WP-P5-S1_19!8!15 General Specification of Main Laying Materials for Waterworks

General Specification of Main Laying Materials For Waterworks

WP-P5/ S1

WP- P5/ S1

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19/08/2015

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Department

Document Type

WP

Standard

WP-P5/ S1

Document Title General Specification of Main Laying Materials for Waterworks

Issue Approval Prepared By

Approved By

Eng. Osama Samaan Sleem Fadayel Engineer (Material Specifications) Specifications) Eng. Eid Auwid Khlaif Al-Idmat Engineer (Material Specifications) Specifications) Eng. Ali Al_obaidly Head, Materials Standards & Specifications Specifications Section

Eng. Mohd Thani E.J. AL-Maadead Manager, Water Planning Department

Signature:

Signature:

Issue No.

Date

Reason for re-issuing Standard

0.0

12/04/2015

First issue of the Standard.

1.0

19/8/2015

Updated & modified the Table of Contents

2.0 3.0 4.0 5.0 Key Words

:

Standard, Specification, materials, Manufacturer, Quality body certifier, ISO, BS, EN, WRc , Ductile Iron Pipes, Fittings & Accessories, valves , Pumps, Water Meter, Copper, Polyethylene Pipes & Fittings and corrosion protection materials .

Review Frequency

Issue : 1

19/08/2015

:

Annually

Unclassified

Page 2 of 128


Department

Document Type

WP

Standard

WP-P5/ S1

Document Title General Specification of Main Laying Materials for Waterworks

Issue Approval Prepared By

Approved By

Eng. Osama Samaan Sleem Fadayel Engineer (Material Specifications) Specifications) Eng. Eid Auwid Khlaif Al-Idmat Engineer (Material Specifications) Specifications) Eng. Ali Al_obaidly Head, Materials Standards & Specifications Specifications Section

Eng. Mohd Thani E.J. AL-Maadead Manager, Water Planning Department

Signature:

Signature:

Issue No.

Date

Reason for re-issuing Standard

0.0

12/04/2015

First issue of the Standard.

1.0

19/8/2015

Updated & modified the Table of Contents

2.0 3.0 4.0 5.0 Key Words

:

Standard, Specification, materials, Manufacturer, Quality body certifier, ISO, BS, EN, WRc , Ductile Iron Pipes, Fittings & Accessories, valves , Pumps, Water Meter, Copper, Polyethylene Pipes & Fittings and corrosion protection materials .

Review Frequency

Issue : 1

19/08/2015

:

Annually

Unclassified

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WP-P5/ S1

Contents

Page

Title Page Document Control & Issue Record Page Contents of General Specification of Main Laying Materials for Waterworks Purpose Scope Responsibilities & Authorities Abbreviations & Terminologies Terminologies

1 2 3 8 8 8 8

Section - 1 General 1.1 Suitability of Materials 1.2 Transport & storage of materials 1.3 Manufacturer ‘s Certification 1.4 Standards 1.5 Material Coating & Internal Components 1.6 Fasteners 1.7 Inspection 1.8 Packing 1.9 Technical clarification 1.10 Samples 1.11 Alternative Materials Section - 2 Ductile Iron Pipes and Fittings 2.1 General 2.2 Joints 2.3 Length of pipes 2.4 Marking 2.5 Certificate of Test 2.6 External & Internal Coating of Ductile Iron Pipes & Fittings During Manufactory 2.7 Factory Applied Polyethylene External Coating 2.8 Protection of Above Ground & Inside chambers D.I. Pipes & Fittings 2.9 special protection of D.I. Pipes & Fittings 2.10 Pipe Cutting 2.11 Packing Section - 3 Slip-On Coupling and Flange Adaptors and Dismantling Joints and Step Couplings 3.1 General 3.2 Slip-on couplings 3.3 Mechanical Collar’s 3.4 Flange adapters 3.5 Dismantling Joints 3.6 Step couplings 3.7 External And Internal Coating of Slip-on Couplings, Step Couplings, Flange Adapters And Dismantling Joints During Manufacture 3.8 Fasteners 3.9 Identification Metal Strip 3.10 Packing Section - 4 Corrosion Protection of Ductile Iron Pipes, Fittings & Accessories 4.1 Pipe Wrapping Tape 4.2 Wrapping Procedure

9 9 10 11 11 11 12 12 13 13 13 13 14 14 14 14 14 15

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4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 4.23 4.24 4.25

Storage Packing Wrapping Tape Property Primer Packing Wrapping Tape Visco Elastic Poly Iso Butene Wrapping Procedure Storage Packing Wrapping Tape Property Polyethylene sleeving Marking Packing PVC Black self adhesive tape Joint molding putty Packing Storage Trench Marker Tape Marking Packing Lubricant Packing Slip-on Couplings, Flange Adapters and Dismantling Joint during Installation 4.26 Heat Shrink Sleeve 4.27 Packing Section - 5 Bedding and Surround Material’s 5.1 General 5.2 Imported Granular Material and Selected Excavated Material Section - 6 Gate valves 6.1 General 6.2 Motorised Actuator 6.3 Testing 6.4 Hand-wheel 6.5 Marking 6.6 Materials of Gate Valves 6.7 Gear box 6.8 Flanges 6.9 Gate valve stem seals 6.10 Material Coating & Internal Components 6.11 Accessories 6.12 Packing Section - 7 Butterfly Valve 7.1 General 7.2 Motorised Actuator 7.3 Testing 7.4 Hand-Wheel 7.5 Markings 7.6 Materials 7.7 Flanges 7.8 Coatings 7.9 Valve Keys

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7.10 Accessories 7.11 Packing Section - 8 Air Valves 8.1 General 8.2 Air Valves construction materials 8.3 Single air valve large orifice type 8.4 Single air valve small orifice type 8.5 Double air valve 8.6 Coatings 8.7 Markings 8.8 Packing Section - 9 Fire Hydrants 9.1 General 9.2 Marking 9.3 Materials 9.4 Connections 9.5 Coatings 9.6 Testing 9.7 Stand pipes 9.8 Accessories 9.9 Packing 9.10 Above Ground Fire Hydrant (pillar type) 9.11 Marking 9.12 Coating 9.13 Testing 9.14 Accessories 9.15 Packing Section - 10 Check Valve 10.1 General 10.2 Check Valves construction materials 10.3 Coatings 10.4 Markings 10.5 Packing Section - 11 Other Types of Valves 11.1 General 11.2 Coatings 11.3 Markings 11.4 Flow Control Valves 11.5 Material Specification 11.6 Pressure Regulating Valves/ Pressure Reducing Valves 11.7 Material Specification 11.8 Altitude Valves 11.9 Material Specification 11.10 Packing Section - 12 Pumps 12.1 General 12.2 Scope 12.3 Conflicts & Deviations 12.4 Applicable Standards and Codes 12.5 Technical Submittal: 12.6 Design Considerations 12.7 General Requirements:

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12.8 Pump Construction Requirements: 12.9 Accessories 12.10 Protection of Moving Parts 12.11 Pumps Coating 12.12 Inspection & Testing 12.13 Site Acceptance Test:12.14 Retention of Pump Efficiency for Sustainable Performance: 12.15 Spare Parts, Tools And Accessories 12.16 Maintenance 12.17 Vibration, Noise And Temperature Monitoring 12.18 Temperature Monitoring: 12.19 Vibration Monitoring: 12.20 Guarantee & Warranty 12.21 Nameplates, Marking & Labeling 12.22 Packing Section - 13 Surface Boxes & Manhole Covers, Marker Posts & Indicator Plates 13.1 General 13.2 Gate valve surface boxes (up to 300mm Ø valves) 13.3 Gate valve manhole covers (400mm Ø valves and above) 13.4 air valve manhole covers 13.5 Butterfly valve manhole covers 13.6 Stopcock and ferrules (SC) surface box 13.7 Under ground fire hydrant manhole covers 13.8 Washout manhole covers 13.9 Marker post 13.10 Indicator plate 13.11 Aluminum Indicator Plate 13.12 Packing Section - 14 Copper Tubes 14.1 General 14.2 Sheathing 14.3 Tube Sizes 14.4 Packing Section - 15 Copper Fittings, Ferrules, Stopcocks & Poly Adapters 15.1 General 15.2 Marking 15.3 Materials 15.4 Universal swivel ferrule 15.5 Marking 15.6 Stopcocks 15.7 Marking 15.8 Saddles 15.9 Packing Section - 16 Electronic Flow Meters District 16.1 General 16.2 Flow Sensor and Transmitter 16.3 Pressure Gauge 16.4 Pressure Transmitters and Differential Pressure Transmitters 16.5 Asset Management System Section - 18 S.S. Repair clamps & under pressure Drilling Tees 17.1 General

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17.2 Marking 17.3 Materials 17.4 Lengths of the clamp 17.5 Flanges 17.6 Packing Section - 18 Concrete and Ancillary Items 18.1 General 18.2 Pre-cast concrete chamber sections 18.3 Impregnated fiber board Section - 19 Polyethylene Pipes & Fittings for Service Connections (MDPE) 19.1 General 19.2 Polyethylene Pipes (Material) 19.3 Length and Size 19.4 Fittings 19.5 Stop Valve: 19.6 Flanged Fittings: 19.7 Saddle Straps 19.8 Ferrule 19.9 Joints 19.10 Marking 19.11 Packaging 19.12 Packing 19.13 Handling & Storage Section - 20 uPVC Duct 20.1 General 20.2 Marking 20.3 Packing Section - 21 Water Service Cabinet 21.1 GENERAL 21.2 Water Service Cabinet (Standard – Flushed Type) 21.3 Water Service Cabinet (Standard – Surface Mounted Type) APPENDIXES I. Typical Drinking Water Quality II. Site Environmental Conditions III. Drawings 1. Water Meter Service Cabinet 2. Precast Concrete Chamber Slab Construction Details 3. Marker Post, Backing Plates, and Plate 4. Surface Box & Manhole Cover IV. WORLDWIDE KNOWN QUALITY BODY CERTIFIER V. PRE - ARRANGEMENT INSPECTION

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1. Purpose This Standard provides “Materials Standards & Specifications Section’s Engineers” the specification of materials used for water works. 2. Scope

This Standard is applicable to all materials used for waterworks. 3. Responsibilities & Authorities

Responsibilities and authority for ensuring that the steps in this guideline shall be carried out are specified at relevant steps in the guideline and include: Manager, Water Planning Department Head, Materials Standards & Specifications Section  Materials Standard Engineer.  Materials Specification Engineer.  If the responsible personnel listed above are absent, these responsibilities shall be designated to the relevant staff. 

4. Abbreviations & Terminology KM : Qatar General Electricity and Water Corporation KAHRAMAA : Qatar General Electricity and Water Corporation WP MSS GIS NDS

:Water Planning :Materials Standards & Specifications Section :Geographical Information System :Planning & Network Development Section Term

Description British Standard- one of the international standard used in BS General Specifications for main laying materials for waterworks International Standards Organization - one of the international ISO standards used in General Specifications for main laying materials for waterworks. Water Research Council- international body who certifies the WRC non-toxicity of material if contact with potable water. Manufacturer A company whose business is manufacturing a certain product An item intended to be used in a certain construction works or Material projects. A detailed exact statement of particulars, especially a Specification statement prescribing materials, dimensions and quality of work for something to be built, installed or manufactured.

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Section - 1

General 1.1

SUITABILITY OF MATERIALS

1.1.1 All materials in direct contact with potable water must have a health certificate issued by Worldwide Known Quality Body Certifier (See Appendix ‘IV’) in accordance with requirement of BS6920 “Suitability of Non-Metallic Products for use in direct contact with Water Intended for Human Consumption with regards to their effect on the quality of Water”. 1.1.2 All pipe-laying materials shall be suitable for use with the range of chemical characteristics of the water and complies with KAHRAMAA Water Quality Requirements & GCC Standards as detailed in Appendix ‘I’. 1.1.3 All materials shall be suitable for using and storing in the environmental conditions detailed in Appendix ‘II’ with minimum working water temperature at 50º C, unless otherwise specified, all works shall conform to PN16 standards and other standards noted elsewhere in this specification. 1.1.4 The Tenderer shall supply materials from any of the latest approved KAHRAMAA manufacturers list and furnish to Water Network Planning Department for review and approval. 1.1.5 All the relevant Technical documents of the materials/manufacturers must be in Original OR Notarized copy and shall be submitted from the Manufacturer for Technical Evaluation. 1.1.6 All materials shall be inspected and tested to ensure compliance with KAHRAMAA requirements and General Specifications for Main laying Materials. The testing shall be carried out according to relevant standards approved by Water Network Planning Department. 1.1.7 All The Engineer may test any materials before they leave the manu facturer’s premises or after delivery to the site. 1.1.8 The Engineer may reject any materials after delivery to the site should he consider them unsatisfactory, notwithstanding any preliminary test approval of the materials at the manufacturers premises. 1.1.9 The cost of all tests necessary to ensure compliance with the Project Documentation, shall be borne by the Contractor. 1.1.10 The number of samples to be tested at the local testing laboratory, must be not less than One Number of each diameter of the ordered materials, the cost of all tests necessary to ensure compliance with the Project Documentation, shall be borne by the Contractor. 1.1.11 The Local test certificates shall be issued by:I. II. III.

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Manufacturer premises Central Materials Laboratory. An approved third party testing laboratory or other organization.

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1.2

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TRANSPORT & STORAGE OF MATERIALS 1.2.1 All materials handling, transporting and storing should comply with KAHRAMAA and manufacturer recommendation to avoid damages due to double handling. 1.2.2 During transport, extra care needed to avoid damaging the coating of the materials. Cleaning any foreign matter deposited on Materials during transport. 1.2.3 All materials to be stored are strictly in accordance with the KAHRAMAA requirements/Manufacturer storage recommendation at all times, all corrosion protection materials shall be stored under the shade and not to be exposed under direct sunlight. 1.2.4 Upon materials delivery to the Contractor’s stores at site, the contractor should unpack, open all crates etc., and unload to areas as directed by the Store controller or KAHRAMAA Site Engineer. The contractor shall provide all timbers and packing, necessary for the correct stacking of pipes, fittings and other delivered materials. 1.2.5 After inspection the contractor shall shift and stack the approved materials to areas as directed by store controller/KAHRAMAA Site Engineer. 1.2.6 All Coated materials such as (Epoxy, Polyurethane, and Risen) shall be handled with special care during loading, transportation and unloading to avoid accidental damage. 1.2.7 The Pipes may be stored in the open areas; however it shall be stacked off the ground on 150 x 100 mm timber skids to be provided by the Contractor. The stacking shall be done according to the manufacturer's recommendations. 1.2.8 Fittings, rubber gaskets, nuts, bolts etc. shall be withdrawn from storage and delivered to the site to suit the daily construction requirements. 1.2.9 All materials which are subject to deterioration by Ultraviolet Light such as Rubber gaskets, fixing materials, instruments, polyethylene sheeting etc. must be stored so that they are not exposed to direct sunlight. 1.2.10 Materials which are liable to deteriorate shall be used in the order of delivery. 1.2.11 The provision and correct usage of broad band slings is particularly important for the lowering of pipes into the trench. The Contractor shall take the utmost care to prevent any damage to the coating or sleeving during lowering-in, alignment, jointing and final removal of the lifting sling. In all cases an approved non metallic sling must be used for the handling of pipes and fittings.

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1.3

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MANUFACTURER ‘S CERTIFICATION 1.3.1 The Applicant must have a valid ISO 9001 Certificate issued by the granting certifier body holding BS EN ISO/IEC 17021:2011 certificates. 1.3.2 The applicant must have successful records of experiences for supplying of minimum 15 year in International market and 5 year minimum in regional / GCC market for prequalifying. 1.3.3 Provide the QA/QC plan. 1.3.4 Provide organization chart including personals Crucial Vita.

1.4

STANDARDS 1.4.1 The Tenderer shall follow the latest KAHRAMAA General Specifications of Main laying Materials for Waterworks. 1.4.2 In case of materials were not mentioned in this document, the Tenderer shall follow the latest edition of one of the following appropriate relevant standards such as BS, ISO, EN or DIN with all subsequent amendments up to the year of the materials order. Submit complete documents to Water Network Planning department for further evaluation.

1.5

MATERIAL COATING & INTERNAL COMPONENTS 1.5.1 All materials in direct contact with potable water must have a health certificate issued by Worldwide Known Quality Body Certifier (See Appendix IV) as per requirement of BS6920 "Suitability of Non-Metallic Products for use in contact with Water Intended for Human Consumption with regards to their effect on the quality of Water” 1.5.2 Coating shall be smooth and mirror finish without any air bubbles or pebbles, and the thicknesses shall as per the relevant specifications given below; I. II. III.

The minimum thickness is 300 micron Fusion bonded epoxy (Polymeric anticorrosion) coating as per WIS No. 4-52-01. The minimum thickness is 300 micron Electrostatic ally applied epoxy coating. The minimum thickness is 300 micron Fluidized bed epoxy coating.

1.5.3 The coating quality shall conform to the following tests as per the relevant specifications given below; 

Adhesion Test: Coating adhesion to metal shall not be less than 12N/mm² (BSI BS EN ISO 4624).

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Holiday Test: Coating porosity shall be “zero” on 3 kV DC tester.

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Hardness: Intrinsic Rockwell hardness shall be between50 - 60.

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1.5.4 Impact resistance: For applying of impact energy of 5 NM on coating the cracks should not be develop, when tested by 3 kV DC tester. 1.6

FASTENERS 1.6.1 All Bolts, Nuts & Washers connected to Valves, Fire Hydrants, Couplings, Adaptors and Dismantling Joints shall be Mild steel with hot dipped zinc galvanized, with minimum thickness 70 micron. 1.6.2

All Bolts, Nuts & Washers connected to Valves, Fire Hydrants, Couplings, Adaptors and Dismantling Joints shall be protect with putty and wrapping tape.

1.6.3 Saddle Strap fasteners should be Stainless Steel “A4”. 1.7

INSPECTION 1.7.1 Pre-Inspection Arrangement shall comply with the requirements as per the attached procedure. (See Appendix V). 1.7.2 KAHRAMAA reserves the right to inspect the materials in the factory. 1.7.3 The manufacturer shall allow access at all times during manufacturing and testing to the premises in which the material being manufactured. 1.7.4 Upon receipt of materials at the contractor's site store, materials to be inspected by Supervising Consultant of the subject project. 1.7.5 Upon KAHRAMAA Engineer receipt of the Materials Request for Inspection, he will visit the contractor store. If any damage on the Pipe’s / Fitting’s is observed and it can be repaired, it's the contractor's responsibility to perform the repair in accordance with the manufacturer's recommendations and the approval of KAHRAMAA - repair works should be carried under direct supervision of the manufacturer. 1.7.6 KAHRAMAA reserves the right to reject the supplied material during final inspection or at later date, if found not as per the General Specification and will have the right to put the Manufacturer under “ ON HOLD “ or “ BLACK LISTED “ until further action. 1.7.7 The non-repairable rejected materials, which were not complying with KM Specifications during inspection and marked by the Engineer (rejected), must be removed by the Contractor and to be shipped outside State of Qatar and proof of shipping documents to be submitted to KAHRAMAA. 1.7.8 KAHRAMAA reserves the right to witness all types of testing locally, and the tests shall be carried out in accordance with applicable standards and codes.

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1.8

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PACKING 1.8.1 The material/item shall be packed in compliances with KM and Manufacturer recommendation and procedure. 1.8.2 At Site, (from the pre-Inspection arrangement) all items shall be packed individually and put into the wooden box, which shall be close and open type. Every layer in wooden box shall be clamped properly to avoid abrasion during transit and damage to coating. 1.8.3 The cutting of pipes shall be kept to a minimum and after cutting the remaining length of calibrated pipes shall be suitably marked and re-stacked together with the remaining calibrated pipes.

1.9

TECHNICAL CLARIFICATION 1.9.1 In case there are disputes, KAHRAMAA shall have the right to ask the manufacturer all the technical documents that will help out in clarifying this dispute.

1.10 SAMPLES 1.10.1 Samples shall be provided when required by the engineer or instructed by the project documentation. Materials subsequently supplied shall conform to the quality of the samples which have been approved by the engineer. 1.10.2 Each sample shall bear a securel y fixed label bearing the following information: I. II. III.

Project Identification. Contractor Identification. Sample Identification including all information as to Manufacturer, Model Number, and Catalogue Number.

1.10.3 Materials subsequently supplied shall conform to the quality of the samples which have been approved by the engineer. 1.11 ALTERNATIVE MATERIALS 1.11.1 The Contractor may propose the use of alternatives to materials specified in the Project Documentation, Due to some problems or delay with the Manufacturer / Supplier, Such proposals shall be complete with all supporting information showing that the alternative Materials are complying with KAHRAMAA latest specification. 1.11.2

The use of alternative materials shall only be permitted if it is approved in writing by the Engineer. 

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Section - 2

Ductile Iron Pipes and Fittings 2.1

GENERAL These Clauses Shall Be Read In Continuation Of Section 1 Of This Specification . 2.1.1 All pipes and fittings shall be manufactured from approved grade of ductile iron. 2.1.2 All manufacture and testing shall be in accordance with the latest edition of BSEN545/ISO 2531, 4179, 8179 including any subsequent amendments and as specified below.

2.2

JOINTS 2.2.1 Spigot & socket pipes & fittings joints shall be provided with approved integrally cast ‘push-in’ type joints, each joint being supplied with an approved jointing - ring designed by the manufacturer solely for the purpose of sealing the joint. 2.2.2 All flanged pipes & fittings shall be provided with integrally cast/ or rotatable flanges drilled to BS EN 1092-2, PN16. 2.2.3 All flanged pipes, fittings and valves shall be supplied with approved EPDM multilayer cotton reinforced rubber gasket; which in comply with the requirement of BS6920 and shall be kept in a sealed sun proof bag with written information of the same. 2.2.4 The manufacture specification of all-joint details, gaskets and jointing rings shall be supplied to the Engineer by the Tenderer / Contractor for approval. 2.2.5 All jointing materials shall comply with Clause 1.1.1 of this specification.

2.3

LENGTH OF PIPES 2.3.1 All pipes shall be supplied in the lengths of 5.50/6.00 meters or as per project requirement.

2.4

MARKING 2.4.1 All pipes & fittings shall be marked in accordance with the latest edition of BSEN545/ISO-2531. 2.4.2 Additional marking on the pipes and fittings must be included such as;

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Tender Number

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Contractor's Name

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Manufacturer's Name

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Year of manufacture

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Standard

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2.5

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CERTIFICATE OF TEST 2.5.1 The Tenderer / Contractor shall provide signed certificates stating the results of all tests as specified in BSEN 545 / ISO 2531, 4179, 8179 and BS 3416. 2.5.2 KAHRAMAA reserves the right to witness tensile tests on bar test pieces selected on the basis of not more than one test piece for every batch of 100 pipes. 2.5.3 Where specified tests are to be witnessed, the tests shall be carried in accordance with the manufacturer’s quality control procedure of the relevant international standard.

2.6

EXTERNAL & INTERNAL COATING

OF

DUCTILE IRON PIPES & FITTINGS DURING

MANUFACTORY 2.6.1 All materials shall conform and meet all the requirements of the latest edition of BSEN545/ISO2531, ISO4179, ISO8179, BS3416 and BS6920. 2.6.2 All ductile iron pipes and fittings shall be internally lined by centrifugal method with Sulphate Resistance Cement (SRC) mortar lining as per requirement of the latest edition of BSEN 545 or ISO 4179 or epoxy coating. 2.6.3 D.I. Pipes and Fittings shall be cured in curing chambers. 2.6.4 For D.I. Fittings coated with epoxy externally/internally, it shall be conformed one of the following method; 

Fusion bonded epoxy coating shall be minimum thickness 300 micron (Polymeric anticorrosion) coating as per WIS No. 4-52-01.

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Electrostatic ally applied epoxy coating shall be minimum thickness 300 micron.

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Fluidized bed epoxy coating shall be minimum thickness 300 micron.

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The color of coating shall be “Blue”, Code RAL-5000/5001/5005/5010/5017 or Black.

2.6.5 The external coating shall be of metallic Zinc coating of 130 gm/m2 on pipes and Zinc rich paint coating of 150 gm/m2 on D.I. Fittings as per the latest edition of BSEN 545 or ISO 8179. 2.6.6 The external finishing layer to all pipes & fittings after the application of the Zinc coating shall be of bitumen coating as per the latest edition of BS3416, Type 2. 2.6.7 The internal cement lining shall be uniformed and smooth as possible and shall be within the tolerance limit acceptable by the International standards. 2.6.8 The thickness of internal cement lining in D.I. Pipes & Fittings shall be as follows in accordance with the latest edition of BSEN 545 as follows (See table 01):Table (01) Thickness of Internal Cement Lining Issue : 1

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Nominal Size 80-300mmØ 350-600mmØ 700-1200mmØ 1400-2000mmØ

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Thickness 4.0mm 5.0mm 6.0mm 9.0mm

2.6.9 The contractor is to supply confirmation from manufacturer that cement lining to be used is suitable for use with the range of chemical characteristics of water detailed in Appendix “I.” 2.6.10 The internal section of sockets of pipes and fittings shall be painted with a minimum 100-micron thick epoxy coating. The coating shall be suitable for use in contact with potable water at +50 C. 2.7

FACTORY APPLIED POLYETHYLENE EXTERNAL COATING 2.7.1 The factory applied polyethylene external coating shall be applied by extrusion or any other approved method as per BSEN 14628-2005 (Ductile iron pipes, fittings and accessories External polyethylene coating for pipes Requirements and test methods). 2.7.2 The factory applied polyethylene external coating shall be type PE-D pipe zinccoated with minimum thicknesses accordance with latest edition of BSEN 146282005 as follows (See table 02):Table (02) MINIMUM COATING THICKNESSES Nominal Size Thickness 80-250mmØ 2.50mm 300-450mmØ 3.0mm 500-1200mmØ 3.50mm 1400-2000mmØ 4.0mm 2.7.3 The color code of polyethylene external coating shall be Blue color RAL5000/5001/5005/5010/5017.

2.8

PROTECTION OF ABOVE GROUND & INSIDE CHAMBERS D.I. PIPES & FITTINGS 2.8.1 External coating of ductile iron pipes & fittings to be laid above ground or inside chambers shall be coated with zinc primer as per ISO 8179, and then followed by an application of bituminous finish coating. Bituminous finish coating shall contain aluminum of not less than 20% in the dry film and shall be in silver.

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2.8.2 The internal section of sockets of pipes and fittings shall be painted with a minimum 100-micron thick epoxy coating. The coating shall be suitable for use in contact with potable water at +50 C. 2.9

SPECIAL PROTECTION OF D.I.

PIPES & FITTINGS

2.9.1 External coating of ductile iron pipes & fittings to be laid on location of high water table shall be coated with Polyurethane/Epoxy coating with minimum thickness of 300 microns. 2.9.2 External coating of ductile iron pipes & fittings to be laid on location of high water table shall be coated with Polyurethane/Epoxy coating with minimum thickness of 300 microns. 2.9.3 Ductile iron pipes and fittings which are completely immersed in water (i.e. piping inside reservoir) shall be coated with a minimum 300microns thickness fusion bonded epoxy. 2.10 PIPE CUTTING 2.10.1 Unless specified otherwise the Contractor shall supply a minimum of 2% of pipes of each diameter gauged (calibrated) along two third of the pipe entire length starting from the spigot end. These pipes shall be clearly marked by the factory and stored separately in the Contractor's store yard. 2.10.2 Where it is necessary to cut pipes, the cutting shall be neatly and accurately performed by machine so as to leave the pipe end a true circle and normal to the pipe axis and the cut ends shall be chamfered and painted as per manufacturer's recommendations for damaged coatings and generally to the original coating (Zinc & Primer / Epoxy) of the D.I. pipes and fittings. 2.11 PACKING 2.11.1 Pipes of small diameters shall be packed in bundles. Every pipe shall be separated from each other with the help of properly designed wooden spacers. The bundle shall be secured firmly with proper straps and well faced wooden base supports for proper transport, handling and storage. Every bundle shall have only one length of pipe. 2.11.2 For big diameters, it should be supplied separately. 2.11.3 All pipes and fittings shall be supplied with plastic end caps & shall be maintain in good condition until the pipe is ready to be installed in the trench. 2.11.4 The packing shall be as per Section 1, Clause 1.8 of this specification.  Issue : 1

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Section - 3

Slip-On Coupling and Flange Adaptors and Dismantling Joints and Step Couplings 3.1

GENERAL These clauses shall be read in continuation of Section 1 of this Specification.

3.2

SLIP-ON COUPLINGS 3.2.1 Slip-on couplings shall be manufactured from either cast iron or rolled steel and shall be suitable for use with ductile iron pipes to BSEN 545 / ISO 2531. 3.2.2 Couplings shall be similar in design to that detailed in BS-8010, Section 2.1, and ‘Slip-on Couplings’. 3.2.3 For New Potable Water Network Construction, Couplings are recommended up to 300mm Ø only, 400mm Ø and above, a mechanical Collar is to be used.

3.3

MECHANICAL COLLAR ’S 3.3.1 Mechanical Collars shall be manufactured from Ductile Iron and shall be suitable for use with ductile iron pipes to BSEN 545 / ISO 2531. 3.3.2 Mechanical Collars shall be suitable for normal pressure test up to PN-16.

3.4

FLANGE ADAPTERS 3.4.1 Flange adapters shall be manufactured from either cast iron or rolled steel and shall be suitable for use with ductile iron pipes to BSEN 545 / ISO 2531. 3.4.2 Flange adapters shall be suitable for jointing the flanges to PN-16, as detailed in BSEN 545 / ISO 2531. 3.4.3 Flange adapters shall be similar in design to that detailed in BS-8010, Section 2.1, ‘Flange adapters’.

3.5

DISMANTLING JOINTS 3.5.1 Dismantling Joints shall be suitable for jointing the flanges to PN-16, as detailed in BSEN 545 / ISO 2531. 3.5.2 Dismantling Joints shall be similar in design to that detailed in BS-8010, Section 2.1, ‘Flange adapters’.

3.6

STEP COUPLINGS 3.6.1 Step couplings shall be manufactured from either cast iron or rolled steel and shall be suitable to joint between two pipes of different materials.

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3.7

EXTERNAL AND INTERNAL COATING

OF

WP-P5/ S1

SLIP-ON COUPLINGS, STEP COUPLINGS,

FLANGE ADAPTERS AND DISMANTLING JOINTS DURING MANUFACTURE 3.7.1 All Slip-on couplings, step couplings, flange adapters and dismantling joints shall be coated both, internally and externally as per one of the following methods; 

Fusion bonded epoxy coating shall be minimum thickness 300 micron (Polymeric anticorrosion) coating as per WIS No. 4-52-01.



Electrostatic ally applied epoxy coating shall be minimum t hickness 300 micron.



Fluidized bed epoxy coating shall be minimum thickness 300 micron.



The color of coating shall be “Blue”, Code RAL-5000/5001/5005/5010/5017 or Black.

3.8

FASTENERS 3.8.1 All nuts and bolts must be made of Stainless Steel Grade “A4” or Grade 316L.

3.9

IDENTIFICATION METAL STRIP 3.9.1 All couplings and flange adapters shall be marked by engraving or embossing on a metal strip, the name of manufacturer, individual serial number, tender number and Year of manufacturing.

3.10 PACKING 3.10.1 The packing shall be as per Section 1, Clause 1.8 of t his specification. 

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Section - 4

Corrosion Protection of Ductile Iron Pipes, Fittings & Accessories 4.1

PIPE WRAPPING TAPE 4.1.1 The tape shall be supplied with width of 150 mm and 225 mm and with length 25 m, 30 m and 75 m per rolls. 4.1.2 Pipe diameters up to 200mmØ, 150mm width tape shall be used. 4.1.3 Pipe diameters 300mmØ and above, 225mm width tape shall be used. 4.1.4 For all types of fitting with diameters 100mmØ and above, 150mm width tape shall be used. 4.1.5 For normal application, high water table (Sabkha), high resistivity and contaminated areas, the self adhesive wrapping tape shall be applied with a 55% overlap shall be applied and sufficient tension in accordance with manufacturer instructions to ensure complete conformability and smoothed out as application proceeds to avoid air pockets. 4.1.6 Prior to backfilling the wrapped Pipes / joints shall be holiday tested, and the porosity shall be “zero” on 3 kV DC tester. 4.1.7 Wrapped pipes shall not be permitted to lie down on the ground except when finally positioned in the trench. 4.1.8 Wrapping tape dimension selection is Subject to Tenderer / Contractor Specification. 4.1.9 The adhesive compound shall be of the pressure sensitive type (that is, not requiring a primer in order to achieve bond to the substrata) and shall have thickness between 0.75 to 0.90mm. 4.1.10 The tape shall be supplied with a wider high quality silicon release paper covering complete tape and both sides of the tape shall have a minimum of 5mm wider silicon release paper to prevent edge contamination. 4.1.11 In case during storage at maximum storage temperature of 50  C for six months, the adhesive material shall not flow out of the release paper and there shall not be any end blocking. 4.1.12 Wrapping tape shall be marking in middle with the following information;    

Issue : 1

Manufacturers name & logo. Date of manufacture Width of the tape Batch Number

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4.2

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WRAPPING PROCEDURE 4.2.1 To increase the wrapping protection efficiency, pipe diameters up to 300mm must be wrapped using semi-Automatic Tape Wrapping Machine and for pipe diameters above 300mm, Fully Automatic Wrapping Machine should be used.

4.3

STORAGE 4.3.1 Wrapping tape shall be stored in dry, cool, well ventilated condition, the temperature of the store shall not exceed 30° C and out of direct sunlight.

4.4

PACKING 4.4.1 Roll shall be placed in a cardboard carton in layers in vertical position. A proper separator for safe storage shall separate each layer. The boxes shall be marked minimum at two places given name and logo of manufacturer, Tender No/ Title, Type, Size and quantity of material in black/blue color letters with a minimum height of 50mm.

4.5

WRAPPING TAPE PROPERTY 4.5.1 The wrapping tape shall be conforming to the following specifications given in Table 03. Table (03) WRAPPING TAPE PROPERTY DATA SHEET SR. Property Test Method Unit No. A. Physical 1 Color 1.1 Backing -----

1.2 1.3 2 3 4 5 6 7 8 9 10

Adhesive Compound Release Paper Backing Type Backing Thickness Min. Adhesive Thickness Min. Total Thickness Min. Elongation Tensile Strength Tape Modulus Tear Strength Impact Resistance (Two layers) 11 Flow coefficient of Bitumen 11.1 Viscosity at 200º C 11.2 Viscosity at 175º C 12 Adhesion to Steel 13 Adhesion to Tape Issue : 1

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Data

------------BS 2782 BS 2782 BS 2782 ASTM D1004 DIN 30627

------mm mm mm % N/mm2 N/mm2 N Nm

Blue RAL 5000/5001/5005/ 5010/5017 Black White/Cream PVC 0.75 0.75 1.5 270 14.8 50 50 15

Cone & Plate Cone & Plate ASTM D 1000 ASTM D 1000

Poise Poise N/mm N/mm

5.5 7.5 2.75 2.75

Unclassified

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B. 13 14 15 C. 16 17 18 D. 19 20 21 4.6

Electrical Dielectric Strength Insulation resistance Cathodic disbandment General Water vapor permeability Water absorption Bacterial growth disbandment Temperature Range For wrapping In service For storage

WP-P5/ S1

BS 2782 ASTM D 257 ASTM G 8

kV 30 Ohm/cm2 1012 mm2 NIL

BS 2782 ASTM D 570 ---

g/m2/24h % ---

0.4 0.1 NIL

-------

ºC ºC ºC

0 to + 50 0 to + 50 up to + 30

PRIMER 4.6.1 The primer shall be of fast drying type. It’s only purpose shall be to maintain the surface cleanliness condition of the cleaned prepared D.I. pipe surface prior to tape application. 4.6.2 The primer shall be supplied in 20 to 25 Liters drums with following specifications given in Table 04. Table (04) PRIMER DATA SHEET Property Flash Point, C º Weight Solid, % Viscosity, CP Coverage m2/l Type

4.7

Data 24 - 34 58 200 - 500 6 - 12 Bitumen solution

PACKING 4.7.1 Drums shall be put into a wooden box, which shall be close and open type. The boxes shall be marked minimum at two places given name and logo of manufacturer, Tender No. or Title, Type, Size and quantity of material in black or blue color letters with a minimum height of 50mm.

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4.8

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WRAPPING TAPE VISCO ELASTIC POLY ISO BUTENE 4.8.1 The specification of visco elastic wrapping tape shall be according to ISO 21809-3 Amendment 1 for Non crystalline Poly Iso Butene tapes. 4.8.2 The tape shall be supplied with width of 100 mm and 200 mm and with length 10 m, 20 m or approved by Engineer depending upon the r equirements. 4.8.3 Pipe diameters up to 200mmØ, 100mm width tape shall be used. 4.8.4 Pipe diameters 200mmØ and above, 200mm width tape shall be used. 4.8.5 For all types of fitting with diameters 100mmØ and above, 100mm width tape shall be used. 4.8.6 The wrapping tape shall consist of a polyolefin based corrosion preventing compound and a PE backing. 4.8.7 The corrosion preventing compound shall be a non-crosslinked, non-crystalline, lowviscosity polyolefin (that is, not requiring a primer in order to achieve bond to the substrate) and shall have thickness between 0.90 to 1.00 mm. 4.8.8 The tape shall be supplied with a high quality silicon release foil covering complete tape. 4.8.9 During storage at maximum storage temperature of +50° C, the adhesive material shall not flow out of the release foil and there shall not be any end blocking. 4.8.10 Wrapping tape shall be marking in middle with the following information;    

4.9

Manufacturers name & logo. Date of manufacture. Width of the tape. Batch Number.

WRAPPING PROCEDURE 4.9.1 Tools & Equipment required Temperature probe, Dew point tester, High voltage holiday tester. 4.9.2 The substrate should be free from condensing water which can be reached by keeping the temperature at least 3°C above dew point. The substrate should be dry, clean and protected against negative weather influences. 4.9.3 The area to be coated has to be clean, dry, and free from oil, grease and dust. All contamination including mill-scale has to be removed. De-gloss and degrease the surfaces by using an abrasive pad and isopropyl alcohol and e.g. a lint-free cloth.

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4.9.4 Minimum requirement for surface preparation is St 2 according to ISO 8501-1. Roughness profile should not be essential for adhesion. 4.9.5 Start wrapping with removal of a small part of the release liner and apply on the substrate without exerting any tension. Avoid air inclusions. Mould the tape tight onto the substrate surfaces. 4.9.6 Release foil should be removed only just prior to application onto the surface.   

Overlap of wraps Side-by-side overlap: > 10 mm Consecutive rolls: = 50 mm Overlap on Existing coating= 50 mm.

4.9.7 The appearance of the tape must look smooth and tight and should be shaped around all details and into corners. 4.9.8 Holiday testing should be carried out immediately after application of wrapping tapes with a voltage of 15 kV. A brush probe is recommended. No further testing is required. 4.9.9 The wrapped pipe should not be exposed to loads e.g. from supports- or lifting equipment. 4.9.10 To increase the wrapping protection efficiency, pipe diameters up to 300mm must be wrapped using semi-Automatic Tape Wrapping Machine and for pipe diameters above 300mm, Fully Automatic Wrapping Machine should be used, manual wrapping is also acceptable. 4.9.11 Pipelines: Machine wrapped or manually wrapped protective coating on buried ductile iron pipelines. Field joints, Flanges, Couplings bell and spigot joint manually wrapped. 4.9.12 If the wrapping on the pipe is damaged during transportation localized repair should be performed as per above procedure. 4.9.13 If required extra mechanical impact resistance for Field Joints,Flanges & couplings can be achieved by applying an extra self-adhesive PE or PVC film on top of the tape wrap material. This will not be considered as extra corrosion prevention. 4.9.14 The self-adhesive PE or PVC film shall be applied with 50% overlap. 4.10 STORAGE 4.10.1 Store indoor, clean and dry, away from direct sunlight in a cool place below +50°C. Material should have Unlimited shelf life.

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4.11 PACKING 4.11.1 Roll shall be placed in a cardboard carton in layers in vertical position. A proper separator for safe storage shall separate each layer. The boxes shall be marked minimum at two places given name and logo of manufacturer, Tender No., Type, Size and quantity of material in black/blue color letters with a minimum height of 50mm. 4.12 WRAPPING TAPE PROPERTY 4.12.1 The wrapping tape shall also conform to the minimum requirement given which is based on ISO 21809-3 Amendment 1(2011) and EN 12068 and shall be conforming to the following specifications given in Table 05. Table (05) WRAPPING TAPE PROPERTY DATA SHEET Property Test Unit Requirements Temp. Minimum thickness 23 °C mm 1.5 mm < Minimum Glass transition temperature °C application temp minus 20 Holiday detection at 5 No holiday kV/mm + 5 kV T + Drip resistance - 15 No drip at 80 °C °C - R S100 ≥ 108 Specific electrical insulation 23 °C Ω.m² R S100/R S70 ≥ 0,8 resistance

Test Method Annex A Annex E Annex B

max

Annex J

Annex K

a

≥ 0.2

23 °C Peel strength test and adhesion test with respect to steel and to plant coating before and after thermal ageing resistance and before and after hot water immersion test, both for 100 days at T + 20 °C (if reinforcement in the compound tape)

Impact resistance (Single layer) Issue : 1

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≥ 0.2

N/mm

T

max

20 °C

J

Unclassified

Cohesive failure Coverage ≥ 95 % The coating shall leave a film of corrosion protective coating material on the substrate. There shall be no evidence of adhesive failure ≥ 4

Annex D 18.5.9.2 (and N.3 and Annex I)

EN12068

Page 25 of 128


N/mm²

Pressure Indentation resistance,

23 °C and Tmax

Holiday detection at 5 kV/mm + 5 kV Cathode disbandment 23 °C resistance at 28 days and Tmax Lap Shear Test 23 °C Peel strength (layer-to-layer) 23 °C before and after thermal ageing resistance and before and after hot water immersion test both for 100 days at Tmax + 20 °C. UV Resistance 23 °C Lap Shear Test 23 °C Peel strength (layer-to-layer) 23 °C before and after thermal ageing resistance and before and after hot water immersion test both for 100 days at Tmax + 20 °C. UV Resistance 23 °C MIC Resistance 23 °C Water absorption 23 °C Water vapour permeability

1

-

mm

EN 12068 ANNEX G

N/mm2 N/mm

Annex F (and Annex B) ≥ 0.02 cohesive failure Annex L ≥ 0.20 Annex M

gJ/m2 N/mm2 N/mm

17,5 EN12068 ≥ 0.02 cohesive failure Annex L ≥ 0.20 Annex M

gJ/m2 %

23 °C g/m2/day

Temperature for wrapping Temperature In service Temperature for storage *Extra mechanical Outer wrap applied.

WP-P5/ S1

°C °C °C

0 mm, no holiday Self-Healing*

17,5 pass < 0.02 <0.2 - 20°C to +70°C -45°C to +70°C up to +50°C

EN12068 EN12068 ASTMD5 70 ASTM E96 -

4.13 POLYETHYLENE SLEEVING 4.13.1 The polyethylene sleeving shall be manufactured to ISO 8180 and shall have the following additional characteristics: 4.13.2 The film shall be manufactured in tubular form in blue color (RAL5000/5001/5005/5010/5017) with a nominal thickness of the film shall be 225 microns with tolerance of  25 microns.

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4.13.3 The film shall be manufactured from polyethylene or a blend of polyethylene and/or copolymer of ethylene and higher olefins. 4.13.4 The film shall have UV absorber and UV stabilizer 4.13.5 No recycled materials shall be used in the manufacture of the sleeving. 4.13.6 The test method of Polyethylene sleeving shall be as pre specifications given in Table 06. Table (06) TEST METHOD FOR POLYETHYLENE SLEEVING Property Data Density Flow Index Tensile Strength Elongation at Fracture:

Between 910-930 Kg/m3 tested as per ISO/R1183. Less than 2.5g/600s tested as per ISO/1133 Both directions not less than 8.3 MPa Not less than 300%.

4.14 MARKING

4.14.1 Polyethylene sleeving shall be supplied with a center guideline printed on the middle of the tape and the markings shall be consist the following;     

KAHRAMAA logo Manufacturers name & logo Date of manufacturing )MM/YY( Width & thickness of the sleeving Size of the Relevant DI pipe in mm.

4.14.2 Lay flat width of PE sleeving for D.I. pipe shall be as given in Table 07. Table (07) DETAILS OF FLAT WIDTH OF PE SLEEVING Sr. No. Nominal Ø of D.I. Pipe in mm Lay flat width in mm 1 80 280 2 100 320 3 150 435 4 200 540 5 300 755 6 400 980 7 450* 1090 8 500* 1215 9 600 1440 10 700* 1610 11 800* 1825 12 900 2025 13 1,000* 2255 14 1,200 2500 15 1,400 2800 16 1,600 3100 Note: * The subject Diameter’s are not be used in a new potable water network construction.

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4.15 PACKING

4.15.1 Each roll shall be individually packed and protected with shrinkable plastic sheet and marked with name and logo of manufacturer, Tender No/Title., Type, Size and quantity of material in black/blue color letters with a minimum height of 50mm. 4.15.2 The packing shall be as per Section 1, Clause 1.8 of this specification. 4.16 PVC BLACK SELF ADHESIVE TAPE

4.16.1 PVC black self adhesive tape shall be 50 mm/2” wide of length 30 meter/100 ft. in Rolls black in color. The tape shall be good quality and from an approved manufacturer. 4.16.2 The adhesive material shall be suitable when used in water and underground. 4.16.3 Each roll shall be individually packed and placed in a cardboard carton for safe storage. 4.17 JOINT MOLDING PUTTY 4.17.1 The joint molding putty used on all types of pipe joints shall be inert/non-toxic putty. 4.17.2 The putty shall be suitable for use with the approved PVC/Bituminous tape wrapping materials. The putty shall be that recommended by the tape manufacturer. 4.17.3 The putty shall be supplied in 20-25 Kg drums or smaller packages as approved by the Engineer. 4.17.4 Putty shall consist of the following properties as given in Table 08. Table (08) PUTTY CONSIST DATA SHEET Property Color Shrinkage: Temperature range Application: Temperature range In service:

Data Black / Beige Nil -10 to + 50 Cº -40 to + 75 Cº

4.18 PACKING 4.18.1 Drums shall be put into the wooden box, which shall be close and open type. The boxes shall be marked minimum at Two places given name and logo of manufacturer, Tender No./Title, Type, Size and quantity of material in black/blue color letters with a minimum height of 50mm. 4.18.2 The packing shall be as per Section 1, Clause 1.8 of this specification.

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4.19 STORAGE 4.19.1 Putty should be stored in original containers until required for use. Store in dry, 4.19.2 Cool, well ventilated condition, out of direct sunlight and other major sources of heat. 4.20 TRENCH MARKER TAPE 4.20.1 The tape shall be manufactured from non-biodegradable low-density virgin polyethylene in blue color (RAL-5000/5001/5005/5010/5017). 4.20.2 The tape shall be 150mm wide and 200 micron thickness with a tolerance of

 5%.

The rolls shall be of 500-meter long tape. 4.20.3 For PE Pipe and Road Crossing Duct, metallic blue Color a detectable warning tape of 150mm wide, 250microns thickness to detect the pipe through metal detector. 4.21 MARKING 4.21.1 The tape shall be inscribed with both Arabic and English in black color with a minimum height of letters 75 mm as follows: FOR WATER MAINS – with the words CAUTION: POTABLE WATER MAIN BELOW -------------- ! ---------------

FOR SERVICE CONNECTIONS – with the words CAUTION: POTABLE WATER SERVICE CONNECTION BELOW -------------- ! ---------------

4.21.2 The trench marker tape shall be supplied with the following printed markings:     

KAHRAMAA logo Manufacturers name & logo Date of manufacturing )MM/YY( Width & thickness of the tape Batch Number

4.22 PACKING 4.22.1 Each roll shall be individually packed and protected with shrinkable plastic sheet and marked with name and logo of manufacturer, Tender No/Title., Type, Size and quantity of material in black/blue color letters with a minimum height of 50mm. 4.22.2 The packing shall be as per Section 1, Clause 1.8 of this specification.

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4.23 LUBRICANT 4.23.1 The lubricant shall be as per manufacturer’s recommendations and conforming to Section 1, Clause 1.1.1. of this specification. 4.24 PACKING 4.24.1 The lubricant shall be packed in 200 – 500 gram steel containers. These steel containers shall be placed in a cardboard carton for safe storage. 4.25 SLIP-ON COUPLINGS, FLANGE ADAPTERS INSTALLATION

AND

DISMANTLING JOINT

DURING

4.25.1 All wrapping tapes used for the corrosion protection of couplings and flange adapters shall be identical to that detailed in Section 4, Clause 4.1. 4.25.2 Moulding putty used for building up the contours on couplings and flange adapters, prior to the application of wrapping tape shall be identical to that detailed in Section 4, Clause 4.5. 4.25.3 All polyethylene sleeving used to cover couplings and flange adapters shall be identical to that detailed in Section 4, Clause 4.3. 4.25.4 All PVC Black adhesive tape shall be identical t o that detailed in Section 4, Clause 4.26 HEAT SHRINK SLEEVE 4.26.1 Heat shrink sleeve method for corrosion protection on pipes and fittings joints, coupling & flange adaptors during installation shall be applied, depends on Tender Requirements. 4.27 PACKING 4.27.1 The packing shall be as per Section 1, Clause 1.8 of this specification.



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Section - 5

Bedding and Surround Material’s 5.1

GENERAL These clauses shall be read in continuation of Section 1 of this Specification. 5.1.1

The pipes shall be laid in such a manner that the whole length of the pipe barrel is supported on the bedding material. At collars, sockets, flanges etc. the bedding material shall be removed to avoid point loads occurring at these locations. Bedding material shall be as per KAHRAMAA Specifications and shall be free from clay, large stones, rubbish, perishable matter or any other material which could damage the pipeline coating or assist in setting up corrosion, and the used material must be non-plastic material.

5.1.2

A samples will be taken from the accumulated piles at the approved source site and it will be tested on laboratory, if the result of the samples are compiling with KAHRAMAA specifications, The contractor is allowed to start having stock piles at the site and the contractor is allowed to start using the approved material (from the approved piles), and a randomly samples will be taken from the trench (preferably every 200.0 linear meters by the supervisors to assure the compliance of the delivered materials to the site.

5.2

IMPORTED GRANULAR MATERIAL AND SELECTED EXCAVATED MATERIAL 5.2.1

Imported Granular Material shall comprise either of natural Dune Sand or Crushed Clean Hard Limestone or be a mixture of these.

5.2.2

Gabbros shall be used in water logged ground, (Sabkha), high resistivity, and contaminated areas.

5.2.3

The sand, crushed limestone or Gabbros shall be obtained from an approved source by the Engineer.

5.2.4

Granular material shall contain no excessive quantities of Dust, Soft or Flaky Particles, Shells congealed lumps, Nodules of soft clay, Shell, Alkali or other contaminated likely to affect adversely the compaction of the material or to cause damage to pipes.

5.2.5

The sulphate content (SO3) of the material shall not exceed 0.4% by weight and the Chlorides as (CI) shall not exceed 0.10 %by weight.

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5.2.6

WP-P5/ S1

The grading of fine aggregate when determined by the method described in BS 812 shall lie within the respective limits specified within the given Table 09.

5.2.7

The total quantity of fine dust through No. 22 mesh sieve in fine aggregate derived by crushing rock, shall be determined by the method described in BS 812 paragraph 14 and shall not exceed 8% by weight.

5.2.8

The total quantity of clay and silt in nature and shall not exceed 4% by weight when determined by the field setting test described in BS 812 paragraph 15. Table (09) Normal Sand / Crushed Rock Percentage Passing by Weight B.S. Sieve Size (mm) Normal Sand Crushed Rock 4.76 95 – 100 90 – 100 2.40 70 – 95 60 – 90 1.20 45 – 85 40 – 80 0.60 25 – 60 20 – 50 0.30 05 – 30 05 – 30 0.15 0.0 - 10 0.0 - 15 

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Section - 6

Gate valves 6.1

GENERAL These clauses shall be read in continuation of Section 1 of this Specification. 6.1.1

All gate valves shall be manufactured and tested in accordance with BS-5163 Type ‘B’/ BSEN 1171, BSEN 1074 and their amendments.

6.1.2

All gate valves shall be: A. B. C. D. E. F.

6.1.3

Gearbox shall be of:   

6.1.4

Double flanged drilled according to BSEN 1092-2 PN16. Face – to-face dimensions according to BSEN 558-1; Series 3 and 14. Designed for use with nominal pressure of 16 Bar. With inside screw, solid wedge and shall be of non-ris ing stem type. Operated by the use of a removable key through a valve cap. Suitable for use in a closed end test.

Standard ratio Torque ranges Thrust range

1.1-10.1 (as specified) 400-40,000 Nm. 4,000-250,000 DaN

All gate valve and gear box shall be suitable for use with water temperature up to 50º C and in climate and soil conditions encountered in the State of Qata r.

6.1.5

All gate valves shall be of the resilient seat type.

6.1.6

All component parts of the valve body i.e. bonnet and stem seal housing shall be bolted together, where setscrews are used, the socket shall be provided with a PVC cap.

6.1.7 6.2

All gate valves shall be designed for clockwise cl osing and be marked accordingly.

MOTORISED ACTUATOR 6.2.1

Electric type actuators shall include the motor, operators unit gearing, limit switches, torque switches, de clutch lever, auxiliary hand wheel, forward reversing and off position switches for local valve operation, local position indicator, local and remote selector switch, terminal for remote control, valve status and position indications(as specified below).

6.2.2

The actuator motor and all electrical enclosure shall be waterproof (IP67) as minimum. Motor shall be totally enclosed non ventilated construction with class F insulation with temperature rise limited to class B.

6.2.3

Actuator shall be suitable for operations in ambient temperature up to 50 degrees centigrade and capable of prolonged operations in a sand laden atmosphere. Available torque shall be at least two times the valve manufacturer's maximum

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torque requirements. The motor shall be designed specially for use on valve operation, having high torque capacity coupled with low inertia. Motor shall be of sufficient size to open or close a valve against the maximum specified differential pressure when the voltage drop at the motor is 10% of the nominal voltage. 6.2.4

Electrical power to the motor shall be 3 phase, 50 Hz, 415 V and motor rating shall be continuous duty. Heater and thermostats shall be provided for high humidity condition.

6.2.5

The power gearing shall be consisting of helical gears of heat treated steel and worn gearing of hardened alloy steel. All power gearing shall be lubricated with high speed parts on anti friction bearing. It shall be possible to remove the motor/actuator from the valve without taking the valve out of service.

6.2.6

Provision shall be made for the incorporation of 4-20 mA position transmitters, powered internally to transmit the valve position remotely. The actuator shall be provided at least or minimum with following normally open/close dry contacts for monitoring following status remotely: Open, Close, Healthy/Available, Failed, In Remote and Local . Also following provision to control actuator from remotely through NO/NC potential free contact. Open & Close (In Desired Position), Stop

6.3

TESTING 6.3.1

The gate valve shall be tested as per BS 5163 as follows:  

6.3.2

Hydraulic test for body Hydraulic test for seat

- 24 Bar - 17.6 Bar

A factory test certificate shall be issued for each Gate valve giving its serial numbers, and the certificate shall be submitted to KAHRAMAA at the time of supply.

6.3.3

KAHRAMAA reserves the right to witness the testing of the valves locally. Testing shall be carried out in accordance with applicable codes and standards for the particular valves. Each valve shall be subjected to hydrostatic body and seat pressure test as mentioned in clause 6.3.1.

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6.4

WP-P5/ S1

HAND-WHEEL 6.4.1

Gate valves shall be supplied with cast iron hand wheels marked “Open” and “Closed” with arrow in appropriate directions. The design shall be such that it can be removed if necessary.

6.5

MARKING 6.5.1

All gate valves shall have clearly marked in the casting of the body the following information; A. B. C. D. E. F.

6.5.2

Size of valve in mm. Pressure rating in Bars. Manufacturer’s name and/or logo. Material type (GGG40/GGG50/SG) Manufacturing Standards Number. Year of manufacture.

All gate valves shall have individual identification strip which shall be marked by engraving or embossing on a metal strip, the name of manufacturer, individual serial number, tender number and Year of manufacturing.

6.5.3

The metal strip shall be of minimum size of 100mm x 30mm and shall be fixed securely and permanently at appropriate location by industrial type cold welded glue and shall not be screwed or riveted. The glue shall be of industrial grade with a melting point higher than 80°C.

6.6

MATERIALS OF GATE VALVES 6.6.1

The valve body, bonnet, gland, yoke and wedge body shall be manufactured of ductile iron as per one of the following standard:   

6.6.2

DIN 1693 GGG-50/40 BS EN 1563: 1997 grade EN-GJS-500-7 ISO 500-7, ISO 400-15

The stem shall be manufactured of acid resistance stainless steel 316L/BS 970 Gr 431 S29 with the threaded portion being formed by rolling process.

6.6.3

Stem nuts shall be gunmetal to BS 1400 LG2 or BS 2874 CZ132.

6.6.4

Dimensions and materials shall conform to those detailed in BS 5163, as applicable for Type “B”, and BS EN 1171.

6.6.5

The wedge body/core shall be manufactured from ductile iron.

6.6.6

The wedge shall be completely vulcanized by EPDM and coupled to the valve stem by gunmetal or dezincification resistance brass nut slide into the specifically

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designed slot hole in wedge or rigidly fastened into the wedge body by forging before rubber vulcanization. 6.6.7

Rubber material shall be of “EPDM EDK - 70” and the minimum thickness shall be 1.5 mm, and all sealing surfaces not less than 4.0 mm.

6.7

GEAR BOX 6.7.1

The properties of the gearbox shall be as given in Table 10. Table (10) Properties of the Gearbox Data Sheet Property Data Body & body cover Ductile Iron GGG 50/40, SG Bevel gear-shaft Steel / Carbon steel Gear SG Iron, BS EN 1563 Grade 700-2, GGG 50 or AISI 1045 Bearing Steel Plate & base plate Carbon steel Stem nut Aluminum Bronze / Steel / DZR Brass

6.8

FLANGES 6.8.1

All gate valve flanges shall be drilled to suite ductile iron flanges as detailed in BS EN 1092-2, PN-16 rating.

6.8.2 6.9

Fasteners for joint shall be as per Section 1, Clause 1.6 of this specification.

GATE VALVE STEM SEALS 6.9.1

Gate valves up to and including 300 mm Ø shall have ‘O’ ring seals which are to comprise of seal, wiper rings and lip seal. There shall be a minimum of two wiper rings or one wiper ring and one lip seal in addition to the seal rings and shall be made of synthetic rubber material.

6.9.2

Gate valves above 300mm may have either ‘O’ ring seals, or stuffing boxes fitted with an approved ‘Teflon’ or graphite based packing material.

6.9.3

The stem sealing shall be maintenance free.

6.9.4

There shall not be any direct contact with spindle and bonnet to avoid cold welding.

6.10 MATERIAL COATING & INTERNAL COMPONENTS 6.10.1 The entire body of gate valves shall be coated both internally and externally with either of the following: 

 

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300 micron Fusion bonded epoxy (Polymeric anticorrosion) coating as per WIS No. 4-52-01. 300 micron Electrostatic ally applied epoxy coating. 300 micron Fluidized bed epoxy coating.

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6.10.2 The color of coating shall be “Blue”, Code RAL-5000/5001/5005/5010/5017. 6.10.3 All materials coating shall be WRC, DVGW, SGS, and DWI. , KIWA, NSF 61 or other Worldwide Known Quality Body Certifiers in contact with potable water at +50 degrees centigrade. 6.10.4 The concern Department / Section has the right to request any Worldwide Known Quality Body Certifier if require. 6.10.5 All casting shall be properly finished, sand blasted and cleaned before coating. 6.10.6 Coating shall be smooth and mirror finish without any hairline cracks. 6.10.7 Adhesion Test: Adhesion of coating to metal shall not be less than 12N/mm2 (BSI BS EN ISO 4624). 6.10.8 Holiday Test: Porosity of coating shall be “zero” on 3 kV DC tester . 6.10.9 Hardness: Intrinsic Rockwell hardness shall be between 50 - 6 0. 6.10.10 Impact resistance: For applying of impact energy of 5 NM on coating the cracks should not develop, when tested by 3 kV DC tester. 6.11 ACCESSORIES 6.11.1 Each valve shall be supplied with all accessories such as:Bolts, nuts, washers and 3 mm cotton reinforced rubber gasket for each flange. Caps. The number of torque wrench with bit / flank socket shall be Supplied: a) From 1 to 20 valves, 1 torque wrench and bit / flank socket should be supplied. b) For 20 valves and above 20% of the supplied quantity of torque wrench and bit / flank socket should be supplied. For the reservoir (RPS) the number of hand wheel shall be Supplied: a) From 1 to 20 valves, 1 hand wheel should be supplied. b) For 20 valves and above 20% of the supplied quantity of hand wheel should be supplied. Extension Operating Spindle as per KAHRAMAA Standard Drawings, rod with all accessories such as coupling, cap, Wall Bracket, etc. 6.11.2 Valve keys shall be of the heavy duty mild steel, lever type, shall be and to be   





capable of opening valves against their designed working pressure heads and shall be capable of producing enough torque to close the valve to a drop tight extent. 6.11.3 For gate valve the number of valve operating “T” keys shall be supplied: o o

From 1 to 20 valves, 1 of operating “T” key should be supplied. For 20 valves and above 20% of the supplied quantity of operating “T” key should be supplied.

6.12 PACKING 6.12.1 The packing shall be as per Section 1, Clause 1.8 of this specification.  Issue : 1

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Section - 7

Butterfly Valve 7.1

GENERAL These clauses shall be read in continuation of Section 1 of this specification. 7.1.1

All butterfly valves shall be manufactured and test ed in accordance with BS EN 593 or equivalent.

7.1.2

Butterfly valves shall be of the following types;

7.1.3

A. Double/Triple Offset or Rubber-lined concentric type. B. Double flanged design. Face-to-face dimensions shall be as per BSEN 558-1: Series 20 for Replaceable lining valves. Series 13 & 14 for Vulcanized and Double/Triple Offset valves. C. The thickness of the EPDM rubber shall be minimum 3mm. D. Designed for use with nominal pressure of 16 Bar. E. Operated by the use of a removable key. F. Suitable for use in a closed end test. All butterfly valves and gear boxes shall be suitable for use with water temperature  

up to 50ºC in climate and soil conditions encountered in the State of Qatar. 7.1.4

All component parts of valve body i.e. bonnet and stem seal housing shall be bolted together where setscrews are used. The socket shall be provided with a PVC cap.

7.1.5

All butterfly valves shall be designed for clockwise closing and to be marked accordingly.

7.2

MOTORISED ACTUATOR 7.2.1

Electric type actuators shall include the motor, operators unit gearing, limit switches, torque switches, de clutch lever, auxiliary hand wheel, forward reversing and off position switches for local valve operation, local position indicator, local and remote selector switch, terminal for remote control, valve status and position indications(as specified below).

7.2.2

The actuator motor and all electrical enclosure shall be waterproof (IP67) as minimum. Motor shall be totally enclosed non ventilated construction with class F insulation with temperature rise limited to class B.

7.2.3

Actuator shall be suitable for operations in ambient temperature up to 50 degrees centigrade and capable of prolonged operations in a sand laden atmosphere. Available torque shall be at least two times the valve manufacturer's maximum torque requirements. The motor shall be designed specially for use on valve operation, having high torque capacity coupled with low inertia. Motor shall be of

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sufficient size to open or close a valve against the maximum specified differential pressure when the voltage drop at the motor is 10% of the nominal voltage. 7.2.4

Electrical power to the motor shall be 3 phase, 50 Hz, 415 V and motor rating shall be continuous duty. Heater and thermostats shall be provided for high humidity condition.

7.2.5

The power gearing shall be consisting of helical gears of heat treated steel and worn gearing of hardened alloy steel. All power gearing shall be lubricated with high speed parts on anti friction bearing. It shall be possible to remove the motor/actuator from the valve without taking the valve out of service.

7.2.6

Provision shall be made for the incorporation of 4-20 mA position transmitters, powered internally to transmit the valve position remotely. The actuator shall be provided at least or minimum with following normally open/close dry contacts for monitoring following status remotely. Open, Close, Healthy/Available, Failed, In Remote And Local. Also following provision to control actuator from remotely through NO/NC potential free contact. Open & Close (In Desired Position), Stop

7.3

TESTING 7.3.1

All valves shall be individually pressure tested at following hydraulic pressure:   

7.3.2

Hydraulic test for Body - 24 Bar Hydraulic test for Seat - 17.6 Bar Hydraulic test for Disc - 24 Bar

A factory test certificate shall be issued for each butterfly valve giving its serial numbers, and the certificate shall be submitted to KAHRAMAA at the time of supply.

7.3.3

KAHRAMAA reserves the right to witness the testing of the valves locally. Testing shall be carried out in accordance with applicable codes and standards for the particular valves. Each valve shall be subjected to hydrostatic body and seat pressure test as mentioned in clause 7.3.1.

7.4

HAND-WHEEL 7.4.1

Butterfly valves shall be supplied with cast iron hand wheels marked “Open” and “Closed” with arrow in appropriate directions. The design shall be such that it can be removed if necessary.

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7.5

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MARKINGS 7.5.1

All valves shall have clearly marked in the casting of the body with the following information: A. Size of valve in mm. B. Pressure rating in Bars. C. Manufacturer’s name and/or logo. D. Material type (GGG40/GGG50/SG) E. Manufacturing Standards Number. F. Year of manufacture.

7.5.2

All valves shall have individual identification strip which shall be marked by engraving or embossing on a metal strip, the name of manufacturer, individual serial number, tender number and Year of manufacturing.

7.5.3


7.6

MATERIALS Butterfly Valves 7.6.1

The butterfly valve shall be of following properties as given in Table 11. Table (11) Properties of the Butterfly valve Data Sheet Property Data Body Body Seat Disc

DI GGG- 40/50, DIN1693 GGG-50/40, BSEN 1563:1997, Grade EN-GJS-500-7, ISO500-7, ISO400-15 Shall be Stainless Steel 316L DI GGG-40/50 or SS 316L shall be of solid one piece casting (non-hollow) coated with 300 micron Rilsan /Epoxy and the retaining ring shall be SS 316L.

Disc Seat

Shall be Stainless Steel 316L

Gasket

Rubber (cotton reinforced)

Bearing

PTFE filled line steel bearing(self lubricated)

Fasteners

Shall be Stainless Steel 316L

Shaft

Duplex Stainless Steel 1.4462 and shall be 100% dry shaft design

Lining

Must be of the highest grade of EPDM rubber

Gear box

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7.6.2

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Gear box shall be of following properties as given in Table 12.

Table (12) Properties of the Gearbox Data Sheet Property Data Body & body cover Ductile Iron GGG 50/40, SG Bevel gear-shaft Steel / Carbon steel Gear SG Iron, BS EN 1563 Grade 700-2, GGG 50 or AISI 1045 Bearing Steel Plate & base plate Carbon steel Stem nut Aluminum Bronze / Steel / DZR Brass 7.6.3 7.7

FLANGES 7.7.1

7.8

Fasteners shall be as per Section 1, Clause 1.6 of this specification.

All butterfly valve flanges shall be drilled to BSEN 1092-2, PN 16.

COATINGS 7.8.1

The entire body of valves shall be coated both internally and externally with either of the following:

7.8.2

300 micron Fusion bonded epoxy (Polymeric anticorrosion) coating as per WIS No. 4-52-01. 300 micron Electrostatic ally applied epoxy coating. 300 micron Fluidized bed epoxy coating. In special cases, Rilsan coating with 300 microns can be approved.

7.8.3

The color of coating shall be “Blue”, Code RAL-5000/5001/5005/5010/5017.

7.8.4

All materials coating shall be WRC, DVGW, SGS, and DWI. , KIWA, NSF 61 or



 

other Worldwide Known Quality Body Certifiers in contact with potable water at 50 degrees centigrade. 7.8.5

All casting shall be properly finished, sand blasted and cleaned before coating.

7.8.6

Coating shall be smooth and mirror finish without any hairline cracks.

7.8.7

Adhesion Test: Adhesion of coating to metal shall not be less than 12N/mm2 (BSI BS EN ISO 4624).

7.8.8

Holiday Test: Porosity of coating shall be “zero” on 3 kV DC tester.

7.8.9

Hardness: Intrinsic Rockwell hardness shall be between 50 - 60.

7.8.10 Impact resistance: For applying of impact energy of 5 NM on coating the cracks should not develop, when tested by 3 kV DC tester.

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7.9

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VALVE K EYS 7.9.1

Valve keys shall be of heavy duty, lever type, and aluminum alloy and to be capable of opening valves against their designed working pressure heads and shall be capable of producing enough torque to close the valve to a drop tight extent.

7.9.2

Valve operating “T” keys of standard length shall be supplied in the ratio of 1 - 20 butterfly valves.

7.10 ACCESSORIES 7.10.1 Each valve shall be supplied with all accessories such as:Bolts, nuts, washers and 3 mm cotton reinforced rubber gasket for each



flange. 

Caps



The number of torque wrench with bit / flank socket shall be Supplied: a)

From 1 to 20 valves, 1 torque wrench and bit / flank socket should be supplied.

b) For 20 valves and above 20% of the supplied quantity of torque wrench and bit / flank socket should be supplied. 

For the reservoir (RPS) the number of hand wheel shall be Supplied:

I.

From 1 to 20 valves, 1 hand wheel should be supplied.

II.

For 20 valves and above 20% of the supplied quantity of hand wheel should be supplied.



Extension Operating Spindle as per KAHRAMAA Standard Drawings, rod with all accessories such as coupling, cap, Wall Bracket, etc.

7.10.2 Valve keys shall be of the heavy duty mild steel, lever type, shall be and to be capable of opening valves against their designed working pressure heads and shall be capable of producing enough torque to close the valve to a drop tight extent. 7.10.3 For butterfly valve the number of valve operating “T” keys shall be supplied: I. II.

From 1 to 20 valves, 1 of operating “T” key should be supplied. For 20 valves and above 20% of the supplied quantity of operating “T” key should be supplied.

7.11 PACKING 7.11.1 The packing shall be as per Section 1, Clause 1.8 of this specification. 

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Section - 8

Air Valves 8.1

GENERAL These clauses shall be read in continuation of Section 1 of this specification. 8.1.1

All Air valves shall be manufactured and tested in accordance with BS EN 1074 – 4 or equivalent.

8.1.2

All valves shall be suitable for a maximum working pressure of 16 Bar.

8.1.3

All materials shall be suitable for use with potable water at a temperature of 50C.

8.1.4

The Tenderer shall supply with his Tender, a detailed specification for the valves he intends to supply under the contract.

8.2

8.1.5

Air valve heads should be positioned vertically.

8.1.6

The flange shall be either welded type, or rotatable type.

8.1.7

Air Valve shall be Anti Surge Vacuum Break Type.

AIR VALVES CONSTRUCTION MATERIALS 8.2.1

The body shall be of ductile Iron, GGG-40/50. DIN1693 GGG-50/40, BSEN 1563:1997 Grade EN-GJS-500-7, ISO500-7, ISO400-15, The Tenderer shall supply with his tender, details of all air valve and check valve component parts and the materials from which they are to be manufactured.

8.2.2 8.3

Fastener shall be as per Section 1, Clause 1.6 of this specification.

SINGLE AIR VALVE LARGE ORIFICE TYPE 8.3.1

Large orifice air valves are for the bulk removal of air (inlet of air from/ to the mains).

8.3.2 8.4

These air valves shall be of BSPT type or flange type to suit the requirement.

SINGLE AIR VALVE SMALL ORIFICE TYPE 8.4.1

Small orifice air valves are for the removal of air under pressure from the main.

8.4.2

These air valves are installed in the pipeline via a 1” (inch) BSPT tapping.

8.4.3

These air valves shall be supplied with an approved isolating cock on the inlet, threaded to suit the air valve.

8.5

DOUBLE AIR VALVE 8.5.1

Double air valves are a combination of both large and small orifices and are used for bulk removal, inlet of air as well as removal of air under pressure.

8.5.2

These air valves are installed into mains via a standard flange drilled to suit ductile iron flanges to BS EN 1092, PN-16 rating. Inlet sizes are to be as shown in the Bill of Quantities.

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8.5.3

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Double air valves are to be supplied with an isolating valve and the stem should be positioned vertically with DAV.

8.6

COATINGS 8.6.1

All valves and gear boxes shall have their entire body coated both internally and externally with either of the following: 300 micron Fusion bonded epoxy (Polymeric anticorrosion) coating as per WIS No. 4-52-01. 300 micron Electrostatic ally applied epoxy coating. 300 micron Fluidized bed epoxy coating. The color of coating shall be “Blue”, Code RAL-5000/5001/5005/5010/5017. All materials coating shall be WRC, DVGW, SGS, DWI, KIWA, NSF 61 or other Worldwide Known Quality Body Certifiers in contact with potable water at 50 degrees centigrade . All casting shall be properly finished, sand blasted and cleaned before coating. Coating shall be smooth and mirror finish without any hairline cracks. Adhesion Test: Adhesion of coating to metal shall not be less than 12N/mm2 

   

 

8.6.2

(BSI BS EN ISO 4624). 8.6.3


8.6.4

Hardness: Intrinsic Rockwell hardness shall be between 50 - 60.

8.6.5

Impact resistance: For applying of impact energy of 5 NM on coating the cracks should not develop, when tested by 3 kV DC tester.

8.7

MARKINGS 8.7.1

All air valves shall have clearly marked in the casting of the body with the following information: A. Size of valve in mm. B. Pressure rating in Bars. C. Manufacturer’s name and/or logo. D. Material type (GGG40/GGG50/SG, etc.) E. Manufacturing Standards Number. F. Year of manufacture.

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8.7.2

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All valves shall have individual identification strip which shall be marked by engraving or embossing on a metal strip, the name of manufacturer, individual serial number, tender number, and Year of manufacturing.

8.7.3


8.8

PACKING 8.8.1

The packing shall be as per Section 1, Clause 1.8 of t his specification. 

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Section - 9

Fire Hydrants 9.1

GENERAL These clauses shall be read in continuation of Section 1 of this specification. Underground Fire Hydrant 9.1.1

All fire hydrants shall be manufactured and tested in accordance with latest BS 750, “Type 2”, and its amendments.

9.1.2

Fire hydrants shall be screw down type with captive stopper.

9.1.3

Fire hydrants shall be medium, fixed type stopper. Simple drain plug with needle hole.

9.1.4 9.2

Drain plug must be Stainless Steel.

MARKING 9.2.1

All fire hydrants shall have clearly marked in the casting of the body the following information. A. Number of BS Code i.e. BS 750 B. Manufacturer’s name and/or logo. C. Material designation of body and bonnet i.e. SG.

9.2.2

All fire hydrants shall have individual identification strip which shall be marked by engraving or embossing on a metal strip, the name of manufacturer, individual serial number, tender number, and Year of manufacturing.

9.2.3


9.3

MATERIALS 9.3.1

All fire hydrant body and bonnet shall be manufactured using ductile iron, GGG 50/40 to BS EN1563, Grade 420-12/500-7.

9.3.2

Fasteners shall be as per Section 1, Clause 1.6 of this specification.

9.3.3

All fire hydrants shall have “O” ring seals which are to comprise of seal and wiper rings and shall be made of synthetic rubber material. Removable gland fire hydrants shall not be accepted.

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9.3.4

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The stem shall be manufactured of acid resistance SS 316L/BS-970 Gr. 431 S29 with the threaded portion being formed by rolling process.

9.3.5

The wedge body/core shall be manufactured from ductile iron, GGG 50/40 to BS EN1563, Grade 420-12/500-7.

9.3.6

The stopper shall be completely vulcanized by EPDM or a suitable designed EPDM seal fasten with properly design arrangement, suitable for li fe of the fire hydrant and coupled to the stem by gunmetal or DZR brass nut slides into specifically designed slot hole in stopper or rigidly fastened into the stopper body by forging before rubber vulcanization.

9.3.7

If stopper is completely vulcanized, the rubber material shall be of “EPDM” EDK 70 or equivalent and the minimum thickness shall be 1.5mm and on all sealing surfaces shall not be less than 4.0mm.

9.3.8 9.4

The stopper nut shall be made of gunmetal to BS 1400 LG-2 or BS 2874 CZ 132.

CONNECTIONS 9.4.1

Inlet flanges shall be drilled to suite ductile iron flanges as detailed in BS EN 1092, PN-16 rating.

9.4.2

Fire hydrants shall have a pressure rating of 16 Bar and shall be subject to a working test pressure of 24 Bar.

9.5

9.4.3

All materials shall be suitable for use with potable water at a temperature of 50C.

9.4.4

Outlets shall be 2.5” (inches) male London Round Thread.

9.4.5

Fire hydrants are to be designed for clockwise closing.

COATINGS 9.5.1

All fire hydrants shall have their entire body coated, both internally and externally with either of the following: 

  

9.5.2

300 micron Fusion bonded epoxy (Polymeric anticorrosion) coating as per WIS No. 4-52-01. 300 micron Electrostatic ally applied epoxy coating. 300 micron Fluidized bed epoxy coating. The color of coating shall be “Blue”, Code RAL-5000/5001/5005/5010/5017.

All materials coating shall be WRC, DVGW, SGS, and DWI. , KIWA, NSF 61 or other Worldwide Known Quality Body Certifiers in contact with potable water at 50 degrees centigrade.

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9.5.3


9.5.4


9.5.5

Adhesion Test: Adhesion of coating to metal shall not be less than 12N/mm2 (BSI BS EN ISO 4624).

9.5.6


9.5.7

Hardness: Intrinsic Rockwell hardness shall be between 50- 60.

9.5.8

Impact resistance: For applying of impact energy of 5 NM on coating the cracks should not develop, when tested by 3 kV DC tester.

9.6

TESTING 9.6.1

All fire hydrants shall be tested as per BS 750 as follows:  

9.6.2

Hydraulic test for body - 24 Bar Hydraulic test for seat - 17.6 Bar

A factory test certificate shall be issued for each fire hydrant giving its serial number. This certificate shall be submitted to KAHRAMAA at the time of supply.

9.6.3

KAHRAMAA reserves the right to witness the testing of the valves locally. Testing shall be carried out in accordance with applicable codes and standards for the particular FH. Each FH shall be subjected to hydrostatic body and seat pressure test as mentioned in clause.

9.7

STAND PIPES 9.7.1

Stand pipes shall be of revolving head type, the heads to be fitted with chained blanking plugs with a minimum height of 950mm and manufactured from aluminum alloy or equivalent.

9.7.2

Inlet shall be 2.5” (inch) female London Round Thread to fit fire hydrants to BS 750 and outlet shall be 2.5” instantaneous male to BS 336.

9.8

ACCESSORIES 9.8.1

9.8.2

Each fire hydrant shall be supplied with following: 

Bolts, nuts, washers and 3 mm cotton reinforced rubber gasket for each flange.



Antifreeze bolts for fire hydrants, 1 per 20 fire hydrants.



Stand pipe, 1 per 20 fire hydrants.

For underground fire hydrant the number of fire hydrant operating “T” ke ys shall be supplied: I. II.

From 1 to 20 fire hydrants, 1 of operating “T” key should be supplied. For 20 fire hydrants and above 20% of the supplied quantity of operating “T” key should be supplied.

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9.9

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PACKING 9.9.1

The packing shall be as per Section 1, Clause 1.8 of this specification.

Aboveground (Pillar Type) Fire Hydrant 9.10 ABOVE GROUND FIRE HYDRANT (PILLAR TYPE) 9.10.1 The aboveground pillar type fire hydrants shall be of the breakable pillar type in accordance with the latest edition of BSI BS EN 14384. 9.10.2 All fire hydrants shall be equipped as given below: 

The fire hydrants shall be approved by Civil Defense of State of Qatar.



The hydrant shall be fitted with 2 No couplings of 2"1/2 including caps made of aluminum alloy or Gunmetal (EN 182, grade CuSnPb5).



Bronze valve seat ring, or Gunmetal (EN 1982 grade CuSn6Zn45Pb2)



Stainless steel 316 spindle.



A frangible section which breaks on impact, at the same time as the clamping washers.



DN 100 mm, PN 16 rating to EN 1092-2 standard.



A screw and nut device fitted on the stem holder so that the valve remains closed in case of impact.



Automatic drain valve.



The pillar type fire hydrant shall be supplied with an aluminum alloy hood (protection box), to be closed and opened through a key, and every pillar hydrant shall be supplied with one key.



Each two pillar hydrants supplied shall be provided with one extra repair kit for the breakable section.



The pillar type fire hydrant shall be supplied with ductile iron ductfoot bend with inlet flange size DN 100 mm, PN 16 rating to EN 1092-2 standard.

9.11 MARKING 9.11.1 All pillar type fire hydrants shall have clearly marked in the casting of the body the following information. B. Number of Standard Code. C. Manufacturer’s name and/or logo. D. Material designation of body and bonnet i.e. SG.

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9.11.2 All pillar type fire hydrants shall have individual identification strip which shall be marked by engraving or embossing on a metal strip, the name of manufacturer, individual serial number, tender number, and Year of manufacturing. 9.11.3 The metal strip shall be of minimum size of 100mm x 30mm and shall be fixed securely and permanently at appropriate location by industrial type cold welded glue and shall not be screwed or riveted. The glue shall be of industrial grade with a melting point higher than 80°C. 9.11.4 The marking plate shall be fixed on the hood at the factory. 9.12 COATING 9.12.1 All pillar type fire hydrants shall have their entire body coated, both internally and externally with either of the following: 




300 micron Fusion bonded epoxy (Polymeric anticorrosion) coating as per WIS No. 4-52-01.



300 micron Electrostatic ally applied epoxy coating.



300 micron Fluidized bed epoxy coating.



The hood shall also be epoxy coated, to achieve an average D.F.T of not less than 60 microns but no value shall be less than 50.



The color of coating shall be “Red”, Code RAL-3000/3001/3002/3016/3024.

9.12.2 All casting shall be properly finished, sand blasted and cleaned before coating. 9.12.3 All materials coating shall be WRC, DVGW, SGS, and DWI. , KIWA, NSF 61 or other Worldwide Known Quality Body Certifiers in contact with potable water at 50 degrees centigrade. 9.13 TESTING 9.13.1 All pillar type fire hydrants shall be tested in factory as the follows:  

Hydraulic test for body - 24 bar in open position. Hydraulic test for seat - 17.6 bar in closed position.

9.13.2 Adhesion Test: Adhesion of coating to metal shall not be less than 12N/mm2 (BSI BS EN ISO 4624). 9.13.3 Holiday Test: Porosity of coating shall be “zero” on 3 kV DC tester . 9.13.4 Hardness: Intrinsic Rockwell hardness shall be between 50- 60.

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9.13.5 Impact resistance: For applying of impact energy of 5 NM on coating the cracks should not develop, when tested by 3 kV DC tester. 9.13.6 A factory test certificate shall be issued for each pillar type fire hydrants giving its serial number and this certificate shall be submitted to KAHRAMAA at the time of supply. 9.13.7 KAHRAMAA reserves the right to witness all types of testing locally, and the tests shall be carried out in accordance with applicable codes and standards for the particular pillar type fire hydrants. 9.14 ACCESSORIES 9.14.1 Each fire hydrant shall be supplied with following: 

Master universal keys 10% of the supplied amount of the fire hydrants



Operating keys 10% of the supplied amount of the fire hydrants.



Additional repair kit 10% of the supplied amount of the fire hydrants, consist of the following:I. II. III.

One set of bracket. Four numbers of fasteners. One set of rubber gasket.



Protection hood Cover, 10% of the supplied amount of the fire hydrants



Master universal key for the protection hood Cover, 10% of the supplied amount of the fire hydrants.


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Section - 10

Check Valve 10.1 GENERAL These clauses shall be read in continuation of Section 1 of this specification. 10.1.1 All valves shall be suitable for a maximum working pressure of 16 Bar. 10.1.2 All material shall be suitable for use with potable water at a temperature of 50 C 10.1.3 Check or non-return valves below the size DN 300 mm (inclusive) shall comply with BS 5153 standards. It shall be of the swing, non-slam, noiseless type having flanged connections. The rating of the flanges shall be as per the design conditions of the operating system and as indicated in the Data Sheet. Non return valves shall be metal. 10.1.4 The internal and external surfaces of the valve and the disc shall be blast cleaned to SA 2.5, ISO 8501 standards and coated with fusion bonded epoxy coating system to a dry film thickness of 300mm. 10.1.5 The design of the valve body shall be such that there is adequate clearance around the back of the door to minimize jamming by rags and debris. Stops shall be provided to limit the back lift of the disc and shall be positioned to prevent fouling. 10.1.6 The hinge pin/shaft shall be stainless steel 316L. Both disc and lever shall be positively and securely fixed to the hinge pin/shaft. Grub screws pins (parallel to taper) or clamps will not be acceptable. All internal fixing devices shall be of stainless steel or bronze. Valves shall carry identification marks in accordance with BS 5153. All nuts and studs subject to vibration shall be fitted with spring washers or locking tabs. 10.1.7 The Check Valve (DN ≤ 300mm) shall be conforming to the following specifications given in Table 13. Table (13) Property Body, bonnet, weight and hinge Flap / Disc Sealing for metal seated Lever Shaft / Pin

Data Ductile Iron GGG 50/40, SG Ductile Iron GGG 50/40, SG Dezincification resistant brass CZ 132 Carbon Steel Stainless Steel 316L

10.1.8 Non return valves of sizes DN 350 mm and above shall be high dynamic, spring loaded, non slam, noiseless long pattern, metal seated type manufactured API 6 D standards. The rating of the flanges shall be in accordance with the standards indicated in the data sheets. The design of the valve internal parts shall allow the Issue : 1

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disc to respond very quickly to any flow changes and shall achieve movement from fully open to fully close in less than 0.15 seconds. The single helical spring shall be fully shielded from the process stream by the central flow diffuser. The metal to metal sealing shall achieve tight shut off with 100% reliability. 10.1.9 The Check Valve (DN ≥ 350mm) shall be conforming to the following specifications given in Table 14. Table (14) Property Data Body, bonnet, weight and hinge Ductile Iron GGG 50/40, SG Flap / Disc ASTM A 351 CF 8m Spring AISI Stainless Steel 316 Seat AISI Stainless Steel 316 10.2 CHECK VALVES CONSTRUCTION MATERIALS 10.2.1 The body shall be of ductile iron, GGG 40/GGG 50/SG, BS EN 1563Grade ENGJS-500-7, ISO 500-7 and ISO 400-15. 10.2.2 Fasteners shall be as per Section 1, Clause 1.6 of this specification. 10.3 COATINGS 10.3.1 All valves shall have their entire body coated both internally and externally with either of the following: 300 micron Fusion bonded epoxy (Polymeric anticorrosion) coating as per WIS No. 4-52-01. 300 micron Electrostatic ally applied epoxy coating. 300 micron Fluidized bed epoxy coating. The color of coating shall be “Blue”, Code RAL-5000/5001/5005/5010/5017. All materials coating shall be WRC, DVGW, SGS, DWI, KIWA, NSF 61 or other Worldwide Known Quality Body Certifiers in contact with potable water at 50 degrees centigrade. All casting shall be properly finished, sand blasted and cleaned before coating. Coating shall be smooth and mirror finish without any hairline cracks. 10.3.2 Adhesion Test: Adhesion of coating to metal shall not be less than 12N/mm2 

   

 

(BSI BS EN ISO 4624). 10.3.3 Holiday Test: Porosity of coating shall be “zero” on 3 kV DC tester. 10.3.4 Hardness: Intrinsic Rockwell hardness shall be between 50 - 60. 10.3.5 Impact resistance: For applying of impact energy of 5 NM on coating the cracks should not develop, when tested by 3 kV DC tester. 10.4 MARKINGS 10.4.1 All check valves shall have clearly marked in the casting of the body with the following information: A. Size of valve in mm. Issue : 1

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B. C. D. E. F.

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Pressure rating in Bars. Manufacturer’s name and/or logo. Material type (GGG 40/GGG 50/SG) Manufacturing Standards Number. Year of manufacture.

10.4.2 All check valves shall have individual identification strip which shall be marked by engraving or embossing on a metal strip, the name of manufacturer, individual serial number, tender number and Year of manufacturing. 10.4.3 The metal strip shall be of minimum size of 100mm x 30mm and shall be fixed securely and permanently at appropriate location by industrial type cold welded glue and shall not be screwed or riveted. The glue shall be of industrial grade with a melting point higher than 80°C. 10.5 PACKING 10.5.1 The packing shall be as per Section 1, Clause 1.8 of this specification.  

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Section - 11

Other Types of Valves 11.1 GENERAL These clauses shall be read in continuation of Section 1 of this specification. 11.1.1 The all valves (Flow Control Valve, Plug Valve, Float Valve, Pressure Regulating Valves/Pressure Reducing Valves and Altitude Valves) shall be complying with the following specifications: 11.1.2 All valves shall be suitable for a maximum working pressure of 16 Bar. 11.1.3 All material shall be suitable for use with potable water at a temperature of 50C. 11.1.4 The body shall be of ductile iron, GGG 40/GGG 50/SG, BS EN 1563Grade ENGJS-500-7, ISO 500-7 and ISO 400-15. 11.1.5 All flanged valves shall be drilled to BSEN 1092-2, PN 16. 11.2 COATINGS 11.2.1 All valves shall have their entire body coated both internally and externally with either of the following: 

300 micron Fusion bonded epoxy (Polymeric anticorrosion) coating as per WIS No. 4-52-01.



300 micron Electrostatic ally applied epoxy coating.



300 micron Fluidized bed epoxy coating.



The color of coating shall be “Blue”, Code RAL-5000/5001/5005/5010/5017.



All materials contact with potable water shall be WRC, DVGW, SGS, DWI, KIWA, NSF 61 or other Worldwide Known Quality Body Certifiers in contact with potable water at 50 degrees centigrade.







11.2.2 Adhesion Test: Adhesion of coating to metal shall not be less than 12N/mm2 (BSI BS EN ISO 4624). 11.2.3 Holiday Test: Porosity of coating shall be “zero” on 3 kV DC tester. 11.2.4 Hardness: Intrinsic Rockwell hardness shall be between 50 - 60. 11.2.5 Impact resistance: For applying of impact energy of 5 NM on coating the cracks should not develop, when tested by 3 kV DC tester.

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11.3 MARKINGS 11.3.1 All valves shall have clearly marked in the casting of the body with the following information: A. Size of valve in mm. B. Pressure rating in Bars. C. Manufacturer’s name and/or logo. D. Material type (GGG 40/GGG 50/SG) E. Manufacturing Standards Number. F. Year of manufacture. 11.3.2 All valves shall have individual identification strip which shall be marked by engraving or embossing on a metal strip, the name of manufacturer, individual serial number, tender number and Year of manufacturing. 11.3.3 The metal strip shall be of minimum size of 100mm x 30mm and shall be fixed securely and permanently at appropriate location by industrial type cold welded glue and shall not be screwed or riveted. The glue shall be of industrial grade with a melting point higher than 80°C. 11.3.4 Fasteners shall be as per Section 1, Clause 1.6 of this specification. 11.4 FLOW CONTROL VALVES 11.4.1 Unless otherwise specified, all control valves shall be axial flow non-diaphragm type relation of valve capacity close valve position with percentage (%) opened shall be linear with approximately 50% close valve position, 50% opened valve position and produce no cavitations throughout the operating range as specified in the data sheet. 11.4.2 The valve shall be capable of bubble tight sealing against 16 bar operating pressure unless specified otherwise. The valve shall be manually operated with clockwise hand wheel closing. Pressure drop across the valve should not exceed 0.10 bar when fully opened at maximum specified flow rate. 11.4.3 The valve shall have positioned indicating 0, 25, 50, 75 and 100% opened. Maximum allowable noise level shall be 70 DBA at 1-meter distance. The control valves shall have flanged ends. 11.4.4 All Flow Control Valve flanges shall be drilled to BSEN 1092-2, PN 16. 11.4.5 If the control valves are electrically activated, then the actuator shall be modulating type and can be complete with a positioned.

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11.5 MATERIAL SPECIFICATION 11.5.1 Body Solid stainless steel to ASTM A351 Gr. CF 8M for valves up to 250mm dia. and ductile iron GGG 40 for valves above 250mm dia.         

Coating internally and externally 300 micron hot cured fusion bonded non-toxic epoxy coating. Piston : stainless steel AISI 316 Piston ring : stainless steel AISI 316 Cage : stainless steel AISI 316 Cage ring : stainless steel AISI 316 Stem : stainless steel AISI 316 or AISI 4340 Guide bushing : stainless steel AISI 316 Piston rod : stainless steel AISI 316 or AISI E3316 Seat retaining bush : stainless steel AISI 316

11.6 PRESSURE R EGULATING VALVES/ PRESSURE R EDUCING VALVES 11.6.1 The Pressure regulating and Pressure reducing valves shall be of the globe type, piston or diaphragm operated to comply with the general requirements of specifications. 11.6.2 The valve must be capable of bubble tight sealing against 16 bar operating pressure unless mentioned otherwise. 11.6.3 The end flange shall be rated and drilled in accordance with the standard BSEN 1092-2, PN 16. 11.6.4 The pressure sustaining valve shall be of the pressure compensated globe type complete with external hydraulic relay system and designed to automatically sustain a predetermined pressure immediately upstream its position. 11.6.5 The pressure reducing valve shall be of the pressure compensated globe type complete with external hydraulic relay system and designed to reduce a constant or variable inlet pressure to a predetermined constant outlet pressure at varying flows. 11.6.6 The controlling pressure point can be either at the valve or at a point on the pipeline some distance from the valve. 11.6.7 The relay control system shall consist of a hydraulic relay valve unit, orifice and strainer block, control valves and interconnecting small bore piping. 11.6.8 The relay valve shall be manufactured completely in stainless steel 316, which shall consist of diaphragm, diaphragm guide, support piston, spindle, etc. 11.6.9 The orifice / strainer unit shall have a body and internals of stainless steel.

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11.6.10

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The pressure setting control valves and control piping shall be constructed in

316 stainless steel, the valves shall be designed such that the hydraulic relay system can be inspected, maintained or replaced without isolating the supply. 11.6.11

All necessary repairs to the valve shall be possible without removing the

valve from the line. 11.6.12

The pressure setting shall be capable of being adjusted on site by the use of an

adjustment screw to alter the compression of the spring. 11.6.13

The opening and closing speeds shall also be field adjustable by adjusting the

flow regulation screw. 11.6.14

The valves shall be capable of being fully opened or fully closed by

respective opening and closing of upstream and downstream ground cocks. 11.6.15

The valves shall be designed to provide the necessary loss of head and shall

operate without hunting. The valve mechanism shall be piston operated, controlled from a servo diaphragm actuated by an adjustable spring balance relay comparing pressure generated across an integral orifice plate. 11.7 MATERIAL SPECIFICATION 11.7.1 The material specification of valve shall be as given bellow:       

Body Trims Ported Guide & Seating Seating on plunger Plunger Pilot Valves (control valves) Pilot parts (fittings) Indicating rod

: Ductile Iron GGG 40/50 : Gunmetal to BS 1400 LG 2C : Rubber : Ductile iron GGG 40/50 : Stainless Steel 316 : Stainless Steel 316 : Stainless Steel 316

11.8 ALTITUDE VALVES 11.8.1 The altitude valves shall be of the globe type and shall comply with the general requirements of the specifications. 11.8.2 The valve must be capable of bubble tight sealing against 16 bar operating pressure unless mentioned otherwise. 11.8.3 The end flange shall be rated and drilled in accordance with the standard BSEN 1092-2, PN 16. 11.8.4 The altitude valves shall be of the straight through type and the operation of the float operated pilot valve shall be through a chamber, which is separated with a plunger from the body.

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11.8.5 The Altitude valves shall be fitted with external hydraulic relay system designed to automatically close the valve at reservoir high level and reopen the valve at pre-set minimum level, and the valve shall be suitable for drop tight shut off by having fullface sealing. 11.8.6 The relay control system shall consist of a three way float operated pilot valve, orifice and strainer block, pilot control valves and interconnecting small bore piping, the float operated pilot valve shall be manufactured completely in 316 stainless steel. 11.8.7 The orifice/strainer unit shall have a body and internals of stainless steel, the pilot control valves and control piping shall be constructed in 316 stainless steel. 11.8.8 The altitude valve shall be designed such that the hydraulic relay system can be inspected, maintained or replaced without isolating the supply the pressure setting shall be capable of being adjusted on site by turning the pilot valve screw, the opening and closing speeds shall also be field adjustable by adjusting the flow regulation screw. 11.8.9 The minimum upstream pressure from the valve must exceed 0.4 bars. The distance between the main valve and the pilot valve should not exceed 50 m for proper functioning of the valve. 11.8.10

The globe valve shall be designed to provide the necessary loss of head and

shall operate smoothly without hunting. 11.9 MATERIAL SPECIFICATION 11.9.1 The material specification of valve shall be as given bellow: 

Body

: Ductile Iron GGG 40/50



Trims Ported guide & seat ring

: Gunmetal to BS 1400 LG 2C



Seating on plunger

: Rubber



Plunger

: Ductile Iron GGG 40/50



Pilot valve

: Stainless Steel 316



Pilot parts




Indicating rod


11.10PACKING 11.10.1

The packing shall be as per Section 1, Clause 1.8 of this specification.  

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Section - 12

Pumps 12.1 GENERAL These clauses shall be read in continuation of Section 1 of this specification. 12.2 SCOPE

12.2.1 This specification covers the minimum requirements for design, manufacture, testing at manufacturer's works, supply, site testing and commissioning of the transmission and distribution pumps. This specification shall be read in conjunction with the relevant data sheets, drawings and other relevant sections of the tender documents. Compliance with this specification shall not relieve the Tenderer from any of his contractual obligations and responsibilities towards fulfilling the performance requirements. This specification and the associated drawings shall be considered to be the absolute minimum requirements for performance and quality and shall be considered in extension of "not in limitation". 12.3 CONFLICTS & DEVIATIONS 12.3.1 Any conflicts between this specification and any other applicable KAHRAMAA specification, other industrial standard, or international code etc. shall be resolved in writing by the KAHRAMAA head of water projects, No deviation from this specification shall be allowed, if the tenderer's offer differs from tender specifications, all such differences shall be specifically listed under the title "Variations” and submitted for review and approval, the tenderer's offer, with the exception of specific variations, shall be considered to be according to specifications, any item of pump submittal not included by the tenderer in the offer must be specifically indicated under the heading "Exclusions" and the reasons given for such exclusions, any item not specifically excluded shall be deemed to be included in the offer. 12.4 APPLICABLE STANDARDS AND CODES 12.4.1 The pumps shall be designed, manufactured and tested in accordance with the latest edition of the standards & codes listed below (See Table 15): Table (15) Applicable Standards and Codes Standards Descriptions & Codes EN 1982 Copper and copper alloy- ingots and casting. EN 1561 Founding, Gray Cast Iron. Specification for wrought steels for mechanical and allied PD 970 engineering purposes. Issue : 0

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EN 1092-1

Circular flanges for pipes, valves and fittings. Ductile iron pipes, fittings, accessories and their joints for ISO 2531 water applications. ISO 9906 Hydraulic performance acceptance test grade 1 & 2. EN 837-1 Bourdon tubes Pressure and vacuum gauges. 12.5 TECHNICAL SUBMITTAL: 12.5.1 The Pumps shall be submit complete and comprehensive technical submittal comprises but not limited to minimum of followings: 1. Compliance statement of pump specifications and technical data and drawings consist from followings:  

       

Data sheet. Performance curves showing duty point, power, efficienc y and NPSH values for variable speed pumps, curves must be show the performance at minimum of four different speeds. Detail drawings showing dimensions, outlines, sectionals & 3D exploded views, mechanical seals details, P& ID etc. Multi pumps operation curves with recorded minimum & maximum flows for 1, 2, 3 etc. pumps running. Catalogues. List of spare parts Coating details and procedures including health certificates shall be as per Section 1, Clause 1.5 of this specification Shop testing procedures with details. Previous approvals, certificates etc. Warranty information.

12.6 DESIGN CONSIDERATIONS 12.6.1 The pumps and associated equipments shall be designed and be suitable for operation in the climatic conditions of state of Qatar. 12.6.2 The Conditions under which the pumps are required to operate is considered to be tropical weather, with excess heat dust and humidity at time. 12.6.3 The pumps shall be conforming to the following specifications for the climatic conditions to be considered at site as given in table 16: Table (16) Specifications for the climatic conditions Descriptions Maximum ambient relative humidity: Maximum ambient temperature: Minimum ambient temperature:

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Design ambient temperature:

50 °C

Maximum metal temperature under the sun:

85 °C

Minimum ambient humidity:

20%

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Design ambient humidity

100%

Design wind velocity

150 km/hr

Yearly rainfall

80-150

100% Maximum ambient relative humidity: Under certain climatic conditions, considerable condensation may take place. A considerable amount of salt is contained in atmosphere, which together with the relative high ambient humidity, can produce sever corrosion problems. 12.7 GENERAL R EQUIREMENTS:

12.7.1 The pump covered by this specification shall be suitable for the specified operation conditions and shall be designed and manufactured for a minimum service of 20 years plus minimum of three years of uninterrupted continuous operation or 25,000 hours operation, whichever is later. 12.7.2 Pumps shall be Single stage, double suction, horizontal shaft, centrifugal split case design, suction and discharge connections shall be located on opposite sides of the lower casing, allowing removal of the rotating assembly without disturbing the system piping connections. 12.7.3 The pump shall be suitable for variable speed operation, pressure control and generally satisfactory operation. 12.7.4 The pump maximum speed shall be 1500 RPM and the minimum operating speed shall not be more than 50% of the maximum speed .accordingly, the pump motor shall be suitable for this range. 12.7.5 The pump operation range shall be located between minimum allowable flow specified by pump supplier and the maximum allowable flow of 110 % of best efficiency point at all pump operating speeds. 12.7.6 Water velocity in pump suction and discharge nozzles shall not exceed 4 and 5 m/s respectively at maximum operating condition within pump operation specified range. 12.7.7 Low maintenance cost, reliability and trouble free operation shall be a prime consideration when selecting pumps.

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12.7.8 The pumps and associated equipment shall include all necessary provisions to prevent contamination of the drinking water being pumped. 12.7.9 The pumps shall be designed for continuous duty at rated parameters and shall be capable of pumping the flow ranges specified above. 12.7.10The rated capacity and head of each pump shall be as specified on relevant particular specifications. 12.7.11The optimum efficiency of the pump shall not be less than 85% at rated duty point unless specifically mentioned otherwise, and shall be designed for parallel operation of duty pumps. The minimum efficiency shall not be less than 70% at any other operating point located within specified pump operation range. 12.7.12The head-capacity curve of the pumps shall be stable at all flow rates. The curve shall be of a continuously rising type, right up to shut-off. 12.7.13The minimum flow for each pump shall not exceed 40% of the best efficacy flow unless specifically mentioned otherwise. 12.7.14The maximum flow for each pump shall not be less than 110% of the rated flow at best efficacy point at rated speed. 12.7.15The pump capacity at run-out conditions shall not be less than 130% of the duty point unless specifically mentioned otherwise. 12.7.16The required net positive suction head (NPSHR) at rated flow shall be at least 1.5 meters less than the available net positive suction head (NPSHA) and 0.5metere less than the available net positive suction head (NPSHA) for all pumps parallel operation range. 12.7.17The contractor shall verify the NPSHA value prior to ordering of pumps. 12.7.18The combined noise level of pump-drive system and motor shall not exceed “85dbA” at 1 meter distance from equipment unless mentioned otherwise. 12.7.19The selected duty impeller should not exceed 95% of the r maximum impeller diameter. 12.8 PUMP CONSTRUCTION R EQUIREMENTS: Casing; 12.8.1 The casing of pumps shall exhibit good strength, corrosion resistance, abrasivewear resistance; material of pump casing shall be close grained cast iron to EN BS 1561 or BS 1452 Grade 260, ASTM A48 CL30 or equivalent and be free of any blow holes and sand pockets resulting from imperfect and defective castings unless specifically mentioned otherwise. Inner surfaces of casing which are in contact with the fluid shall be ideally shaped to match the streamlines and be finished so that Issue : 0

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minimum head loss and favorable efficiency could be attained. The casing shall be provided with vent and drain connections, screwed type, and fitted with removable cocks. The material of construction for the removable cocks shall be stainless steel 316 all screw or bolt and nut seating in the casing shall be machined and the joint face of the pump casing shall be sealed by means of flat gasket and bolted together. Pump feet shall be casted as an integral part of the lower casing. Casing shall be hydrostatically tested at 150% the pressure developed by the pump at shut-off. Flanges shall be drilled to EN BS 1092-1 PN 16 rating. All pump casings shall have a minimum corrosion allowance of 3 mm unless otherwise specified on the data sheets. Sufficient clearance shall be provided between the drain opening and base plate, to allow for assembly of pipes and fittings, as required without dismantling the pump. All auxiliary piping connected to the casing shall be made of stainless steel 316L. IMPELLER 12.8.2 The impeller of pump shall be double entry suction manufactured from duplex stainless steel EN 1.4517 (G-X3CrNi Mo Cu N 26633) or equivalent and should exhibit excellent corrosion resistance, abrasive-wear resistance and casting and machining properties. They shall be machined where practicable and made as smooth as possible elsewhere. The vanes of each impeller shall be identical as regards form and dimensions to ensure hydraulic balance in operation. The impellers together with shaft shall be statically and dynamically balanced to ensure a smooth and free of vibration running throughout its operating range. The impeller shall be keyed to the shaft using one piece key; details of the fixing arrangement shall be indicated by the Tenderer in his proposal. Impellers shall be fixed to the shaft such that they do not loosen or become detached when the pump is rotating in the wrong direction by reverse flow or reversed motor connections. Shaft

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12.8.3 The shaft of pumps should exhibit high tensile strength, endurance limit and corrosion resistance. Material of pump shaft shall be of high tensile steel to BS 970 or PD 970, forged stainless steel or other approved material and shall properly be turned all over, ground at the bearings and finished. Sealing of shaft is made by means of mechanical seals. Shafts shall be provided with suitable hard faced sleeves. All pumps shall have renewable shaft sleeves and shall not be in contact with water anywhere. Shaft sleeves material shall be stainless steel EN 1.4571 (316Ti) or other proper equivalent material. The uni-shaft or combined assembly (shaft and impeller) are not a cceptable. Wearing Rings 12.8.4 The pump shall have wearing rings at casing and impeller. Material of renewable rings shall be stainless steel EN 1.4571 (316Ti). Clearance within the rings shall be acceptable and according to manufacturer standard or other approved standards. Wearing rings shall be of renewable type and should be easily replaceable. Impeller wear rings shall be the softer material of the two. End Bearings & Bearing Housing 12.8.5 Both radial and thrust bearings shall be of antifriction maintenance free type. Bearings shall be self alignment type. Bearings shall be sized to offer a minimum L10 life of 100000 hours when operating at any flow rate. Bearings shall be of grease lubricated and protected from water ingress by appropriate means. Bearing housing shall be of cast iron or similar and consist of bearing end cover, thrower, vent, etc. Bearing supports shall not be bolted type and shall be part of pump casing lower half only. Base Plate 12.8.6 Base plate shall be secured to the foundation with foundation bolts and should withstand the weight and vibrations of the pump. Material shall be made of fabricated steel. The design of base plate shall be ratified by the Original Equipment Manufacturer of the pumps. Mechanical Seal

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12.8.7 The shaft seals shall be of the mechanical type by an approved specialist manufacturer. The seals shall be designed and suited for both intermittent and continuous running under all operating conditions. Lubricating and cooling water for the seals shall be drawn from connections on the pump casings. The sealing construction and design should enable the inspection and removal of the seals without disturbing the pumps. The seal chamber size should be proper for all the well-known mechanical seals. An inline filter must be used in the flush line to prevent any foreign material from entering the seal chamber. Bearings 12.8.8 Pumps bearing shall be Ball or roller bearing of anti friction maintenance free standard

type

provided

in

accordance

with

the

pump

manufacturers

recommendations.(insert standards) The bearings shall be easy to replace and available from manufacturer's normal stocks. In the design of bearing assemblies, due consideration must be given to the ambient temperatures. The bearings shall be protected against ingress of dust and moisture by effective seals. If the bearing housing brackets and/or gland bowls(amend the sentence) are not integral with the pump casing, they must be positively located by s tainless steel dowel pins to ensure correct repositioning of the brackets in the event of the joints being distributed. Bearing supports shall not be bolted type and shall be part of pump casing lower half only. Where pump bearings are pressure lubricated, they shall be supplied complete with the associated lubricating oil system. Bearing shall have an ISO L10 life of 100,000 hours as minimum. GAUGES & FITTINGS 12.8.9 Each pump shall be fitted with liquid filled type pressure gauges on the suction and delivery sides complete with isolating cocks and snubbers & 2 way manifold. Pressure gauges shall be 6 inch (150mm) nominal diameter "Industrial" bourdon type in accordance with BS 1780 or equivalent. The suction gauges shall be of compound type with vacuum figures calibrated in red (please add the range of value). The gauges shall be of robust construction, tropicalised with dust and damp proof sealed brass cases or other approved non-corroding solid (not plated) materials. The movements shall be of robust design, capable of withstanding the degree of vibration shocks and pressure fluctuations normally encountered with pump operation when protected by snubbers & 2 way manifold. Where pressurised oil lubricated sleeve bearing are proposed, a dial type temperature gauge shall be provided on shaft bearing. This shall be waterproof and provided with two Issue : 0

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adjustable contacts for two stage alarm and shut down. All gauges on a pump shall be visible from one position and shall be mounted separately as a single panel with SS 316L impulse line, fixed close to both suction and discharge sides of the pump. VENTS & DRAINS 12.8.10An air-release priming cock shall be fitted at the top of the top of the volute casing on each pump and the discharge piped to one of the shaft gland bowls. The gland and body drains shall be collected in a drip-tray and the final discharge shall be piped individually from each pump to the drainage channel in the pump house. The drain pipes shall be in 25mm nominal size heavy wall copper or stainless steel tube fitted with couplings so as to facilitate removal of any possible blockages. NOZZLE & FLANGES 12.8.11Suction and Discharge connections shall be suitable to be connected to PN 16/25, EN 1092-1 flanges as provided in relevant tender document unless mentioned otherwise. The suction nozzles shall be designed for the same pressures as the discharge nozzles. The suction nozzle size shall be selected to keep the suction velocity low, so as to avoid cavitations. Flanges shall be raised face, drilled to PN 16/25, EN 1092-1 unless mentioned otherwise. Necessary tapping shall be provided on the suction & delivery flanges to allow for install ation of the pressure gauges. 12.9 ACCESSORIES Driver (Electric Motor) 12.9.1 The pumps shall be driven by suitably rated electric motor, conforming to applicable specifications and to relevant tender document.

The motor shall be

designed with over-rating factors to take the below mentioned conditions into consideration: 

An over-rating of 15% higher than the maximum power required at point of 110 % of the duty point. Of Q-H curve.



Temperature de-rating for the motor from 40°C to 50°C in addition to above.

The CONTRACTOR shall submit the motor rating calculations to KAHRAMAA for review and approval, prior to initiating motor design. Variable speed drive: 12.9.2 Variation of speed shall be achieved by frequency converters. The variable speed 

pumping system shall be designed to operate over the entire range of operation. The combination of pump and drive shall be designed to operate under changing loads without getting overloaded and/or tripped. The offered Variable Speed Drive System (V.S.D.S.) shall comply to relevant particular specifications and data sheets. Couplings

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12.9.3 The pump shall be coupled to the motor via flexible coupling. The flexible couplings shall be of rigid maintenance free type and shall be of an approved design. The type of coupling offered shall be submitted for KAHRAMAA approval. 12.10PROTECTION OF MOVING PARTS 12.10.1Moving parts of pump including all shafts, couplings, and collars, projecting key heads, gear wheels, chain drives and all other moving machinery shall be guarded where necessary to give complete protection to operating personnel. 12.10.2All set screws on revolving shafts shall be countersunk or suitably protected. The guards shall be of an approved design and shall be fitted where necessary with inspection doors. All guards shall be arranged so that they can be removed without disturbing the parts of the gears and equipment they protect. Guards for shaft couplings shall comply with requirements not less than BS 1649. 12.11PUMPS COATING 12.11.1

All pumps shall be suitably coated and painted on both outer and inner

surfaces. All surfaces are to be thoroughly cleaned free of rust, scale, grease, dirt and moisture before being painted. Grease and oily matter is to be removed by means of a suitable solvent. After surface preparation, the coating system shall be applied. The finish coat(s) shall be applied over the dry intermediate or first coat as recommended by the manufacturer. The internal coating shall consist of primer, intermediate and final coat(s).If more than one coat shall be applied, the second coat shall be applied within time limits recommended by the manufacturer to prevent delaminating between coats. The total dry film thickness for the proposed coating system shall be not less than 300 microns The external coating of the pump shall comprise 2 pack epoxy resin to a minimum dry film thickness of 300 microns. The colour of the coating shall be blue. Coating of the pumps shall be plastic enamel paint (epoxy resin) inside and outside applied by electrostatic spray process. The coating shall exhibit excellent protection for surfaces of pump and should be resistant against impact and sag resistant quality. The adhesion or bond of the primer to the steel and the inter coat adhesion of the finish coats and primer should be perfect The coating shall be suitable for drinking water and shall be certified as non-toxic by an internationally recognised testing organisation prior to internal coating applying. The proposed coating system should be submitted for KAHRAMAA approval

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complete with a guarantee of at least 7 years under all operating conditions. The internal coating system shall be tested in accordance with ISO 2178. 12.12INSPECTION & TESTING Factory TESTS & INSPECTIONS During the course of manufacture, each one of the pumps shall be subject to minimum of followings standard inspection and testing procedures: 12.12.1 Mechanical property tests and chemical analyses for structural materials and alloys of all pump components. The material certificates for same tests shall be reviewed and approved by KAHRAMAA prior to any manufacturing process in accordance with ISO 10474 3.1B certificate. 12.12.2

Hydrostatic pressure tests for the casing, body, and seating of pumps and

valves at 1.5 times of the design pressure plus the suction pressure if the operating pressure is above 5 bars or as per the relevant code. If the design pressure is below 5 bars, the test pressure shall be the shut off pressure plus the suction pressure. 12.12.3

Performance tests for each pump coupled to its own motor in accordance with

ISO 9906 part 1&2.These tests shall be witnessed by KAHRAMAA and shall be at the manufacturer's factory to show that pumps are capable of achieving the duty point values as provided in the Contract. The pump curves shall be plotted at minimum of seven heads/flow rates together with efficiencies, NPSH, power etc. Certified data, curves, etc. both for witnessed test conditions and corrected for actual site conditions shall be plotted & furnished for each test and submitted for approval by KAHRAMAA. Tolerance of curves shall be in accordance with ISO 9906 grade 1. Tolerance for Q & H shall be in accordance with EN ISO 9906- Grade 1 tolerance grade. However for efficiency, no negative tolerance is acceptable. 12.12.4

Noise and vibration tests for motor-pump sets.

12.12.5

Painting test: inspection shall cover colours, thickness and general

appearance, blisters, bubbles, voids or other discontinuities 12.12.6

Temperature rise test for bearings of motor-pumps.

12.12.7

Static and dynamic balancing of rotors and impellers of each motor-pump set.

12.12.8

Visual inspection shall include detection of defects, appearance, dimensions

etc. 12.12.9

Works tests of any other items of the plant not specifically mentioned above

as may be required by the Engineer. 12.12.10

KAHRAMAA reserve the right for shop inspection/stage inspection by their

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The CONTRACTOR/Manufacturer shall submit detailed and complete shop

testing procedure for the pump as per above mentioned type of tests at early stage, and inform KAHRAMAA sufficiently in advance to enable their representatives to witness the tests. The procedure shall be brief, comprehensive mentioning all governing standards and limitations of acceptable range of values to be obtained in the tests. 12.12.12

If any defects / faults / deformations detected during test or after delivery

before end of warranty period, it shall be repaired or replaced by Contractor / Manufacturer after obtaining approval of KAHRAMAA. If the fault cannot be rectified, the manufacturer must then replace the detective pump. 12.12.13

If witnessing of any tests is not satisfactory and a retest is required, the cost

of the witnessed retests shall then be borne by the Contractor. 12.12.14

All instruments used during shop tests at manufacturer's premises shall be

duly calibrated by recognised laboratories and the calibration certificates shall be inspected and certified by inspectors prior to starting the shop tests. The calibration certificates should not be more than six month old. The data and results done during test shall be recorded and submitted after end of the tests. 12.13SITE ACCEPTANCE TEST:12.13.1

Following the completion of the installation and satisfactory start-up of the

equipments, site acceptance tests for all pumps, shall be conducted over the entire speed range and pumps shall be free of cavitations or excessive vibration or noise. Performance of each pump shall be within acceptable tolerance of EN ISO 9906, Grade-2.

In

case

of

non-compliance

to

this

required

performance,

the

manufacturer/contractor shall take corrective actions as necessary to improve the performance

of

pumps.

Considering

this

stringent

performance

criteria,

manufacturer must review the water qualit y, the piping & installation layout of pump station with locations of key equipments such as pressure & flow transmitters and all other components that may affect the pump performance test at site. 12.14R ETENTION OF PUMP EFFICIENCY FOR SUSTAINABLE PERFORMANCE: 12.14.1

Pumps shall offer sustainable performance over a longer period. Manufacturer

shall specify efficiency after defect liability period (2 years), with tolerance limit at the time of the bidding & give warrantee for the retention of efficiency after defect liability period (2 years). After completion of defect liability period but before issuing final taking over certificate, Site tests shall be performed as explained above, Issue : 0

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to ascertain the performance with agreed tolerance. In case of non-compliance to this required performance, the manufacturer/contractor shall take corrective actions as necessary to improve the performance of pumps at his cost. Otherwise KAHRAMAA may carry out such rectifications from other contractor. 12.15

SPARE

PARTS,

TOOLS AND ACCESSORIES 12.15.1

The Contractor should include all necessary and required spare parts for pump

and relating special of standard tools and accessories. Spare parts shall suitably be packed and labeled as to the related apparatus for long storage under the climate conditions prevailing in Qatar. The spare parts should be sufficient for two years operation of pumps and as recommended by the manufacturer. Contractor should provide the complete list of spare parts and relating unit prices. The minimum spare parts required shall be comprised as given in Table 17: Table (17)Specifications for the climatic conditions N Number of pumps including stand by Spare part Name o. pumps 1 2 3 4 5 1 Impeller (each) 1 1 1 2 3 2 Impeller wear ring(set) 1 2 4 6 8 3 Casing wear rings 1 2 4 6 8 (set) 4 Shaft with key and nut 1 1 2 3 4 (set) 5 Shaft protection 1 2 4 6 8 sleeves (set) 6 Pumps bearings & 1 2 4 6 8 washers (set) 7 Mechanical seals 1 2 3 6 8 (each) 8 O-rings, V-rings , and 4 4 8 12 16 gaskets (set) 9 Pump/motor coupling 1 1 1 2 2 10 Bearing housing 1 1 1 2 2

6 3 8 8 4 8 8 8 16 2 2

12.16MAINTENANCE 12.16.1

The pumps shall be designed to permit fast and economical maintenance. The

major parts of pump such as casing, impeller etc. shall be designed and manufactured to insure accurate alignment during installation in the pump hall. The pumps and motor assembly shall be installed in a way allowing for sufficient space for dismantling any component of the assembly without the need of removing from the base plate. The package shall include any special tool required for dismantling Issue : 0

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and reassembling of the pump. These shall be packed separately and clearly labeled as special tool for the pump. The package shall include also Operating instructions and maintenance manual, illustrated spare parts list, list of recommended spares for five years operation, instructions for daily checking and seasonal maintenance, troubleshooting guide, lubrication and bearing schedule, drawings for installation. The package shall include also information about start-up, shutdown, emergency shutdown, operation limits and the normal operating conditions. Package shall include charts indicating the performance curve, models, type and sizes of pump, operation points of equipment with reference to the performance charts including outline and sectional drawings, schematics and illustrative sketches identifying the components, method of inspection and repair. 12.17VIBRATION, NOISE AND TEMPERATURE MONITORING 12.17.1

Special care shall be taken to ensure that all parts of the plant are free from

vibration and noise. All the rotating parts should be statically and dynamically balanced so that no vibration, noise or excessive heat is produced at any part of machinery or surroundings as long as the system is working at the nominal load and speed. Special care shall also be taken to ensure that resonance of any part of the pumps does not occur as a result of harmonics which although not apparent when the items of machinery in question are tested by themselves nevertheless give rise to objectionable vibrations when installed in their final positions. The Contractor shall take whatever steps may be necessary to remedy any vibrations or noise which in the opinion of the Engineer is excessive. 12.17.2

The pumps supplier shall provide props in the pumps for measuring and

monitoring vibration and temperature and coordinate with contractor to have the followings parameters/signals for On-line monitoring of motors and pumps (Vibration & Temperature) locally control desk , SCADA and remotely at NWCC: 12.18TEMPERATURE MONITORING: 12.18.1 Pump • • 12.18.2

Real time (4-20 mA) temperature monitoring for DE, NDE bearings Separate alarm contact for High & High- High bearing temperature for DE, NDE bearings to alert & trip the pumps. Motor

• •

Real time (4-20 mA) temperature monitoring for DE, NDE bearings Separate alarm contact for High & High- High bearing temperature for DE, NDE bearings to alert & trip the pumps. • Real time temperature reading (4-20 mA) for individual three motor winding. Issue : 0

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•

Separate alarm contact for High & High- High winding temperature for all three winding to alert & trip the motor. 12.19VIBRATION MONITORING: 12.19.1 Pump • • 12.19.2

Real time (4-20 mA) X & Y direction Vibration reading for DE, NDE bearings. Separate alarm contact for High & High- High bearing X & Y Vibration for both bearings (DE, NDE) to alert & trip the pumps. Motor

• •

Real time ( 4-20 mA) X & Y direction Vibration reading for DE, NDE bearings Separate alarm contact for High & High- High bearing X & Y Vibration for both bearings (DE, NDE) to alert & trip the motor. • The above signals shall have indication in, Wall mounted LED screens display system, local PLC & NWCC SCADA as attached. 12.20GUARANTEE & WARRANTY 12.20.1

The warranty period for all of the pumps shall be two years as defined in the

General Conditions of Contract. The Contractor shall be responsible for the correction of any defects to the pumps during the Warranty Period and shall make all necessary repairs and replacements free of charge including labour charges. 12.21NAMEPLATES, MARKING & LABELING 12.21.1

All pumps shall be identified by marking and labeling. A stainless steel

nameplate shall be provided for each pump including complete information i.e. pump identification, manufacturers name, type & size, serial No., speed, rated flow , rated head, maximum casing pressure, weights of pump & motor & base plate, in kilograms. The direction of rotation shall be clearly indicated, preferably on the pump, otherwise on the name plate. The plate shall be securely riveted or screwed in a readily accessible position on the pump .If screwed, heads are to be deformed to prevent removal, and on no account shall the method of fixing involve drilling into the wall of a pressure part. The name plate dimensions shall be according to DIN 825 standard. 12.22PACKING 12.22.1

The packing shall be as per Section 1, Clause 1.8 of this specification. 

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Section - 13

Surface Boxes &Manhole Covers, Marker Posts & Indicator Plates 13.1 GENERAL These clauses shall be read in continuation of Section 1 of this specification. 13.1.1 All surface boxes and manhole covers shall be manufactured from ductile iron in accordance with BS-5834, Part 2 Grade A or EN 124, Class D-400 heavy duty or equivalent as specified. 13.1.2 All surface boxes and manhole covers shall be coated with a cold applied black bitumen solution in accordance with BS-3416. 13.1.3 All surface boxes and manhole covers shall be kite marked or a BIS Certificate of compliance with the relative standard must be supplied with all deliveries. 13.1.4 All surface boxes and manhole covers shall have open keyways and prising slot in frame. 13.1.5 Lifting keys, of malleable cast iron with loop handles or “T” handle as appropriate suitable for all surfaces box and manhole covers and shall be supplied One (1) set per Twenty (20) surface boxes. 13.1.6 All surface boxes and manhole covers shall have a height and depth of raised for recessed pattern, Letters, Symbols and KAHRAMAA logo with minimum of 5mm raised (See Appendix III). 13.1.7 All surface boxes and manhole covers shall have bounding ribs on the base frame. 13.2 GATE VALVE SURFACE BOXES (UP TO 300MM Ø VALVES) 13.2.1 The SV surface boxes shall be of the square type with a minimum 150 x 150mm clear opening or double triangular loose coupled t ype, with a nominal 150 x 150mm clear opening to BS 5834, Part 2 Grade A or EN 124, Class D-400 heavy duty or equivalent as specified. 13.2.2 The covers of the SV surface boxes shall have open keyways and prising slot in frame. 13.2.3 The covers of SV surface boxes are to have in the casting the letters ‘SV’ and Water/W with a minimum height of 25mm and the raised as per clause 13.1.6. 13.2.4 The covers of the SV surface boxes shall be fitted with security chains. 13.2.5 The SV surface box shall have KAHRAMAA Logo for identification and the raised as per clause 13.1.6. Issue : 0

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13.3 GATE VALVE MANHOLE COVERS (400MM Ø VALVES AND ABOVE) 13.3.1 The GV manhole covers shall be of the square type with a minimum 750 x 750mm double triangular type clear opening, and shall conform to BS-5834, Part 2 or EN124, Class D-400 heavy duty or equivalent as specified. 13.3.2 The covers of the GV manhole covers shall have closed keyways and prising slots in frame. 13.3.3 The covers of GV manhole covers are to have in the casting, the letters ‘GV’ and Water/W with a minimum height of 50mm and the raised as per clause 13.1.6. 13.3.4 The GV manhole covers shall have KAHRAMAA Logo for identification and the raised as per clause 13.1.6. 13.4

AIR VALVE MANHOLE COVERS

13.4.1 The AV manhole covers shall be of the square type with a minimum 750 x 750mm double triangular type clear opening, and shall conform to BS-5834, Part 2 or EN124, Class D-400 heavy duty or equivalent as specified. 13.4.2 The covers of the AV manhole covers shall have closed keyways and prising slots in frame. 13.4.3 The covers of AV manhole covers are to have in the casting, the letters ‘AV’ and Water/W with a minimum height of 50mm and the raised as per clause 13.1.6. 13.4.4 The AV manhole covers shall have KAHRAMAA Logo for identification and the raised as per clause 13.1.6. 13.5 BUTTERFLY VALVE MANHOLE COVERS 13.5.1 The BV manhole covers shall be of the square type with a minimum 750 x 750mm double triangular type clear opening, and shall conform to BS-5834, Part 2 or EN124, Class D-400 heavy duty or equivalent as specified. 13.5.2 The covers of the BV manhole covers shall have closed keyways and prising slots in frame. 13.5.3 The covers of BV manhole covers are to have in the casting, the letters ‘BV’ and Water/W with a minimum height of 50mm and the raised as per clause 13.1.6. 13.5.4 The BV manhole covers shall have KAHRAMAA Logo for identification and the raised as per clause 13.1.6. 13.6 STOPCOCK AND FERRULES (SC) SURFACE BOX 13.6.1 The Surface Connection (SC) surface boxes shall be of the square type with a minimum 150 x 150mm clear opening or double triangular loose coupled type, with

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a nominal 150 x 150mm clear opening to BS 5834, Part 2 Grade A or EN 124, Class D-400 heavy duty or equivalent as specified. 13.6.2 The covers of the SC surface boxes shall have open keyways and prising slot in frame. 13.6.3 The covers of SC surface boxes are to have in the casting the letters ‘SC’ and Water/W with a minimum height of 25mm and the raised as per clause 13.1.6. 13.6.4 The covers of the SC surface boxes shall be fi tted with security chains. 13.6.5 The SC surface box shall have KAHRAMAA Logo for identification and the raised as per clause 13.1.6. 13.7 UNDER GROUND FIRE HYDRANT MANHOLE COVERS 13.7.1 Fire hydrant (FH) manhole covers shall be of the Rectangle type with a minimum 380 x 230mm clear opening and shall conform to BS-5834, Part 2 or EN-124, Class D-400 heavy duty or equivalent as specified. 13.7.2 The covers of the FH manhole covers shall have closed keyways and prising slots in frame. 13.7.3 The covers of FH manhole covers shall have in the casting either the words ‘Fire Hydrant’, in letters 25mm minimum in height or the letters ‘FH’ and Water/W with a minimum height of 50mm and the raised as per clause 13.1.6. 13.7.4 The covers of the FH manhole covers shall be fitted with security chains. 13.7.5 The FH manhole covers shall have KAHRAMAA Logo for identification and the raised as per clause 13.1.6. 13.8 WASHOUT MANHOLE COVERS 13.8.1 The WO manhole covers shall be of the square type with a minimum 750 x 750mm double triangular type clear opening, and shall conform to BS-5834, Part 2 or EN124, Class D-400 heavy duty or equivalent as specified. 13.8.2 The covers of the WO manhole covers shall have closed keyways and prising slots in frame. 13.8.3 The covers of WO manhole covers are to have in the casting, the letters ‘WO’ and Water/W with a minimum height of 50mm and the raised as per clause 13.1.6. 13.8.4 The BV manhole covers shall have KAHRAMAA Logo for identification and the raised as per clause 13.1.6. 13.9 MARKER POST 13.9.1 Marker post shall be manufactured from steel channel as detailed in the standard drawing No. 1/49/C (See Appendix III). Issue : 0

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13.9.2 Each post will be supplied with a steel backing plate use for GV, AV and FH, and Each post will be supplied with:A) Six (6) Nos. of M-8 x 30mm long counter sunk bolts with hexagon drive. B) Four (4) Nos. of M-6 x 30mm long slotted round head bolts with nuts and spring washers. 13.9.3 All posts and backing plates are to be grit blasted prior to the application of a suitable three stages epoxy paint system. The color shall be light aircraft gray color Code RAL 7035. 13.9.4 All post & backing plates shall have identification metal strip (i.e. name or logo of the manufacturers). 13.10INDICATOR PLATE 13.10.1 Indicator plates and tiles will be from the ‘F’ range. The Engineer will notify Numbers and letters in Arabic and English to be shown on the tiles. 13.10.2 Fire hydrant plates will have the letter ‘H’ cross and commas be empty of tiles and have a plastic backing plate. 13.10.3 Gate valve and air valve plates will have the Arabic ‘Water’ ‘T’ cross and commas, be empty of tiles and have a plastic backing plate. ALUMINUM

13.11

INDICATOR PLATE 13.11.1 All aluminum indicator plate shall be designed as per the standard drawing No. NDSSD-902 (See Appendix III). 13.11.2 Aluminum Plate Thickness: 3mm 13.11.3 Type of Coating: Electro static powder coating 13.11.4 International coating cooler code: RAL 5019 (Blue)/ RAL 3002 (Red) 13.11.5 Coating thickness: 100 micron 13.11.6 Depth of engraved letters: 0.8mm 13.11.7 Coating UV resistance: ASTM G 154 (UVB- 131) cycle at 50C UV and 4 hours at 40C condensation, no chalking, excellent gloss retention & color stability after 1000 hours testing. Series: 1307, Gloss: 77 ±7, Finish: smooth. 13.12PACKING 13.12.1 The packing shall be as per Section 1, Clause 1.8 of this specification. 

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Section - 14

Copper Tubes 14.1 GENERAL These clauses shall be read in continuation of Section 1 of this specification. 14.1.1 The copper tubes shall be manufactured to BS-2871, Part 1, Table ‘Y’/ EN 1057 R 220 250 and marking shall be engraved as per relevant standard. 14.1.2 The tubes shall be suitable for underground use for the transmiss ion of potable water. 14.1.3 The tubes shall be supplied in the following forms: 14.1.4 15mm to 28mm Ø - soft coils of 20 meters length. 14.1.5 42mm & 54mm Ø - half-hard 5.8 meters straight length. 14.1.6 Tube samples and test results including ‘Drift Test’ results shall be provided at the client’s request. 14.1.7 The coiled tubing is to be secured against uncoiling during transit, the straight lengths to be supplied in wooden boxes and is to be fitted with end caps to prevent damage during transit. 14.1.8 All tubes are to be new and factory fresh, tubes which have developed thick ‘patina’ through standing in stockyards etc. will not be accepted. 14.2 SHEATHING 14.2.1 The copper tubes shall be externally coated over their entire length with continuous seamless polyethylene sheathing. The color of this sheathing shall be Green/Blue. 14.3 TUBE SIZES 14.3.1 The copper tubes shall be complying with the following specification with size as given in Table 18: Table (18) The Specification for copper tubes. Tube Nominal size

Outside Ø (mm)

Nominal wall Thickness(m m)

Thickness sheathing (mm)

(mm)

Max.

Min.

15

15.04

14.965

1.0

1.0

21.975

1.2

1.0

27.975

1.2

1.0

5 22

22.05 5

28

28.05 5

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42

42.07

41.99

1.5

1.6

54

54.07

53.99

2.0

1.6

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14.4 PACKING 14.4.1 The packing shall be as per Section 1, Clause 1.8 of t his specification. 

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Section - 15

Copper Fittings, Ferrules, Stopcocks 15.1

GENERAL These clauses shall be read in continuation of Section 1 of this specification.

15.1.1 The compression fittings shall be manufactured to BS-864, Part 2, Type ‘B’, and shall be the ‘manipulative’ type with 2 locking rings and marked as BS 864.2. All mater ial and associated components intended to be used for this project must be approved by the Materials Standards Section of KAHRAMAA, prior to place firm order for purchasing. 15.1.2 The capillary fittings shall be manufactured to BS-864, Part 2, and shall be of the ‘integral’ solder ring type and marked as BS 864. 15.1.3 All the above fittings as referred in Clause 15.1.1 & 15.1.2, shall be suitable for use with copper tube to BS-2871, Part 1, Table ‘Y’/ EN 1057 R -220-250, shall also be suitable for underground use with potable water and shall be wrapped by lubricated tape. 15.1.4 All poly fittings shall be compression type and shall be manufactured to BS 864, Part 3, Type A marked as BS 864.3 and shall also be suitable for use with potable water. 15.1.5 All nuts on these fittings shall be hexagonal or octagonal. 15.1.6 All fittings must be new, clean and recent manufactured. 15.2 MARKING 15.2.1 All fittings shall have engraved and/or casted the following:     

The manufacturer’s name and identification mark. British Standard Number: Compression Fittings BS-864.2 or BS-864.3 Capillary Fittings BS-864 Poly Adapters BS-864.5 The size of the fitting in mm.

15.2.2 In the case of universal swivel ferrule, these will not have the BS number on them. However, ferrules may have their size indicated in “imperial” measurement. In addition to the above, an arrow indicating the “direction of flow” engraved and/or cast i nto them. 15.3 MATERIALS 15.3.1 All fittings including nuts & bolts, unions, etc., are to be manufactured from ‘gunmetal’ to BS-1400 LG2 or DZR Brass except material specified elsewhere in the specifications. Samples with complete material specifications shall be supplied at the time of tendering. 15.3.2 UNIVERSAL

SWIVEL

FERRULES,

MANUFACTURED FROM ‘gunmetal’,

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ADAPTERS

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15.3.3 Stopcock, material option will depends on the application type: 



For Above ground application: Stopcock is to be manufactured from gunmetal to BS-1400 LG2 or DZR brass. For underground application: If the Stopcock will be in direct contact with soil then it must be manufactured from gunmetal to BS-1400 LG2. If not (inside chamber with wrapping protection) either DZR brass/ gunmetal. Note. Specifications of both applications will depend in the tender requirements.

15.3.4 Gaskets to be supplied with fittings in this section must be suitable for use with potable water and the type of gasket to be set out in the offer. 15.4 UNIVERSAL SWIVEL FERRULE 15.4.1 The ferrule shall be suitable for connecting copper service pipes, (copper tubes to BS2871, Part 1, Table ‘Y’/ EN 1057 R 220 -250), to cement lined ductile iron distribution mains to, (BS-4772/ISO 2531/EN545), and shall be ductile iron distribution pattern. Screws down type ferrules with crutch heads are not acceptable. 15.4.2 The ferrules shall be suitable for insertion under-pressure by the use of a normal under pressure-tapping machine, as well as for normal dry installation. 15.4.3 The ferrules shall be manufactured throughout in ‘gunmetal’ to BS -1400 LG2 including the inner plug, the top plug may be of PVC. 15.4.4 The following inlet/outlet connection will be required as per given in Table 19: Table (19) The Inlet / Outlet connection Size of ferrule

½”

x 15mm

¾”

x 22mm

1”

x 28mm

1½” x 42mm 2”

x 54mm

Type of outlet connection Copper compression , Type ‘B’ Copper compression , Type ‘B Copper compression , Type ‘B Copper compression , Type ‘B Copper compression , Type ‘B

BS 864-2, BS 864-2, BS 864-2, BS 864-2, BS 864-2,

15.5 MARKING 15.5.1 All fittings shall have engraved and/or casted the following:   

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 

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Poly Adapters BS-864.5 The size of the fitting in mm.

15.6 STOPCOCKS 15.6.1 Stopcocks are to be manufactured to BS-1010, with crutch heads and loose jumpers. The stopcock shall be manufactured from gunmetal to BS-1400 LG2 or DZR according to the type of the application as mentioned in clause 15.3.3. 15.6.2 Stopcock washers are to be suitable for use with potable water at a normal temperature of 50 C. 15.6.3 Stopcocks will be required with the following types of connection as given in Table 20: Table (20)The required types of connection Size of stopcock 15mm 22mm 28mm 42mm 54mm

Type of connection Copper compression Type Copper compression Type Copper compression Type Copper compression Type Copper compression Type

‘B’ ‘B’ ‘B’ ‘B’ ‘B’

15.7 MARKING 15.7.1 All fittings shall have engraved and/or casted the following:     

The manufacturer’s name and identification mark. British Standard Number: Compression Fittings BS-864.2 or BS-864.3 Capillary Fittings BS-864 Poly Adapters BS-864.5 The size of the fitting in mm.

15.8 SADDLES 15.8.1 Saddle strap shall be manufactured from ‘Gunmetal’ to BS-1400 LG2 with bolts size suitable for ferrule connections up to 54mm, (2 Inches). 15.8.2 All bolts and nuts shall be stainless steel grade A4. 15.8.3 The saddles shall be suitable for use with ductile iron pipes to BSEN 545 / ISO 2531. 15.9 MARKING 15.9.1 All saddles shall have engraved and/or casted the following:  

The manufacturer’s name and identification mark. British Standard Number: The size in mm.

15.10 PACKING 15.10.1 The packing shall be as per Section 1, Clause 1.8 of this specification.

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Section - 16

Electronic Flow Meters District 16.1

GENERAL These clauses shall be read in continuation of Section 1 of this specification.

16.1. 1

Electromagnetic flow meters shall be of a robust construction; generally with the requirements of BS 5792. Materials of construction shall have a high level of corrosion resistance, be durable and where normally exposed, be resistant to degradation by sunlight and high temperatures.

16.1. 2

The meter installation shall include a microprocessor transmitter of a similar durable construction to that of the meter. The transmitter shall incorporate a display indicating a four digit flow rate.

16.1. 3

All connections shall be watertight and be of a heavy duty design with high reliability.

16.1. 4

The flow meters and transmitters shall be protected to the International Protection Code IP68.

16.1. 5

Manufacture/vendor clearance shall be obtained for flow meter installation drawings with respect to its performance for the selected range.

16.1. 6

The installation shall be powered from a UPS power mains supply.

16.1. 7

Electromagnetic Flow Meters components shall comply with the following:

16.2

FLOW SENSOR AND TRANSMITTER

16.2.1

Magnetic flow meters shall have flanged connections PN 16(.Material: Carbon Steel)

16.2.2

Vendor shall recommend and provide all accessories and fittings necessary for earthing / grounding Electromagnetic flow meters for a noise-free signal (clean Instrument earthing shall be checked and being less than 1 ohm)

16.2.3

The upstream and downstream straight lengths required for the offered Magnetic flow meters are to be furnished along with bid. The criterion for location of piping reducers, valves, tees, bends etc shall be checked by contractor.

16.2.4

The flow sensor should be buriable and to have a protection to IP 68, N EMA 6P.

16.2.5

Ambient Temperature Limits: 70º C

16.2.6

Process Temperature Limits: 70º C

16.2.7

The flow meter shall be bi-directional.

16.2.8

The sensor shall be constructed of stainless steel grade 316L and coated with a certified epoxy coating (Minimum 300 micron).

16.2.9

Hastelloy electrodes shall be used.

16.2.10 The liner material should withstand minimum 100ppm of CL2 and Clo2 and the contractor should submit a WRAS certification for their Flow Meters with liner Material for Hot Portable water application in line with project specification. 16.2.11 The sensor operating temperature range shall be 0 to +70º C a t 16 bars. 16.2.12 The flow sensor cable has to be armored, fitted and potted to the sensor prior to shipping from the manufacturer's location. The electrical connection should be 20 mm armored glands. 16.2.13 The Flow sensor shall be potted at site for the flow meter having remote transmitter installation ( more than 20 M away from flow sensor ) Issue : 0

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16.2.14 The Flow sensor Terminal Box shall be of stainless steel. 16.2.15 The contractor should install only the manufacture Flow meter sensor cable for better accuracy. 16.2.16 The sensor shall be to IP68 rated for permanent submergence up to 2 meters. 16.2.17 The Transmitter Operating temperature range shall be 0 to +60º C. 16.2.18 The Transmitter shall have housing with IP68 rating. 16.2.19 The transmitter has to be mounted away from the sensor in an Air condition environment and if any limitation in distance than it will install such a way that it is protected by a sunshade and can be enclosed in IP68 enclosure as per Kahramaa engineer approval. 16.2.20 The converter shall have background illumination with a three button menu driven alphanumeric 5 lines, 40 character display to indicate flow rate, totalized values, settings and faults. 16.2.21 The transmitter power supply shall be suitable for both 240Vac and 24Vdc. 16.2.22 The transmitter shall have four separate digital programmable outputs; open collector transistor useable for pulse, frequency or alarm settings, for standard converters and Modbus configuration. 16.2.23 The totalizer value has to be independently stored both in the sensor and the transmitter. 16.2.24 The transmitter analogue output shall be 4 – 20 mA into 800 ohms max. 16.2.25 The user interface shall be via hand held (HART) and via Asset Management System. 16.2.26 The Signal interface shall traditional I/O, Modbus and HART. 16.2.27 The totalizer shall be configurable pulses. 16.2.28 Minimum three Configurable alarms (Low Flow Alarm and High Flow Alarms , Empty pile line detection alarm) 16.2.29 Accuracy; 0.2% at 0.5 M/S and 0.5% at 0.2 M/S of actual flow not full range of the flow meter. 16.2.30 Each flow sensor shall be wet calibrated with the relevant/Paired transmitter and all of the calibration information and factory settings matching the sensor/Transmitter shall be stored integrally within the converter’s non-volatile memory. At initial commissioning, the flow meter shall commence measurement without any initial programming. The certificate of calibration shall be provided with each flow meter (having both flow sensor and transmitter details) 16.2.31 The contractor shall submit the finger print of the flow meter along with calibration certificate. 16.2.32 The signal converter/ Transmitter shall have the facility to replace a new signal converter/ Transmitter to upload all previous settings and resume measurement without any need for reprogramming or rewiring. 16.2.33 The offered bid price shall cover the manufacturer review of installation drawings, approval and their physical presence during site installation to confirm their recommendation for the minimum upstream and downstream installation requirements and other vital criteria for stable measurement. 16.2.34 The proposed Flow meter sensor / transmitter shall have wet calibration facility in Qatar or Middle East. Issue : 0

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16.2.35 The contractor should submit minimum 5 point calibration certificate for each Flow meter with 0.2 m/s , 0.3 m/s ,0.4 m/s ,0.5m/s and 1 m/s Velocity points as Mandatory and the calibration certificate should have upstream and Downstream Downstream distance details in the certificate ) 16.2.36 During FAT Kahramaa Representative will check the 5 point calibration for each Flow meter type (as per Pipe Size). 16.2.37 The Contractor shall submit the Calibration facility details with its accredited certificate during material submittal stage. 16.2.38 The contractor shall provide the calibration certificate validity as follows 16.2.39 On shelf – shelf – 16.2.40 After site installation – installation – 16.2.41 The Flow Transmitter should have a self-diagnostic or Verification facility (internally or externally) to cross check the function of the Transmitter and Sensor. 16.2.42 The verification should read all the diagnostics for preventive maintenance. 16.2.43 The verification should be supported by necessary verification software and shall be able to be printed as a certificate to prove that the meter is within the limits of all parameters as the finger print. 16.2.44 The self-calibration method shall be stated in details to demonstrate the elements under calibration. 16.2.45 The measurement draft and MTBF shall be stated. 16.2.46 The software and the special tools shall be provided to Kahramaa for future maintenance and trouble shooting. 16.2.47 The contractor should do yearly instu- verification for the installed flow meter till the end of contract maintenance period. 16.2.48 The flow meter shall have the facility to link any further monitoring & data acquisition systems such AMR (Automatic Meter Readings), SCADA ... etc. 16.2.49 Provision of service passwords for security should be an essential feature of the transmitter to prevent tampering of the transmitter configuration. Write access should be prevented by an internal switch. 16.2.50 The transmitter shall have a simulation mode wherein simulation for Velocity, Q, Q%, I out, Pulse, Logic2 / Pulse 2, Logic 3 and HART can be carried out (internally / externally through source). 16.3

PRESSURE GAUGE

16.3. 1 Bourdon tube pressure gauges should be of the safety-pattern type in accordance withEN60837-1. Where such gauges are not suitable due to corrosion, plugging, etc., pressure gauges with a diaphragm seal shall be used. 16.3. 2 Pressure gauges shall have a circular dial and shall be of the direct sensing type, with bourdon element. Gauges shall have a 4 inch (100 mm) dial and shall be of 316L SS construction as a minimum and shall have ½” NPT male bottom process connections. 16.3. 3 Pressure gauges shall be of the safety pattern construction and shall be fitted with full blowout backs and shatterproof lens (laminated safety glass).

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16.3. 4 Pressure gauge dial shall be white, non rusting plastic with black figures. Pointers shall have external micrometer adjustment for gauge zero adjustment. 16.3. 5 Pressure gauges shall be weatherproof and shall have features like screwed bezels, externally adjustable zero, over range protection and blowout discs. 16.3. 6 Pressure gauge ranges shall be selected from the following series so that the normal operating pressure is between 50 to 75% of scale, and the gauge is suitable for the lower design pressure and the upper design pressure. 16.3. 7 For pressures above atmospheric the following ranges shall be considered, in barg. 1 to 1 0 to 16

0 to 1.6 0 to 25

0 to 2.5

0 to 4

0 to 40

0 to 60

0 to 6

0 to 10

16.3. 8 Pressure gauges shall have an accuracy of 1% of URV as a minimum. Differential pressures gauges shall have an accuracy of 2% of URV. 16.3. 9 Over range protector and pulsation dampener, whenever used, shall be of SS316L, as a minimum. Pulsation dampeners shall be used for all pulsating services. These shall be floating pin type, externally mounted and externally adjustable. 16.3. 10 Process connection shall normally be 1/2" NPT-M bottom, except for diaphragm seal where11/2" flanged connection shall be used. 16.3. 11 Cases shall be weatherproof to IP-68 as per IEC-60529. Blow-out discs shall be provided for all gauges. 16.3. 12 Filled gauges shall not be used for any service, except where needed due to vibration. 16.3. 13 Primary isolation valves at main pipe tapping point are provided by Piping for all installations. 16.3. 14 All the pressure gauge shall install through Impulse line without fail as per Kahramaa engineer approval. 16.3. 15 The contractor shall install the Pressure Gauge with online calibration facility using Manifold (2 or 3 way manifold SS316) with other accessories (snubber and so on.). 16.3. 16 The calibration certificate shall show the valve in 25% increment and decrement to confirm the linearity / repeatability of the gauges. 16.3. 17 The contractor shall supply the special tools (Pressure source and standard reference with all the accessories) to do Future maintenance and Trouble shooting. 16.4

PRESSURE TRANSMITTERS AND DIFFERENTIAL PRESSURE TRANSMITTERS

16.4. 1 The accuracy is 0.1% of calibrated span (including temperature drift, linearity and repeatability). 16.4. 2 Smart type and the output signal shall be 4-20mA besides HART. 16.4. 3 The pressure range and other specifications are as mention in the pressure gauge specification. 16.4. 4 Transmitters shall have no vent or drain connections in the body. They shall also have overrange protection up to 150% of the maximum chamber rating on one or either side without temporary or permanent damage. 16.4. 5 All wetted parts and body for Transmitters and fitting shall be SS316L as a minimum. 16.4. 6 The signal output, transmitter protection, Certification, susceptibility, EMC compliance, cable entry etc shall comply with IEC and be approved by KM Issue : 0

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16.4. 7 All Transmitters' process connection shall normally be 1/2" NPTF. 16.4. 8 The ambient temperature is up to 70º C. 16.4. 9 The power supply 24VDC. 16.4. 10 Primary isolation valves at main pipe tapping point are provided by Piping for all installations. 16.4. 11 Transmitter shall be installed through Impulse line without fail as per Kahramaa Engineer approval. 16.4. 12 The contractor shall install the Transmitter with online calibration facility using Manifold (3 or 5 way manifold SS316) with all the required accessories. 16.4. 13 The calibration certificate shall show the valve in 25% increment and decrement to confirm the linearity / repeatability of the Transmitter reading. 16.4. 14 The Transmitter, its Electrical connection and Accessories shall have ingress protection class according to IP68. 16.4. 15 The Transmitter should have display with Push Button option for basic settings and the contractor shall supply the special tools ( HART Communicator / OEM recommendation) to do Future maintenance and details diagnostic (while trouble shooting). 16.4. 16 The Special tool shall be the latest model ( not less than 2 years old) with all the option 16.5

ASSET MANAGEMENT SYSTEM

16.5. 1 The contractor shall supply a workstation complete with an asset management system compatible with the provided flow meters to be installed with all needed accessories that ensures the functionality of the system. The provided asset management system shall support OPC connectivity with the NWCC SCADA.

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Section - 17

S.S. Repair clamps & under pressure Drilling Tees 17.1 GENERAL These clauses shall be read in continuation of Section 1 of this specification. 17.1.1 The repair clamps and under pressure drilling tees shall be suitable for use with Ductile Iron pipes manufactured to BSEN 545/ISO 2531. All pipe diameters being metric. 17.1.2 All units shall be supplied complete and ready for use. 17.1.3 All units are to be supplied in minimum of Two (02) bands segments for easy handling during installation. 17.1.4 All units are to have ‘Finger’ lugs to ensure bolt guidance and alignments of units un its during installation. 17.1.5 All units are to have a suitable method of jointing between the stainless steel band of the clamp body and the lugs containing the bolts etc.. The preferred method of jointing is by ‘pinning’; the Tenderer Tenderer shall specify the method of jointing at the time of tendering. 17.1.6 In the case of under pressure drilling tees, the method of jointing the branch to the main clamp body shall also be set out in the offer. In the case of welded joints, the method and standards of welding and preparation shall be set out. 17.1.7 The packing of all units shall provide protection from damage during transit and be suitable for storage once delivered. 17.1.8 The inner diameter of S.S. Repair clamps shall be suitable to the outer diameter of the D.I. Pipes as per ISO 2531 / BSEN 545. 17.2 MARKING 17.2.1 Repair camps and under pressure tees are to be supplied with each unit marked with the following information:     

Manufacturer’s name. Size of pipe for which the unit is manufactured for. Direction of rotation. Size of branch Grade of stainless steel.

17.3 MATERIALS 17.3.1 The repair clamps and under pressure drilling tees shall be manufactured from high grade Stainless Steel to BS-1449, Para 2 - 316L/S12 or similar approved. 17.3.2 ‘Finger’ lugs may be manufactured from cast or malleable iron, ductile iron, steel or stainless steel. In all cases, other than the lugs manufactured from stainless steel, the Issue : 0

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lugs must be protected from corrosion by a suitable coating; this is to be specified at the item of tendering. 17.3.3 Fasteners shall be manufactured from stainless steel. 17.3.4 The gaskets used in all units shall be of EPDM (EDK-70), suitable for use with potable water and full details of the same shall be included with the tender offer. 17.4 LENGTHS OF THE CLAMP 17.4.1 Lengths of the repair clamp must fall within the ranges as given in Table below 21. Table (21) The length of the repair clamp Type Minimum Length A 300 mm B 500 mm C 750 mm

Maximum Length 450 mm 600 mm 1000 mm

17.4.2 The Tenderer shall specify at the time of tendering the exact length of the clamp he is to offer to comply with each of the above ranges. 17.5 FLANGES 17.5.1 The flanges fitted to the branch outlet of the under pressure drilling tees are to be drilled to BS 4504, PN-16. 17.5.2 The branch must be of stainless steel. 17.6 PACKING 17.6.1 The packing shall be as per Section 1, Clause 1.8 of this specification.

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Section - 18

Concrete and Ancillary Items 18.1 GENERAL These clauses shall be read in continuation of Section 1 of this specification. 18.1.1 All concrete shall be made using the sulphate resisting cement and shall comply fully with the specification set by the Ministry of Municipal Affairs & Agriculture in the QNBS. 18.2 PRE-CAST CONCRETE CHAMBER SECTIONS 18.2.1 Pre-cast concrete chamber sections shall be of grade SRC-30/20, concrete made with sulphate resisting cement. 18.2.2 Pre-cast concrete chamber shall have steel bars reinforcement to strengthen the concrete. 18.2.3 Pre-cast concrete chamber sections shall be of the size and shape as per the approved contract/project drawings. 18.3 IMPREGNATED FIBER BOARD 18.3.1 Pipelines that are surrounded with concrete are to have expansion joints as specified. These joints are to be formed by the use of bitumen impregnated fiber board. 18.3.2 The fiber board shall be bitumen impregnated 19mm thick and generally conform to ASTM-1751 standard. 18.3.3 The contractor is to supply details of fiber board to t he Engineer for approval. 

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Section - 19

Polyethylene Pipes & Fittings for Service Connections (MDPE) 19.1 GENERAL These clauses shall be read in continuation of Section 1 of this specification. 19.1.1 Polyethylene Pipes & Fittings used for conveyance of potable water shall be manufactured in accordance with DIN-8074, BS 6730, BS 6572, ISO 4427 or equivalent and shall be manufactured by ISO Certified Company. 19.1.2 Polyethylene Pipes shall be MDPE, PE-80, SDR 11, PN-12.5 bar. 19.1.3 Polyethylene Pipes shall be multi-layer construction. (Black MDPE with outer layer blue MDPE) 19.1.4 Hydrostatic Test Pressure shall be 1.5 times the working pressure. 19.1.5 Polyethylene Pipes & fittings shall be Kite Marked certifying it complies with ISO 4427 or equivalent DIN, BS Standard. 19.1.6 Pipe manufacturers must furnish test certificate in accordance with EN 10204-3.1 for batches of MDPE supplied. 19.1.7 Polyethylene Pipe shall be protected with GRP duct when laid aboveground along customer wall premises. Two sizes are allowed; 2” duct for 20mm (1/2"), 2 5mm (3/4") & 32mm (1") and 3”duct for 50mm (11/2") & 63mm (2"). The GRP duct shall be of semi-circular shape and be firmly fixed to the wall with brackets. 19.1.8 Polyethylene Pipe shall have detectable warning tape of 150mm wide, 250 microns thickness to detect the pipe through metal detector. 19.2

POLYETHYLENE PIPES (MATERIAL) 19.2.1 All materials coating shall be WRC, DVGW, SGS, and DWI. , KIWA, NSF 61 or other Worldwide Known Quality Body Certifiers in contact with potable water at +50 degrees centigrade.

19.2.2 The Pipes & Fittings used for conveying potable water or likely to come into contact with potable water shall not constitute a toxic

hazard, shall not support microbial

growth and shall not give rise to unpleasant taste, or odor, cloudiness or discoloration of water. 19.2.3 Polyethylene shall be manufactured from virgin polyethylene resin of a single or bimodal process of manufacture. Master batching and/or re-grind material is not permitted.

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19.2.4 Polyethylene pipes installed in the water meter service cabinet between stop cock and water meter or in direct sunlight shall be black in colour, UV resistant, of solid wall construction to ISO 4427, all as per discretion of the Engineer. 19.2.5 The polyethylene pipe shall be confirming the specification as given in Table 22. Table (22) Specification

The specification of the polyethylene pipe Value

Min density measured according to ISO 1872

949 Kg/m

Melt flow rate measured according to ISO 1133

@ 2.16 Kg. Load= 0.18g/10min. @ 5 Kg. Load = 0.18/10min.

Tensile Strength at yield

18 Mpa

Elongation at break

600 %

Elongation

10 %

Thermal conductivity

0.32 W/mº K

Vicat Softening point at 1 kg. load

122ºC

Flexural Modulus- ASTM D790

900 MPa

Tensile strength ASTM D638

30 MPa

HDT @ 0.46 MPa – ASTM D648

90ºC

HDT @ 1.82 MPa – ASTM D648

58ºC

19.3 LENGTH AND SIZE 19.3.1 The polyethylene pipes are normally supplied in coils as per the specification given in Table 23 (or in bundles of straight lengths of 12 up to 500m as per the discretion of the Concerned Engineer): Table (23) The polyethylene pipe sizes (in mm) and coils (in mete rs). Min. Wall Max. Wall Nom. Ø Min. Ø Max. Ø Thickness Thickness 20 20 20.30 2.30 2.80 25 25 25.30 2.30 2.80 32 32 32.30 3.00 3.50 40 40 40.30 3.70 4.30 50 50 50.30 4.60 5.30 63 63 63.40 5.80 6.70

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Max. Coil Length 500 400 300 300 300 200

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19.3.2 The ovality of the pipe in coils as manufactured shall not exceed the value of 0.06 of the nominal size of the pipe. 19.3.3 The ovality of the pipe in coils after relaxation and straight pipe shall not exceed the value of “1 + (0.008 of the nominal size of the pipe). 19.4

FITTINGS

19.4.1 All fitting for polyethylene pipes (MDPE) shall be compression type (Gunmetal) and all details are given in Section 15. 19.5 STOP VALVE: 19.5.1 For underground installation - Stop Valve shall be made of Gunmetal BS 5433 crutch head with gunmetal ended compression couplings to fit MDPE pipe both sides for all size range from 20mm up to 63mm. 19.5.2 For aboveground installation inside/outside service cabinet before water meter – Stop valve shall be of Brass tamper proof lockable type as per discretion of the concerned Engineer. Suitable size of gunmetal compression couplings at both sides shall be used in connecting MDPE Pipe of all size range from 20mm up to 63mm. 19.6 FLANGED FITTINGS: 19.6.1 Flange Adaptor to join MDPE pipe to flanged equipments (63mm OD MDPE pipe to 2" Ø flange to BS 4504/ISO 7005, BS EN 1092-2 with PN 16 rating), material: black coated Steel or SG Iron to BS EN 1563:1997 Grade EN-GJS-450-10, Gasket: EPDM compound Grade 'E'. 19.7 SADDLE STRAPS 19.7.1 Saddle straps for service connections shall be flat boss type suitable for tapping from ½” up to 2” diameter ferrule. The strap shall be suitable for making service connections under pressure or dry using approved tapping machine into DI, AC Steel or PVC pipes. The saddle shall be of two parts fitted with EPDM sealing gasket in a groove on the underside of the flat boss. 19.7.2 The flat boss shall be cast with a hole or marking through the boss to facilitate the drilling and tapping process. The straps shall be supplied un-drilled. 19.7.3 The saddle strap shall be of gunmetal to BS 1400-LG2 with stainless steel nuts, bolts and washer to ISO 3506 and shall be suitable for a working pressure of up to 16 bar. 19.7.4 The name of manufacturer, patent number, pipe diameter to which the strap is suitable, and pipe material shall be engraved on the saddle strap. 19.7.5 The saddle strap shall be accompanied by manufacturer’s certificate stating date of manufacture, material specification. Issue : 0

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19.8 FERRULE 19.8.1 Ferrule shall be of gunmetal BS1400 LG2 body with gunmetal compression coupling outlet suitable to fit directly with MDPE service pipe of all size from 20mm to 63mm, for Underground application. Gunmetal with PE compression coupling outlet is unacceptable. 19.8.2 Ferrules shall be the screw down valve type allowing for the shut off of the flow by means of Ω” square head spindle extending from the top cap for opening and closing. The valve shall close clockwise. 19.8.3 The ferrule stern, banjo, spindle, inner plug and top cap shall be of gunmetal to BS 1400LG2. The washers shall be of EPDM and shall provide the sealing between the outer body and the ferrule stem. A polyethylene top plug shall prohibit the ingression of dirt. 19.8.4 The ferrule shall be designed as a main stem with a 360  swivel outlet at 90  with control of water flow via the threaded inner plug. The inlet shall be male taper thread to BS 21. 19.8.5 The ferrule shall be suitable for drinking water at a temperature of up to 50 C and capable to sustain a working pressure of up to 16 bar without leakage. 19.8.6 The ferrule shall permit the installation of service connection using under pressure tapping through flat boss saddle straps. 19.9 JOINTS 19.9.1 Fittings shall be of the slide and tighten type using a dynamic sealing method and positive grip. 19.10 MARKING 19.10.1 Pipes shall be marked as follows:1. 2. 3. 4. 5. 6. 7.

Manufacturer’s name Standard Nominal size of pipe in mm [ nominal outside diameter x nominal wall thickness] SDR Pressure rating in Bar Month & year of manufacture. Body of the fittings should have Manufacturer’s name/ logo.

19.11 PACKAGING 19.11.1 All compression fittings must be individually packed in transparent protective bags indicating its type and size.

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19.11.2 All compression fittings must be packed in cartoon boxes. 19.11.3 If only one type of product is packed all cartoon boxes shall have a label showing the manufacturer identification, the description of the product, the drawing of the product, the relevant size and the quantity. 19.12 PACKING 19.12.1 The packing shall be as per Section 1, Clause 1.8 of this specification. 19.13 HANDLING & STORAGE 19.13.1 Pipes and Fittings shall be handled and stored carefully as per manufacturer’s recommendation. 19.13.2 From manufacturer to laying stage, Pipes & Fittings shall be stored and transported in covered area to avoid direct sunlight. 19.13.3 All damaged Pipe & Fitting due to mishandling shall be rejected. 19.13.4 The height of stack of pipes shall be as per manufacturer’s recommendation. 

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Section - 20

uPVC Duct 20.1 GENERAL These clauses shall be read in continuation of Section 1 of this specification. 20.1.1 All uPVC Duct should be manufactured, and test according to BS EN 1401-1. 20.1.2 The Color of uPVC Duct pipes shall be orange-brown (approximately RAL 8023) or dusty grey (approximately RAL 7037) in color. 20.1.3 All Dimensions of uPVC Duct pipes shall be in millimeters as given in Table 24: Table (24)

The Dimension of the uPVC Ducts Pipe. Mean Outside Nominal Nominal Size Diameter Outside (DN/OD) Diameter (dn) dem,min dem,max. 110 110 110.0 110.3 160 160 160.0 160.4

Wall Thickness SN2 SDR 41 emin emax. 3.2 3.8 4.0 4.6

20.1.4 All Ducts should be supplied in 4 meters or 6 meters in length. 20.1.5 The external and the internal surface of the pipe shall be smooth, clean, and free from grooving, blistering, impurities and any other surface irregularity. 20.1.6 Pipe ends shall be cleanly cut and the ends of the pipes shall be square to their axis. 20.2 MARKING 20.2.1 uPVC Duct should be supplied with a center guideline printed on the middle of the duct, where the marking consists of the following:    

Number of Standard. (e.g. EN 1401) Manufacturer name and/or trade mark. Nominal Size. Minimum wall thickness.


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Section - 21

Water Service Cabinet 21.1 GENERAL These clauses shall be read in continuation of Section 1 of this specification. 21.2 WATER SERVICE CABINET (STANDARD – FLUSHED TYPE) 21.2.1 Bottom punch to be revised to 80 mm dia instead of 42 mm 21.2.2 Canceling the pad lock tongue and pin pieces 21.2.3 Provision of (2) additional 3 mm holes for riveting the new serial number with logo plate area between the louver punches and vision panel. Cancel the previous emboss on the top right side. 21.2.4 Position the Kahramaa logo emboss on the top left side of the door (To be eliminated from the list of requirements, since the Customer Number accommodating KM Logo). 21.2.5 Provision of internal handle to open the cabinet door to avoid damages on the lock. 21.3 WATER SERVICE CABINET (STANDARD – SURFACE MOUNTED TYPE) 21.3.1 Remarks 1, 2, 3 and 4 are maintained as in the Flushed Type 21.3.2 No profile is required (flange) minimum lip bend or alternative proposal is acceptable 21.3.3 Provision of (3) punches 42 m dia back/left/ and right aligned on the box top side 21.3.4 Cancel the Top punch and provide propose alternative preparation if future needed 21.3.5 Provision of (3) plastic end caps for the 3 top punches 21.3.6 Provision of internal handle to lift cabinet door easily

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APPENDIXES I. Typical Drinking Water Quality . II. Site Environmental Conditions. III. Drawings. 1. WATER METER SERVICE CABINET. 2. Precast Concrete Chamber Slab Construction Details. 3. Marker Post, Backing Plates, and Plate. 4. Surface Box & Manhole Cover IV. Worldwide Known Quality Body Certifier. V. Pre - Arrangement Inspection.

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I.

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TYPICAL DRINKING WATER QUALITY

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II.

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SITE ENVIRONMENTAL CONDITIONS

State of Qatar is classified as being among the worlds most arid and desert regions. The rainfall is concentrated in the Winter & Spring period (December to March) with an average of 50 – 80mm per annum. No discernible pattern in rainfall occurrence is apparent, but there is a tendency of rainfall to occur more often during February & March. Rainfall can be heavy with poor natural drainage resulting in surface flooding.

Month January February March April May June July August September October November December

Temperature Degrees Centigrade Mean Mean Max. Min. 22.3 13.1 22.7 12.7 27.5 16.8 31.3 20.0 37.6 24.3 41.0 26.0 41.5 28.3 40.7 28.3 38.3 25.9 35.2 23.0 29.8 19.5 24.8 14.5

Mean Daily 17.5 17.5 21.8 25.3 30.7 33.6 34.6 34.1 32.0 29.0 24.5 19.4

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Minimum-recorded related humidity is 100 %.

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Maximum recorded direct sunlight temperature is 75  C.

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Maximum recorded ambient shade temperature is 51  C.

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Minimum recorded ambient shade temperature is 0  C.

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Site elevation is 2 – 20 M AOD (State of Qatar).

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Humidity % Mean Max. 90.7 82.8 85.3 80.9 67.6 64.2 71.0 77.7 86.5 83.7 89.9 86.1

Mean Min. 51.9 38.7 40.9 37.3 20.8 20.1 24.6 30.7 38.9 37.0 37.6 46.5

Prevailing winds are mainly Northerly occasionally with Southeasterly gusts up to 140 Km/h. Sandstorms though not severe, do occur and can persist for several days. The site is not subject to Industrial pollution, but due to being near the coast; the air can be salt laden with occasional fog. During the winter and spring periods, sever electrical storms with sheet and forked lightning can occur. 

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III.

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DRAWINGS 1. WATER METER WATER METER SERVICE SERVICE CABINET 

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Aluminum 2” Bulk Electronic Meter Cabinet – Aluminum

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2. PRECAST CONCRETE CHAMBER SLAB CONSTRUCTION DETAILS

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3. MARKER POST, BACKING PLATES, AND PLATE 

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Valves

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Fire Hydrant

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4. SURFACE BOX & MANHOLE COVER 

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Manhole Covers

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IV.

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WORLDWIDE K NOWN QUALITY BODY CERTIFIER

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WRc Evaluation &Testing Center, o WRAS "Water Regulations Advisory Scheme” o Fern Close, Pen-y-Fan Industrial Estate Oakdale, Gwent NP11 3EH, U.K. Tel.: 44 - 01495 248454 Fax: 44 - 01495 249234 o Website: http://www.wras.co.uk E-mail: [email protected]

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WRc-NSF o Henley Road, Medmenham, Marlow Bucks SL7 2HD, U.K. Tel.: 44 – 01495 636500 Fax: 44 – 01495 636501 Website: http:// www.wrcnsf.com E-mail: [email protected]

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LaboratoRI SpA Via Vitorchiano, 165/167 00189 Roma, Italy Tel.: 0039 06 57992600 Fax: 0039 06 57992629 Website: http:// www.laboratorispa.it E-mail: [email protected]

DVGW “The German Technical and Scientific Association for Gas and Water “. Josef-Wirmer-Straße 1-3, D-53123 Bonn, Germany Tel.: 49-228-9188-5 Fax: 49-228-9188-990 

Website: http://www.dvgw.de E-mail: [email protected]

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NSF "National Standard Foundation". P.O. Box 130140 789 N. Dixboro Road Ann Arbor, MI 48113-0140, USA 

Tel.: (+1) 734-769-8010 Toll Free (USA): 800-NSF-MARK Fax: 734-769-0109 Website: http:// www.nsf.org [For Water System → http://www.nsf.org/dwa/] E-mail: [email protected] Aquacheck Aquacheck Ltd Europa Business Park, Barcroft Street BURY, Greater Manchester BL9 5BT, U.K. 

Tel.: +44 (0)161 7638777 Fax: +44 (0)161 7638788 Website: http:// www.aquacheck.co.uk E-mail: [email protected]

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KIWA Kiwa Water Research Groningenhaven 7 3433 PE Nieuwegein PO Box 1072 3430 BB Nieuwegein, Holland Tel: +31 30 606 95 11 Fax: +31 30 606 11 65 E-mail: [email protected] SIRIM QAS International Sdn.Bhd 1 , Persiaran Dato Menteri ,Seksyen 2 , Peti Sural 7035 40911 Shah Alam Seiangor Darul Ehsan, Malaysia Tel: 60-3-5544 6400 Fax: 60-3-5510 9439 Website: http : // www.sirim-qas.com.my

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Australian Water Quality Center Hodgson Road, Bolivar, South Australia Postal Address: Private Mail Bag 3, Salisbury SA 5108 Tel.: (08) 8259 0211 Fax: (08) 8259 0228 E-Mail: [email protected] Website: http://www.awqc.com.au Hygiene Institute Hygiene-Institute des Ruhrgebietes, Abt. Wasserhygiene, KTW-Prüfung Rotthauser Str. 19 D-45879 Gelsenkirchen Tel: +49 (209) 92 42 210 Fax: +49 (209) 92 42 212 E-Mail: [email protected] Website: http://www.hyg.de DWI- Drinking Water Inspectorate Drinking Water Inspectorate Area 7e 9 Millbank c/o Nobel House 17 Smith Square London SW1P 3JR Telephone: 0300 068 6400 E-mail: [email protected]

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V.

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PRE - ARRANGEMENT INSPECTION

Pre-inspection arrangements for DI pipes, fittings, Valves, and Corrosion protection materials (Wrapping Tape, PE Sleeving, Putty, Primer):

In order to facilitate the onsite inspection for Materials Specifications Engineers, these following points are to be followed:

1. For any materials inspection (especially DI Fittings & valves), the items shall be segregated as per their type/sizes on different pallets. 2. Each pallet shall have a post with an A-4 page with the description of the items clearly written on it. 3. There shall be appropriate spaces between the pall ets so that the engineer/inspector can freely go around them and inspect the materials thoroughly. 4. Staking the materials all over each other & in one corner is strictly not allowed. 5. All valves shall be kept under the shade away from direct sun light. The valves shall not be kept on the floor; they shall have wooden pallets underneath them. 6. Corrosion protection materials (Wrapping Tape, PE Sleeving, Putty, and Primer) shall never be kept under direct sunlight or exposed to harsh site environment. They shall be stored inside the site warehouse. 7. Wrapping tape shall be stored as per the manufacturer recommendations in cool / ventilated area, and A/C equipped room during summer. 8. The wrapped/PE Sleeved DI pipes & Fittings Shall never be exposed to direct sunlight and shall be covered with tarpaulin in order to protect them from the UV of the direct sunlight which deteriorates the sleeve and the wrapping tape. 9. If the items in one pallet are more than 10 do not arrange it on top of the others, and provide space in between to inspect easily.

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WP-P5-S1_19!8!15 General Specification of Main Laying Materials for Waterworks

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