02610 Pipe & Pipe Fittings

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SECTION 02610 PIPE AND PIPE FITTINGS

PART 1 – GENERAL 1.1 A. DESCRIPTION OF WORK This specifications section applies to underground utilities piping required for site work. For specifications applicable to plumbing and process piping work refer to Division 15 and Section 01012. Related Work: 1. 2. 3. 4. 5. 6. 7. 1.2 A. Section 01086: Section 02200: Section 02617: Section 02615: Section 02622: Section 02623: Section 09875: Color Codes and Color Standards Earthwork Steel Pipe Ductile Cast Iron Pipe Plastic Pipe (PVC), HDPE Glass fiber Reinforced Plastic Pipe Corrosion Resistant Coatings

B.

QUALITY ASSURANCE Reference Standards: The latest editions of the following standards shall apply: 1. American Standards: (a) American Society for Testing and Materials (ASTM): ASTM A 449 Specifications for quenched and tempered steel bolts and studs. (b) American National Standards Institute (ANSI): ANSI A 21.51 Polythene and ductile cast-iron piping for water and other liquids. ANSI B 18.2.1 Square and hex bolts and screws including hex head cap screws and lag screws.

P.O. Number : 7200018725

ANSI B 18.2.2. Square and hex nuts. ANSI B 31.3, Petroleum refinery piping. ANSI B 16.3 Malleable-iron threaded fittings. (c) American Water Works Association (AWWA): AWWA C 110, Gray-iron and ductile-iron fittings, 3 in. through 48 in., for water and other liquids. (d) American Petroleum Institute (API): API 5 L, Specification for line pipe. 2. International Standards: (a) International Organization for Standardization (ISO): ISO 1461 Metallic coatings - Hot dip galvanized coatings on fabricated ferrous products – requirements. Unplasticized polyvinylcholoride (PVC) pipes - Determination of Vicat softening temperature. Ductile iron pipes, fittings and accessories for pressure pipe- lines. Assembled joints between fittings and polyethylene (PE) pressure pipes - Test of leak proofness under internal pressure. Polyethylene (PE) pressure pipes Joints assembled with mechanical fittings – Internal under-pressure test method and requirements. Assembled joints between fittings and polyethylene (PE) pressure pipes - Test of resistance to pull out. Assembled joints between fittings and polyethelene (PE) pressure pipes - Test of leak proofness under internal pressure when subjected to bending.

ISO 2507

ISO 2531

ISO 3458

ISO 3459

ISO 3501

ISO 3503

P.O. Number : 7200018725

ISO/DIS 4422

Unplasticized polyvinylchloride (PVC) pipes and fittings for water supply Specification.

3.

German Standards: Deutsches Institute fur Normung e.V. (DIN): DIN 2632 Welding neck flanges; nominal pressure 10.

4.

British Standards: (a) British Standards Institution (BS):

BS 1400 Copper alloy ingots and copper alloy castings. BS 2494 Materials for elastomeric joint rings for pipework and pipelines. B. Source Quality Control: The following tests shall be performed: 1. All steel fittings shall be tested in accordance with API Spec. 5 L, but at a minimum hydrostatic test pressure of 1.5 MPa. All cast iron fittings shall be tested in accordance with AWWA C110, but at a minimum hydrostatic test pressure of 1.5 MPa. All ductile iron fittings shall be tested in accordance with AWWA C110, but at a minimum hydrostatic test pressure of 1.5 MPa in accordance with additional test, Section 10-12 in this standard or in accordance with ISO 2531 but with the same minimum hydrostatic test pressure. PVC fittings shall be tested in accordance with ISO/DIS 4422. In addition, the following tests shall be carried out:

2.

3.

4.

(a)

Determination of resistance to internal hydrostatic pressure in accordance with ISO/DIS 4422, Clause 6.2, Quality Test (1,000 hour test). The tests shall be performed at nominal pressure. Determination of resistance to external blows on five samples from the batch. The test shall be carried out in accordance with ISO/DIS 4422, Clause 6.1.2.1. Determination of the Vicat softening point in accordance with ISO 2507.

(b)

(c)

P.O. Number : 7200018725

4.

If the total number of PVC fittings exceeds 3000, one set of additional tests shall be carried out for every batch of 3000.

PART 2 – PRODUCTS 2.1 A. GENERAL All goods and products covered by these specifications shall be procured, when available, from an in-kingdom manufacturer. Procurement of all goods and products manufactured out-of-Kingdom must be approved by MARAFIQ. For color code requirements for utility piping systems, see Section 01086, Color Codes and Color Standards. MATERIALS Steel Fittings: 1. Welding Fittings: Steel fittings shall comply with API Spec. 5 L for seamless or welded pipe. For the design and calculation of the minimum wall thickness of the fittings, the internal working pressure, external earth load, traffic load, etc., shall be specified. The wall thickness shall under no circumstances be less than: External diameter (mm) 323.9 404.6 508.0 812.8 1061 1219 Wall thickness (mm) 5.6 6.3 6.3 9.5 10.0 10.0

B.

2.2 A.

Bends shall be long radius, smooth bends with the radius about 1.5 times the nominal diameter. Tees shall either be of the extruded welding type or of the direct welded branch type. Reducers shall be made with a length L = 3 (OD-Od), where L is the construction length, OD the outer diameter of the large end and Od the Outer diameter of the small end. 2. Threaded Fittings: Threaded fittings shall comply with ANSI B16.3 and be hot dip galvanized in accordance with the relevant standards. The minimum thickness of the zinc layer shall be 80 micrometers.

B.

Cast Iron Fittings: Cast iron fittings shall comply with AWWA C110.

P.O. Number : 7200018725

C.

Ductile Cast Iron Fittings: Ductile cast iron fittings shall comply with AWWA C110 or ISO 2531. Fittings complying with ISO 2531 shall be of at least class K = 14 for tees and K = 12 for other fittings. PVC Fittings: All PVC fittings and joining material shall comply with ISO/DIS 4422. However, the Vicat softening point and K-value shall not be less than plus 76 and 61 degrees C respectively. PVC pressure connected to the pipes by use of threaded coupling adapters or by installation of Schedule 80 PVC nipples, Type 1, Grade 1, ASTM D1784, D1785 and D2464. FABRICATION AND MANUFACTURE General: External and internal surfaces of all fittings and valves made from steel, ductile iron, and cast iron shall be coated in accordance with Section 09875. Pipe and Pipe Fittings: Pipe shall be as long as practicable with regard to reducing the number of joints, but not longer (excluding the socket, if any) than 6.0 m for PVC, DCI and CIP. Steel pipe shall have an average length of about 10 m. If the manufacturer of GRP pipe normally produces pipe longer than 6.0 m, this length may be accepted on special request. All metallic surfaces in contact with or exposed to soil including valves, couplings, adapters and pipes shall be wrapped with adhesive waterproofing tape or polythene encasement whichever is approved by MARAFIQ. Bolts and Nuts: 1. Bolts, nuts, and washers for flange connections shall be of hot dip galvanized steel with at least 80 micrometers of zinc in accordance with ISO 1461. Bolts and screws shall comply with ANSI B 18.2.1, specification ASTM A 449. Nuts shall comply with ANSI B 18.2.2. Bolts, nuts, and washers which will be exposed to the soil or which are below water table shall be made of stainless steel, Grade 316L. The length of thread protruding from the tightened nut in bolt couplings shall be equivalent to at least once and at most twice the bolt diameter. Flange connections with bolts and nuts exposed to the soil shall be wrapped with adhesive water proofing tape.

D.

2.3 A.

B.

C.

D.

2. 3.

4.

5.

P.O. Number : 7200018725

E.

Rubber Joint Rings: Rubber joint rings shall be free from any substances which could affect the water and shall in all respects be resistant to water having the characteristic properties given in Section 02713. Attention is again drawn to the extreme conditions in the country such as the high air temperature. Rubber joint ring to be used for potable water pipeline shall be ethylene propylene (EPDM) rubber. Nitrile rubber (NBR) shall be used for sewer systems rubber joint rings. Bends, Elbows, Reducers and Tees: 1. All bends, elbows, reducers and tees for PVC pipes size 63 mm nominal diameter and below shall be solvent weld type. Sizes larger than 63 mm diameter shall be flexible rubber ring joint type. All bends, elbows, reducers and tees for FRP pipes shall be FRP, plain ended type, compatible with Amiantit double beel Reka couplings. Bends, elbows, reducers and tees to be installed inside valve chambers shall be made of steel, ductile iron, cast iron, bondstrand or FRP subject to approval by the MARAFIQ Water & Sanitary Sewage Department. New branch tee material for connection to existing asbestos cement pipe, shall be FRP suitable for ACP Class 24.

F.

2.

3.

4.

G.

Couplings: 1. General: Couplings shall permit the connection of two pieces of pipe without displacing the pipe longitudinally. The couplings will be used forfitting closing lengths on pipelines, for withdrawing a pipe for cleaning or inspection or for repair purposes and shall thus not be supplied with any center register. Metallic coupling with external stud bolts shall be coated in accordance with Section 09875. In addition to above, the external surfaces shall be wrapped with adhesive waterproofing tape or polythene encasement as directed by MARAFIQ. PVC Couplings: Couplings for PVC pipe of 280 mm diameter or less shall be class 5 with rubber gaskets for water distribution system and force mains; and shall be class 3 for sanitary and industrial wastewater gravity systems. GRP Couplings: Couplings for glassfibre reinforced plastic pipe shall be made of GRP, double bell Reka coupling type.

2.

3.

P.O. Number : 7200018725

4.

Repair Couplings: Repair couplings shall be used for repairing asbestos cement pipe, PVC or GRP pipe and shall be manufactured in accordance with AWWA C110 or ISO 2531. The coupling shall be made of PVC, GRP, carbon steel, PVC coated carbon steel or hot dip galvanized carbon steel and the minimum thickness of the zinc layer shall be 80 micrometers. Metallic coupling shall be protected with a corrosion resistant coating in accordance with Section 09875. All metallic repair couplings exposed to the soil shall be wrapped with adhesive waterproofing tape. Stepped Couplings: Stepped couplings shall be used for connection of dissimilar pipe diameter and be made of carbon steel, ductile iron or cast iron. All metal surfaces shall be coated in accordance with Section 09875. Dismantling/Detachable Joint: Detachable or dismantling joint shall be installed and used for repair or maintenance of pipework and valve in air release/vacuum, isolation and washout valves in chamber, metering chamber and lift station valve/diversion chamber.

5.

6.

H.

Adapters: 1. Double Socket Adapters - AC/GRP or AC/DCI: Double socket adapters suitable for use between spigot ends of asbestos cement pipe of Saudi Arabian Standard, Class 24, glassfiber reinforced plastic, PVC, carbon steel or ductile iron pipe shall be made of steel, ductile iron, GRP or cast iron. Double Spigot Adapters Suitable for use: (a) AC/GRP, AC/DCI, GRP/DCI or GRP/Steel: Double spigot adapters suitable for use between socket ends of glassfiber reinforced plastic or ductile iron pipe, and sockets formed for connection with asbestos cement pipe of Saudi Arabian Standard, Class 24, shall be made of steel, ductile iron, GRP or cast iron and shall have corrosion resistant coating. DCI/PVC: Double spigot adapters suitable for use between socket ends of ductile iron pipe and socket ends of PVC pipe shall be made of steel, ductile iron, or cast iron and shall have corrosion resistant coating.

2.

(b)

3.

Socket/Spigot Adapters - DCI/PVC: Socket/spigot adapters suitable for use between spigot ends of ductile iron pipe and socket ends of PVC pipe shall be made of steel, ductile iron, GRP or cast iron.

P.O. Number : 7200018725

4.

Flanged Adapters: Flanged adapters used for jointing steel/PVC, ACP/ACP, PVC/PVC, Steel/Steel or DCI/DCI shall be made of steel, ductile iron, cast iron or GRP. All metal surfaces shall be protected with corrosion resistant coating per Section 09875.

I.

Fittings in Valve Chambers: 1. All pipe spools in chamber shall be made of GRP, carbon steel, ductile iron or stainless steel, as approved by MARAFIQ. Dismantling/detachable joint(s) shall be installed in valve chamber to facilitate easy maintenance of pipe spools, valves and fittings. The required minimum clearance between wall/or bottom slab and flanged spool/coupling as well as valve shall be 500 mm. A minimum clearance of 150 mm shall be maintained from top of any fitting or valve to the underside of the top slab. All metal surfaces shall be protected with corrosion resistant coating, refer to Section 09875.

2.

3.

4.

J.

Flanged Couplings: 1. The couplings shall be in accordance with the drawings with regard to location, type and dimension. The couplings shall be made of steel or GRP. Bolts and nuts shall be as specified. Flanges: (a) Cast iron or ductile iron flanges shall comply with ISO/R 13 or with ISO 2531 class PN 16 respectively. The flanges for steel pipework shall be welding neck type complying with DIN 2632. The corrosion protection applied on the internal surfaces of pipe and fittings shall also be applied on the flange face. The finish of the coating on the sealing surface must meet the gasket sealing requirements.

2.

3.

(b)

K.

Blind Flanges: When pipelines are to be closed, blind flanges made of steel, stainless steel, ductile iron, cast iron, PVC or GRP shall be used. All metallic surfaces in valve chambers as well as those in contact with soil shall be coated with corrosion resistant epoxy paint in accordance with Section 09875. All metallic surfaces in contact with soil shall also be wrapped with adhesive waterproofing tape or

L.

P.O. Number : 7200018725

polythene encasement whichever approved by MARAFIQ. Before taping, irregular contours shall be filled –in by filler mastic. PART 3 – EXECUTION 3.1 A. B. PREPARATION See Section 02200 and specific usage section. Pipe Laying: 1. Regardless of which pipe material is used, the manufacturer's installation instructions shall be followed. Contractor shall ensure that all pipelines are placed within the assigned area in the actual cross-section. Before any pipe or fitting is lowered into the trench, it shall be carefully checked to ensure that it is not cracked or damaged in any way. Depending on MARAFIQ's decision, damaged pipe shall either be cut, so that flawless pipe is obtained with least possible waste and so that the protective covering and lining, if any, is not damaged, or the whole pipe shall be rejected. The outer coating, if any, is to be inspected and any defects made good. All foreign matter such as soil, rags, etc., is to be removed from the interior of the pipe. All lumps, blisters and excess coating shall be removed from the ends of all pipe and fittings and the joints shall be brushed and wiped clean and free from oil and grease before the pipe is laid. When placing pipe in the trench, fabric slings shall be used at the balancing points. The pipe shall not be dragged along the bottom of the trench, nor humped, and it shall be supported by the sling while being fitted to the adjacent pipe. Should there be a coating on the underside of the pipe, it shall be inspected while the pipe is suspended from the sling and any damage to the coating shall be repaired before the pipe is lowered into the trench. No metal tools or heavy objects should be permitted to come into unnecessary contact with the pipe or fittings. All damage to the protective coating from any cause shall be repaired. The pipe shall be laid at the level and gradient stipulated, on a prepared bed 150 mm deep with special hollows made for the joints. The pipe shall be aligned carefully in both the horizontal and vertical planes and at no point be laid more than 10 mm from the theoretical straight line; for plastic pipe 20 mm. Supports must not be placed under the pipe.

2.

3.

4.

5.

P.O. Number : 7200018725

6.

Every precaution shall be taken to prevent foreign matter from entering the pipe or fittings. During laying operations, no debris, tools, cloth or other materials are to be allowed to enter the pipe. After placing a length of pipe with socket/spigot joints in the trench with the socket end upstreams, the spigot end shall be centered in the socket (or similar) and the pipe forced home and brought to correct line and grade. The angle between any piping or fittings shall not exceed the manufacturer’s recommendations. The pipe and fitting shall be secured in place with approved backfill material tamped under it except at the joints. At times when pipe laying is not in progress, the open ends of the pipe shall be sealed by watertight plugs supplied by Contractor. All pipelines shall be inspected and approved by MARAFIQ before they are back filled.

7.

8.

C.

Field Coating: 1. Repair of Factory Coating: After joining, damage to the coating on pipe, fittings, valves, etc., shall be carefully repaired with approved coating to original standard. Before field coating, the surfaces shall be dry and free from grease, oil and other foreign matter. A reasonable quantity of coating material for repair work shall be included by the pipe supplier. Flange Protection: Corrosion protection tape shall be wound round any flange joints after which a polythene encasement shall be applied in accordance with ANSI A 21.51. Before taping, irregular contours shall be filled-in with filler mastic. All material used for flange protection shall be delivered to and applied by Contractor.

2.

D.

Flanges: Flange connections shall be located in valve chambers or elsewhere above ground. Flange connections buried in the ground are not allowed, except for direct buried valves where permitted by these specifications. Bolts, Nuts, and Washers: 1. 2. See Clause 2.2 in this Section. ashers shall be placed under both nuts and bolt- heads.

E.

F.

Rubber Ring Joints: Where rubber ring joints are to be used, the instructions issued by the manufacturer of the rings shall be followed carefully. When joining pipe, a mark shall be made to check the position of the end of the pipe unless it has a marking ring. In view of

P.O. Number : 7200018725

the flexibility of the joint, a gap shall be left between the ends of the pipe in accordance with the manufacturer's recommendations. For asbestos cement pipe, this gap shall be at least 15 mm in order to compensate for the expansion due to water absorption. When the connection is complete, the ends of the pipe is laid at curves, the pipe may not be bent sideways until the connection has been made. Bolts shall be tightened up gradually so that the coupling is drawn together uniformly. 3.2 A. FIELD QUALITY CONTROL Hydrostatic Test: 1. After completing the installation of a pipeline or section, hydrostatic tests of the line shall be made as soon as possible. The initial hydrostatic test shall be made with partial backfilling keeping all joints exposed. For 300 mm diameter pipe and larger, the length of the piping being tested shall not be more than 3 km. The tests on lines for potable and fire water shall be carried out using potable water. Parallel lines with common thrust blocks are to be tested one at a time. Before the first hydrostatic test is carried out, permanent and temporary supports shall be installed. Thrust blocks and valve chambers shall be cast not less than 7 days before the test is carried out and backfill shall be placed around all thrust blocks and valve chambers. The tested sections shall be provided with stop ends; the use of valves to close off the tested section will not be permitted. Simple stop ends are to consist of flanged socket or spigots with blank flanges containing the necessary openings for accommodating incoming water and outgoing air. The stop end may also include an opening through which the test water may be pumped from the line should it prove necessary. Thrust blocks shall be provided to hold the stop ends in place against the test pressure. These may take the form of concrete abutments on either side of the trench with steel joints spanning the thrust block by screw jacks and wedges. The trench shall be sand backfilled to 300 mm above the pipe and compacted in accordance with the specification for backfilling, see Section 02200.

2.

3.

4.

5.

6.

7.

P.O. Number : 7200018725

8.

The line shall be filled very slowly at low point and care shall be taken to remove all the air. To prevent possible water hammer, the velocity of the water in the pipe shall not exceed 0.05 m/sec while filling the pipe. For proper filling of the pipe with water, allow the water to reach the same temperature as the pipe and for removal of all air, 70% of the test pressure shall be applied for a period of at least 24 hours, after which the trench shall be carefully inspected for evidence of leakage. The test pressure shall be applied by means of a hand or motorized pump connected to the pipe in a manner approved by MARAFIQ. The pressure meter shall have an accuracy of plus/minus 10 kPa (0.1 kg/cm2) within the range of pressures in question. The pumps and all necessary apparatus for the test shall be furnished by Contractor. The pipe in the partially backfilled trenches shall be carefully examined during the test. All joints showing leaks shall be rejointed until tight or the pipe material replaced. Any cracked or defective pipes, fittings or valves discovered as a result of this pressure test shall be removed and replaced by Contractor with sound material after which the test shall be repeated. If the pressure should fall by more than 20%, water shall be pumped into the pipe until the test pressure is reached. When the pressure required is reached and applied for 24 hours, the allowable 5% pressure drop shall be calculated. Upon approval from MARAFIQ, the leakage calculation in liter per kilometer per 24 hours can be performed in lieu of pressure drop method. When leakage method is directed by MARAFIQ, no section of the pipe will be accepted until the leakage calculated in liters per km (pro-rated for lesser distance) per 24 hours at the test pressure is less than: Liters per km per 24-hours 20 40 60 100 140 180 220

9.

10.

11.

12.

13.

14.

Dia Pipe (mm) 100 (110 mm dia PVC) 150 (160 mm dia PVC) 200 (225 mm dia PVC) 300 400 500 600

P.O. Number : 7200018725

290 380 15.

800 1,000

Contractor shall, as soon as possible after the approved initial hydrostatic test, start and complete backfilling the entire trench up to ground level or subgrade of pavement in accordance with the specifications for backfilling. The final hydrostatic test shall be performed when the backfilling has been completed up to ground level or subgrade of pavement and compacted in accordance with the specification for backfilling. No final hydrostatic test shall be performed unless all interior test and points were connected. Interior test end point or joint adjoining two tested section shall be tested by closing adjacent isolation valve(s) in one tested section and pressurizing the other tested sections. Single joint between interior tested sections can be tested with the main working pressure, provided it is approved by the MARAFIQ Water & Sanitary Sewage Department. The final hydrostatic test pressure for all distribution lines and force mains (except for seawater system) shall be: Maximum Operating Pressure 0.60 MPa Hydrotest Pressure (1.5 x Maximum Operating Pressure) 0.90 MPa 1.30 Mpa

16.

17.

18.

19.

System Potable and Fire Water Wastewater force mains 20.

See Section 02625 for test pressure requirements for seawater pipe system.

3.3

WARNING TAPE After initial hydrostatic test is approved, warning tape shall be installed above 300 mm of the top of pipe. The tape shall have one of the following printing designation. "Caution Potable/Fire Water Line Below", "Caution Industrial Waste Water Line Below" or "Caution Sanitary Sewer Line Below", whichever is applicable. The words shall be printed on tape in both Arabic and English, alternately, in durable black letters of 50 mm height.

P.O. Number : 7200018725

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