joint Number

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Machine Number

Cooling time (i.e. time at weld completion + cooling time) 16. Mark Fusion joint number on as-built drawing for future cross reference of welding

records. 17. Check for cleanliness around the joint area.

4. TESTING AND (PRE) COMMISSIONING 4.1 Hydrostatic Testing

General

Upon completion of the line or a substantial part thereof, sections of the line shall be cleaned and hydrostatically tested to prove integrity of the pipe section and to detect any leakage prior to commissioning. Testing shall be performed in accordance with the applicable codes and standards, as listed in section 2. Contractor shall supply all necessary fittings, equipment, facilities, etc. including test ends.

Method Statement

Contractor shall prepare detailed Method Statements (MS) for the pressure test, subject to FEWA/Engineer's approval. These MS shall be based, but not limited to the requirements as set forward in the applicable codes and standards and in this Specification.

Test Pressures

Test Pressure shall be (whichever the largest) 1.5 times the maximum allowable operating pressure (MAOP) for the lowest element of the pipeline section under test for a maximum of 3 hours or as in the phases shown below .

Under no circumstances shall the total time under test exceed eight (8) hours at 1.5 times the maximum allowable operating pressure MAOP. If the test is not complete within this time limit (due to leakage, equipment failure, etc.), the test section shall be permitted to "relax" for eight (8) hours prior to the next test sequence.

Stages for Pressure Testing STAGE 1 All the main PE pipelines, of required segment, with all the bends and tees installed, including the air valves, Isolation valves, wash out valves, and the branched portion up to the connection point with the existing pipeline shall be tested in stage 1.

STAGE 2 The hose 1" for each house connection up to the existing water meter from the tapping valve, shall be tested in stage 2 Principles

Pressure testing of Thermoplastic Pipes Distinguishes Between

Pressure pipes

Non-pressure pipes / Gravity pipes A closed pipe sections is filled with water and the tightness of that section is checked by a method applied to the pipe system, i.e. whether we have a pressure pipe or a non pressure pipe.

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General requirements: Water: Clean water, free from air bubbles.

For submarine pipes, seawater can be used Section length: Pressure pipes, no limitation

Non pressure pipes, section length equal to distance between inspection chambers.

Water Tightness Test for Pressure Pipes Principles A closed pipe section is filled with water. An overpressure is applied in pipe, following a specified time / pressure scheme. At the end of the pressure test scheme, a certain amount of water has to be added to the pipe volume to maintain a given constant pressure. The criterion of tightness is deduced from that volume of added water. Test Pressure

Required test pressure up to now has been: Phase I Pt = Nominal Pressure (PN, bar) Phase II Pt = (1.3 or 1.5) times the Nominal Pressure, i.e. = 1.3 PN (bar) Phase Ill Pt = Nominal Pressure (PN, bar)

As a consequence of the improvement in the mechanical properties of modem Thermoplastics, the test pressure Pt during Phase II sometimes is raised to Pt = 1.5 PN (bar) The factor 1.3 and 1.5 are both used today.

Note: Due to high ambient temperatures experienced in the Gulf Region pressure test should be carried out according to manufacturer's recommendations if the overstressing of PE Pipes is to be avoided. In some cases it will not be possible to pressure test at 1.5 x PN. Methods

The testing programme shall be performed as follows — in short

Phase I Test Pressure (=overpressure) raised to Pt = PN (bar) = nominal pressure for a period of t = 2 hours ±0.1 h

Whenever pressure drops by 20kPa = 0.2 bar, water has to be added to maintain an internal pressure Pt = PN

Phase II Test pressure raised — within a period of max. 6 minutes to Pt = 1.3 PN (bar) Alternatively, Pt = 1.5 PN (bar) in an internal pressure For a period of t = 2 hours ± 0.1 h Adding of water as for Phase I whenever the Pressure drops by 20kPa = 0.2 bar

Phase III Test pressure returned to initial nominal pressure, i.e. Pt = PN (bar) within a period of 6 minutes. The valve is then closed. After a period of one hour, the test programme requires measuring of the quantity of water — if any — which must be added to raise the

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pressure back to its initial value, ie. To Pt = PN (bar) Test Result The tightness of the pipe section is acceptable if the quantity of additional water needed during Phase III appears under the straight line illustrated in Fig. 1.1 or fulfils the expression (1.1 ):

Q < 1 Di -1 ( litre/km.h ) 50

Where Q = added water (if any) in litre Di = internal diameter of pipe (mm) for all diameters up to 1600mm

Fig. 1.1

When pressure testing submarine pipe installations please note the following requirements:

The submarine pipe shall rest on sea bed or on trench bottom at least for a period of 48 hours prior to pressure testing.

No air pockets are allowed inside pipe. The water filling of each submarine

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section shall follow standard sinking method to avoid air pockets.

Air is not allowed as medium for pressure testing of thermoplastic pressure pipes. 4.2 HDPE Pipe Testing Method Statement & Recommendations

Method statement to be read in conjunction with the above Field Pressure Testing Procedure (Hydro Testing).

Site Hydro Test

1. Seal the Pipeline. Fix all blank flanges. Remove air valves. Remove all on line equipment that may be damaged by high pressure.

2. Do not attempt to test against closed gate valves. 3. Cover the pipe with sufficient backfill to protect it from direct sunlight. 4. If backfilling is not possible schedule tests for early morning or evening. 5. Fill the pipeline from the lowest point. Bleed the air from all the flange points where it is

possible and tighten once water begins to spill. 6. When the line is full close off the filling valve and check all flanges and the small

diameter test plumbing for leaks. 7. Commence raising the pressure to Phase I levels (refer attached) from the filling point. 8. Hold this pressure and top up as directed in the Phase I procedure. 9. After two hours raise the pressure as directed in the Phase II procedure. 10. Again maintain this pressure for two hours by topping up as directed in the Phase II

procedure. 11. At the end of the second two hours release the pressures back to the phase I level

(operating pressure). 12. Note this should be done quickly. 13. After one hour top up to raise the pressure back to the initial valve (operating

pressure) if any loss has occurred. First note the pressure before adding the top up. 14. Measure the added water by draining it off into a measuring cylinder. (i.e. reduce

pressure to the low value and save the water bled off) 15. The measured quantity is then compared with the allowable quantity. See calculation

and chart attached.

Equipment:

1. Pressure gauge reading to accurate to 0.1 bar

2. Small dia test plumbing a) Bleed valve at upper point b) Feed line at lower point with valve

c) Gauge connection at lower end with valve

3. Measuring cylinder (2 liter) graduated to 100 mls. 4. Thermometer (for air temperature and water temperature)

Additional Notes In some specifications a second hydro test is called for once the entire system has been completed. During this test it will be necessary to remove the air valves and replace then with blank flanges. It is not advisable to test against closed valves as these are not always guaranteed to be drop tight. Care should be taken that any mechanical elements on the system are protected from elevated pressure or completely removed from the line.

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Do not subject the line to prolonged over-pressure. Always aim to complete the procedure within one working day. During the summer make sure that the pipe is not subject to direct sunlight during testing. During pressure testing pay full attention to the HSE aspects of the procedure. In particular keep the general public away from high pressure test areas.

Differences in elevation Care should be taken not to over pressure the lower end of the system during testing. Gauges should always be placed at the lower end of the length under test. As far as possible the difference between the lower and upper end should be kept to one bar. It is recognized that this may not always be possible when longer lengths are being tested, or where the slope of the pipeline makes it impractical.

4.3 Disinfection and Flushing of Water Pipeline General

All water lines shall be disinfected by Contractor to the satisfaction of FEWA/Engineer.

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Method Statement

Contractor shall prepare a detailed MS for disinfection. This MS shall describe in detail how the Contractor proposes to perform the various disinfection activities to ensure compliance with the requirements as set forward in this Specification and applicable Codes and Standards, as well as with all requirements as set forward by the relevant Authorities.

4.3.1 Disinfection and Flushing

Before the pipeline is placed in service, and before issue of the Provisional Acceptance Certificate by FEWA/Engineer, all pipelines shall be disinfected and flushed as per AWWA C651 or as directed by FEWA/Engineer.The pipelines shall normally be disinfected at the same time as the hydrostatic tests performed or as directed by FEWA/Engineer.One (1) week before the Contractor intends to undertake disinfecting/flushing of all or part of the pipelines, the Contractor shall submit a detailed proposal for the work showing the quantity of water required. The chlorine dose shall be obtained from a chloral solution or other suitable solution to be approved FEWA/Engineer.Samples taken from the pipeline during disinfection at locations directed FEWA/Engineer shall be checked by a suitable comparator in order to ensure that chlorine is present throughout the system and at sufficient concentration. Samples shall be immediately submitted for chemical and bacteriological testing at the approved laboratories. All charges for water sample testing shall be paid by the Contractor.

At the end of the 24 hour period at operating pressure the chlorine concentration shall be checked. If there is less than 1 mg/l of free available chlorine in the water, more chloral solution shall be introduced and left for a further 24 hour period after which the free available chlorine concentration shall be checked again. This procedure shall be repeated as necessary until the free available chlorine taken after 24 hours exceeds 1 mg/l for all samples taken from the area of pipeline under test. The hydrostatic test shall not be commenced until this requirement is satisfied.Should the hydrostatic test fail and repair work involve emptying the pipeline then the disinfection and subsequent testing procedures shall be repeated in full.After all hydrostatic testing has been completed and section of pipeline is ready for handing over in all other respects including the installation of connections where appropriate, the new pipeline shall be flushed out by potable water from the existing mains to which the new pipeline or network is or will be connected. Flushing entry and exit points shall be designed to allow a minimum of 1.0m/s water velocity in the main pipeline to remove any sand or other debris. The quantity of flushing water shall be calculated as the equivalent to 3 times the volume of the pipeline to be flushed unless directed otherwise.The water at the point of extraction shall register a minimum of 0.4 mg/l of free available chlorine when tested with a site comparator prior to any approval being given to commence flushing. If obtained reading is less than this, then FEWA/Engineer shall be informed and the Contractor instructed accordingly.

4.3.2 Acceptance Criteria for Disinfection

The pipeline shall not be considered acceptable until faecal coliforms are undetectable in a 100 ml sample, the bacterial count is within approved limits, the recorded total chlorine content is a minimum of 0.2 mg/l and the pH is within acceptable limits.

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If the tests show that a satisfactory drinking water standard has not been achieved, the Contractor shall repeat the disinfection procedure, tests and flushing, all at his own expense, until these requirements are met.

Flushing water shall be discharged via temporary discharge lines to the surrounding open desert area or into the existing storm water system or, if feasible, into road tankers.Discharging of flushing water into the existing storm water system shall be subject to approval of the relevant Authorities.Any temporary connections required for flushing shall be at the Contractor's cost. All other materials, equipment and labour required for the disinfection, flushing operation and discharge of water shall also be furnished by the Contractor and included in his construction rates.

4.4 Connection to Existing Water Pipelines and Commissioning With respect to the connection of newly completed pipelines into the existing distribution ortransmission system, and when successful pressure, chemical and bacteriological test results for the same are available, the Contractor may request for connection into the existing system in advance of preparing the new pipeline or network for handing over to FEWA/Engineer. At least two weeks should be allowed for the application to be processed. The Contractor shall follow strictly the timings and periods of shutdown of the existing system as allowed by FEWA/Engineer. The Contractor shall prepare all labour, plant and equipment well in advance of the proposed shutdown date and shall make advance preparations at the site of the connection so as to minimise the amount of work required during the limited period of shutdown allowed.No cutting of existing pipework shall be allowed until a representative of FEWA/Engineer's Operation and Maintenance section has given his authority for the work to commence after the necessary valves are closed also be present prior to works being allowed to commence.After the successful completion of the connection works and if agreed by FEWA/Engineer's operation and maintenance section shall again be called to re-pressurise the network. If a valve is installed at the subject connection it shall be maintained in a closed position and shall only be opened for specific flushing requirements at the instruction of FEWA/Engineer's representative.Commissioning shall only be considered for approval by FEWA/Engineer when the pipeline or network is complete in all respects and chemical and bacteriological tests have been successfully concluded.Handing over to FEWA/Engineer shall only be considered with respect to the appropriate Clauses for “Provisional Acceptance” of the Works.

4.5 Pipeline Commissioning

Contractor shall commission the pipelines after pressure testing, disinfection, flushing and after acceptance by FEWA/Engineer using approved procedures and plans. Contractor shall prepare detailed Method Statements (MS) with Work Procedure for the commissioning activities pipeline, subject to FEWA/Engineer's approval. This MS shall be based on, but not be limited to the requirements as set forward in the applicable codes and standards and in this Specification.Once a procedure has been approved, any change in procedure shall be subject to written approval from FEWA/Engineer.

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5. QUALITY ASSURANCE/QUALITY CONTROL A copy of the Contractor's QA/QC program shall be submitted to FEWA/Engineer with its quotation for review. If Contractor's is ISO 9001:2008 certified, then only a copy of the ISO certificate is required. The Contractor shall identify in documents to its manufacturers, suppliers, vendors and subcontractors all applicable QA/QC requirements imposed by FEWA/Engineer, and shall ensure compliance. On request, Contractor shall provide objective evidence of its QA/QC surveillance for all levels of its activity.

5.1 Documentation and Records

Contractor shall submit daily, weekly, monthly and after completion to various records and reports, for documentation purposes during and immediately after the construction.

5.2 As Built Drawings and Pipe Book

Contractor shall prepare and submit 'as built ' drawings 6 month after issuing PAC at the latest of all FEWA/Engineer issued drawings and of all Contractor work drawings including vendor drawings.The documents shall be provided as hard copy (number to be agreed during contract award) and as soft copy. The drawings shall be prepared fulfilling FEWA’s GIS system requirements and using the comptable AutoCad version.Sample format of pipe book shall be submitted FEWA/Engineer approval for all identified pipe elements.

6. APPENDICES

6.1 Welders Identification Badge 6.2 Recommended Shelters for protection of welding areas during fusion 6.3 Generator Recommendation for Butt and Electro fusion Machines 6.4 Specification for PE100 Fittings and Electro fusion Machines 6.5 Specification for Butt Fusion Machines 6.6 Specification for Large Tolerance Mechanical Fittings <_ DN300 6.7 Specification for Large Tolerance Mechanical Fittings DN300 to 5 DN600 6.8 Specification for Stepped Coupling Mechanical Fittings >_DN300 to 5 DN600

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APPENDIX 6.1 6.1 Welders Identification Badge

The welder's identification badge which should be carried by welders at all times on-site should contain the following information:- Company name Name of welder ID number of welder (this number will also appear on fusion records for traceability) Expiry date of welders certification. Colour photograph Bar code for entry of welders data into welding machine

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APPENDIX 6.2 6.2 Recommended Shelters for protection of welding areas during fusion: -

Temperature

Weather Conditions

Shelter Recommendation

-20°C <30°C

Sunny / Cloudy No wind or rain (i.e. trees still, no airborne sand / dust particles

None required.

>30°C Sunny / Cloudy No wind or rain (i.e. trees still, no airborne sand / dust particles

Cover of welding machine and welding area recommended (i.e. umbrella).

-20°C + 48°C

Raining or Hailing Full cover all sides by use of a tent or purpose built welding container.

-20°C + 10°C

Snowing Full cover all sides by use of a tent or purpose built welding container.

-20°C + 48°C

Windy (i.e. trees moving airborne sand / dust particles).

Full cover all sides by use of a tent or purpose built welding container.

>48°C All weather conditions

Welding should be stopped

-20°C + 48°C

Flooding Welding should be stopped

APPENDIX 6.3

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6.3 Generator Recommendation for Butt and Electro fusion Machines

Note: if generator stops always disconnect butt or electro fusion machine before re-starting and allow generator to run for 2 minutes before re-connection. The generators shall be suitable for the required power of butt and electro fusion machines.

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APPENDIX 6.4

6.4 BELOW GROUND APPLICATION OF POLYETHYLENE PRODUCTS AND SUPPLEMENTARY PRODUCTS FOR WATER DISTRIBUTION AT MAXIMUM OPERATING PRESSURES OF 16 BAR

SPECIFICATION

All fittings, saddles, adaptors and spigot end fittings included in this document should be designed for use with water distribution systems.

1. SPECIFICATIONS FOR ELECTROFUSION FITTINGS AND SADDLES 1.1 All fittings shall be injection moulded from recognized top quality PE 100 resin. 1.2 All fittings must conform to the requirements of EN 12201-3 and be suitable to be used in

conjunction with pressure pipes from polyethylene manufactured to the appropriate ISO and CEN standards.

1.3 All fittings must be packed in such a way to allow instant use on site without additional cleaning.

1.4 Each carton or protective package must clearly indicate its contents. 1.5 The heating coils contained in each individual fitting and saddle should be so designed

that only one complete process cycle is necessary to fully electro fuse the fitting to the adjoining pipe or pipeline component as applicable.

1.6 No heating element may be exposed and all coils are to be fully imbedded into the body of the fitting for protection purposes.

1.7 The pipe fixation device shall be an integral part of the body for all fittings in the sizes up to and including nominal diameter 63 mm and on saddles up to 250mm.

1.8 An individual data carrier card in compliance with ISO 7810 and ISO 7811 containing a magnetic strip and an appropriate barcode or codes as well as manual setting information for data transfer purposes must be supplied with each fitting.

1.9 All fittings must have moulded-in identification and appropriate product information. 1.10 Process voltage of all fittings must not exceed a maximum of 39.5 v 1.11 Insulated contact heads for the terminal pins are to be provided. 1.12 Terminal pin size shall be 4 mm in diameter. 1.13 A limited path style fusion indicator acting for each fusion zone as visual recognition of

completed fusion cycle should be incorporated into the body of the fitting or saddle near or adjacent to the terminal.

1.14 The design of the fusion indicators must prevent the escape of fusion melt. 1.15 All couplers in the sizes up to and including nominal diameter 250 mm must have an

easily removable centre stop not requiring tools for removal. 1.16 All internal or externally threaded transition adaptors in the nominal sizes up to and

including 2" must be designed with an integrated polyethylene collar from PE 100 for jointing purposes not relying on rubber or synthetic seals for leak prevention.

1.17 Threaded adapter bodies may be from brass or stainless steel and should be the modular principle, not being supplied moulded into an electro fusion fit ting socket.

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2. ADDITIONAL SPECIFICATIONS FOR ELECTROFUSION SADDLES 2.1 All saddles up to mains size nominal diameter 250 mm should be designed with two

separate halves having a single hinge type attachment and are to be correctly processed without specialized external spring-loaded tooling.

2.2 For tapping saddles above and including 75mm, the top half of the saddle shall be

equipped with an electro fusion outlet which can accept various other modular system components such as tapping tees, adapters. valve tees, caps, stop-off attachments, pipes etc., that are simultaneously fused together with the saddle to mains joint in one operation.

2.3 For Duo block saddles, each branch outlet is to be equipped with an integral clamping

device. 2.4 The branch spigot of tapping tees must be long enough to allow a second joint if

necessary or to attach a compression fitting. 2.5 Safe tapping into a mains must be possible under the defined allowable maximum

water pressure according to the respective pipe series and ambient temperature. 2.6 The tapping saddle cutter is to be designed to seal-off the central passage way in the

uppermost position. 2.7 The cutter design must fully contain the cut-out coupon and not produce shavings. 2.8 It must be possible to permanently seal-off the top of the saddle with an electro fused

cap in the mains sizes from nominal diameter 63 mm and above. 3. SPECIFICATIONS FOR ELECTROFUSION CONTROL UNITS 3.1 The control units are to operate automatically with magnetic card and/or barcode data

transfer method transmitted via a reader pen or scanner. 3.2 All units are to be provided with a single push button start. 3.3 All Control units must comply with the following standards: EN 60335-1, EN 60335-2-45,

EN 50081-1, EN 50082-1, EN 55014, EN 61000-3-3 3.4 All Control units must be able to produce fusion joint protocols either by direct connection

to a printer or via a computer. 3.5 The primary power supply to enable the control unit to function correctly for all fitting

and saddle sizes up to nominal diameter 500 mm should not exceed 4 KvA. 3.6 The unit is to be designed with a automatic compensator so that it can fully operate

within input tolerances of between 180 and 264 Volt, respectively 45 and 65 Hz. 3.7 The units are to operate with a stabilized fusion voltage.

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3.8 It must be possible to input fusion information manually in cases where damaged barcodes adversely affect the operation of the reader pen.

3.9 The range of fusion voltage is to be between 8 and 42 volts. 3.10 A galvanic separation must exist between the primary and secondary circuits by means

of a high frequency transformer. 3.11 After completion of the fusion, the display must show information to indicate that the

fusion process has been successful or must indicate what went wrong during the fusion process by means of a code or in writing.

3.12 The display shall give information about the fusion time, the voltage and the cooling

time of the fitting if this information has been programmed in the barcode of the fitting. 3.13 An automatically compensating temperature sensor is to be provided. 3.14 The minimum operating range of ambient temperatures is to be between -10° and

+45°C and the unit must equipped with an external ventilator for continual operation. 3.15 The unit must be capable of processing different manufacturers products. 3.16 Adapter

clips for both 4 mm and 4.7 mm terminal pins are to be available. 3.17 The complete control unit must be contained in one single housing and not exceed a

maximum weight of 12 kilograms including all primary and secondary cables. 3.18 The supplier must be able to provide a full range of system software and data

transmission accessories as applicable for data processing and management. 3.19 The protection class of the unit shall be at least IP 65. 3.20 A light-weight transport box with internal document pocket is to be provided. 3.21 All control units must fulfill the Electro-Magnetic Compatibility regulations in

accordance with the latest European standards. 4. SPECIFICATIONS FOR SPIGOT END FITTINGS 4.1 All fittings must be injection moulded from recognized top quality PE 100 resin or be

manufactured from injection moulded parts. 4.2 All fittings are to conform to the requirements of EN 12201-3. 4.3 All fittings shall be packed to allow instant use on site without additional cleaning. 5. PACKAGING 5.1 All Electrofusion fittings must be packed in transparent protective bags.

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5.2 All Electrofusion fittings must then be packed in carton boxes. 5.3 If only one type of product is packed all carton boxes shall have a label showing the

manufacturer identification, the description of the product, the drawing of the product, the relevant size and the quantity.

6. PRODUCT TRAINING AND TECHNICAL INFORMATION 6.1 The manufacturer or material supplier shall provide a specialized theoretical and

active practical product training given by qualified instructors to enable installers of the above mentioned products to be able to understand and use the products and associated tooling correctly and efficiently under site conditions.

6.2 The courses are to be held on the purchaser's own premises upon demand. 6.3 In addition to the main subject matter all training courses shall additionally cover other

associated distribution pipeline products as well as routine repair and maintenance procedures.

6.4 Successful trainees must be provided with an authorized certificate of competence bearing an individual registration number.

6.5 Additional training courses for line inspectors, planning personal, group leaders and teaching staff are to be provided upon request.

6.6 The manufacturer is to provide accurate and easy-to-understand assembly instructions in at least one internationally recognized language, which can be used at any subsequent time for reference purposes.

6.7 Clearly defined information in book or leaflet form concerning the full range of relevant products and accessories to ease product selection and their usage are to be provided by the supplier in at least one major international language.

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APPENDIX 6.5 6.5 TECHNICAL SPECIFICATION FOR BELOW GROUND APPLICATION OF

POLYETHYLENE PRODUCTS AND SUPPLEMENTARY PRODUCTS FOR WATER DISTRIBUTION AT MAXIMUM OPERATING PRESSURES OF 16 BAR

Butt Fusion Tooling Equipment

This specification gives general requirements for butt fusion machines and is specifying design features of the basic machine, planer unit, heating element and data recording. The specification will be a guidance to ensure that the quality of the butt fusion tools is on a high level.

Definitions: Must: indicates a mandatory requirement Should: indicates best practice and is the preferred option. If an alternative method is used then a suitable and sufficient risk assessment must be completed to show that the alternative method delivers the same, or better, level of protection.

GENERAL SPECIFICATION

All Butt fusion equipment must conform with the requirements of ISO 12176-1 and DVS 2207-1 and 2208-1.

The machines must be able to joint straight or coiled pipes. The preferred nominal maximum and minimum pipe sizes are given in Table 1. Individual pipe sizes must be accommodated by the use of not more than two layers of clamping inserts, which have to be filly interchangeable within the machine.

Table - 1

Maximum Pipe Size (mm)

Minimum Pipe Size (mm)

160 40 250 75 315 90 400 125 500 200 630 315 800 500 1000 710 1200 800

Specification of the Basic Machine The base framework shall be fitted with four aluminium clamps, to guarantee proper pipe alignment. Clamps inclination about 35° - 45° , to guarantee a good accessibility for removing the welded pipe, must be warranted. With machines up to maximum diameter 500mm the op clamps must be hinged to the frame enable opening/closing more easy. With machines up to a maximum of 400 mm no tools must be needed to close and fix the

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clamping units. Removable or re-locatable clamping units must be foreseen in order to weld elbows or special fittings such as T or Y pieces.

Specification for Planer

The planer tool shall be a single and double-side surface planer. Load transfer via maintenance-free mechanism has to be provided. A safety lock mechanism to hook the planer on the Base machine must be integrated. Safety micro switch to prevent undesired start-up is a mandatory request. The cutting plates must have two cutting edges in order to change once during life time.

Specifications for Heating Element The heating surface must be coated with non-stick PTFE-coating. The colour of the PTFE coating must be such that, after the plate has been used for jointing operations, the presence of any surplus pipe material (PE,PP) on the plate must be readily visible, regardless of any degradation of the pipe material or the coating. The heating element temperature must be electronically controlled. The heating element shall be provided for an easy placement in the correct working position.

Specifications for Hydraulic Unit The housing of the hydraulic unit should consist of metal or casting iron. Two handles for carrying should be mounted. A clearly visible pressure gauge with precision scaling has to be implemented. The control and refilling of the oil has to be easily done. SPECIFICATIONS OF FUSION DATA RECORDER.

The data recorder must record the complete fusion process. All fusion parameters — pressure, time, temperature- shall be recorded on a memory card and could be called up and shown on the display. The operator must be guided through the preparation and the complete fusion process by the data recorder unit An error analysis system will recognize deviation from the defined parameters and will signalize the deviation during the fusion cycle. A printer interface should be integrated. The data recorder must be fitted with a battery to bridge power failures. The data of the fusion record has to be available in electronic format for further analysis with software tools provided by the manufacturer.

The operator language must be selectable. All instructions as well as the print out has to be in the selected language. The fusion parameters must be corresponding to the standards and directives of the country in use. The data recorder must have the possibility of configuration to the specific applications in terms of use: of operator identity card, job number, input of trace ability data of the pipes and fusion machine parameters (like piston area). Technical Specifications

Working Temperature Range Voltage -10°C - + 45°C Voltage 176 VAC to 276 VAC Rated Voltage 230 VAC Battery Operation 1 hour. Built in battery with

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automatic charging connection Standard Frequency 47 Hz up to 65 Hz Power Consumption 60W Protection Rating I/IP43 Memory Storage On memory card capacity 64 up to

1024 KB respectively 40 to 734 protocol records and additional on

internal memory storage. Interface RS232, 4800 Baud, 7 Databit, 1 Stopbit, even Parity, XON/OFF-protocol Main cable Length upto 4m Dimensions (Without frame: length 420mm; width

300mm; height 170mm Product Training and Technical Information The manufacturer or the sales representative shall provide a specialized theoretical and active practical product training given by qualified instructors to enable installers of the above mentioned products to be able to understand and use the products and associated tooling correctly and efficiently under site conditions. The courses are to be held on the purchaser's own premises upon demand. In addition to the main subject matter all training courses shall additionally cover other associated distribution pipeline products as well as routine repair and maintenance procedures. Additional training courses for inspectors, group leaders and teaching staff are to be provided upon request. The manufacturer has to provide accurate and easy-to-understand operating instructions in at least one internationally recognized language, which can be used at any subsequent time for reference purposes.

Clearly defined information in book or leaflet form concerning the full range of relevant products and accessories to ease product selection and their usage are to be provided by the supplier in at least one major international language.

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AP P E N D I X 6.6 6.6 TE C H N I C AL S P E C I F I C AT I O N F O R L AR G E TO L E R AN C E F I TT I N G S

F O R U S E I N F L U I D S L I K E P O TAB L E W ATE R AN D S E W AG E & W AS TE W ATE R Scope: This tender specification specifies the requirements for large tolerance couplings, flange adaptors and other fittings (hereinafter called mechanical joints), restrained or non -restrained, sized DN50 up to and including DN300, for conveying fluids like potable water, waste water and cooling water, suitable for fluid temperatures between 0° C and 50° C, suitable to be installed under and above ground, and inside and outside buildings. The mechanical joints shall be constructed in conformity with ISO 2531.

Ranges: The mechanical joints shall be suitable for all pipe materials, both metal and non-metal, like PE, PVC, GRP, PB, asbestos cement, copper, steel, galvanized steel, stainless steel 304 and 316, grey cast iron, ductile cast iron and concrete.

Mechanical joints shall be designed to cover following pipe outside diameters per nominal diameter:

ON-size Minimum range (mm) Maximum range (mm)

DN50 46 71

DN65 69 90

DN80 84 105

DN100 104 132

DN125 132 155

DN150 154 192

DN200 192 232

DN225 232 257

DN250 267 310

DN300 315 356

Possibility of Changing Configuration on the Spot The mechanical joint shall offer the possibility of changing the configuration from restrained to non-restrained or vice versa at the time of installation, by either inserting or removing gripping elements on the spot.

Material Specifications: Body & clamp rings: Ductile cast iron in conformity with EN-GJS-450-10-HB200.

Coating : Coating shall be a Resicoat ® RT9000R4 epoxy powder coating or equal, with a minimum layer thickness of 250 micron. Coating shall be approved by an internationally accepted institute for potable water or other fluids (e.g. WRc, KIWA, DVGW) and shall fulfill the requirements of GSK (Gutegemeinschaft Schwerer Korrosionsschutz).

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Bolts, Nuts and washers:

- Bolts, nuts and washers shall be made of stainless steel A2- 70 or A4-80.

- Bolts shall have an anti friction Teflon coating to prevent cold-welding due to fretting - Nuts shall be yellow passivated

Rubber gasket: EPDM according to EN 681-1, for the type WA for cold potable water supply up to 50°C.

NBR according to EN 682 (GB) for cold non-potable water supply, drainage, sewerage and rainwater pipes (continuous flow up to 45°C) with oil resistance. Gripping elements: Gripping elements shall be made of stainless steel A4

(AISI 316).

Flanges: Flanges shall be constructed in such a way that may be attached to flanges who's dimensions and tolerances comply with EN 1092-2. Flange face shall have concentrical grooves. Pressures: Non-restrained: Max. working pressure: 25 bar Restrained: Max. working pressure: 16 bar / 8 bar,

depending on DN-size and/or pipe material Ambient Temperature at Installation: The mechanical joints with EPDM gasket shall be suitable for installation at ambient temperatures between - 20 °C and + 50°C. Marking Requirements: All mechanical joints shall be legibly and durably marked. Marks shall be cast on the body and shall bear at least the following information:

The manufacturer's name or mark

Identification of the year of manufacture

Identification of ductile cast iron

Identification of DN size

Identification of the range of external diameters over which the mechanical joint works.

Additional information to be supplied with the mechanical joint: The following information shall be supplied on or with each mechanical joint:

- installation instructions

maximum joint gap

maximum depth of engagement

maximum allowable angular deflection

pipe materials for which the mechanical joint is intended to be used with non-restrained and restrained joints. - need for supporting sleeves (inserts)

bolt torque

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Information about re-usability of the mechanical joint

Quality Assurance:

The manufacturer's quality system shall conform to ISO 9001.

The manufacturer's environmental system shall conform to ISO 14001.

Technical Support: - The manufacturer must be able to give technical and product training by qualified

personnel. - The manufacturer must have in-house test facilities to execute basic tests.

WAM






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AP P E N D I X 6 . 7 6 . 7 TE C H N I C AL S P E C I F I C AT I O N F O R L AR G E T O L E R AN C E F I TT I N G S

F O R U S E W I TH P O TAB L E W ATE R , S E W AG E & W AS T E W ATE R .

Scope: This tender specification specifies the requirements for large tolerance couplings and flange adaptors (hereinafter called mechanical joints), non-restrained, sized DN350 up to and including DN600, for conveying fluids like potable water, waste water and cooling water, suitable for fluid temperatures between -5° C and 50° C, suitable to be installed under and above ground, and inside and outside buildings.

The mechanical joints shall be constructed in conformity with ISO 2531.

Ranges:

The mechanical joints shall be suitable for all pipe materials, both metal and non-metal, like PE, PVC, GRP, PB, asbestos cement, copper, steel, galvanized steel, stainless steel 304 and 316, grey cast iron, ductile cast iron and concrete.

Mechanical joints shall be designed to cover following pipe outside diameters per nominal diameter and have the following minimum length:

DN Size

Minimum range (mm)

Minimum range (mm)

Minimum length coupling (mm)

Minimum length flange adaptor (mm)

DN350 356 380 500 360

DN400 400 429 500 360

DN450 450 482 500 360

DN500 500 532 500 360

DN600 605 637 500 360

Individual Clamping Rings:

To ensure optimal clamping of pipes with differing tolerances, outside diameters and/or materials the coupling must be supplied with individual clamping rings and separate bolt sets which work independently from each other to ensure each end of the coupling can be tightened individually.

Material specifications:

Body & clamp rings: Ductile cast iron in conformity with EN-GJS-450-10- H13200.

Coating : Coating shall be a Resicoat® RT9000R4 epoxy powder coating or equal, with a minimum layer thickness of 250 micron and chemical resistance of Ph 2 up to pH 13. Coating shall be approved by an internationally accepted institute for potable water or other fluids (e.g. WRc, KIWA, DVGVV) and shall fulfill the requirements of GSK (Gutegemeinschaft Schwerer Korrosionsschutz).

WAM






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Bolts, Nuts and washers: - Bolts, nuts and washers shall be made of Stainless steel

A2-70 or A4-80.

Bolts shall have an anti friction Teflon coating to prevent cold welding due to fretting.

Nuts shall be passivated Rubber gasket: EPDM according to EN 681-1, for the type WA for cold potable water supply up to 50°C. NBR according to EN 682 (GB) for cold non-potable water

supply, drainage, sewerage and rainwater pipes (continuous flow up to 45°C) with oil resistance.

Flanges: Flanges shall be constructed in such a way that may be attached to flanges who's dimensions and tolerances comply with EN1092-2. Flange face shall have concentrical grooves. Pressures: Maximum working pressure: 10 bar Ambient Temperature at Installation:

The mechanical joints with EPDM gasket shall be suitable for installation at ambient temperatures between - 20 °C and + 50°C.

Marking Requirements:

All mechanical joints shall be legibly and durably marked. Marks shall be cast on the body and shall bear at least the following information:






Additional Information to be Supplied with the Mechanical Joint:

The following information shall be supplied on or with each mechanical joint:

-- installation instructions

maximum joint gap



pipe materials for which the mechanical joint is intended to be used with.

need for supporting sleeves (inserts)

WAM






52 of: 555

bolt torque

Information about re-usability of the mechanical joint Quality Assurance:

- The manufacturer's quality system shall conform to ISO 9001.

The manufacturer's environmental system shall conform to ISO 14001. Technical Support:

The manufacturer must be able to give technical and product training by qualified personnel.

The manufacturer must have in-house test facilities to execute basic tests.

WAM






53 of: 555

AP P E N D I X 6.8 6.8 TE C H N I C AL S P E C I F I C AT I N F O R L AR G E TO L E R AN C E S TE P P E D

C O U P L I N G S F O R U S E W I TH P O TAB L E W ATE R , S E W AG E AN D W AS TE W AE R Scope: This tender specification specifies the requirements for large tolerance couplings and flange adaptors (hereinafter called mechanical joints), non-restrained, sized DN350 up to and including DN600, for conveying fluids like potable water, waste water and cooling water, suitable for fluid temperatures between -5° C and 50° C, suitable to be installed under and above ground, and inside and outside buildings. The mechanical joints shall be constructed in conformity with ISO 2531.

Ranges: The mechanical joints shall be suitable for all pipe materials, both metal and non-metal, like PE, PVC, UPVC, Asbestos Cement, Copper, Steel, Galvanized Steel, Stainless Steel 304 and 316, Grey Cast Iron, Ductile Cast Iron and Concrete.

Mechanical joints shall be designed to cover following pipe outside diameters per nominal diameter and have the following minimum length:

DN-size Connection(1) (mm)

Connection (2) range (mm)

Minimum length coupling (mm)

DN300x350 315-337 356-380 500

DN400x450 400-429 450-482 500

DN500x550 500-532 548-580 500

DN600x600 605-637 605-637 500

Individual Clamping Rings: To ensure optimal clamping of pipes with differing tolerances, outside diameters and/or materials the coupling must be supplied with individual clamping rings and separate bolt sets which work independently from each other to ensure each end of the coupling can be tightened individually.

Material Specifications: Body & Clamp Rings: Ductile cast iron in conformity with EN-GJS-450-10-HB200.

Coating: Coating shall be a Resicoat® RT9000R4 epoxy powder coating or equal, with a minimum layer thickness of 250 micron and chemical resistance of Ph 2 up to pH 13. Coating shall be approved by an internationally accepted institute for potable water or other fluids (e.g. WRc, KIWA, DVGW) and shall fulfill the requirements of GSK (Gutegemeinschaft Schwerer Korrosionsschutz).

WAM






54 of: 555

Bolts, Nuts and Washers: - Bolts, nuts and washers shall be made of Stainless steel A2-70 or A4-80.

Bolts shall have an anti friction Teflon coating to prevent cold welding due to fretting.

Nuts shall be passivated Rubber Gasket: EPDM according to EN 681-1, for the type WA for cold potable water supply up to 50°C. NBR according to EN 682 (GB) for cold non-potable water

supply, drainage, sewerage and rainwater pipes (continuous flow up to 45°C) with oil resistance.

Flanges: Flanges shall be constructed in such a way that may be attached to flanges who's dimensions and tolerances comply with EN1092-2. Flange face shall have concentrical grooves. Pressures: Maximum working pressure: 10 bar Ambient Temperature at Installation:

The mechanical joints with EPDM gasket shall be suitable for installation at ambient temperatures between - 20 °C and + 50°C.

Marking Requirements:

All mechanical joints shall be legibly and durably marked. Marks shall be cast on the body and shall bear at least the following information:






Additional Information to be supplied with the Mechanical Joint:

The following information shall be supplied on or with each mechanical joint:

-- Installation instructions

maximum joint gap



Pipe materials for which the mechanical joint is intended to be used with.

need for supporting sleeves (inserts)

WAM






55 of: 555

bolt torque

Information about re-usability of the mechanical joint Quality Assurance:

- The manufacturer's quality system shall conform to ISO 9001.

The manufacturer's environmental system shall conform to ISO 14001. Technical Support:

The manufacturer must be able to give technical and product training by qualified personnel.

The manufacturer must have in-house test facilities to execute basic tests.

STANDARD SPECIFICATIONS TECHNICAL TERMS Pipeline... · STANDARD SPECIFICATIONS ... 4.1...

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