Specification for Steel Piping

0 02- Approved Issuerev. date Description/issued for prepared authorised

client: ADWEAproject: STANDARD SPECIFICATIONS FOR WATER WORKStitle: SPECIFICATION FOR STEEL PIPING FABRICATION, ERECTION AND TESTING

tender: project: document: W-P-SS-012 rev: 0 sheet: 1 of: 28

SPECIFICATION FOR STEEL PIPING

FABRICATION, ERECTION AND

TESTING

Client ADWEAProject: STANDARD SPECIFICATIONS FOR WATER WORKSTitle: SPECIFICATION FOR STEEL PIPING FABRICATION, ERECTION AND TESTING

tender: project: document: WP-SS-012 rev: 0 sheet: 2 of: 28

Table of Contents page

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

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

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

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

5. TECHNICAL REQUIREMENTS FOR PIPE MANUFACTURING ANDTESTING................................................................................................55.1 Process of Manufacture..............................................................55.2 Chemical Properties ....................................................................65.3 Mechanical Properties .................................................................65.4 Inspection and Testing ................................................................95.5 Packing, Marking and Shipping Documentation ........................14

6. INTERNAL AND EXTERNAL PROTECTION......................................15

7. FABRICATION AND ERECTION REQUIREMENTS...........................157.1 Fabrication.................................................................................157.2 Erection .....................................................................................20

8. INSPECTION AND TESTING ..............................................................248.1 General......................................................................................248.2 Hydrotest ...................................................................................248.3 Test Procedure..........................................................................258.4 Disinfection and Flushing of Pipeline.........................................258.5 Protective Coating .....................................................................27

9. VENDOR DOCUMENTATION .............................................................27

10. QUALITY ASSURANCE / QUALITY CONTROL.................................28

11. SAFETY AND ENVIRONMENT...........................................................28



1. SCOPE

This section describes the requirement of fabrication, erection and testing of steel piping. Thecontents of this section shall not be interpreted in anyway as limiting the CONTRACTOR'sresponsibilities and obligations to provide a safe and working installations complete with allnecessary accessories/auxiliaries to facilitate and ensure trouble free operation, maintenanceand safety of the complete installation.

2. APPLICABLE STANDARDS AND CODES

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

ASME B31.3 Process Piping

ASME B1.1 Unified inch screw thread (UN and UNC thread form)

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

ASME B16.5 Steel Pipe Flanges and Flanged Fittings

ASME B16.9 Factory Made Wrought Steel Butt Welding Fittings

ASME B36.10 Welded and Seamless Wrought Steel Pipes

ASME B36.19 Stainless Steel Pipes

ASME B16.11 Forged Steel Fittings Socket Welding and Threaded

ASME B16.25 Butt welding ends

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

ASME Section V Non-Destructive Examination

ASME Section VIII Div.1 Pressure Vessels

ASME Section IX Welding and Brazing Qualifications

ASTM A 105/A 105M Standard Specification for Forgings, Carbon Steel forPiping Components

ASTM A 106 Seamless Carbon Steel Pipe for High TemperatureService

ASTM A 193 Alloy Steel and Stainless Steel Bolting Materials forHigh Temperature Service



ASTM A182 Forged or Rolled alloy Steel Pipe Flanges, ForgedFittings and Valves and similar parts for HighTemperature

ASTM A 312 Seamless and Welded Austenitic Stainless Steel Pipes

ASTM A 403 Wrought Austenitic Stainless Steel Piping Fittings

ASTM A 234 Piping Fittings of Wrought Carbon Steel and AlloySteel for moderate and elevated temperatures

ASTM E94 Standard Recommended Practice for RadiographicTesting

APL 5 L Specification for Line Pipe

BS 4504 Sect 3.1 Circular Flanges for Pipes, Valves and Fittings (PNDesignated)

ISO 9000 Quantity management and quality assurancestandards, Guidelines for selection and use.

ISO 10474 Steel and steel products – Inspection documents

AWWA C651 Disinfecting Water Mains

3. SITE CONDITIONS

For site and climatic conditions refer, "General Technical Requirements" Document.

4. DESIGN CONSIDERATION

a) Pipe, pipe fittings, flanges, valves, gaskets, studs, bolts etc. used in a given pipingsystem shall be as per the Specification for Carbon Steel Piping Materials and StainlessSteel Piping Materials, for the design conditions in accordance with ASME B 31.3 codes.

b) Pipework system shall be designed to withstand the maximum internal and externalforces which could occur in service and under hydraulic test pressure. The configurationand method of support shall minimise bending stresses.

Systems shall be sized so that the maximum design flow through the pipework will notproduce cavitation, erosion, excessive noise or vibration. System shall also be sized wherepracticable so that the minimum operating flow of fluid will prevent deposition of suspendedsolids. No forces developed within pipework system shall be transferred to the civil structurewithout the approval of ADWEA/ENGINEER.



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

Facilities shall be provided for draining pipework systems and releasing air. The drainage fluidshall be piped into the appropriate drainage system and the period of time for drainage shallnot exceed 30 minutes.

5. TECHNICAL REQUIREMENTS FOR PIPE MANUFACTURING ANDTESTING

5.1 Process of Manufacture

The pipe shall conform to the Grades of API 5L line pipe as specified in the Requisitionsand/or Data Sheets, and as modified by the supplemental requirements as stipulated in thisSpecification. Pipe diameter(s), wall thickness(es), lengths and quantities shall be as definedin the Purchase Order.

The steel shall be manufactured by the Basic Oxygen Furnace (BOF) or Electric Arc Furnaceprocesses and shall be fully killed and made to fine grain particle. The grain size shall beASTM No. 7 or finer, as defined in ASTM E 112.

The pipe shall be manufactured by seamless process upto size DN 400 mm (14" NB) and DN450 mm (18" NB) and above by ERW process.

Pipe shall be manufactured from hot rolled coil and furnished in the "non-expanded"condition.

The weld seam and heat affected zone shall be normalised after welding by re-heating theweld area above the upper critical temperature of 870 °C (1600 °F) minimum and cooling instill air to below 540 °C (1000 °F). The normalising temperature shall be measured byrecording and indicating thermometers. Full body normalising, normalising and tempering, orquenching and tempering shall also be acceptable. Details of the proposed heat treatmentsshall be submitted for ADWEA/ENGINEER approval prior to the start of production.

The MANUFACTURER shall conduct all tensile, bend, flattening, weld ductility, fracturetoughness, and hardness tests described in this specification. Results of all tests shall berecorded and provided to ADWEA/ENGINEER for their acceptance before despatch of thepipes. The test results must conform to the requirements of this specification and API 5L foracceptance.

The following documents shall be provided to ADWEA/ENGINEER for review prior to the startof production (if material is to be supplied from stock).

• A description of the steel-making process that includes steel making and castingtechniques, chemical composition, etc.



• MANUFACTURER's Quality Control Manual that provides details of the inspection andtesting procedures. The details shall include inspection frequency, dimensionaltolerances, acceptance criteria, calibration procedures and frequencies, etc. QualityControl Manuals shall be provided by both the Steel MANUFACTURER and the PipeMANUFACTURER.

• A description of the plate or strip rolling practices to include rolling ratio, reductiontemperature range per pass, coiling temperature range and post-rolling heat treatment, ifapplicable.

A higher grade of API 5L pipe shall not be substituted for the grade of pipe specified in thePurchase Order without the approval of ADWEA/ENGINEER in writing.

First day production tests and production testing frequencies shall be conducted inaccordance with clause 5.4.1 of this Specification.

5.2 Chemical Properties

5.2.1 Composition: Product Analysis

Element Maximum Weight Percent

C 0.26

Mn 1.15

S 1.030

P 0.030

The MANUFACTURER shall provide to ADWEA/ENGINEER, via the CONTRACTOR a reportgiving the heat analysis of each heat of steel used in the manufacture of pipe furnished.

The MANUFACTURER shall provide to ADWEA/ENGINEER, via the CONTRACTOR acertified product analysis of the finished pipe. The product analysis shall include all elementslisted and any other intentionally-added elements, and shall be performed on two pipes perheat.

Recheck analysis requirements and acceptance criteria shall conform to API Specification 5L,except that in the event a recheck analysis fails to meet the criteria and theMANUFACTURER elects to test the remaining pipe lengths individually, the analysis shall bemade for all elements listed.

The MANUFACTURER shall furnish reports on all heat analyses, product analyses, andrecheck analyses. These analyses shall include all elements listed.

5.3 Mechanical Properties

The tensile tests and properties shall conform to API 5L for the grade of pipe specified in thePurchase Order. Tensile testing frequency shall be two pipes per heat.

Transverse tensile properties shall be determined on flattened rectangular specimens.



The actual yield strength of the pipe shall not exceed the specified minimum yield strength bymore than 140 MPa.

The ratio of yield strength to tensile strength shall not exceed 0.90.

The following tests shall be required.

Flattening tests shall be conducted in accordance with API 5L and the following requirements.No cracks or breaks shall occur in either weld or parent metal during flattening of the testspecimen to 50 percent of its original OD. The specimen shall be further flattened to 1/3 oforiginal OD without cracks or breaks other than in the weld.

Weld ductility tests shall be conducted on full section specimens in accordance with API 5L.

The fracture toughness of the pipe shall be determined by the use of Charpy V-notch impacttests in accordance with API 5L Supplementary Requirement SR5. The test temperature shallbe 0 °C (32 °F).

Charpy test specimens shall be full-size (10 mm x 10 mm) transverse specimen's wheneverpossible. If pipe size (geometry) does not permit extraction of a full size specimen, the largestobtainable sub-size specimen shall be used. Sub-size specimens shall be in accordance withAPI 5L SR5. When one-half size transverse specimens are not obtainable due to pipe size,longitudinal specimens may be substituted with the approval of ADWEA/ENGINEER.

The Charpy v-notch energy requirements shall meet the following requirements :

Pipe GradeMinimum Average

Value(Joules)

Minimum IndividualValue

(Joules)

Gr. B 27 22

X52 36 27

NOTES: (1) Minimum absorbed energy requirements for full size (10 mm x 10 mm) transverse specimens at 0°C.

(2) For other specimen sizes and orientations, the above values shall be multiplied by the following factors:

Size (mm) Orientation Factor

10 x 10 Longitudinal 1.5

10 x 7.5 Transverse 0.75

10 x 7.5 Longitudinal 1.125

10 x 5.0 Transverse 0.5

10 x 5.0 Longitudinal 0.75

The percent shear area shall be reported for all Charpy test specimens. The percent shearfor each specimen shall not be less than 50 percent.



During the first day of production, the following additional tests shall be performed. For eachtest described below, one complete set of specimens shall be taken from each of three pipesselected by the CONTRACTOR's representative, subject to ADWEA/ENGINEER's approval.Specimens shall be taken from the head of the coil, the middle of the coil, and the tail of thecoil.

The pipe MANUFACTURER shall conduct tensile, bend, flattening, weld ductility, fracturetoughness, and hardness tests. Results for all tests shall conform to the requirements of thisSpecification and API 5L.

Charpy test specimens shall be transverse with the axis of the notch perpendicular to the pipesurface. The notches shall be located on the centre line of the weld and on the heat affectedzone (HAZ), i.e. two sets of specimens are required.

The weld of one pipe per one hundred (100) pipes or less from each pipe lot shall beevaluated by removing a pipe cross section containing the weld. The section shall include theweld, the complete heat-treated zone and the parent metal on both sides of the weld, andshall be polished and etched for examination at 50x magnification. The weld shall havecomplete penetration and fusion. The geometry, including plate or coil edges and inside andoutside weld profile shall be within the tolerances specified in the Manufacturing ProcedureSpecification. There shall be no evidence of defects. The etched section shall demonstratethat the normalised zone is completely through the pipe wall thickness and of sufficient widthto encompass the entire weld and heat-affected zone. The grain size shall be ASTM No. 7 orfiner. A photomicrograph at 100x magnification shall be furnished for each specimen and thegrain size shall be reported in the mill test report.

Vickers hardness testing with a 10 kg load shall be conducted on the weld cross sections.Three hardness traverses shall be made across the weld area, two (2) millimetres from eachpipe surface and one in the middle of the pipe wall thickness. Hardness tests shall be madein the parent metal (each side), heat-affected zone (each side), and weld fusion face. Thespacing between hardness impressions shall be 0.75 mm. The hardness impressions nearestthe fusion line shall be within 0.5 mm of the fusion line. The hardness shall not exceed 290HV10.

After removal of the external and internal flash of the pipe, the thickness of the weld area shallnot exceed the thickness of the parent metal by more than 0.75 mm (0.030 inch), nor shall itbe less than the thickness of the parent metal unless otherwise agreed upon byADWEA/ENGIEER. Examination of protrusion shall comply with the frequency specified in theinspection requirements.



5.4 Inspection and Testing

5.4.1 Production Testing

First-day Production Tests During ProductionTest/Inspection

Frequency *) Remarks Frequency Remarks

VISUALINSPECTION- dimensions

- pipe end squareness

- straightness

- surface defects

all pipes

all pipes

all pipes

all pipes external

all pipes

2 pipes per shift

random

all pipes external

ULTRASONICEXAMINATION

- pipe ends

- plate/skelp

- weld seam

all pipes

all plates/skelp

all pipes

25 mm of pipeends

25 mm oftrimmedplate material

all pipes

all plates/skelp

all pipes

25 mm of pipe ends

25 mm of trimmedplate material

MT- seam weld

- bevel faces

all selectedpipes

all pipes only if ultrasonictesting isimpossible

all pipes only if ultrasonictesting isimpossible

*) initial frequency for first day production tests:

for destructive testing: two pipes to be selected by ADWEA/ENGINEER;

for non-destructive testing: all pipes frequency can be changed, depending on test results, atthe sole discretion of ADWEA/ENGINEER.



5.4.2 Hydrostatic Testing

Hydrostatic testing of the pipe shall be in accordance with API 5L and the following.

Each length of pipe shall withstand, without leakage, a hydrostatic test to a test pressure suchthat the hoop stress, calculated on the basis of minimum specified wall thickness andincluding stresses from end loading, is at least 95 percent of the specified minimum yieldstrength. If applied, the end load compensation factor as determined by the formula given inAPI 5L, Appendix F, SR14 shall be used. The test pressure shall be held for not less than 10seconds, during which time the full length of the weld seam shall be inspected for leaks.

The hydrostatic test equipment shall be equipped with a recording gauge that will record testpressure and duration of test applied to each length of pipe which shall be identified by PipeNumber. Hydrostatic test records shall be made available to the ADWEA/ENGINEER'sRepresentative.

5.4.3 Non Destructive Inspection

Immediately following welding and weld heat treatment, the longitudinal weld and adjacentparent material of each pipe shall be examined ultrasonically by both compression and shearmethods along its entire length. The examination of the adjacent parent material shall extenda minimum distance of 15 mm each side of the weld centre line.

Following manufacture each pipe shall be subjected to an off-line full body ultrasonicexamination for laminar flaws. The minimum coverage of the pipe surface shall be 25%.Acceptance criteria for laminations shall be in accordance with API 5L.

The entire length of weld seams shall be ultrasonically tested after hydrostatic testing. Weldseams of pipe shall be inspected for longitudinal defects. Acceptance criteria for welddiscontinuities shall be in accordance with API 5L.

Calibration of ultrasonic equipment may be based upon either notches or holes; however,reference standards shall contain both notches and holes. The MANUFACTURER shallfurnish, for ADWEA/ENGINEER approval, a complete description of his proposed procedures,including a description of the equipment; the number, size, angle, frequency, mode, andlocation of the transducers; continuity checking; scanning speed; method of weld tracking;defect marking methods; operator qualification; calibration reference standards, andacceptance limits. During the first day of production, the MANUFACTURER shall demonstrateto the satisfaction of ADWEA/ENGINEER's Representative, the effectiveness of hisequipment and procedures, using a standard, approved by ADWEA/ENGINEER. The detailsof this standard shall be in accordance with API 5L.

Apart from the off-line full body scan examination, the complete circumference of each pipeend shall be examined for laminations. The examination shall cover a width that includes theentire bevel. This may be accomplished by ultrasonic testing from the inside of the pipe.Alternatively the pipe may be tested from the outside surface prior to bevelling, and in suchcase a band of at least 25 mm wide shall be examined. Laminations are not acceptable in thisarea.



All non destructive inspection equipment shall be checked at least twice per eight (8) hourworking shift to demonstrate effectiveness of calibration and operational procedure.

Such inspection equipment shall also be checked immediately following any equipment failureor equipment adjustment. These equipment checks shall either be regularly scheduled, orwith enough notice so that the ADWEA/ENGINEER's Representative may witness equipmentchecks each time.

When grinding repairs are made because of imperfections found by non destructive testing,the section of pipe containing such repairs shall be subjected to additional Non Destructivetesting using the same Non Destructive Testing techniques, and magnetic particle testingafter the grinding operation.

Any detrimental magnetic fields resulting from magnetic particle (wet or dry) inspection,electro-magnetic inspection, or any other magnetic equipment shall be checked and removedif it exceeds the following requirements. The pipe shall be checked subsequent to anyinspection that uses a magnetic field, handling with any electromagnetic equipment and priorto shipment from the mill. The pipe ends shall be checked for residual magnetism as follows:

a. Measurements shall be made on the root face using a Hall-effect Gauss-Meter or othertype of instrument approved by ADWEA/ENGINEER. However, in the case of dispute,measurements with the Hall-effect Gauss-Meter shall govern. The Gauss-Meter shall beoperated in accordance with written instructions demonstrated to produce accurateresults. The accuracy shall be verified at least once each day that the Gauss-Meter isused.

b. Measurements shall be made on each end of at least three (3) pipes per working shift.One pipe shall be taken from the beginning of the shift, one from near the middle, andone from the end of the shift.

c. Readings shall be taken around the circumference of each end of the pipe. No readingshall exceed 30 gauss when measured with a Hall-effect Gauss-Meter, or equivalentvalues with other types of instruments.

d. Any pipe that does not meet the above requirements shall be considered defective.

e. In addition, all pipe produced between the defective pipe and the last acceptable pipeshall be measured. Alternately, if the pipe production sequence is documented, pipe maybe measured in reverse sequence beginning with the pipe produced prior to thedefective pipe until at least three (3) consecutive pipes meet the requirements. Pipeproduced prior to the three consecutive acceptable pipes need not be measured. Pipeproduced after the defective pipe shall also be measured until at least three (3)consecutive pipes meet the acceptance requirements.

f. All defective pipe shall be de-gaussed full length and re-measured or permanentlyrejected.



5.4.4 Dimensions, Weights and Lengths

5.4.4.1 General

Dimensions, length, weights, and straightness of pipe shall comply with API 5L and thefollowing. Measuring equipment shall have a resolution and accuracy at least five (5) timesfiner than the tolerance of the parameter being measured.

5.4.4.2 Length

The pipe shall be supplied to the following length requirements unless otherwise specified inthe Purchase Order.

• A minimum of 95% of the pipes shall be between 11.0 and 12.2 m in length.

• No pipe shall be less than 9.0 m in length.

• No pipe shall be more than 12.5 m in length.

5.4.4.3 Wall Thickness

Pipe wall thickness at any point shall not deviate from the nominal by more than plus 10percent or minus 5 percent.

5.4.4.4 Diameter

a) Pipe Body:

The outside diameter of the pipe shall not be more than 0.75 percent larger thanspecified, nor more than 0.25 percent smaller than specified as measured with adiameter tape.

b) Pipe Ends:

Pipe up to 10.75 inch OD, (273 mm) inclusive, shall not be more than 1/64 inch (0.40mm) smaller than the specified outside diameter for a distance of 4 inches (101.6 mm)from the end of the pipe and shall permit passage over the ends, for a distance of 4inches (101.6 mm), of a ring gage that has a bore 1/16 inch (2.38 mm) larger than thespecified outside diameter of the pipe.

5.4.4.5 Out-Of-Roundness

The out-of-roundness of the outside diameter of the pipe shall not exceed the following:

(Maximum OD - Minimum OD) / Nominal OD < 1.5 percent



5.4.4.6 Straightness

Pipe shall be checked for straightness and deviation from a straight line and shall not exceed0.20 percent of the pipe length. Measurements shall be made using a taut string or wire fromend to end along the side of the pipe measuring the greatest deviation. No less than fivepipes per shift (at random) shall be checked as well as any pipe that does not appear to meetthis requirement. Depending on the results ADWEA/ENGINEER may decide to increase thetest frequency.

5.4.4.7 Bevels

Pipe ends shall be bevelled in accordance with API 5L unless otherwise specified in thePurchase Order.

5.4.4.8 Jointers

Jointers shall not be supplied.

5.4.5 Workmanship, Visual Inspection and Repair of Defects

All first-day production tests will be witnessed by the ADWEA/ENGINEER's Representative.In addition, all pipes will be subject to inspection by the ADWEA/ENGINEER'sRepresentative. MANUFACTURER shall give sufficient notice (15 days) via theCONTRACTOR of the time pipe production is to begin (if material is to be supplied fromstock).

The ADWEA/ENGINEER's Representative shall have free entry at all times to all parts of theworks which concern the manufacture, testing, inspection, quality control, and shipping of thepipe ordered, including the steel mill, the plate or strip mill and the pipe mill.

The pipe mill and steel mill shall make available to the ADWEA/ENGINEER's Representativewithout charge all reasonable facilities to inspect, measure, and test the pipe in all stages ofproduction including, for example, ultrasonic equipment for wall thickness measurements aftergrinding repairs.

The ADWEA/ENGINEER's Representative shall have the option to examine all materialsrejected for any reason. The causes for rejection shall be brought to the attention of theADWEA/ENGINEER's Representative and all affected materials shall be retained untilexamined by the ADWEA/ENGINEER's Representative.

The MANUFACTURER shall take all reasonable precautions to ensure that the pipe surfaceis free from imperfections that might interfere with the efficient application of an externalcoating. The metal surfaces shall be sufficiently clean and smooth to permit non-destructiveexamination. All loose scale shall be removed, and pitting and rough surfaces removed bygrinding. Pipe shall have a workmanlike finish, and the MANUFACTURER shall remove bygrinding, mechanical marks and abrasions, such as cable marks, scores, etc., and alsoimperfections such as scabs, seams, laps, tears, and slivers, even though theseimperfections may be shallow enough to be within wall thickness tolerances.



The pipe shall contain no dents which affect the curvature of the pipe at the longitudinal weldor at the pipe ends. Pounding out or jacking out dents is prohibited.

All cold formed dents with a sharp bottom gouge, and all sharp gouges, deeper than one mmwithout dents shall be considered defects which require repair or rejection. Repair shall onlybe permitted with the approval of the ADWEA/ENGINEER's Representative.

The radial offset of the plate edges for pipe with a specified wall thickness of 10 mm or lessshall not exceed 0.5 mm. For pipe with wall thickness greater than 10 mm, the maximumradial offset shall not exceed 5 percent of the specified wall thickness.

No welding repairs are permitted to the weld or parent metal.

5.5 Packing, Marking and Shipping Documentation

5.5.1 Marking and Coating

Pipe shall be furnished bare and free of mill coating.

No die stamping, hot or cold, shall be permitted.

The pipe shall be paint stencilled at both ends, in accordance with API 5L on the surface ofthe pipe within 200 mm of the ends. Pipe markings shall show: steel grade, service ("NS", for"non-sour"), pipe diameter (OD), length, weight and wall thickness. Sizes, weights, lengths,and pressures shall be given in metric units. Colour of marking as specified in the MaterialRequisition for Line Pipe.

Pipe marking shall include the unique pipe number, lot number, heat number, and whateverother designation is required so that complete traceability is maintained, and each length ofpipe can be specifically linked to all applicable chemical, mechanical and other required tests,and to each step of the manufacturing, testing and inspection operations.

The location of the longitudinal weld shall be marked on the inside of each pipe end with a 2-inch (50 mm) daub of heat-resistant white paint.

ADWEA/ENGINEER approved end caps / bevel protectors shall be furnished for all pipes.End caps / bevel protectors shall be of a re-usable type, and shall seal the bore againstingress of any contamination and permit the lifting of the pipe, using end hooks without havingto remove the end cap / bevel protector.

5.5.2 Records and Test Reports

The following records and test reports shall be furnished by the MANUFACTURER at no costto ADWEA/ENGINEER.

Heat treatment records when any pipe is subjected to full body heat treatment.

Certified chemical analysis and mechanical properties tests.

The results of grain size evaluation.



Charpy V-notch impact tests and hardness tests.

5.5.3 Shipping and Handling

All pipe shall be handled, loaded and shipped in accordance with API RP 5L1, RecommendedPractice for Railroad Transportation of Line Pipe, and API RP 5LW, Recommended Practicefor Transportation of Line Pipe on Barges and Marine Vessels.

MANUFACTURER shall submit loading instructions and diagrams for ADWEA/ENGINEERapproval for all pipe shipped by rail, truck, or marine vessel. However, approval of thesedocuments shall not relieve the MANUFACTURER of its responsibility for damage duringshipment.

All dimensional tolerances and pipe surface conditions specified herein and in API 5L shallapply to the pipe as received at the shipping destination.

5.5.4 Guarantee

MANUFACTURER shall bear all costs to seek, find, and repair all leaks and/or ruptures whichoccur during field hydrostatic testing, and which result from defects traceable to themanufacture of the pipe. The field test will not exceed a pressure that will cause acircumferential fibre stress greater than 100 percent of the specified minimum yield strengthof the pipe based on the minimum specified wall thickness. ADWEA/ENGINEER may elect toraise and lower the field test pressure one or more times either as part of a planned testingroutine, or as a consequence of a failure in the pipeline, or in the testing equipment; however,these pressure cycles shall in no way relieve the MANUFACTURER of its obligations.

6. INTERNAL AND EXTERNAL PROTECTION

Reference shall made to the following Specification for Internal and External Protection ofPipes & Fittings.

- Specification for Painting and External Coating of Metal Pipes and Structures.

- Specification for Yard and Field Cement Mortar Lining of Steel Pipe.

7. FABRICATION AND ERECTION REQUIREMENTS

7.1 Fabrication

7.1.1 Dimensional Tolerances

a) Length

Length less than 1.5 m 1.5 M and longer

Centre to centreCentre to flange face + 1.5 mm + 3 mmFlange face to flange face



b) Thinning of wall thickness and ovality in bends

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

For tolerances on the maximum flattening, ASME B31.3 code shall be referred.

c) Flange face alignment

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

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

d) Position of bolt holes for flanged piping

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

7.1.2 Pipe Joints

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

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

7.1.3 Butt Welded Piping

a) Pipe lengths and butt weld fittings will be generally supplied/ purchased with endsprepared in accordance with ASME B16.25.

b) Spool pieces with ends for site fit welding shall have an excess 100 mm plain end lengthon one component of the joint.

c) Whatever the end condition supplied, the CONTRACTOR shall modify it as necessary tosuit the applicable welding procedure. Modification by weld build up is only permittedwith the approval of ADWEA/ENGINEER.

d) Permitted radial misalignment of adjacent butt weld preparations shall be no greater than1.0 mm.

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



7.1.4 Proximity of Welds

a) Weld joints shall not be arranged so close to each other. Sufficient weld clearance shallbe maintained to prevent thermal stresses near the joint. Circumferential butt welds onthe pipelines shall be separated by maximum possible distance. Longitudinal butt weldsof adjacent pipes shall be separated by at least 100 mm or 5 times the thickness of thethicker pipes whichever is greater. Should the site conditions warrant, short pipe lengthsbetween fittings can be used and its butt welds shall not be closer than 75 mm or 5 timesthe thickness of the thicker pipes whichever is greater.

b) In principle, the longitudinal welded joint of welded pipe shall be located above thehorizontal centerline, when the pipe is installed horizontally.

7.1.5 Screwed Piping/Galvanized Piping

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

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

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

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

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

7.1.6 Flange Connections

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

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

c) Slip-on flanges shall be welded to pipe by inside and outside fillet welds. The inside filletwelds shall be so applied, that the flanges do not require refacing. The distance from theflange face to the pipe end shall equal to the pipe wall thickness plus 3 mm.

d) Internal weld surfaces at orifice flanges and other flow measuring instruments shall beground flush.



e) During fabrication, damage to sealing/seating surfaces of flanges and other mechanicaljoint fittings shall be avoided. In particular such surfaces shall be protected during anyPWHT by the application of a suitable coating as approved by ADWEA/ENGINEER.

7.1.7 Branch Connections

a) Branch connections shall be made as indicated in the relevant piping materialspecification and/or isometrics drawings.

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

c) Reinforcement pads if required shall be provided as shown on piping drawings and/orisometric drawings of the applicable project. Reinforcement pad shall be attached afterexternal and internal visual inspection of the branch welds, and DP or MP inspection asrequired has been performed.

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

7.1.8 Fittings

a) Standard fittings shall be used in the pipeline wherever possible. Pipe may be bent andcomponents may be formed by any hot or cold method which is suitable for the material,the service medium, and the severity of the bending or forming process. The finishedsurface shall be free of cracks, excessive thinning or flattening and substantially freefrom wrinkling. Wall thickness after bending or forming shall not be less than designthickness.

b) Cold bending is limited normally upto DN 100 mm and shall be done in pipe bendingmachine or pressurising formers. Excessive scratches gauges or die marks on the pipesshall be rejected.

i) For carbon steel pipes after cold bending no additional heat treatment is required iffollowing requirements are met :

- hardness < 248 HV 20

- hardness increase < 100 HV or 100 HB

- Bending radius > 1.3 times outer diameter of the pipe

ii) For stainless steel pipes, no additional heat treatment is required if deformation of the SSis < 20%. If it is more than 20% solution annealing and a rapid water quench is required.

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



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

e) Pipe bends, elbows and mitre bends shall be in accordance with Para 304.2 of ASMEB31.3 Code.

7.1.9 Cutting and Trimming of Standard Fittings

Fittings like elbows, couplings, half-couplings, long-neck flanges for thermowell-connection,etc. shall only be cut/trimmed where required to meet fabrication and erection requirements,as per drawings and/or instructions of ADWEA/ENGINEER.

7.1.10 Shop Fabrication/Pre-Fabrication

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

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

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

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

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

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

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

7.1.11 Pipe Supports

Almost all pipe supports and pipe support components shall be pre-fabricated at shop, beforeerection, as per support drawings. CONTRACTOR shall prepare pipe support drawings andsite verified for its height, level and other salient dimensions, before fabrication.

In the event of non-availability of any specified support material/profile/component, theCONTRACTOR may use alternate substitute material which is better than or equal to the onespecified, with dimensions as required by specification and design.



The CONTRACTOR shall forward Guarantee for the substitutions and confirm that it does notweaken the design/construction.

7.1.12 Miscellaneous

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

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

7.2 Erection

7.2.1 Cleaning of Piping Before Erection

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

7.2.2 Piping Routing

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

No deviations from the piping route, indicated on the approved drawings, shall be permittedwithout the approval of ADWEA/ENGINEER.

Pipe to pipe, pipe to structures/equipment's distances/clearances as shown on the drawingsshall be strictly followed as these clearances may be required for the free expansion ofpiping/equipment. No deviations from these clearances shall be permissible without theapproval of ADWEA/ENGINEER.

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

7.2.3 Slopes

Slopes specified for various lines in the drawings shall be strictly maintained. Correctiveaction shall be taken under consultation with ADWEA/ENGINEER wherever it is not possibleto maintain the specified slope.



7.2.4 Flange Connections

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

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

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

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

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

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

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

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

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

j) Where a pipe passes through a wall, retaining wall or is subject to thrust, it shallincorporate a puddle flange which shall conform to the dimensions stated in BS 4504 butremain undrilled.

7.2.5 Vents and Drains

a) Valved high point vents and low point drains with plug/blind flange shall be additionallyprovided as per the instructions of ADWEA/ENGINEER and as necessary.



7.2.6 Valves

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

b) Valves shall be installed with spindle/actuators orientation/position as shown on thelayout drawings and/or isometric drawings. In case of any difficulty in doing this in viewof operation or passage, they shall be corrected after consultation withADWEA/ENGINEER.

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

d) Care shall be taken to ensure that globe valves, check valves and other uni-directionalvalves are installed correctly as marked with 'flow direction arrow' on the valve body. Ifthe directional arrow is not marked on such valves, this shall be confirmed and marked inpresence of ADWEA/ENGINEER before installation.

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

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

7.2.7 Instruments

a) Installation of in-line instruments, whichever is applicable, such as restriction orifices,shutdown valves, control valves, safety valves, relief valves, rotameters, orifice flangeassembly, flowmeters etc., shall form part of the piping erection work.

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

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

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

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

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



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

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

h) PSV shall not be installed until successful testing and flushing of connecting piping iscompleted.

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

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

7.2.8 Line Mounted Equipments and Miscellaneous

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

7.2.9 Bolts and Nuts

All bolts and nuts shall be hot dip galvanized/cadmium plated and shall be suitably protectedto prevent any damage for the coating and threads. Stud bolts shall be threaded full length.Necessary washers shall be supplied with bolts and nuts.

7.2.10 Pipe Supports

a) Pipe supports shall be designed and located as shown on drawings, to effectively sustainthe weight and thermal effects of the piping system and to prevent vibrations.

b) All supports shall be strictly in accordance with the drawings/instructions ofADWEA/ENGINEER. Extra care shall be taken in the correct installation and setting ofsupports around pumps, compressors, and other machinery etc., as per detaileddrawings and suppliers erection instructions etc.

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

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

e) The following points shall be checked after installation:

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



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

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

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

7.2.11 Welding

Welding shall be in accordance with the "Specification for Welding and Welding inspection ofshop and field fabricated piping".

8. INSPECTION AND TESTING

8.1 General

The CONTRACTOR shall submit to ADWEA/ENGINEER for approval a comprehensiveprocedure for Inspection, flushing and testing of the piping systems.

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

8.2 Hydrotest

(a) Field hydrotesting shall be performed for all erected piping, except where this provesimpractical. In such cases, the prefabricated spools shall be shop hydrotested. Theduration of testing shall be minimum one hour, unless otherwise specified in the relevantcode.

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

(c) Carrying out radiography & other NDE shall not be taken as reasons for not performinghydrotest.

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

(e) After Hydrotest, the water shall be drained out and blown dry with oil free compressedair.

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



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

8.3 Test Procedure

8.3.1 General

Upon completion of the line or a substantial part thereof, sections of the line shall be cleanedand hydrostatically and/or pneumatically tested to prove integrity of the pipe section and todetect any leakage prior to commissioning. Testing shall be performed in accordance with theapplicable codes and standards. CONTRACTOR shall supply all necessary fittings,equipment, facilities, etc. including test ends.

8.3.2 Method Statement

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

8.3.3 Test Pressures

Test Pressure shall be maximum 1.5 times the maximum allowable operating pressure(MAOP) of the pipeline section under test for the pipe class selected for the project.

8.3.4 Test Medium

In general Test Medium shall be fresh potable water, except for instrument air and plant airpiping which shall be tested by air.

8.3.5 Test Records

The CONTRACTOR shall prepare, maintain and submit Records/Result of the testing in aformat and shall be approved by ADWEA/ENGINEER.

8.4 Disinfection and Flushing of Pipeline

8.4.1 General

All water lines shall be disinfected by CONTRACTOR to the satisfaction ofADWEA/ENGINEER and all involved authorities.

8.4.2 Method Statement

CONTRACTOR shall prepare a detailed MS for disinfection. This MS shall describe in detailhow the CONTRACTOR proposes to perform the various disinfection activities to ensurecompliance with the requirements as set forward in this Specification and applicable Codesand Standards, as well as with all requirements as set forward by the relevant Authorities.



8.4.3 Disinfection and Flushing

Before the pipeline is placed in service, and before issue of the Provisional AcceptanceCertificate by the ADWEA/ENGINEER, all pipelines shall be disinfected and flushed as perAWWA C651 or as directed by ADWEA/ENGINEER.

The pipelines shall normally be disinfected at the same time as the hydrostatic testsperformed or as directed by ADWEA/ENGINEER.

Ten (10) days before the CONTRACTOR intends to undertake disinfecting/flushing of all orpart of the pipelines, the CONTRACTOR shall submit a detailed proposal for the workshowing the quantity of water required. This quantity of water may be obtained by theCONTRACTOR from the nearest available ADWEA source.

The chlorine dose shall be obtained from a chloral solution or other suitable solution to beapproved by ADWEA/ENGINEER. Samples taken from the pipeline during disinfection atlocations directed by ADWEA/ENGINEER shall be checked by a suitable compractor in orderto ensure that the sterilising liquid is present throughout the system and at sufficientconcentration.

At the end of the 24 hour period at operating pressure the chlorine concentration shall bechecked. If there is less than 1 mg/l of free available chlorine in the water, more chloralsolution shall be introduced and left for a further 24 hour period after which the free availablechlorine concentration shall be checked again. This procedure shall be repeated asnecessary until the free available chlorine taken after 24 hours exceeds 1 mg/l for all samplestaken from the area of pipeline under test. The hydrostatic test shall not be commenced untilthis requirement is satisfied.

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

After all hydrostatic testing has been completed and section of pipeline is ready for handingover in all other respects including the installation of connections where appropriate, the newpipeline shall be flushed out by potable water from the existing mains to which the newpipeline or network is or will be connected. Flushing entry and exit points shall be designed toallow a minimum of 1.0m/s water velocity in the main pipeline to remove any sand or otherdebris. The quantity of flushing water shall be calculated as the equivalent to 3 times thevolume of the pipeline to be flushed unless directed otherwise.

It shall be a condition that the water in the existing network at the point of extraction shallregister a minimum of 0.4 mg/l of free available chlorine when tested with a site comparatorprior to any approval being given to commence flushing. If a reading of less than this isobtained ADWEA/ENGINEER shall be informed and the CONTRACTOR instructedaccordingly. Once flushed, the water in the new pipelines shall be allowed to stand for afurther 24 hours. Samples shall then be taken from locations directed by ADWEA/ENGINEERand immediately submitted for chemical and bacteriological testing at the approvedlaboratories. Chemical and bacteriological tests shall normally be undertaken at ADWEA's



Laboratory and a charge may be made for testing. All charges for water sample testing shallbe paid by the CONTRACTOR.

8.4.4 Acceptance Criteria for disinfection

The pipeline shall not be considered acceptable until faecal coliforms are undetectable in a100 ml sample, the bacterial count is within approved limits, the recorded total chlorinecontent is a minimum of 0.2 mg/l and the pH is within acceptable limits.

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

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

The CONTRACTOR is responsible for making himself fully aware of the statutoryrequirements for achieving acceptance of bacteriological and chemical standards of the waterin the pipelines under construction.

Flushing water shall be discharged via temporary discharge lines to the surrounding opendesert area or into the existing storm water system or, if feasible, into road tankers.Discharging of flushing water into the existing storm water system shall be subject to approvalof the relevant Authorities.

Any temporary connections required for flushing shall be at the CONTRACTOR's cost. Allother materials, equipment and labour required for the disinfection, flushing operation anddischarge of water shall also be furnished by the CONTRACTOR and included in hisconstruction rates.

8.5 Protective Coating

a) Protective coating on the pipes and fittings shall be carried out as per painting systemdocument applicable for the relevant project.

b) Pipework shall be colour coded to the approval of ADWEA/ENGINEER. The normaldirection of flow shall be clearly marked on the pipe near each valve, junction, terminaland other positions as required by ADWEA. Where applicable, colour coding shall bemarked after protective coatings, have been applied.

9. VENDOR DOCUMENTATION

The CONTRACTOR shall maintain a complete documentation of work and testing performedand this shall be submitted to ADWEA/ENGINEER on completion of fabrication. The reportshall be authenticated by the CONTRACTOR and ADWEA/ENGINEER and shall include thefollowing information:

1. Line number and spool number of each spool plus an identifying number for each weld.



2. Fabricator's procedure(s) for storing, drying and handling electrodes and fluxes.

3. Welding procedure(s) employed on each weld.

4. Identification of welder(s) employed on each weld.

5. NDE performed and results (including identification of NDE inspector).

6. Details of any repair(s) and NDE performed.

7. Hardness values of welds wherever specified.

8. Details of pressure test.

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

10. QUALITY ASSURANCE / QUALITY CONTROL

A copy of the VENDOR's QA/QC program shall be submitted to ADWEA/ENGINEER with itsquotation for review and concurrence prior to award. If VENDOR's QA/QC program is ISO9000 certified, then only a copy of the ISO 9000 certificate is required. In addition, ifVENDOR's facility is ISO certified, QA audit requirements will be waived in favour of ISO 9000register audits, unless the ADWEA/ENGINEER trend analysis program indicates areas ofconcern.

The vendor shall identity in documents to its manufacturers, suppliers, vendors andsubcontractors all applicable QC/QC requirements imposed by ADWEA/ENGINEER, andshall ensure compliance. On request, VENDOR shall provide object evidence of its QA/ACsurveillance for all levels of its activity.

11. SAFETY AND ENVIRONMENT

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

Specification for Steel Piping

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