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Specification For Fabrication, Construction & Testing of Steel Pipe System

This document provides specifications for the fabrication, construction, testing and installation of a steel pipe system. It outlines 20 sections that cover topics such as applicable standards, site conditions, design considerations, pipeline route surveys, excavation, transport and handling of pipes, laying of pipes, welding requirements, fabrication of above and below ground piping, coating, lining, testing, safety and documentation. The specifications are intended to ensure the pipe system is designed and installed to facilitate safe and trouble-free long-term operation.

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0% found this document useful (0 votes)

296 views43 pages

Specification For Fabrication, Construction & Testing of Steel Pipe System

Uploaded by

ALI

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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SPECIFICATION FOR FABRICATION,

CONSTRUCTION & TESTING OF STEEL

PIPE SYSTEM

I:\WATER STANDARD SPECIFICATION\DOCUMENTS FOR MEETING\CARBON STEEL 2019\FINALIZED SPECS 2020\W-P-SS-012 REV 01 SIGNED FINAL DRAFT FORMAT UPDATED.DOC

1 Dec 2019 Overall update n compliance to revised spec W-P-SS-002 AK/MI

0 02-02-02 Approved Issue
rev. date Description/issued for prepared authorised
client: TRANSCO / ADDC / AADC
project: STANDARD SPECIFICATIONS FOR WATER WORKS
title: SPECIFICATION FOR FABRICATION, CONSTRUCTION & TESTING OF STEEL PIPE
SYSTEM

tender: project: document: W-P-SS-012 rev: 1 sheet: 1 of: 43

Table of Contents page

1. SCOPE .................................................................................................. 3

2. APPLICABLE STANDARDS AND CODES .......................................... 3

3. SITE CONDITIONS ............................................................................... 4

4. DESIGN CONSIDERATION .................................................................. 4

5. PIPELINE ROUTE SURVEY ................................................................. 5

6. EXCAVATION OF TRENCHES AND PITS ........................................... 5

7. CROSSINGS OF ROADS, SERVICES AND WATER CHANNELS ...... 5

8. TRANSPORT, HANDLING AND STRINGING ...................................... 5

9. PIPE LAYING IN TRENCHES AND CASINGS ..................................... 9

10. PIPELINE BACKFILLING ................................................................... 13

11. WELDING ............................................................................................ 13

12. STEEL PIPING FABRICATION REQURMENTS ................................ 13

13. ABOVE GROUND PIPING ERECTION ............................................... 20

14. EXTERNAL COATING AND PROTECTION OF JOINTS AND

REPAIRS ............................................................................................. 24

15. LINING AND INTERNAL COATING OF JOINTS AND REPAIRS ...... 25

16. CONNECTION TO EXISTING PIPELINES.......................................... 26

17. CATHODIC PROTECTION FOR BURIED CS PIPELINE ................... 27

18. INSPECTION AND TESTING .............................................................. 27

19. TESTING AND AS-BUILT DOCUMENTATION .................................. 35

20. SAFETY AND ENVIRONMENT........................................................... 35

ANNEXURE A: BURIED CS WELDED JOINT EXTERNAL COATING

PROPERTIES .................................................................................................. 36

I:\WATER STANDARD SPECIFICATION\DOCUMENTS FOR MEETING\CARBON STEEL 2019\FINALIZED SPECS 2020\W-P-SS-012 REV 01 SIGNED FINAL DRAFT FORMAT UPDATED.DOC
Client TRANSCO / ADDC / AADC
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR FABRICATION, CONSTRUCTION & TESTING OF STEEL PIPE
SYSTEM

tender: project: document: W-P-SS-012 rev: 1 sheet: 2 of: 43

1. SCOPE

This section describes the requirement of steel pipes fabrication, construction, erection,
testing and commissioning for line pipes and Pumping & Tank Stations Piping (buried &
above ground). The contents of this section shall not be interpreted in anyway as limiting the
CONTRACTOR's responsibilities and obligations to provide a safe and working installations
complete with all necessary accessories/auxiliaries to facilitate and ensure trouble free
operation, maintenance and safety of the complete installation. The following terms where
mentioned in the specification are considered synonyms: pipeline, piping, pipework and pipe
system.

2. APPLICABLE STANDARDS AND CODES

All material and workmanship shall comply with the latest edition of the applicable standards
and codes which shall include but not be limited to the following:

ASME B31.4 Pipeline Transportation Systems for Liquids and

Slurries
ASME B31.3 Process Piping

ANSI B1.20.1 Pipe threads, General purpose (inch)

ASME B16.11 Forged Steel Fittings Socket Welding and Threaded

ASME Section II Part C Welding Rods, Electrodes and Filler Metals

ASTM E94 Standard Recommended Practice for Radiographic

Testing
APL 5 L Specification for Line Pipe

APL STD 1104 Welding of Pipelines and Related Facilities

BS EN 1092-1 Flanges and their joints. Circular flanges for pipes,

valves, fittings and accessories, PN designated. Steel
flanges
ISO 9000 Quantity management and quality assurance
standards, Guidelines for selection and use.
ISO 10474 Steel and steel products – Inspection documents

AWWA C651 Disinfecting Water Mains

AWWA M11 Steel pipe - A Guide for Design and Installation

EN 805 Water Supply - Requirements for systems and

components outside buildings
EN 12068 External organic Coatings for the Corrosion Protection
of buried or immersed Steel Pipelines used in
Conjunction with Cathodic Protection - Tapes and
shrinkable Materials
I:\WATER STANDARD SPECIFICATION\DOCUMENTS FOR MEETING\CARBON STEEL 2019\FINALIZED SPECS 2020\W-P-SS-012 REV 01 SIGNED FINAL DRAFT FORMAT UPDATED.DOC
Client TRANSCO / ADDC / AADC
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR FABRICATION, CONSTRUCTION & TESTING OF STEEL PIPE
SYSTEM

tender: project: document: W-P-SS-012 rev: 1 sheet: 3 of: 43

3. SITE CONDITIONS

For site and climatic conditions refer, "General Technical Requirements" Document W-G-SS-
001.

4. DESIGN CONSIDERATION

Pipe, fittings, flanges, gaskets, studs, bolts etc. used in a water transmission/distribution steel
pipe system shall be as per the Specification for Carbon Steel Pipes & Fittings Materials W-P-
SS-002 and Specification for Stainless Steel Piping Material W-P-SS-003 for the design
conditions in accordance with ASME B 31.4 codes unless otherwise mentioned.

Air/Gas piping system shall be for the design conditions in accordance with ASME B 31.3.

Reference also shall be made to TRANSCO/ADDC/AADC Design Guideline and Abu Dhabi
Department of Energy (DOE) Water Transmission/Distribution codes.

The Pipe system shall be designed to withstand the maximum internal and external forces
which could occur in construction, service, maintenance and under hydrostatic test pressure.
The configuration and method of support shall minimise bending stresses. For buried pipeline
in open ground area, the pipeline shall be designed considering external single wheel load
SWL 30 as per DIN 1072. For paved, graded and future road crossings, the pipeline shall be
designed to sustain the traffic loads of SLW 60 or H-20.

Systems shall be sized so that the maximum design flow through the pipework will not
produce cavitation, erosion, excessive noise or vibration. Systems shall also be sized where
practicable so that the minimum operating flow of fluid will prevent deposition of suspended
solids. Attention shall also be paid to piping which does not permanently carry fluid flow.
These lines shall be designed as short as possible to avoid "dead ends".

The Pipework shall be laid out to have sufficient flexibility to prevent expansion or contraction
from causing excessive stresses in the piping material, excessive bending moments at joints,
or excessive forces or moments at points of connection to equipment or at anchorage or
guide points.

No forces developed within pipework system shall be transferred to the civil structure without
the approval of OWNER/ENGINEER.

None of the forces and moments transmitted by the pipes to the connected machines,
apparatus and other components must exceed the maximum permissible values given by the
manufacturer of these items.

The Pipework shall be capable of withstanding satisfactorily all resultant forces exerted by
normal pressures and any design surge pressures which may arise from sudden reversal of
flow during pump trip, closure of valves along the line and starting up or shutting down of any
portions of the system. The piping shall also be designed to withstand all other loads such as
but not limited to external load, thermal expansion, seismic loads, construction loads, vacuum
pressure, etc.

tender: project: document: W-P-SS-012 rev: 1 sheet: 4 of: 43

Material grades, wall thickness, branch connections, etc. shall be as per design calculations
and applicable drawings.

Where required for maintenance purposes of valves and other equipment, dismantling joints
shall be provided.

Facilities shall be provided for draining of water, vacuum breaking and releasing of air. For
piping within the pumps hall, the drainage water shall be piped into the appropriate drainage
system and the period of time for drainage shall not exceed 30 minutes.

5. PIPELINE ROUTE SURVEY

Route survey for Carbon Steel (CS) pipeline shall comply with Specification W-P-SS-010
Section 3 “PIPELINE ROUTE SURVEY”.

6. EXCAVATION OF TRENCHES AND PITS

Excavation of trenches and pits for Carbon Steel pipeline shall comply with Specification W-P-
SS-010 Section 4 “EXCAVATION OF TRENCHES AND PITS”.

7. CROSSINGS OF ROADS, SERVICES AND WATER CHANNELS

The type of suitable crossings shall be jointly agreed between municipality, relevant
Authorities and Owner/Engineer.

In addition to requirements of this specification, reference shall be made to the following

specifications:

- W-P-SS-010, Section 8 “ROAD CROSSINGS”

- W-P-SS-010, Section 9 CROSSING OF SERVICES

- W-C-SS-016 “SPECIFICATION FOR HORIZONTAL DIRECTIONAL DRILLING FOR

CROSSING WATERWAYS/CHANNELS/ROADS”

8. TRANSPORT, HANDLING AND STRINGING

This section defines the minimum requirements and necessary precautions that shall be
exercised during transportation, handling and stringing of the pipes and fittings after their
coating and/or cement mortar lining are completed. The requirements start from taking over of
the pipes and fittings from the lining yard/coating facility after they are ready for transportation
up to the site where they shall be strung along the right of way. This section also enumerates
the conditions for handling of the pipes and fittings to avoid negative impact on the integrity of
the coating/cement mortar lining.

8.1 General Conditions

The pipes and fittings shall be properly protected for transportation to the destination, as
detailed below, to prevent damage to coating and cement lining. All relevant regulations

tender: project: document: W-P-SS-012 rev: 1 sheet: 5 of: 43

concerning transport of pipes (height and weight of trucks) on the roads or highways shall be
strictly observed.

Transportation of cement lined pipes and fittings shall commence only after 7 days subject to
achieving min. value of compressive strength of 31 N/mm2.

Since the curing process of the cement lining is not complete by the time the pipes/fittings are
transported from the lining yard to the pipeline construction site for stringing, measures shall
be taken to make certain that the pipes/fittings are prepared for transport in a way that the
cement lining cannot dry out. For this purpose, the pipes/fittings shall be fitted with end caps
of sufficient strength to withstand the forces acting on the end caps during road
transportation. The end caps shall be bound to the pipes/fittings with steel bands or bands of
equal strength. The steel bands shall not come in contact with the coating. A small volume of
water shall be maintained inside the cement lined pipes/fittings during transport and storage
on site.

8.2 Loading and Unloading of Pipes/ Fittings

Loading and unloading shall be performed by a crane or pipe layer (side boom) equipped with
a spreader bar and wide strong textile or leather belt slings, to avoid damage of the coating
and lining of pipes/fittings. Chains, metal hooks, etc. shall not be used to lift the coated and
lined pipes/fittings.

During the loading/unloading operations, pipes and fittings shall be handled suitably to avoid
dents, cuts, cracks and other damages especially at bevelled ends. If the pipes/fittings are
damaged during transportation, the damages shall be marked upon delivery and stored
separately from the rest of the pipes/fittings at the stringing areas.

During loading, all necessary precautions shall be taken to prevent pipes/fittings, their ends,
coatings, and linings from being damaged. Care shall be taken to ensure the integrity of the
coating and the canvas covers at the end of the pipes/fittings as well as the curing water
contained inside the pipes/fittings. If any damage or leaks on the end covers are observed,
they shall be immediately repaired/replaced upon delivery. If the water quantities inside the
pipes/fittings are not sufficient, they shall be increased before transportation.

Before a loaded truck leaves the loading area the trailer shall be checked carefully to make
sure that it is safe and properly loaded. For this final inspection, qualified personnel shall be
provided to supervise the loading operation. Respective records shall be completed at load-
out. The pipe trucks shall provide supporting by suitable cradles that fit the curvature of the
pipe and having sufficient area and padding to prevent damages in case of oscillation of the
pipe. For the transport by truck all necessary precautions to prevent coatings and linings from
damage and breaking shall be adopted.

8.3 Transportation of Pipes to the Construction site

Suitable trailers shall be used for transporting of the lined pipes/fittings. All relevant
regulations concerning transport of pipes (height and weight of trucks) on the roads or
highways within the UAE shall be strictly observed.

tender: project: document: W-P-SS-012 rev: 1 sheet: 6 of: 43

Before the transportation commences the route shall be analyzed carefully not to interrupt the
transportation activity. The truck drivers shall take maximum care and drive defensively not to
cause any trouble or problems. All drivers shall have a valid license and be familiar with local
traffic regulations and rules.

The transportation vehicles shall not be over loaded.

Enough number of supervisors shall be provided at site to unload the pipes/fittings safely and
properly. At delivery to site, the pipes/fittings shall be inspected and delivery records shall be
filled-out.

8.4 Stringing of Pipes/fittings to the Pipeline Route

Prior to pipe/fittings stringing, all clearing and grading operations of the area of the pipeline
route shall be completed. Stringing shall be done after trench excavation. Pipes/fittings may
be strung directly form the truck into the pipeline trench or be strung along the working strip.

During stringing along the right of way the line of strung pipes/fittings shall be interrupted at
intervals suitably spaced and at passages, roads and water course crossings.

The aforesaid shall be carried out, as far as necessary, to avoid damages and mishandling to
pipes/fittings and not to stop traffic, passage of herds, if any, and the natural water flow during
the interval of time elapsing between the stringing period and the beginning of the
.subsequent stage of work.

During the stringing, direct contact between pipe/fitting and ground shall be prevented to
avoid damages to the pipe/fitting ends, to lining and coating.

Stringing shall be done safely and properly to protect the cement mortar lining of the
pipes/fittings. The supervisors shall make a visual check of the pipes coating and cement
mortar lining.

The lengths of the pipes/fittings shall be adequately spaced in order to facilitate subsequent
handling. Pipes/fittings shall be laid on bags filled with sand and in appropriate position to
avoid the impact of vehicles in transit or the danger of being damaged due to surface flow of
rainwater.

8.5 Special Precautions for Cement Mortar Lined Pipes/fittings

If not properly maintained the cement mortar lining will develop cracks. To avoid any negative
impact on the lining the below listed precautions shall be observed:

The condition of all end caps of pipes strung along the pipeline route shall be monitored daily
by a special team of workers designated for this purpose.

Defective pipe/fittings end caps shall be immediately replaced. Reduced water in individual
pipes/fittings shall be restored immediately to suitable levels. The progress of the stringing
interval may precede the welding interval by 10 days at the most.

tender: project: document: W-P-SS-012 rev: 1 sheet: 7 of: 43

The end caps may be removed from the ends of the pipe/fittings only just before beveling and
welding of the pipe/fitting is undertaken. In case of longer construction breaks, e.g. overnight,
weekend, etc. all uncapped pipes/fitting shall be refitted with end caps.

8.6 Handling of Other Permanent Material

Materials other than pipes/fittings and which are susceptible of dispersing, deteriorating or
suffering from damages, especially from humidity, exposure to high temperature or other
adverse weather conditions shall be suitably stored and protected. In particular, materials for
protective coatings and wrappings, cement mortar mixture, etc. are falling within this category.

The materials mentioned above shall always be handled so as to prevent any damage,
alteration and dispersion. When supplied in containers and envelopes, they shall not be
dropped or thrown, or removed by hooks which might damage the material during the
unloading and during the following handling operations till their use.

Tape for outer protective coating and cement mortar mixture shall be permanently stored,
hoisted from the ground in a dry and weather protected location and transported to the point
of utilization only at the moment and in the quantity necessary for immediate use.

In any case, material supplied in rolls (e.g. geo-textile, glass felt, etc.) shall be kept in a place
protected from dust, humidity and heat sources, piled up in layers to a height not exceeding
1.50 m. Moreover the rolls core shall always be kept up-right.

During unloading, transport and utilization any contact with water, mud, earth, dust, crushed
stone and any other foreign material shall be avoided.

Primer or mastic containers shall be kept at ambient temperature perfectly tight in order to
prevent solvent from evaporating and being polluted with dust, water or other foreign
materials.

In any case suppliers' instructions shall strictly be followed regarding storage temperature of
volatile materials which are susceptible of modification in properties and primary
characteristics due to unsuitable storage.

Therefore, where necessary for any materials, a proper thermal conditioning shall be provided
for.

Materials with machined surfaces such as flanges, fittings, equipment, wire mesh etc. shall be
stored and handled so as to avoid the contact of the machined surfaces with the ground or
with substances which may damage them.

tender: project: document: W-P-SS-012 rev: 1 sheet: 8 of: 43

9. PIPE LAYING IN TRENCHES AND CASINGS

9.1 Pipe Trench Preparation

9.1.1 General

All timber, sticks, stones, hard clods of earth, projecting rocks and other hard objects, which
might damage the pipe or pipe coating shall be removed from the bottom of the trench.

Before lowering the pipe into the trench, the trench depth shall be checked to ensure that the
specified cover on the pipe as depicted in the pipeline drawings can be maintained, taking
account bedding depth as specified hereinafter.

Sizes of DN 900 and below 150 mm depth

Sizes above DN 900 up to DN 1200 200 mm depth

Sizes above DN 1200 300 mm depth

The minimum cover on top of pipe shall be 1.00 m.

In areas at which the pipe is crossing paved road, maintenance road and graded road, the
minimum cover on top of pipe shall be 1.50 meters in case of provision of protection slab or
min 1.00 m in case of concrete duct, box culvert and utility bridge crossings.

9.1.2 Bedding and Surround Material

Suitable graded material free from sharp stones or flints, perishable matter or other materials
which could damage the pipe coating, shall be selected from the excavated material other
than top soil, and sieved if necessary for use as bedding material provided to comply with
specified bedding and surround material in the standard specification W-C-SS-004. Where
excavated material is unsuitable for use as bedding and surround, suitable specified material
shall be imported.

Reference shall be made to W-C-SS-004 “Specification for Earth Work” Section 11 for
bedding material.

If required protective shields shall be placed along the trench walls to prevent damage to the
coating during lowering-in. The shields shall be removed only after the pipe is in place and
subject to no further movement.

9.1.3 Safety Inspection

Before any individual may enter the pipe trench, CONTRACTOR has to visually inspect the
stability and safety of the trench slopes and embankments.

Any unstable trench wall has to be stabilized either by decreasing the inclination or by
adequate support. Loose stones and boulders shall be removed from the edge of the trench
and the trench walls.

tender: project: document: W-P-SS-012 rev: 1 sheet: 9 of: 43

9.2 Pipe Internal Cleaning

All necessary precautions shall be taken to keep the internal surface of pipes free of dirt,
waste and other foreign matter. Before laying and welding, each single length of pipe and
fitting shall be visually inspected and, if necessary, cleaned inside by appropriate tools such
as brushes or swabs.

Special care shall be taken to avoid contamination or damage of the internal lining. All tools
used for cleaning shall be adequate for the special use paying due consideration to the
internal lining/coating.

A plate cover or other suitable cover of a type approved by the OWNER shall be placed at
each open end of a section of pipes already connected every time the pipe laying or welding
work is interrupted, so as to prevent dirt, water, animals and any other foreign substance from
entering the pipe.

Covers shall remain in place for the whole period of interruption of the Work; therefore, at
crossings and at other points of interruption of each section, they shall be removed only when
the tie-ins are carried out.

Special care shall be taken to avoid under all circumstances that any substance which might
cause deterioration to the quality of the drinking water, shall come in contact with the internal
surface of the pipeline at any stage of the construction work.

9.3 Pipe Laying in the Trench

9.3.1 General

Pipe installation shall be performed by laying pipe by pipe into the trench and welding in the
trench (single laying method). Special care shall be taken to ensure that the deformation of
the pipes is within acceptable limits which shall prevent any damages of the lining.

During pipe laying the pipe shall not be lifted in excess in order to protect the lining. The pipe
must not be moved during welding on any of the passes.

At the position of the welding joints the trench shall be prepared in an adequate width and
depth to allow the welding and coating operation in a proper manner. The required working
space underneath the joints (bell holes) shall be min. 50 cm and at a length of at least 100 cm
with the joint in the centre. This trench preparation shall be performed before pipe laying.
Backfilling of the bell holes shall be performed prior to backfilling of the pipe trench.

In any case before starting the laying of pipes all checks and tests pertaining to coating, lining
and cleaning of the pipes shall be terminated .

9.3.2 Particular Requirements

a) The laying bed shall be sufficiently wide, in any case not less than the dimensions defined
in the construction drawings, so that the swaying of the pipe during laying does not cause

tender: project: document: W-P-SS-012 rev: 1 sheet: 10 of: 43

rubbings between pipe and trench walls. When necessary, trenching shall be touched up, in
order to get the pipeline resting continuously on the bottom of the trench.

b) The pipes shall be lifted and laid using flat bands or belts, of non abrasive material of a
width adequate to the fragility of the coating. The type of the lifting equipment used for pipe
laying (side boom, crane) shall prevent temporary stresses and deformations which could
cause damages to the internal lining.

c) Each single pipe shall be lowered into the trench and lined up with the last welded pipe by
means of a pneumatic or hydraulic internal line-up clamp. After completion of root and hot
passes of the foregoing joint the internal line-up clamp is moved to the new joint position and
locked in the pipe end section by means of the first expanding unit. After this the pipe to be
welded on is led over the clamp and the gap between the pipes is aligned. Then the second
expanding unit is activated and the joint is ready for being welded.

d) The pipes shall be laid in such a way that they rest over the entire length on the trench
bottom. For the welding and external coating, bell holes shall be excavated. For welding in
rock sections where bell hole excavation is not practical the pipes shall be placed on
temporary supports made of sand bags within the pipe trench. These supports shall be
removed as soon as the joint coating is complete.

e) Where coating comes into contact with welding supports or lifting equipment during the
laying operation, thorough inspection shall be performed to discover possible damages or
dents or other defects which shall be completely repaired. Before laying the pipe into the
trench the coating of the complete pipe shall be inspected. If after inspecting and repairing the
coating, the pipe has to be put again on supports on the trench bottom, these supports shall
be suitably padded in order not to damage the coating, thus avoiding carrying out more
repairs when the pipe is finally lifted and laid.

f) In case of presence of water in the trench, dewatering shall be carried out as much and so
long as necessary to inspect the laying bed visually, before commencing pipe laying. The
trench shall be kept free of water until completion of backfilling.

9.4 Pipe Installation in Casing

At major road and highway crossings, the product pipes may have to be installed into casing
pipes or culverts made of reinforced concrete.

Design calculations for casing pipes or culverts shall be handed over to the Owner/Engineer
for approval prior to commencement of casing pipe respectively culvert installation.

9.4.1 Preparatory Works

The casing pipe installation shall be completed and checked before the preparatory works
can start. The tunnel provided by the casing pipes shall be as straight as to allow safe
installation of the water pipe.

Before starting the operation, one side of the crossing is decided to be the launching side and
the other, the receiving side. At both sides the trench shall be prepared. At the launching side,
I:\WATER STANDARD SPECIFICATION\DOCUMENTS FOR MEETING\CARBON STEEL 2019\FINALIZED SPECS 2020\W-P-SS-012 REV 01 SIGNED FINAL DRAFT FORMAT UPDATED.DOC
Client TRANSCO / ADDC / AADC
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR FABRICATION, CONSTRUCTION & TESTING OF STEEL PIPE
SYSTEM

tender: project: document: W-P-SS-012 rev: 1 sheet: 11 of: 43

depending on the availability of working space, a welding and launching platform is to be
prepared.

Pipes shall be welded triple, double or single joints at the launching platform. All weld joints
shall be 100 % radio graphed, repairs completed and certified. The joints shall be coated as
per the applicable procedures. The pipes shall be holiday detected and repairs made if
required.

A pulling head with a lug shall be welded to the front of the first length of welded pipe(s) to
attach a pulling cable.

After a welded length of pipe(s) is ready, insulator rings (spacers) of adequate design shall be
installed. The insulator rings shall be spaced according to the manufacturer's
recommendation.

The purposes of installation of the insulator rings are electrical insulation between the casing
and the carrier pipes and providing a sliding support as well as to protect the coating of the
pipe during pulling.

After the insulator rings are installed, protection sleeves for the fibre optic cable conduit shall
be fixed to the insulator rings. Also cathodic protection reference cells and cables shall be
fixed according to the design.

After the pipe length is ready for installation, it shall be checked for a last time before pulling
operation starts.

9.4.2 Pipe Installation

The casing pipe assembly shall be checked and cleaned from any debris before start of
pulling. Some soft soap may be applied at bottom of the casing to decrease the friction factor.

A pulling cable shall be attached to the pulling head and pulling equipment (a tractor or a
ground winch) shall be prepared on the receiving side.

First length of pipe(s) shall be lifted by the pipe layer and led to the casing as the tractor at the
receiving side pulls.

Sling position shall be changed after the pipe layer progresses until the beginning of the
casing. During sling position change, the pipe shall be supported on wooden skids and/or
sand bags.

When the first welded pipe length is almost completely inserted, sling shall be released and
the pipe left on skids.

Second length of the pipe shall be aligned and welded to the first. Joint shall be 100 % radio
graphed, coated and holiday detected.

Insulator rings shall be fitted to the second pipe length, final checks done and pulling
continued.

tender: project: document: W-P-SS-012 rev: 1 sheet: 12 of: 43

When the product pipe is in its final position, the pulling cable shall be removed; the pulling
head shall be cut off.

Tie in to the rest of the pipeline shall be done after pulling is completed, or can be left to
another operation.

After pipe installation is complete, the annular void between the carrier pipe and the casing
shall be filled with grout. In high water table areas, this operation should be done before the
dewatering installations are removed.

10. PIPELINE BACKFILLING

Backfilling of Steel pipeline shall comply with Specification W-P-SS-010 section 6

“BACKFILLING” and W-C-SS-004 ““Specification for Earth Works”.

Backfilling works shall be carried out as soon as possible after coating of joints and bedding
and surround are completed in order to give the pipe a natural anchorage, avoiding harmful
weather impact (rapid temperature change) and erosion of the trench walls.

Backfilling shall be performed within 6 days of the welding interval at the latest in order to
assure that the pipeline is no longer exposed to direct solar radiation or floatation during rain
storm.

11. WELDING

Shop and Field welding and welding inspection of steel pipework shall be in accordance with
the W-P-SS-011 "Specification for Shop and Field Welding and Welding Inspection Carbon
Steel Piping.

12. STEEL PIPING FABRICATION REQURMENTS

12.1 General

Fabrication shall be accomplished in a specialized piping fabrication shop, where portions of

the piping system are fabricated into subassemblies or modules for transfer to the location of
the final installation. The proposed fabrication shop shall be subject to inspection and
approval of OWNER/ENGINEER.

Qualified personnel and all equipment, tools, instruments, etc. necessary to carry out
fabrication works shall be available.

The provided equipment shall be in first class operating condition and adequate replacement
parts (spare parts and consumable) shall be available.

Stainless steel shall be processed in separate workshops or in separated areas of the

workshop, using special tools and equipment, to prevent contamination with ferrous metals
(carbon steel).

tender: project: document: W-P-SS-012 rev: 1 sheet: 13 of: 43

The fabrication shop shall have available suitable ovens for drying and conservation of low
hydrogen electrodes. An alternative would be to use electrodes contained in vacuum
packages and observe the requirements of welding consumable manufacturer.

Suitable equipment for preheating, post-heating and stress relieving shall be available.

The work shall be done in a continuous and skilful manner, taking all necessary precautions
to ensure that good work will result and that the approved completion schedule will be met.

12.2 Dimensional Tolerances

a) Length

Length less than 1.5 m 1.5 M and longer

Centre to centre

Centre to flange face + 1.5 mm + 3 mm

Flange face to flange face

b) Thinning of wall thickness and ovality in bends

The maximum decrease of wall thickness shall not exceed 10% of the nominal wall thickness.

For tolerances on the maximum flattening, reference shall be made to relevant international
standard.

c) Flange face alignment

The maximum misalignment measured in any direction shall not exceed 2.5 mm/m.

When branches are in the same plane and their flanges are also positioned in one plane,
the flange facings shall not deviate more than 1 mm from the latter plane in the same
direction.

d) Position of bolt holes for flanged piping

The maximum deviation allowed from the required position as measured along the bolt
circle is 1.5 mm.

12.3 Piping Joints

a) The piping diameter and internal coating of each line specifies the type of pipe joints to
be adopted. In general, joining shall be accomplished by butt welds unless specified
otherwise.

b) Flanged joints shall be used at connections to Tanks, Vessels, Equipment, Valves and
where required for ease of erection and maintenance as indicated on drawings.

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12.4 Butt Welded Piping

a) Pipe and butt weld fittings will be generally supplied/ purchased with bevel ends
prepared in accordance with API 5L.

b) Spool pieces with ends for site fit welding shall have coating cut back at each end of
sufficient length as per relevant coating specification.

c) Whatever the end condition supplied, the CONTRACTOR shall modify it as necessary to
suit the applicable welding procedure. Modification by weld build up is only permitted
with the approval of OWNER/ENGINEER.

d) Permitted radial misalignment of adjacent butt weld preparations shall be no greater than
1.0 mm.

e) In case of pipes/components with different wall thickness, internal misalignment upto 3.2
mm may be corrected by machining pipe ends in accordance with welding specification,
provided this does not reduce the finished wall thickness below the required minimum
wall thickness.

12.5 Proximity of Welds

Weld joints shall not be arranged so close to each other. Sufficient weld clearance shall
be maintained to prevent thermal stresses near the joint. Circumferential butt welds on
the pipework shall be separated by maximum possible distance. For pipeline welding of
cement mortar lined pipe, the minimum weld separation for circumferential seams shall
be equal to the pipe diameter D or 750 mm whichever is the smaller.

In case of longitudinally or spirally welded pipes, a minimum distance of 10 inches (254

mm) between each longitudinal or spiral weld shall be maintained in lining-up pipes and
these weld seams shall be located in the top half of the pipe (120º). Particular relaxations
in case of welding pipe to bend or bend-to-bend shall be subject to approval.

12.6 Screwed Piping/Galvanized Piping

a) Screwed piping/galvanized piping shall have threads as per ASME B1.20.1-NPT unless
specified otherwise.

b) Galvanized carbon steel piping shall be completely cold worked. Threads shall be clean
cut without any burrs or stripping and the ends shall be reamed.

c) All threads of components shall be thoroughly cleaned of cuttings, dirt, oil or any other
foreign matter prior to joining. The male threads shall be applied with seal tape or thread
sealant and the joint tightened sufficiently. Threaded joints shall be made with 12.5 mm
(0.5 inch) wide PTFE jointing tape.

d) When threaded joints are seal-welded, (except galvanized piping) all foreign matter,
including seal tape and sealant shall be removed through full thread engagement before
the welding.

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Seal welding shall be performed by a qualified welder and all exposed threads shall be
covered by a seal weld. Use of electrodes of 3.2 mm dia. or less or GTAW is preferable.

12.7 Flange Connections

a) All the flanges shall be welding neck raised face type. Slip on raised face flanges shall
be accepted inplace of welding neck flanges to suit the project requirements and as
approved by OWNER/ENGINEER.

b) All flange facings shall be true and perpendicular to the axis of pipe to be attached.
Flange bolt holes shall straddle the normal centerlines unless different orientation is
shown on the drawing.

c) Where 4" and larger spectacle blind or spacer and blind is provided, the mating flange
shall be drilled and tapped for the jack screws prior to fit-up. Details of Jack Screws &
holes shall be similar to Jack Screws of orifice flanges.

d) Slip-on flanges shall be welded to pipe by inside and outside fillet welds. The inside fillet
welds shall be so applied, that the flanges do not require refacing. The toe of the pipe
inside weld on the flange shall be 1.5 mm from the flange face after welding to the pipe.

e) Internal weld surfaces at orifice flanges and other flow measuring instruments shall be
ground flush.

f) During fabrication, damage to sealing/seating surfaces of flanges and other mechanical

joint fittings shall be avoided. In particular such surfaces shall be protected during any
PWHT by the application of a suitable coating as approved by OWNER/ENGINEER.

g) Buried flanged joints shall be avoided as possible.

h) Bolt tightening shall be done in sequential manner as per related international standard.

12.8 Branch Connections

a) Branch connections shall be made as indicated in the relevant piping material

specification and/or isometrics drawings.

b) Branch connections shall be made from equal tees, reducing tees or integral reinforced
branch fittings as approved by OWNER/ENGINEER.

c) The branch size shall be big enough to allow for internal coating/lining as per
specification.

d) Elbowlets shall not be used for branch connections, instrument taps or vent and drain
connections unless space considerations dictate. Drain and vent connections shall not
be installed in elbows. Thermowells installed at other than 90 degrees to the pipe
header or vessel wall are not allowed.

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e) When the main run pipe is welded pipe, branch connections shall be located so as to
avoid crossing of welds.

f) Reinforcement pads if required shall be provided as shown on piping drawings and/or

isometric drawings of the applicable project. Reinforcement pad shall be attached after
external and internal visual inspection of the branch welds, and DP or MP inspection as
required has been performed.

Pads shall be provided with 1/8" tapped hole which shall be plugged after pneumatic leak
test.

12.9 Miter bends and pipe bending

Standard bends are preferred to be used in the pipework wherever possible.

a) Shop fabricated mtier bends are allowed for sizes larger than DN 600 (24”) in
accordance with ASME B31.3 and the following:

- Minimum three miter joints for 90o miter bend and minimum two miter joints for 45o miter
bends are required. Other bends degree is also acceptable subject to Owner/Engineer
approval.

- The nominal radius of the miter bend shall not be less than 1½ times the diameter of the
pipes.

- Mitre bends shall not be used in locations where space is limited or where smooth flow is
required such as upstream and downstream of pumps.

- All miter welds shall be examined by 100% radiography.

- Deflections caused by misalignment up to 3 deg are not considered miter bends.

b) Pipe may be bent and components may be formed in accordance with ASME B31.4 by
any hot or cold method which is suitable for the material and the severity of the bending or
forming process.

- The finished surface shall be free of cracks, excessive thinning or flattening and
substantially free from wrinkling.

- Wall thickness after bending or forming shall not be less than design thickness. The pipe
diameter shall not be reduced at any point by more than 2 ½ % of the nominal diameter.

- For hot bending of normalised carbon steel, no heat treatment is required if hot bending
is carried out between 720 - 950 Deg. C.

- After bending the bent items shall be subjected to non-destructive testing such as visual
examination and dye penetrant and/or magnetic particle examination.

- Only pipes without lining shall be bent.

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- Bending shall be performed in accordance with the applicable API and ASME
regulations.

- Bending shall be carried out at the yard or workshop and under "yard/shop-conditions"

- Internal lining/coating shall be performed after bending at the yard/coating shop and
under "yard/shop-conditions"

12.10 Cutting and Trimming of Standard Fittings

Fittings like elbows, couplings, half-couplings, long-neck flanges for thermowell-connection,

etc. shall only be cut/trimmed where required to meet fabrication and erection requirements,
as per drawings and/or instructions of OWNER/ENGINEER.

12.11 Shop Fabrication/Pre-Fabrication

The purpose of shop fabrication or pre-fabrication is to minimize work during erection to the
maximum extent possible. All relevant dimensions, levels and heights shall be site verified
and confirmed before prefabrication.

All prefabricated pipe spools that have been inspected shall be protected as follows until they
are installed:

a) All dust, rust, weld slags, or other foreign matter in the pipe shall be removed carefully by
brushing, hammering air blowing, or by other suitable means.

b) After cleaning, all openings shall be blanked with suitable materials. Care shall be taken
to avoid any physical damage to flange faces, welding ends and threads.

c) All flange faces (gaskets contact surfaces) and threads shall be adequately protected by
coating with a removable rust preventive.

d) After cleaning and protection, pipe spools shall be stored with proper identification marks
(location code, line number, spool piece number and/or colour marking), so as to
facilitate their withdrawal at any time during erection.

e) Size of prefabricated pipe spools and location of the field weld points shall be determined
by the CONTRACTOR by consideration of the conditions for transportation, erection, etc.

12.12 Piping Supports

The aboveground piping or piping inside chambers shall be laid on steel supports installed on
concrete supports raised from the finished grade level. Supports shall be designed to support
the pipe without causing excessive local stress in the pipe and keep the desired freedom of
movement.

All pipe steel supports and steel support components shall be pre-fabricated at shop, before
erection, as per support drawings unless found not possible. CONTRACTOR shall prepare

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pipe support drawings and site verified for its height, level and other salient dimensions,
before fabrication.

In the event of non-availability of any specified support material/profile/component, the

CONTRACTOR may use alternate substitute material which is better than or equal to the one
specified, with dimensions as required by specification and design.

The CONTRACTOR shall forward Guarantee for the substitutions and confirm that it does not
weaken the design/construction.

Where a pipe passes through a wall and is subject to thrust due to internal design pressure,
the pipe shall be equipped with a thrust flange (anchor ring) which shall conform to the
dimensions stated in AWWA M11. Otherwise, passing through walls without thrust load
transfer shall be through wall sleeves equipped with link seals. For longitudinal loads other
than internal design pressure thrust, the puddle flange (anchor ring) shall be specifically
designed for the applied load.

For all design and construction of concrete supports, reference shall be made to relevant
Standard Civil Specifications.

Coating of steel piping supports shall be in accordance with Specification for Painting &
External Coating of Metal Pipes & Structures W-C-SS-014.

12.13 Miscellaneous

Miscellaneous components like field supports, brackets, pads, small operating platforms, etc.
shall be fabricated to make the piping work complete.

Flexible joints shall be provided where necessary to facilitate removal of plant and/or to allow
for differential settlement of building structure. Wherever practical, flexible joints shall be
provided with tie bolts or other means to transfer longitudinal thrust along the pipework as a
whole.

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13. ABOVE GROUND PIPING ERECTION

This section is applicable for above ground piping as well as piping within chambers.

13.1 Cleaning of Piping Before Erection

Before erection all pre-fabricated spool pieces, pipes, fittings, etc. shall be cleaned inside and
outside by suitable means. The cleaning process shall include removal of all foreign matter
such as scale, sand, weld spatter, cutting chips, etc. by wire brushes, cleaning tools, etc. and
blowing out with compressed air.

13.2 Routing

The pipework shall be laid out and designed so as to facilitate the erection, painting in-situ
and dismantling of any section for maintenance, and to give a constant and uniform flow of
working fluid with a minimum of head loss. The number of flanges shall be kept to a minimum
and the size of each unit of pipework shall be determined by the ease of handling installation
and general appearance of the completed pipe system. Positions of flanges shall take into
account any necessary concrete pipe supports or thrust blocks.

No deviations from the piping route, indicated on the approved drawings, shall be permitted
without the approval of OWNER/ENGINEER.

Pipe to pipe, pipe to structures/equipment's distances/clearances as shown on the drawings

shall be strictly followed as these clearances may be required for the free expansion of
piping/equipment. No deviations from these clearances shall be permissible without the
approval of OWNER/ENGINEER.

In case of fouling of a line with other piping, structure, equipment, etc., the matter shall be
brought to the notice of OWNER/ENGINEER, and corrective action shall be taken as per their
instructions.

13.3 Slopes

Slopes specified for various lines in the drawings shall be strictly maintained. Corrective
action shall be taken under consultation with OWNER/ENGINEER wherever it is not possible
to maintain the specified slope.

13.4 Flange Connections

a) While fitting up mating flanges, care shall be taken to properly align the pipes and the
flanges for trueness, so that faces of the flanges can be pulled together, without inducing
any stresses in the pipe and the equipment nozzles. Extra care shall be taken for flange
connections to rotating equipment like pumps, etc. The flange connections to these
equipment shall finally be checked against misalignment, excessive gap, etc., after the
final alignment of the equipment is over. The joint shall be made up after obtaining
approval of OWNER/ENGINEER.

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b) Unless otherwise specified, the misalignment between pipe flanges and rotating
equipment nozzles shall be within the permissible limits with bolt free condition.

c) If the piping alignment specified above is not within the permissible limits, it shall be
corrected. The correction of piping alignment or the adjustment work of supports shall be
performed after dismantling piping from the equipment. Care shall be taken so that
expansion or distortion due to welding, etc., does not have a detrimental influence on the
equipment.

d) Before connecting the flanges, gasket contact faces of pipe flanges and equipment
nozzles shall be cleaned and checked. If the gasket contact face is damaged, it shall be
reported to OWNER/ENGINEER and shall be repaired by approved manner or replaced.

e) Gasket paste shall not be applied on flange facing for all type of gaskets.

f) Temporary protective covers shall be retained on all flange connections until the piping is
finally connected, so as to avoid any foreign material from entering these equipments.

g) The assembly of a flange joint shall be done in such a way that the gasket between the
flange faces is uniformly compressed. To achieve this the bolts shall be tightened in a
proper sequence.

h) All bolts shall extend completely through their nuts but not more than 12.5 mm of
projection. Projection of all flange bolts shall be kept uniform.

i) Metallic to non-metallic flange joints shall be made up with extreme care, tightening the
bolts uniformly after bringing flanges flush with gasket with accurate parallel and lateral
alignment. Full face gaskets and flat faced steel flanges shall be used.

13.5 Manual Vents and Drains

a) Manual Valves for high point vents and low point drains with plug/blind flange shall be
additionally provided as per the instructions of OWNER/ENGINEER and as necessary.

13.6 Valves installation

a) Valves, strainers and other devices mounted in the pipework shall be supported
independently of the pipes to which they connect.

b) Valves shall be installed with spindle/actuators orientation/position as shown on the

layout drawings and/or isometric drawings. In case of any difficulty in doing this in view
of operation or passage, they shall be corrected after consultation with
OWNER/ENGINEER.

c) The valve shall be confirmed by its tag/name plate for its type, class, body materials, and
trim materials with respect to specification before installation in position.

d) Care shall be taken to ensure that control valves, check valves and other uni-directional
valves are installed correctly as marked with 'flow direction arrow' on the valve body. If

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the directional arrow is not marked on such valves, this shall be confirmed and marked in
presence of OWNER/ENGINEER before installation.

e) Locking arrangement for LO/LC valves shall be by means of chain and padlock system
(material supplied by the CONTRACTOR).

f) Fabrication of stem extensions for chain or lever operated valves (if required for
operation from operating platform/floor) shall be carried out as per the instructions of
OWNER/ENGINEER.

13.7 Piping Instruments installation

a) Installation of in-line instruments, whichever is applicable, such as restriction orifices,

shutdown valves, control valves, safety valves, relief valves, rotameters, orifice flange
assembly, flowmeters etc., shall form part of the piping erection work.

b) Fabrication and erection of piping up to the first block valve and/or nozzle flange for
installation of off-line instruments for measurement of level, pressure, temperature, flow,
etc. shall also form part of the piping construction work. The limits of piping as per the
assembly figures Orientations/locations, etc. shown on drawings shall be maintained.

c) The inside surface of welds of orifice flanges shall be ground smooth and approved by
OWNER/ENGINEER.

d) The straight runs of pipe, if required for upstream and downstream for orifice flanges,
flowmeters shall be kept as per drawings and manufacturer's recommendation. In
principle, the upstream straight pipe length shall be of one piece. The straight runs of
pipe shall not be provided with a vent, drain, or other similar branch.

e) Jack screws wherever required shall be installed so that they are 180 o apart from each
other.

f) When orifice taps are to be taken off from a pipe, the holes shall be drilled strictly in the
positions shown on the drawings, the burrs removed and the holes made smooth.

g) Orifice plates and restriction orifice plates shall not be installed before flushing and
pressure test.

Mating flanges for orifice plates shall be installed with temporary gaskets during
construction, and consideration shall be given to keep the required distance for orifice
plate to be installed after pressure test.

h) All control valves, pressure safety valve and strainers shall not be installed until
successful testing and flushing of connecting piping is completed.

i) Valves shall be installed in the correct flow direction.

j) Care shall be exercised and adequate precaution taken to avoid damage and entry of
foreign matter into instruments during transportation, installations, testing, etc.

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13.8 Line Mounted Equipment and Miscellaneous installation

Installation of line mounted items like strainers, flexible compensators, etc. including their
supporting arrangements shall form part of piping erection work.

13.9 Pipe Supports installation

a) Pipe supports shall be designed and located as shown on drawings, to effectively sustain
the weight and thermal effects of the piping system and to prevent vibrations based on
the outcome of the stress analysis

b) All supports shall be strictly in accordance with the drawings/instructions of

OWNER/ENGINEER. Extra care shall be taken in the correct installation and setting of
supports around pumps, compressors, and other machinery etc., as per detailed
drawings and suppliers erection instructions etc.

c) Reinforcement pad of adequate size shall be welded to the pipe for welding the pipe
supports. The material of the pad and the welding parameters shall be the same as
approved for piping material. When the main pipe requires heat treatment, the welds for
attachment of pipe supports shall also be heat treated.

d) When welding dummy pipe to elbow, tees, etc., the welding shall not melt through to
their interior. Welds for anchor supports shall be at least double-layer welds to provide a
bond of sufficient strength.

e) The following points shall be checked after installation:

i) All restraints have been installed correct. Clearances have been maintained as per
drawings.

ii) All temporary tack welds provided during erection have been fully removed.

iii) Adequate provisions shall be made to anchor, drain, vent, pressure test, dismantle
and clean all pipework.

f) Special care shall be taken in the design of pipe hangers and supporting elements. They
shall be arranged, dimensioned and fastened in such manner that no vibration and
undue stresses appear during start-up, operation, shut down or during field tests. The
reaction forces and moments of the piping system shall be borne by fixed points. Loads
on walls, foundations and other civil structures, are to be reduced to the utmost
minimum.

g) During piping installation, when handling, lifting and laying pipe, the spacing of lifting
points and supports shall not be greater than the maximum support spacing shown in the
table below. Also when installing pipe on above ground supports or piperacks, the
support spacing shall not be more than that shown in the table. However, the maximum
support spacing shall be confirmed by stress analysis for above ground piping.

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Nominal Minimum Bending Maximum
Pipe Size Radius Support
(mm) (metres) Spacing
(millimetres)

DN 80 530 5240
DN 100 700 5980
DN 150 1050 6960
DN 200 1400 7320
DN 250 1770 7730
DN 300 2110 8080
DN 350 2310 8720
DN 400 2650 8980
DN 450 2990 9240
DN 500 3320 9890
DN 550 3680 10090
DN 600 4000 10320
DN 700 4690 10600
750 and larger 172 x inside 10720
diameter of steel
pipe

Note : No allowance has been made for the additional weight of valves and fittings; where
these are used, additional supports shall be provided.

13.10 Protective Coating

a) Protective coating on the pipes and fittings shall be carried out in compliance with W-P-
SS-002 specification and relevant coating specification. Coating of joints and repairs
shall be as per sections 14 and 15 hereunder.

b) Above ground pipework shall be colour coded to the approval of OWNER/ENGINEER.

The normal direction of flow shall be clearly marked on the above ground piping near
each valve, junction, terminal and other positions as required by OWNER. Where
applicable, colour coding shall be marked after protective coatings, have been applied.

14. EXTERNAL COATING AND PROTECTION OF JOINTS AND REPAIRS

For buried Carbon Steel (CS) pipes, external coating and protection of welded joints shall be
performed with heat shrinkable sleeves as per Annexure A of this specification.

For welded joints of above ground CS piping or within chambers, the external coating of
welded joints shall be Fusion Bonded Epoxy coating (FBE) as per Specification W-P-SS-020
or high build liquid epoxy coating as per AWWA C210 with dry film thickness of 300 microns
after adequate surface preparation by blasting. The epoxy used on the joint shall be fully
compatible with the coating material used on the pipe.

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All buried nuts, bolts, washers, flanged joints, push-in joints, mechanical joints, saddles,
couplings and other appurtenances shall be protected by cold tape wrapping of minimum
thickness of 1.5mm with 55% overlap as per Specification W-P-SS-010 item 7.2.

15. LINING AND INTERNAL COATING OF JOINTS AND REPAIRS

15.1 General

For cement mortar lined pipes, cement mortar lining shall be applied for butt welded joints and
concrete glue lining shall be applied for sleeve welded joints. The requirements of the
Specification for Cement Mortar Lining W-P-SS-013 shall be observed.

The lining of the butt welding joints shall be performed within the first ten days after welding.

Prior to application of lining for buried joints, installing of heat shrinkable sleeve and backfilling
of pipeline trench shall be completed.

For handling of the cement mortar mixture in general reference is made to the above
mentioned specification.

For Fusion Bonded Epoxy (FBE) internally coated pipes, the welding joints shall be internally
coated by the same material (FBE) after adequate surface preparation by blasting and using
induction heat apparatus. FBE coating and repairs shall comply with Specification W-P-SS-
020. Other coating materials are subject to Owner / Engineer approval.

Above ground pipes with internal FBE coating shall be designed with flanged spool pieces in
sizes which allow for fusion bonded epoxy application.

15.2 Method Statement for Welded Joints Cement Mortar Lining

A detailed description of the method to be used for applying the cement mortar lining, for
curing and the inspection of the completed lining shall be prepared by the CONTRACTOR.

The method shall be demonstrated in practical use before starting of work and shall be
subject to approval by the OWNER.

15.3 Inspection of Internal lining

Prior to commencement of hydrostatic testing the completed lining shall be visually inspected.

For the inspection of the lining the Specification for Internal Cement Mortar Lining as well as
the below stipulations shall be followed. Adequate equipment and qualified personnel shall be
provided for the inspection works.

Visual inspection shall be carried out before hydrostatic testing of the pipeline sections by an
independent QC Inspector with adequate experience in the field of Cement Mortar Lining. The
QC Inspector shall summarize the findings in an inspection report, which shall be subject to
approval by the OWNER.

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15.4 Surface Condition

The surface of the cement mortar lining of the joints and repairs shall have the same
appearance and shall be as smooth and even as the lining of the pipes and shall comply with
acceptance criteria stipulated in Specification of Cement Mortar Lining W-P-SS-013.

16. CONNECTION TO EXISTING PIPELINES

The CONTRACTOR shall make connections to existing pipelines generally where indicated
on the drawings or as directed by the OWNER/ENGINEER.

The CONTRACTOR shall drain off existing lines for making the necessary connections or
disconnections and shall also dispose of the contents through approved methods and shall
maintain the water supply as far as possible during the execution of the works.

The exact location of connection in the site shall be determined from local sources of
information and confirmed by exploratory excavations carried out by the CONTRACTOR. Any
such trial excavations to locate or expose existing pipelines shall be made at the
CONTRACTOR's own cost.

Before the CONTRACTOR connects into any existing lines, he shall have completely tested,
disinfected and flushed the new pipelines, at least up to the nearest line valve, or as directed
by the OWNER/ENGINEER.

The CONTRACTOR shall ensure that the materials supplied for the WORKS are wholly
suitable and complete for the connection work.

Measures to maintain water supplies in the network during connection works shall be as
instructed by the OWNER/ENGINEER. Disturbance of the water supply shall in all cases be
kept to an absolute minimum by the adoption of efficient connection procedures. Fully
detailed procedures shall be proposed two weeks in advance of any connection works and
shall be modified if required by the OWNER/ENGINEER. No connection shall be carried out
without the written approval of the procedure for the specific works to be undertaken.

The connection to existing pipeline shall not induce excess forces/moments/stresses on the
existing pipeline and new pipeline. Contractor shall submit design calculation as required to
proof that forces/moments/stresses are acceptable as per design code and specifications and
to implement any necessary piping arrangements to ensure sufficient pipeline flexibility and
stability.

17. CONNECTION BETWEEN PIPING WITH DIFFERENT MATERIAL AND

COATING

For connection carbon steel pipeline to other pipeline of different material, consideration shall
be taken for force balancing/anchoring, thermal expansion/contraction absorption, galvanic
corrosion prevention and proper selection of the required type of joints. For connection
between cement lined pipeline and epoxy internally coated pipeline, flanged connection shall
be used with consideration to ensure smooth transition between the internal lining/coating.

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Connection between carbon steel (CS) pipeline and other metallic pipeline such as (ductile
iron (DI) and stainless steel) shall be by flanged connection inside valve/equipment chambers
or above ground. In case there is no valve/equipment chambers in vicinity of the pipelines
connection and subject to OWNER/ENGINEER approval, buried stepped couplings of proven
design may be used.

Connection between carbon steel (CS) pipeline and other non-metallic pipeline such as
(HDPE, GRE, GRP, etc.) shall be by buried flanged connection or buried couplings of proven
design.

Connection between buried CS pipeline and chambers CS piping shall be made in the first
flange in the chambers. Therefore, the coating and lining of buried pipeline will be up to the
first flange in the chamber.

18. CATHODIC PROTECTION FOR BURIED CS PIPELINE

The design, material selection and construction/erection of Cathodic Protection System for
buried carbon steel pipework shall be in accordance with Standard Specification for Cathodic
Protection for Carbon Steel Pipe Lines W-P-SS-019.

The protected pipe segment shall be made electrically continuous through the adoption of
joint bonding where required.

Cathodically protected pipework shall be electrically isolated from existing pipework,

flowmeters, earthed valves and at pipework ends by means of isolation kit or isolation
coupling.

19. INSPECTION AND TESTING

19.1 General

The CONTRACTOR shall submit to OWNER/ENGINEER for approval a comprehensive

procedure for Inspection, flushing and testing of the piping systems.

However, the following shall be taken into consideration while developing this procedure.

19.2 Pressure test

19.2.1 General

Upon completion of the line or a substantial part thereof, sections of the line shall be cleaned
and hydrostatically or pneumatically tested (as applicable) 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. CONTRACTOR shall supply all
necessary fittings, equipment, facilities, etc. including test ends.

The basic standards for hydrostatic testing of the carbon steel pipeline section are:

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• AWWA M11 regarding the test pressure and test duration,

• EN 805 regarding standards of acceptability.

(a) Field pressure testing shall be performed for all pipeline/piping, except where this proves
impractical. In such cases, the prefabricated spools shall be shop pressure tested.

(b) Furthermore, if shop pressure testing is also not practical for any reason, which shall be
substantiated comprehensively by the CONTRACTOR, all the welds in the spool shall
undergo 100% radiography, irrespective of the extent of NDE specified otherwise.

(d) Pressure test, shall not be performed against any closed valve. However the
CONTRACTOR shall test the tightness of the instrument process isolation valves at a
pressure not exceeding the valve manufacturers stated seat test pressure.

(e) All tie-in welds shall be 100% radiographed.

(f) Water piping/pipeline shall be hydrostatically tested by potable water and air piping shall
be pneumatically tested by oil free air.

(g) The CONTRACTOR shall provide potable water required for testing and cleaning the
pipelines. For this purpose OWNER wherever possible and if required by the
CONTRACTOR may arrange metered supplies of water from the existing mains at the
points shown in the drawings. OWNER/ENGINEER will not guarantee the quantities, the
flow rates or the pressure of the metered supply.

(h) Any pressure testing activity shall only be carried out after completion of civil works,
welding, NDE, coating, lining and backfilling along the pipeline section to be tested.

19.2.2 Method Statement

CONTRACTOR shall prepare detailed Method Statements (MS) for the pressure tests, for
OWNER/ENGINEER approval. These MS shall be based, but not limited to the requirements
as set forward in the applicable codes and standards and shall specify the following:

• hydrostatic test profile and - in case the test cannot be done in a single section due to
pressure limitations - a hydrostatic test section map, showing line sections with which every
single test is concerned.

• the complete list of envisaged equipment, material and installations, safety measures,

• source and quality of testing water and detail of the proposed compressor for air piping.

• list of personnel charged with carrying out testing operations, including names and
experience records of the responsible key personnel,

• filling and testing record forms, structure of final hydrostatic testing report.
I:\WATER STANDARD SPECIFICATION\DOCUMENTS FOR MEETING\CARBON STEEL 2019\FINALIZED SPECS 2020\W-P-SS-012 REV 01 SIGNED FINAL DRAFT FORMAT UPDATED.DOC
Client TRANSCO / ADDC / AADC
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR FABRICATION, CONSTRUCTION & TESTING OF STEEL PIPE
SYSTEM

tender: project: document: W-P-SS-012 rev: 1 sheet: 28 of: 43

In addition all safety measures defined by the manufacturer of the internal cement mortar
lining shall be observed, that means for instance:

• time between filling the line and pressure test

• speed of pressure rising

• speed of pressure reducing

• period of line to remain filled between pressure test and emptying.

19.2.3 Test Equipment

Besides personnel all equipment, materials, instruments and necessary installations to

perform the tests shall be supplied as required, such as: test heads, all valves, test flanges,
pipe fittings, calibrated tanks, test pumps that capable to produce the required test pressure,
flow meter, dial gauges, recorder gauges and temperature measuring devices with high class
accuracy capable to record values higher than specified test values, dead weight tester, high
accuracy manometric scale for pressure gauge calibration, communication along the pipeline
routes, means of transport for working, observation and supervision personnel.

19.2.4 Test Pressures for water pipework system

The test pressures for water pipework system shall be 125 % of the internal design pressure
at the lowest point of the tested section. The maximum difference in elevation in any one
section under test shall not exceed 20m. Also the test pressure at any point shall be always
higher than the internal design pressure.

No pressure may occur (e.g. developed due to a temperature increase during testing) which
exceeds 95% of the specified minimum yield strength. .

Relevant calculations and the resulting test section distribution shall be part of the detailed
method statement.

19.2.5 Test Medium

In general Test Medium shall be fresh potable water, except for instrument air and plant air
piping which shall be tested by oil free air. The disinfection may be combined with hydrostatic
pressure testing as per section 19.3 if cleaning was done as per section 19.2.6 below and
subject to Owner/Engineer approval. In such case, the water used for hydrostatic test shall be
chlorinated for minimum of 25 mg/L free chlorine.

19.2.6 Cleaning and Inspection of the Pipeline

Before commencement of test water filling, and possibly during construction, the pipeline
sections of DN 600 and above shall be pre-cleaned from any construction debris.

Cleaning shall be carried out before the blind flanges on the 600 mm Tee pieces are installed.
Pipe line shall be cleaned manually in sections between the 600 mm Tee pieces.

tender: project: document: W-P-SS-012 rev: 1 sheet: 29 of: 43

All drain valves and flanges at 600 mm Tee pieces of the section to be cleaned shall be
opened one or two days in advance of cleaning to drain any remaining cement lining curing
water and to aerate the pipeline interior to prepare for personnel entry.

Fresh air shall be blown into the pipeline by fans and large flexible hoses, before and during
the period when cleaning crews are working inside the pipeline.

Internal cleaning crews shall carry emergency breathing apparatus with them. Spare
breathing apparatus units shall be kept at site, and regular safety precautions shall· be
observed.

Internal cleaning crews shall first collect all debris into trolleys and remove the debris via the
DN 600 manholes of the automatic air release valve chambers. The pipeline interior shall thus
be cleaned of construction debris.

After cleaning of the pipeline a gauging tool consisting of soft metal plates has to be pulled
through the line to verify that the actual minimum internal diameter of the pipes shall be
97.5% of the calculated minimum diameter.

If found necessary, the pipeline interior surface shall then be cleaned by using water, brooms
and squeegees. The cleaning crew shall be trained, equipped with safety devices and be fully
aware that they are working to drinking water cleanliness standards, wear hygienic clothing
and shall not take any foreign material into the pipeline.

After cleaning the final inspection of the pipeline including the cement lining and internal
coating shall take place. Inspection is visual and is done by inspectors equipped with safety
devices and walking through the entire length of the pipeline interior. If the cement mortar
lining and the internal epoxy coating are not properly applied and/or destroyed or dents and/or
ovalities are found, proper repair shall be carried out.

19.2.7 General Set-up of Pipeline Test Sections

Test heads shall be flanged or prefabricated and welded to the test sections as per approved
welding procedures.

Fittings and valves used in test headers shall be of required pressure rating. Generally,
pressure testing shall not be carried out against closed valves, i.e. all valves shall be opened
before the commencement of hydrostatic pressure test.

All branches of drain and vent stations shall be fitted with blind flanges before the
commencement of hydrostatic pressure test.

Pressure gauges shall be installed to the test heads. All instruments shall have valid
calibration certificates issued by an accredited testing laboratory.

19.2.8 Filling

• Filling shall take place slowly and shall proceed without interruption. Flow rates, volume of
water introduced, temperatures etc., shall be recorded manually by responsible staff on an

tender: project: document: W-P-SS-012 rev: 1 sheet: 30 of: 43

inspection sheet at the point. The empty pipeline filling velocity shall not be greater than 0.3
m/sec and maximum allowed by hydraulic study.

• The vents installed at each highpoint shall be used to release the air from the pipeline.

• Filling shall continue until the whole test section is filled with water.

19.2.9 Performance of Hydrostatic Testing

Once filling has been completed, the line shall be isolated from any parts which are not to be
tested, and the test pump shall be connected for raising the internal pressure. Moreover,
conditions of pressure and temperature measuring instruments shall be checked and made
sure that all preparatory operations and other installations required have been completed. In
particular, dial gauges shall be calibrated.

Tests shall commence not earlier than 24 hours from completion of filling so that thermal
equilibrium is established between filled pipeline and soil temperature and to provide enough
time for soaking of the cement lining. During this period all parameters shall be recorded
continuously. Temperature equilibrium shall be deemed to be achieved when the average
pipe temperature and the average soil temperature of the section is within 1 degree C. For
soaking purposes, a pressure of around 50% of the test pressure shall be applied.

During pressurisation, the pressure and volume readings shall be recorded at an interval of 1
bar.

After the soaking period the pressure shall be increased continuously to the final test pressure
and checked by means of two gauges. The rate of pressurisation shall be in accordance with
the cement mortar lining manufacturer’s but shall not exceed 1 bar per minute.

The hydrostatic test shall be carried out according to the "pressure loss method" based on EN
805. The duration shall be minimum 1 h. During the test period the pressure loss shall display
a regressive tendency. The hydrostatic testing is considered successful when the pressure
loss at the end of the first hour of testing does not exceed 0.2 bar.

Throughout testing, pressure and temperatures shall to be continually recorded by calibrated

automatic recorder and pressure gauges.

19.2.10 Evaluation of Results and Final Report

At the end of the test a report shall be prepared including the following:

• responsible engineer for the test

• denomination and location of tested line

• characteristics of pipeline (diameter, wall-thickness, type of pipe and grade of steel)

• test point, installed apparatus and equipment

• data and times of each operation

tender: project: document: W-P-SS-012 rev: 1 sheet: 31 of: 43

• all information, and any necessary descriptions, concerning execution of each operation

• characteristic data regarding filling fluid, pressures, temperatures

• test/measuring records and protocols

• details of any accidents, which may have occurred

• any other information considered significant.

19.2.11 De-watering after Hydrostatic Test

If the pipeline section after hydrostatic test shall be emptied and/or the water used for the
hydrostatic test of the next section, the pipeline may have to be completely emptied. Where
all sections of pipe are laid at a convenient altimetry, drainage shall be achieved by gravity.

During drainage operations, the necessary arrangements shall be taken for the drained water
to be suitably disposed subject to related authority approval, in order to avoid pollution,
damage to crops and/or land, to existing works and obstruction to traffic.

When a pipeline section shall be emptied, it shall be ensured that cement mortar lining shall
not be negatively affected. Some water shall remain in the pipe to maintain humidity to avoid
cracks in the cement mortar lining.

At the end of testing operations provisional test heads as well as other temporary installations
connected with the test shall be removed.

19.3 Disinfection and Flushing of Pipeline

19.3.1 General

All water lines shall be disinfected by CONTRACTOR to the satisfaction of

OWNER/ENGINEER and all involved authorities.

19.3.2 Method Statement

RACTOR shall prepare a detailed method statement for disinfection. This method
statement 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.

19.3.3 Disinfection and Flushing

Before the pipeline is placed in service, all pipelines shall be disinfected and flushed as per
AWWA C651 unless otherwise specified or as directed by OWNER/ENGINEER.

For DN 600 pipelines and above, the pipeline may be disinfected at the same time as the
hydrostatic tests subject to pre-cleaning as per section 19.2.6 subject to OWNER/ENGINEER
approval.
I:\WATER STANDARD SPECIFICATION\DOCUMENTS FOR MEETING\CARBON STEEL 2019\FINALIZED SPECS 2020\W-P-SS-012 REV 01 SIGNED FINAL DRAFT FORMAT UPDATED.DOC
Client TRANSCO / ADDC / AADC
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR FABRICATION, CONSTRUCTION & TESTING OF STEEL PIPE
SYSTEM

tender: project: document: W-P-SS-012 rev: 1 sheet: 32 of: 43

Ten (10) days 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. This quantity of water may be obtained by the
CONTRACTOR from the nearest available OWNER source with required measures to
prevent risk of contamination of OWNER source and providing backflow protection.

During water disposal operations, the necessary arrangements shall be taken for the drained
water to be suitably disposed subject to related authority approval, in order to avoid pollution,
damage to crops and/or land, to existing works and obstruction to traffic. Neutralization of
highly chlorinated water shall be used where required to avoid environmental impact in
compliance with relevant authority and standard requirements.

19.3.4 Pipeline filling:

The empty pipeline filling velocity shall not be greater than 0.3 m/sec and maximum allowed
filling rate by hydraulic study. Precautions shall be taken to ensure that air pockets are
eliminated. Pipeline filling from high profile points along the pipeline shall be avoided.

19.3.5 Preliminary flushing:

For pipeline of main size below DN 600 diameter, preliminary flushing is required before
pipeline disinfection/chlorination. The preliminary flushing is not required for pipeline of DN
600 and above where pipeline cleaning is performed as per section 19.2.6 above.

Preliminary flushing shall be with potable water for minimum one pipeline volume with
minimum of 1.0m/s water velocity in the main pipeline or as directed by OWNER/ ENGINEER
to remove debris and other particles.

19.3.6 Pipeline Disinfection:

The disinfection shall be done either by using Continuous-Feed Method or Slug Method. For
small piping length with diameter greater than DN 600 and subject to OWNER/ENGINEER
approval, spray disinfection method using 200 mg/L free chlorine is also acceptable.

The chlorine dose shall be obtained from a chlorine solution or other suitable solution to be
approved by OWNER/ENGINEER. Samples taken from the pipeline during disinfection at
locations directed by OWNER/ENGINEER shall be checked on site by a suitable calibrated
digital comparator by approved Third party in order to ensure that the sterilising liquid is
present throughout the system and at sufficient concentration.

For disinfection using Continuous-Feed Method, the entire pipeline shall be filled with potable
water that has been chlorinated to 25 mg/L. At the end of the 24 hour period, the chlorine
concentration shall be checked. If there is less than 10 mg/l of free available chlorine in the
water, more chlorine 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 10
mg/l for all samples taken from the area of pipeline under test.
I:\WATER STANDARD SPECIFICATION\DOCUMENTS FOR MEETING\CARBON STEEL 2019\FINALIZED SPECS 2020\W-P-SS-012 REV 01 SIGNED FINAL DRAFT FORMAT UPDATED.DOC
Client TRANSCO / ADDC / AADC
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR FABRICATION, CONSTRUCTION & TESTING OF STEEL PIPE
SYSTEM

tender: project: document: W-P-SS-012 rev: 1 sheet: 33 of: 43

For disinfection using slug method, the pipeline shall be completely filled, then slow flowing
slug of water dosed with chlorine to a concentration of 100 mg/L through the pipeline is
performed. The slow rate of flow ensures that all parts of the pipeline and its appurtenances
will be exposed to the highly chlorinated water for a period of not less than 3 hr. The free
chlorine concentration shall be measured at regular time intervals as it moves through the
pipeline. If at any time it drops below 50 mg/L, the flow shall be stopped; chlorination
equipment shall be relocated at the head of the slug; and, as flow resumes, chlorine shall be
applied to restore the free chlorine in the slug to not less than 100 mg/L.

As chlorinated water flows past fittings and valves, related valves and hydrants shall be
operated so as to disinfect appurtenances and pipe branches.

Records of free chlorine tests results during disinfection and calibration certificates of used
instruments shall be submitted upon disinfection completion.

Should the hydrostatic test fail and repair work involve emptying the pipeline then the
disinfection and subsequent testing procedures shall be repeated in full at the
CONTRACTOR's own expense.

19.3.7 Final Flushing

After completion of hydrostatic testing and disinfection 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 with a minimum of 1.0m/s water
velocity from the existing pipeline to which the new pipeline or network is or will be connected
or as directed by OWNER/Engineer. 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 final flushing water shall be calculated as the equivalent to minimum one (1)
volume of the pipeline subject to satisfying preliminary flushing/cleaning and the required
flushing velocity.

The pH value of water contained in newly constructed cement mortar lined pipes can be
significantly higher than normal. The CONTRACTOR should thus make allowance for
additional flushing if required, in order to reduce the pH to a value which is acceptable and
within 2.5% of source pH value.

It shall be a condition that the water in the existing network at the point of extraction shall
register a 0.3 to 0.5 mg/l of free available chlorine when tested by a third party approved
competent person with a site calibrated comparator prior to any approval being given to
commence flushing. If a reading of less than this is obtained OWNER/ENGINEER shall be
informed and the CONTRACTOR instructed accordingly. Once flushed, the water in the new
pipelines shall be allowed to stand for a further 24 hours.

Onsite pH and residual chlorine shall be tested by approved third party to ensure satisfactory
results. Samples shall then be taken by a third party approved competent person from
locations directed by OWNER/ENGINEER and immediately submitted for physical and
microbiological testing at an approved laboratory. All charges for water samples collection
and testing shall be paid by the CONTRACTOR.
I:\WATER STANDARD SPECIFICATION\DOCUMENTS FOR MEETING\CARBON STEEL 2019\FINALIZED SPECS 2020\W-P-SS-012 REV 01 SIGNED FINAL DRAFT FORMAT UPDATED.DOC
Client TRANSCO / ADDC / AADC
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR FABRICATION, CONSTRUCTION & TESTING OF STEEL PIPE
SYSTEM

tender: project: document: W-P-SS-012 rev: 1 sheet: 34 of: 43

19.3.8 Acceptance Criteria for disinfection and flushing

The pipeline shall not be considered acceptable until physical and microbiology parameters
are within Abu Dhabi Emirate Water Quality Regulation limits

The pH value of water contained in newly constructed cement mortar lined pipes can be
significantly higher than acceptable limits. The CONTRACTOR should thus make allowance
for additional flushing if required, in order to reduce the pH to a value which is acceptable.

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.

The CONTRACTOR is responsible for making himself fully aware of the statutory
requirements for achieving acceptance of bacteriological and chemical standards of the water
in the pipelines under construction.

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.

20. TESTING AND AS-BUILT DOCUMENTATION

The CONTRACTOR shall maintain a complete documentation of work and testing performed
and this shall be submitted to OWNER/ENGINEER on completion. The report shall be
authenticated by the CONTRACTOR and OWNER/ENGINEER.

In addition to the above, the CONTRACTOR shall maintain As-built mark up print on daily
basis, so as to produce final as-built drawings.

21. SAFETY AND ENVIRONMENT

CONTRACTOR shall submit HSE Plan for OWNER/ENGINEER approval, in compliance with
applicable national, state or local codes and regulations and safety orders and practices of
OWNER/ENGINEER covering working conditions, plant/equipment, hand tools, excavations,
painting/coating, hydrostatic pressure testing, safety equipment, personnel protective
equipment (PPE), environmental protection, etc.

tender: project: document: W-P-SS-012 rev: 1 sheet: 35 of: 43

Annexure A: Buried CS Welded Joint External Coating
Properties
1. Epoxy And Sleeve Properties

The corrosion coating shall consist of a high build epoxy applied to the steel surface, followed
by a wrap-around heat shrinkable sleeve, and shall be suitable for an operating temperature
not exceeding 80o C in wet conditions.

As one of the requirements for Quality Control of proper shrinking of sleeve, the shrink sleeve
backing shall have a built-in permanent change indicator. This shall be in the form of a special
pattern on the backing. Prior to shrinking the pattern shall be clearly visible and feelable to the
touch. Once the sleeve has been shrunk down properly, the pattern shall disappear and the
sleeve surface shall become completely smooth.

2. Epoxy and Sleeve Thickness

The first layer of the joint coating system shall be a 100 % solids two component epoxy of a
minimum dry-film thickness of 150 microns when applied on the steel surface. The epoxy
layer shall be the primary anti-corrosion barrier and shall be capable of corrosion protection of
the steel surface on a standalone basis.

The heat shrink sleeve shall provide mechanical protection to the epoxy layer and shall seal
onto the epoxy layer and the adjacent line coating:

Once installed the sleeve system shall have an average minimum thickness of 3.00 mm.

3. Sleeve Width

The sleeves on the weld joint shall be wide enough so as to overlap onto the factory coating
by a minimum of 50 mm on each side of the weld joint once installed. The installed sleeve
width shall be considered as the edge-to-edge width of the backing of the sleeve once fully
shrunk down.

The sleeves on bends may be wider and shall overlap onto each other by a minimum of 50
mm once installed.

4. Coating Performance Requirements

 It shall be ensured that all material proposed for field joint coating has been tested and
meet the requirements for physical, chemical and electrical properties as detailed below.

 Test certificates of all materials shall be provided, detailing the information described in
this Specification.

 The self-adhesive layer of the coating shall be homogeneous, free from flaws, defects,
pinholes, bubbles, cracks and inclusions.

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 The corrosion coat shall be resistant to bacterial attack and shall not deteriorate during
the design life of the pipeline.

 The sleeve shall be resistant to the high Ultra Violet light of the UAE summer without
requiring any sort of painting or covering. To confirm suitability, the sleeve shall be tested
for UV resistance as per EN 12068 standard. An independent lab test report shall be
provided to confirm compliance.

 To ensure that the sleeve is suitable for the high ambient temperature and Black Body
temperatures of the UAE in the summer, the backing and adhesive shall be of a high
enough temperature rating. It shall not be necessary, to paint or cover the installed shrink
sleeve with any protective cover during the peak of the summer.

The requirements for the physical, chemical and electrical properties have to be proven by the
test methods shown in the below table.

Performance Parameter Test Method Required Result

Ring and Ball Softening Point of adhesive ASTM E-28 More than 90°C up to 120 °C

Lap Shear Strength of Adhesive ASTM D-1002 > 0.35 Mpa (50 psi) @ 80°C

Peel Strength of installed sleeve to steel at

EN 12068 > 2 N/Cm
80°C (Pull Rate of 10 mm/min)
ASTM G-17 Holiday / No Holiday at10 kV /
Indentation Resistance @ 80°C for 24 hours
residual thickness > 0.6 mm residual thockness

Impact Resistance at 23°C EN 12068 Class C Pass

Ultraviolet Resistance EN 12068 – Annex F Pass

Cathodic Disbondment of installed sleeve at

ASTM G-42 < 15 Mm
80°C after 30 Days
Hot Water Immersion Resistance of installed No Blisters Or Determination.
ASTM D-870
sleeve at 80°C for 120 Days No Water Under Sleeves.

Holidays Detection Pass At 25 Kv

Specific electrical insulation resistance EN 12068 ≥ 108 Ωm2

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5. Coating Application

Installation of shrinkable sleeves mush be done according to regulations and usual safety
precautions.

Joint coating shall be carried out by qualified staff that have been trained and certified by the
manufacturer of the shrink sleeves.

6. Joint Coating Applicator Qualification

In presence of the OWNER/ENGINEER each member of the joint coating application crew
shall be prequalified.

Each member of the application crew shall apply coating to a minimum of three joints in the
presence of the manufacturer who shall certify the applicator as acceptable for carrying out
the coating application.

7. Joint Coating Procedure

The coating application sequence shall be as follows:

• The exposed steel area and adjacent pipe coating shall be cleaned of all dust dirt, moisture,
salts, grease or other contaminants, if necessary using a non-contaminant solvent.

• Weld area shall be thoroughly abraded to a near white metal finish, SIS SA 2.5 to yield an
anchor pattern of 50-100 microns. Anchor pattern shall be checked using suitable film tape.
Blasting material shall be grit of acceptable quality, approved by the OWNER/ENGINEER
prior to its use at site. No blasting shall be carried out if Relative Humidity is above 80 %. The
line coating adjacent to the weld area shall also be sweep blasted and should be bevelled to
less than a 30° angle. The exposed steel and coated areas should be wiped clear of all
foreign materials. Blasting material shall be free of any salt contaminants and shall be of a
grade to give the required anchor pattern.

• Adjacent line coating over which the shrink sleeve shall be shrunk, shall be sweep blasted to
give it a rough finish. The sweep blasting shall extend 25 mm beyond the edge of the shrink
sleeve.

• Just prior to sleeve shrinking, the surface of the blast cleaned joint steel area shall be tested
for salt contamination using an Elcometer Salt contamination test instrument or equivalent
apparatus. The level of salt contamination on the joint steel shall not exceed 4
microgram/sq.cm. If the contamination level exceeds this value, the joint shall be cleaned with
clean water and reblasted. Contamination of the blasting medium shall also have to be
checked regularly to ensure that the 4 microgram/sq.cm level is not exceeded.

• After blasting and as soon as possible (within ½ hour of blasting), the joint area shall be
preheated to the manufacturer's recommended minimum temperature. A pyrometer shall be
used to ensure that correct temperature is reached on steel and the line coating. The total
elapsed time between the start of blasting and the heating to the specified temperature shall
not exceed the following time-humidity table:
I:\WATER STANDARD SPECIFICATION\DOCUMENTS FOR MEETING\CARBON STEEL 2019\FINALIZED SPECS 2020\W-P-SS-012 REV 01 SIGNED FINAL DRAFT FORMAT UPDATED.DOC
Client TRANSCO / ADDC / AADC
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR FABRICATION, CONSTRUCTION & TESTING OF STEEL PIPE
SYSTEM

tender: project: document: W-P-SS-012 rev: 1 sheet: 38 of: 43

Percent Relative Humidity (Elapsed Time Hours)
85 0.5
80 1.0
70 1.5
60 1.75
50 2.0
Any pipe surface not processed within the above time-humidity table shall be re-cleaned
and reblasted before coating.

 The two component epoxy shall be mixed together thoroughly in the ratio recommended by the
manufacturer and brush, pad, roller or airless spray applied to the bare steel surface to yield a
Dry Film Thickness of minimum 150 microns. Runs, sags, or other application defects shall be
removed and coating re-applied.

 The heat shrink sleeve shall be wrapped loosely around the pipe, centering it over the epoxy
coated weld area and evenly overlapping the adjacent pipe coating by 50 mm or more.

 Using a torch with flame length adjusted to approximately 500 mm to produce a yellow flame at
the end, the closure shall be heated evenly until the pattern of the fabric reinforcement is
visible. The closure shall then be put down with a gloved hand and any wrinkles shall be
smoothened by gently working them outward from the centre of the closure.

 A small hand roller shall be run over the closure to push out any trapped air.

 Heating shall start at the centre of the sleeve and move circumferentially around the pipe, using
a constant paintbrush motion.

 Heating shall be continued toward one end of the sleeve, followed by the other, starting at the
shrunk down weld bead area and continue to the other end of the sleeve.

 Alternatively, shrinking may be started from one end and continued to the other end of the
sleeve.

 During shrink-down, adhesive flow shall occasionally be checked with finger. Wrinkles should
disappear automatically.

 When the sleeve has been shrunk onto the joint area and is still hot and soft, a small hand
roller may be run over the sleeve to push out any trapped air. Particular attention shall be paid
to the weld and cutback area. If necessary, areas shall be reheated to roll out air.

 Sleeve shall be fully recovered when all of the following have occurred:

tender: project: document: W-P-SS-012 rev: 1 sheet: 39 of: 43

The QC permanent change indicator has disappeared completely and the sleeve is smooth to the
touch. The sleeve has fully conformed to the pipe and adjacent coating. There are no cold spots
or dimples on the sleeve surface. Weld bead profile can be seen through the sleeve. After sleeve
is cooled, adhesive flow shall be evident on both edges.
8. Inspection and Testing:

A) General

The OWNER shall have the right to inspect at all times, any tools, instruments, materials or
equipment used or to be used in the manufacturing process.
The OWNER shall have the right to reject any or all tools, instruments, materials,
equipment or work which does not conform to this Specification.
Any rejected material, tools, instruments or equipment not conforming to this Specification
shall be replaced / rectified.

B) Test and Inspection Requirements

Factory Testing
Prior to purchasing of shrink sleeve materials factory test procedures shall be provided. In
addition test results of factory testing shall be provided for each batch of material.
Field Installation Inspection and Testing Procedures
The inspectors at site may check the application procedure without any limitation. Any non
compliance with the agreed procedure may constitute reason for rejection of heat shrink
sleeves and their replacement.
Installation shall be subjected to the tests detailed below, which shall also be the basis of
the record to be kept of the joint coating.
a) Visual
The inspection of joints shall only be done after the cool down of the sleeve and the
substrate to ambient temperature. The sleeve shall be visually inspected for the following
points:

 The QC permanent change indicator has disappeared completely and the sleeve is
smooth to the touch.

 The weld bead profile contour shall be visible through the sleeve.

 The ends of the sleeve shall be firmly bonded to the mainline coating.

 There shall be no upstanding edges.

 Adhesive flow shall be evident at both edges of sleeve.

 The sleeve shall be smooth; there shall not be any dimples, cold spots, bubbles,
punctures, burn holes or any signs of holidays.

 There shall be no signs of entrapment of foreign materials in the underlaying adhesive.

tender: project: document: W-P-SS-012 rev: 1 sheet: 40 of: 43

 The sleeve shall overlap the adjacent factory coating for at least 50 mm each side.

b) Coating Thickness
The thickness of the cooled, field joint coating shall be checked using an approved
Elecometer ultrasonic or electro-magnetic type thickness gauge. Measurements shall be
made as follows:

 4 readings of the installed sleeve thickness shall be taken, 1 each at the 12, 3, 6 and 9
o’clock positions of the installed shrink sleeves on the main body of the pipe away from
the girth weld and the closure patch.

 The average of the four readings shall result in an average thickness of 3.00 mm and
no individual reading shall be less than 2.70 mm.

A sleeve which does not meet the above thickness requirements shall be rejected and
replaced.

c) Holiday inspection

 After complete cooling down, holiday inspection shall be done.

 Holiday inspection shall be done using a voltage setting of 25 kV or Suppliers

recommendation with a full encirclement contact electrode for every joint.

d) Adhesion (Peel) Test

 One out of every 50 sleeves shall be subjected to a manual peel test.

 Peel strength inspection shall be done at a sleeve temperature of up to 40° C; both the
substrate and the sleeve shall be at this temperature.

 Strips of 25 mm x 200 mm shall be cut perpendicular to the pipe axis either at 9 or 3

o’clock positions halfway between the circumferential weld bead and the mill coating.

 The first 30-40 mm of the leading edge of the strip shall be manually removed by using
a screwdriver. It has to be ensured that the initial adhesive bond line cut is essentially
centred within the adhesive layer.

 The peel strength test gauge shall be attached to the leading edge of the test strip and
the clamp fastened.

 Holding the test gauge with both hands a steady force shall be exerted with a slow
pulling speed of 100 mm/min., and at an angle of 90° to the circumference of the pipe.

tender: project: document: W-P-SS-012 rev: 1 sheet: 41 of: 43

 At this point the peel strength shall be greater than 30 N/cm, and the bulk of the
adhesive shall remain on the epoxy coated pipe.

9. Repair of Defects

Damaged Polyethylene coating or shrink sleeves damaged during destructive testing shall be
repaired with repair materials that meet the following criteria:

Small Damages Extending up to 1.0 cm²

Small damages to the factory applied PE line coating or sleeve shall be repaired using PE
melt sticks; with epoxy primer if bare metal is visible.

Damages Extending up to 300 mm or 100 cm²

Polyethylene repair patches pre-coated with hot melt adhesive, shall be used in conjunction
with a hot melt filler adhesive and epoxy primer (if bare steel visible) as per manufacturer’s
recommendations. Repair patches when installed shall overlap the damaged area by
minimum 50 mm all round.

Damages Extending Over 300 mm or 100 cm²

Full encirclement heat shrink sleeves with epoxy primer shall be used.

Following repair, the repaired section shall be tested for any Holidays at 25 kV.

10. Documentation

A) Pre-Production Documentation

The Pipe Coating Contractor shall submit the following documentation to the
Engineer for approval prior to commencing production:

1)The manufacturer’s trade name and data sheets for all proposed coating
materials. This includes cleaning and abrasive blasting consumables.

2)Procedure for identifying, or maintaining the identification of each coated item.

3)Handling procedure.

4)Stacking procedure.

5)Materials control and traceability procedure for the batches of coating

materials.

6)Materials storage procedure (pipe and coating materials).

7)Procedure for steel surface preparation including materials, cleaning,

inspection, verification of cleanliness and surface profile.

tender: project: document: W-P-SS-012 rev: 1 sheet: 42 of: 43

8)The results of the batch tests for batches to be used for pre-qualification tests.

9)Details of testing methods including instrument types and copies of current

calibration certificates.

10) Details of inspection methods for bare and coated pipe.

11) Full test results from the coating Procedure Qualification Test (PQT).

12) Repair procedure and results of tests on demonstration of repairs.

13) Project specific Quality Plan.

Work shall not commence until these procedures have been reviewed and approved
by the Engineer.
The selection of proposed coating materials shall be subject to Engineer’s approval.

B) Coating Application Records

A daily log containing the following data shall be maintained and be available for
inspection by the Engineer during and/or after coating application. Data shall be
recorded against the joint unique identification number.
1) Bare joint inspection data
2) Ambient temperature (every 4 hours)
3) Humidity (every 4 hours)
4) Coating progress (no. of joint coated)
5) Blast pipe surface amplitude
6) Tests for cleanliness of blast surface
7) Average, maximum and minimum coating thickness
8) Details of any coating defects recorded and defect density on
respective joints
9) Details of any coating repairs
10) The unique identification number of all items that are stripped for
recoating.
11) m) Joint coating test results
The log shall be available to the Engineer throughout all coating operations.

tender: project: document: W-P-SS-012 rev: 1 sheet: 43 of: 43

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