Beruflich Dokumente
Kultur Dokumente
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7.4 Extra Depth and Clearances .................................................................................................. 12
7.5 Crossing and Laying Adjacent to Existing Utilities................................................................. 12
7.6 Trenching Across or Along Roads and Tracks ....................................................................... 13
7.7 Grading and Finishing of Trench or Formation ..................................................................... 14
8 BACKFILLING.................................................................................................................................. 14
8.1 General.................................................................................................................................. 14
8.2 Pipe Bed and Surround ......................................................................................................... 14
8.3 Geotextile Filter Fabric .......................................................................................................... 16
8.4 Selection and Placing of Backfill Materials ........................................................................... 16
8.5 Backfill and Reinstatement of Trenches in Roads and Tracks .............................................. 17
9 NON-DISRUPTIVE CROSSINGS ....................................................................................................... 17
9.1 General.................................................................................................................................. 17
9.2 Construction Methods .......................................................................................................... 17
10 PIPE LAYING .............................................................................................................................. 18
10.1 General.................................................................................................................................. 18
10.2 Minimum Allowable Bending Radius .................................................................................... 18
11 PIPE JOINTING ........................................................................................................................... 18
11.1 General.................................................................................................................................. 18
11.2 Pipe Jointing Personnel ......................................................................................................... 19
11.3 Method Statement................................................................................................................ 19
11.4 Electro-fusion Jointing .......................................................................................................... 20
11.5 Electro-fusion Joint Inspection.............................................................................................. 20
11.6 Butt Fusion Jointing............................................................................................................... 21
11.7 Butt Fusion Joint Inspection .................................................................................................. 21
11.8 Testing of Fusion Joints ......................................................................................................... 22
12 TYING-IN .................................................................................................................................... 22
12.1 Joining Unconnected Sections .............................................................................................. 22
12.2 Tie-ins after Hydro-testing .................................................................................................... 22
13 RESTORATION OF THE CONSTRUCTION RIGHT-OF-WAY .......................................................... 23
13.1 General.................................................................................................................................. 23
13.2 Progress of ROW Restoration ............................................................................................... 23
13.3 Pipeline Markers ................................................................................................................... 23
13.4 Equipment Nameplates ........................................................................................................ 23
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14 DETECTABLE WARNING TAPES ................................................................................................. 23
15 HYDROSTATIC TESTING ............................................................................................................. 24
15.1 General.................................................................................................................................. 24
15.2 Method Statement................................................................................................................ 24
15.3 Outline Test Procedure ......................................................................................................... 24
15.4 Test Result ............................................................................................................................. 26
15.5 Notes on Test Equipment ..................................................................................................... 27
15.6 Differences in elevation ........................................................................................................ 27
15.7 Test pressures at elevated temperature............................................................................... 27
15.8 Additional Notes ................................................................................................................... 28
16 DISINFECTION AND FLUSHING OF WATER PIPELINE................................................................. 28
16.1 General.................................................................................................................................. 28
16.2 Method Statement................................................................................................................ 28
16.3 Disinfection and Flushing ...................................................................................................... 28
16.4 Acceptance Criteria for Disinfection ..................................................................................... 29
17 CONNECTION TO EXISTING WATER PIPELINES AND SERVICES ................................................. 30
18 PIPELINE COMMISSIONING ....................................................................................................... 30
19 QUALITY ASSURANCE/QUALITY CONTROL................................................................................ 30
20 CONSTRUCTION RECORDS ........................................................................................................ 31
20.1 General.................................................................................................................................. 31
20.2 Brief Daily Reports ................................................................................................................ 31
20.3 Detailed Weekly Reports ...................................................................................................... 31
20.4 Detailed Monthly Reports ..................................................................................................... 31
20.5 Completion Report................................................................................................................ 32
20.5.1 General .......................................................................................................................... 32
20.5.2 As-Built Drawings .......................................................................................................... 33
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SPECIFICATION FOR CONSTRUCTION, TESTING & COMMISSIONING OF PE100 PRESSURE
PIPELINE SYSTEMS
1 SCOPE OF SPECIFICATIONS
This specification covers minimum requirements for the construction, installation and testing of
pipelines comprising PE100 (High Density Polyethylene - HDPE) pipes and fittings.
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of all existing facilities, utilities, roads other infrastructure and property affected by the Contractor
undertaking their work.
The Contractor shall be deemed to have inspected the work area(s) and their surroundings and to
have satisfied themselves as to their nature, including sub-surface conditions, hydrological and
climatic conditions, the extent and nature of the work, the materials necessary for the completion of
the work and the means of access to all the work area(s).
The Contractor shall be deemed to have obtained all necessary information related to the risks,
contingencies and all other circumstances that may influence the work.
The Contractor shall, in connection with the work, provide and maintain all lights, safety barriers,
fencing, watchmen and associate facilities required to undertake the works in a safe manner. They
shall also comply with the requirements of Engineer and any relevant authority having jurisdiction
over the works or the safety and convenience of the public or others. The Contractor shall adapt their
method of work to suit any changing conditions on site in order to ensure that the works are
undertaken in a safe manner. Such changes shall however be subject to approval by the Engineer.
4 PRE-CONSTRUCTION SURVEY
Prior to any construction activities the Contractor shall carry out a pre-construction survey to stake
the pipeline centreline and identify all relevant features along the pipeline route. They shall define the
Right-of-Way (ROW) by stakes placed at locations where they shall not be disturbed and from where
the boundary of the ROW can be determined.
The Contractor shall stake the entire pipeline route(s) as per the data available on the alignment
drawings in compliance with the MS be submitted to and approved by the Engineer.
The construction survey controls shall be staked at a maximum distance of 100 m from each other.
The staking shall be based on the markers set along the pipeline route and construction drawings. The
Contractor shall establish references offset from pipeline centreline such that they shall not be
disturbed by the construction works.
The final pipeline alignment shall be subject to approval of the Engineer.
5 RIGHT-OF-WAY (ROW)
5.1 General
The ROW shall have the dimensions indicated on drawings approved by the Engineer. The pipeline
shall be located at the centre of the ROW, unless indicated otherwise.
The Contractor shall co-ordinate with all local authorities and utility owners to obtain the approval for
the ROW.
Prior to any clearing operation the Contractor shall make themselves familiar with all restrictions along
the ROW and shall use their best endeavours to avoid any damage to property and existing
infrastructure on or adjacent to the ROW.
Prior to the commencement of any construction activities in an area the Contractor shall locate and
identify all existing buried facilities, such as cables, pipelines, water mains and sewers etc. including
those not shown on the drawings, crossed or at close proximity to the pipeline. This shall be achieved
by liaison with the relevant authorities, carrying out surface and sub-surface surveys and exposing any
buried utilities by hand excavation, unless exempted in writing by the Engineer.
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Once located, the underground facilities crossed by the pipeline route or running parallel to it within
the ROW shall be clearly marked by methods approved by the Engineer.
The Contractor shall submit a detailed MS setting out the precautions to be taken for avoiding or
preventing damage to existing utilities, fences, roads or other infrastructure, existing above or below
ground or any property adjacent to or crossing the pipeline being constructed. All work carried out in
the vicinity of such infrastructure or property shall be undertaken only after the issue of a permit or
written approval by the relevant authorities.
5.2 Crossings
Crossing of roads, buried services and other infrastructure shall only be permitted after the Contractor
has obtained written approval from the appropriate authorities. The Contractor shall undertake their
work in such a manner as to not interrupt the operation of existing infrastructure and to minimise the
risk of the infrastructure being damaged.
The Contractor shall acquaint themselves with all relevant requirements and regulations of the
authorities responsible for roads, utilities and other infrastructure on or crossing the ROW and obtain
their approval in writing together with all necessary permits before commencing work.
Notwithstanding the provisions of the drawings and specifications, it shall also be the Contractor's
responsibility to ensure that the work is performed in accordance with the requirements of the
relevant authorities. In the event that the requirements and specifications of the authorities are more
stringent than those of the Engineer, then the authorities' requirements shall be followed.
Highways, main roads and their verges shall not be used for loading, unloading or stacking of materials
and/or equipment. For secondary roads, such loading/unloading is permitted only after prior approval
from the relevant authorities. The Contractor shall not close or divert roads without prior approval
from the Engineer and the concerned authorities. The Contractor shall never unnecessarily hamper
the activities of road users.
Any diversion arrangements, if required, shall conform to the requirements of the relevant authorities
and be approved by them.
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otherwise obstructed without approval of the relevant authority. Such written approval shall provide
to the Engineer prior to commencing any associated work.
The Contractor shall establish any additional survey monuments required and shall maintain and
preserve survey monuments (already staked on ground) such as Bench Marks and
Intersection/Turning Points until the construction is completed. If any Bench Marks are missing the
Contractor shall re-establish them, as directed by the Engineer, to carry out levelling work during
laying or the as-built survey of the pipeline.
The Contractor shall carry out all survey and levelling of line and grade including an as-built survey
necessary to complete the work and shall be responsible for the accuracy of such survey works.
The Contractor shall install distinct markers locating and indicating special points, such as but not
limited to contract limits, warning notices, presence of buried structures, obstacle crossings and any
change of pipe wall thickness including the corresponding chainage, etc.
Markers shall be of a sufficient height and of material and type approved by the Engineer so as to
serve their purpose. The Contractor shall be responsible for the maintenance and replacement of the
reference line markers until the permanent pipeline markers are placed and the as-built drawings are
submitted and approved.
Upon completion of the construction works the topsoil shall be reinstated in the areas from where it
was removed, to the satisfaction of the Engineer, the relevant authorities and the land owner, if any.
Any shortfall in material shall be made of with imported topsoil of the same type.
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5.6 Removal of Debris
The Contractor shall remove all debris, loose rock or other hard material from the ROW and dispose
of it in a manner satisfactory to the Engineer and the relevant authorities.
The Contractor shall be responsible for all surplus material disposals, if any, arising out of clearing and
grading operations.
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5.12 ROW in Areas Having Poor Ground Conditions
The ROW in areas having poor ground conditions such as swamps, salt flats, sabkha and marsh areas
shall be constructed using a granular material, that shall be placed and compacted to provide a firm
and safe working surface. The type of fill material to be used by the Contractor shall be approved by
the Engineer and shall comply with the specification.
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Pipe materials shall be stocked, chocked, padded, and secured in position during transportation,
storage and stringing in a manner approved by the Engineer. If pipes or fittings are supplied in bundles
or on pallets, they shall remain so packaged until they are delivered to the location of installation on
site.
Care and attention should always be applied when handling pipe materials, not only for the protection
of the pipe materials but also for the safety of the handling personnel.
Pipe materials shall never be dropped onto hard or uneven surfaces, thrown from vehicles or be
dragged or rolled along the ground.
Where pipe weights exceed practical personnel handling then rope or web slings shall be used with
mechanical lifting equipment. Metal chains, hooks or cables shall never be used.
Pipes shall be transported on vehicles with a flat bed and free from sharp edges or protrusions and
they shall generally be supported over their full length at intervals recommended by the
manufacturer.
Materials shall be stored in accordance with the pipe manufacturer’s recommendations and this
specification.
The storage area should have a relatively smooth, level surface free of sharp stones, debris or other
materials that could damage the pipe or fittings. Where adequate ground conditions do not exist or
when a level gravel bed cannot be prepared, the pipe shall be placed on timber supports evenly
spaced along the pipe length. The support size and spacing shall be as advised by the pipe
manufacturer.
Stacks shall only contain pipes of one size and wall thickness and shall be constructed in a pyramid,
with each successive layer having one less pipe than the layer below. The bottom layer should be
braced to prevent movement and the stack shall not exceed a height of 2.0 m.
Coils should be stored horizontally on pallets and they shall not overhang the sides of the pallets.
Coils may be stacked as ‘silos’ but the height of any silo shall not be higher than 2.0 m.
Pipes materials shall be kept away from lubricating or hydraulic oils, gasoline, solvents or other
materials that may cause damage.
Fittings and accessories shall be stored under cover, protected from direct sunlight and have good
ventilation.
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If they so choose, the contractor may place the pipes on a racking system adjacent to where they are
to be jointed.
7 TRENCHING
7.1 Excavation
The Contractor shall excavate the pipeline trench on the surveyed route as staked and to the design
profile, but they shall not commence excavation operations until the pipeline centreline has been
approved by the Engineer.
The Contractor shall excavate the pipeline trench within the cleared and graded ROW using any
method approved by the Engineer. Care shall be taken to ensure that fresh material recovered from
trenching operations, intended to be used for backfilling over the pipe in the trench or at the berms,
is not mixed with loose debris or with foreign or rejected material, required to be removed from site.
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7.3 Minimum Pipe Cover Requirements
The minimum cover to the pipeline shall be 0.9 m or the pipe outside diameter, whichever is greater,
with the following exceptions.
Main roads, highways and rig road crossings: 1.5 m or the pipe outside diameter, whichever is
greater.
River, wadi and channel crossings: 2.0 m or as directed by the Engineer
Service connections may be buried with a cover of no less than 0.6 m in circumstances
approved by the Engineer
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The use of excavation plant close to existing utilities and underground structures may result in their
damage and the Contractor shall only excavate the trench within 2 m of such utilities and structures
manually unless they received the written approval of the Engineer.
Where the pipeline crosses other underground utilities and structures, the Contractor shall first
manually excavate and expose such utilities and structures and clearly record their details and location
on as-built drawings i.e. type, diameter, horizontal and vertical location and angle relative to the new
pipeline. This work shall be completed before mechanical excavation plant is allowed to operate
within 10 m of the utility location shown on the drawings or indicated by utility organisation personnel.
Temporary underpinning, trench sheeting or any other supports and protective devices necessary to
protect existing utilities and structures affected by the pipeline works shall be provided by the
Contractor. The excavation works shall be undertaken in such a way that even under the worst
weather and flooding conditions, the existing pipelines/utilities shall remain stable and not be either
undermined or slide towards the trench.
If, despite all precautions, any damage should occur to any utilities or structures the relevant owner
or authority, together with the Engineer shall immediately be informed by the Contractor and repairs
shall be completed at the Contractor's expense. The repairs shall be completed under the direction
and to the satisfaction of the Engineer and the relevant authority. If The Contractor fails to complete
the repairs within a time agreed upon or to the satisfaction of the relevant authority, the Engineer
reserves the right to have the repairs completed by others at the cost of the Contractor.
The Contractor shall also arrange and provide all permanent protection measures to utilities and
structures which the pipeline crosses, as required by relevant authority and to their satisfaction.
If it is deemed necessary, the Contractor shall, subject to clearance of all the relevant authorities,
arrange to re-route existing utilities that are obstructing the pipeline works. The rerouting design and
arrangements shall be fully approved by the relevant authority and shall be undertaken by an
approved sub-contractor designated by the authority.
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7.7 Grading and Finishing of Trench or Formation
The trench or formation shall be cut or made to a grade that shall provide a firm, uniform and
continuous support for the pipe, allowing for any necessary pipe bedding. Bends shall be made in the
pipe at significant changes in the grade of the trench.
The minimum number of vertical bends shall be laid to ensure that the pipe conforms to the general
contour of the ground and to maintain the minimum cover. Where practical, this instead shall be
accomplished by cutting the trench slightly deeper at the crest of ridges and by gradually deepening
the trench in approaches to road and channel crossings.
The bottom of the pipe trench shall be dug as square as practical using mechanical plant and if
required, the Contractor shall trim the bottom and lower sides of the trench by hand to ensure the
bottom of the trench is flat and square with the sides and free of loose rock and other hard lumps of
material. Any soft spots shall be excavated and filled with selected excavated material approved by
the Engineer.
8 BACKFILLING
8.1 General
No backfilling shall be performed until the pipeline is at the proper alignment and depth shown in the
drawings, taking in to account any amendments approved by the Engineer. Before any backfilling is
commenced it shall be the Contractor's responsibility to first secure the approval of the Engineer. If
any backfilling is done without the Engineer’s approval, the Engineer has the right to require removal
of backfill for examination. The cost of such uncovering and re-backfilling shall be borne by the
Contractor.
The backfill shall be maintained by the Contractor against being washed out etc. until the completion
and final acceptance of the work by the Engineer.
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Where pipes are laid in poor quality ground conditions such as those native soils comprising soft or
silty materials, the pipe bed and surround shall comprise an imported granular material complying
with one of the grades given in the UK WIS 4-08-02, which are given in Tables 7.2 and 7.3 below.
Table 7.1 – Grading of sand (fine aggregate)
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10.00 0–5 0 – 25 0 – 50 85 – 100 100
5.00 – 0–5 0 – 10 0 – 25 45 – 100
2.36 – – – 0–5 0 – 30
Note: Single sized aggregate shall not be used for the pipe bed and surround in conditions where the
native soil comprises of sandy, silty or soft material unless it is wrapped in a geotextile filter fabric to
prevent migration of fine material from the surrounding soil in to the bed and surround
The maximum particle size of the granular material shall not exceed 10% of the pipe outside diameter.
When the grade at which the pipeline laid exceeds 10o trench breakers or clay dams shall be installed
to prevent the migration of bed and surround material due to the flow of water along the trench.
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Any depressions caused by settlement of the trench backfill shall be made good by the Contractor
using fill material approved by the Engineer.
9 NON-DISRUPTIVE CROSSINGS
9.1 General
Non-disruptive crossings shall be defined as the crossing of roads, tracks, railway lines, channels,
existing infrastructure and utilities that is achieved without the excavation of a trench and the
conventional laying of a pipeline.
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10 PE100 PIPE LAYING
10.1 General
Laying of the pipe and making of connections shall be undertaken in a dry trench.
During pipe laying operations the ends of the pipe shall remain sealed by end closures, until
immediately prior to jointing.
Pipe handling shall be in accordance with the requirements of Section 6 above and the pipe
manufacturer’s recommendations. Exposed PE pipe shall be properly supported and protected from
mechanical damage.
The induction of stresses in the pipe or in joints during installation shall be avoided where possible
and the following precautions shall be taken:
Ensure that the pipe is not damaged by coming in to contact with sharp or abrasive materials
during handling, jointing or installation and that it is regularly supported along its length.
When pipes are pulled as part of the jointing or laying process care shall be taken to ensure that
the drag force does not exceeding the allowable force as specified by the pipe manufacturer.
Pipes shall only be pulled when they are supported by roller assemblies and are free of the
ground surface and other obstructions in order to ensure that they are not damaged during the
process.
The contractor shall comply with the minimum allowable bending radii specified in section 10.2
of this specification.
Ensure that the trench is in compliance with the requirements of section 7 of this specification
and that proper bed and surround material are used.
Whilst placing the bed and surround material ensure that no stones or other hard materials
impinge on the surface of the pipe.
If the pipe is laid in a sleeve, ensure that the sleeve ends are fitted in such way that no stress or
cutting effect can be transmitted to the PE carrier pipe.
11 PIPE JOINTING
11.1 General
The Contractor shall abide by the following guidelines with regards to jointing PE100 pipes and
fittings unless otherwise approved by the Engineer.
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PE100 pipes and fittings of 90 mm OD and above shall joined by butt fusion whenever possible.
PE100 Pipes and fittings of less than 90 mm OD shall be joined together using electro-fusion
couplings and fittings.
Electro-fusion fittings may also be used to undertake repairs and install off-takes or connections
on existing pipelines. They may also be used for the joining together of pipe strings where it is
not practical to use a butt fusion welding machine.
To join PE pipes to metal pipes and fittings such as valves, restrained mechanical transition
fittings and stub flanges shall be used.
Restrained mechanical fittings may, with the permission of the Engineer, also be used to join
together service connection pipework
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11.4 Electro-fusion Jointing
Only barcode labelled electro-fusion fittings incorporating fusion indicators and complying with the
requirements of ISO4427, Part 3 shall be used.
The equipment used for electro-fusion jointing of pipes and fittings shall comply with the
requirements of ISO 12176 Part 2. It shall incorporate an automatic control unit with data input
through the use of a bar code reader pen and a data retrieval facility to allow historical fusion data to
be read on the unit’s screen and to be exported to an external computer or memory stick.
The electro-fusion control box shall deliver the correct fusion parameters to the electro-fusion fitting.
The power generator shall provide the power requirements of the control box, taking into account the
electrical characteristics of the control box.
Positioning tools including suitable alignment clamps shall at all times be used to minimise
misalignment and prevent movement during the fusion and cooling cycle of the joint. A suitable
shelter shall be used in cold, windy, dusty or wet weather conditions.
Prior to commencing the welding process the Contractor shall measure and ensure that the ovality of
the pipe or spigot end is within the limits given in Table 3 of ISO 4427, Part 3.
All pipework shall be cleaned with disposable alcohol impregnated wipes prior to undertaking the pipe
scraping, in order to remove any contamination. Prior to scraping the Contractor shall measure and
mark the area of the pipe or spigot end to be scraped in order to remove the oxidized surface to a
depth between 0.2 and 0.4 mm. The length of the pipe or spigot end to be scraped shall be equivalent
to the insertion depth of the electro-fusion joint plus a distance of between 10 and 20 mm.
Only rotating mechanical scrapers or peelers, which are capable of cutting a continuous strip or ribbon
over the insertion length of the coupler or fitting, shall be used.
Only after preparation and scraping of the pipe end shall the fitting be removed from its packaging
and immediately inserted over the pipe end.
Each pipe or spigot end shall penetrate completely its relevant part of the electro-fusion socket.
Alignment clamps shall not be removed before the appropriate cooling time has elapsed. Abnormal
displacement of the electric wire coils shall not occur. This shall be checked prior to commencement
of the fusion process.
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11.6 Butt Fusion Jointing
The equipment used for butt fusion jointing of pipes and fittings shall comply with the requirements
of ISO 12176 Part 1. It shall incorporate a control unit that shall comply with the type A requirements
of table B.2 of ISO 12176, Part 1 and the following points.
Automatically preset the fusion jointing parameters based on the pipe dimensions, material
type and fusion jointing procedure
Automatically control and monitor the fusion jointing process
Comply with the requirements of Annex A of ISO 12176, Part 1
Assign a unique joint number to each joint and have a data retrieval facility to allow historical
fusion parameters to be read on the unit’s screen and to be exported to an external computer or
memory stick
The butt fusion jointing procedures shall comply with the requirements of ISO 21307. The Contractor
shall generally follow the single low pressure fusion jointing procedure described in section 5.1 of ISO
21307.
In the case of pipes having a wall thickness in excess of 20 mm the Contractor may propose to instead
follow the single high pressure fusion jointing procedure described in section 5.2 of ISO 21307.
Only pipes and fittings of the same size, SDR and material are to be butt fusion jointed.
A dummy joint shall be made at the start of each welding session using pipe off cuts of the same size,
material and SDR as the pipe being installed. The normal trimming, bead up and full heat soak cycles
will be adhered to.
If the pipe size is changed during the day, if the heater plate is allowed to cool below 180°C or if
maintenance of the butt fusion equipment is carried out then a new dummy weld shall be performed.
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The width of each external bead width shall be measured using bead gauges and the width of
the bead shall be within the range given by the pipe and / or welding equipment manufacturer.
No signs of damage (such as scratches or deep impressions caused by clamps) shall be visible on
either side of the joint.
Any joints the do not comply with the above requirements shall be cut out and a new joint
made; the failed joint shall be handed over to the Engineer.
Records of all tests and inspections shall be maintained by the Contractor and made available
for review and approval by the Engineer.
12 TYING-IN
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13 RESTORATION OF THE CONSTRUCTION RIGHT-OF-WAY
13.1 General
After completion of backfilling operations, the construction Right Of Way (ROW) and any other area
affected or used in connection with the pipeline construction shall be restored to its original contour
and condition to the approval of the Engineer and to the satisfaction of the relevant authority.
Any surplus excavated materials, defective materials from the construction of the pipeline, refuse and
unusable spoil materials shall be collected and disposed of by the Contractor to an approved site.
Any loose rock scattered over the ROW or adjacent property shall be collected and disposed of by the
Contractor to an approved site.
The construction ROW shall be graded smooth and any topsoil removed shall be reinstated in its
original location with utmost care and the land restored to its original condition.
Terraces, drainages or gutters, whether earth or masonry, damaged or destroyed by the construction
operations shall be reinstated to their original condition.
All fences cut or damaged shall be reinstated by installing, if necessary, new sections of fencing equal
to or better than the sections cut or damaged. Temporary gates shall be removed and replaced by
new fence sections to the satisfaction of the Engineer and owner.
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encapsulated between two plastic layers, which shall allow the tape to be detected by a cable locating
device.
The ends of the aluminium foil or cables shall be connected to adjacent warning tapes laid above the
pipeline so as to give a continuous detection signal along the length of the pipeline between each
chamber when used in conjunction with a cable detection signal generator.
The tape shall have the warning "CAUTION – WATER PIPELINE BELOW" or similar text approved by the
Engineer, in languages instructed by the Engineer.
15 HYDROSTATIC TESTING
15.1 General
Upon substantial completion of the pipeline or major sections, the line shall be cleaned and
hydrostatically tested to prove integrity of the pipeline section and to detect any leakage prior to
commissioning. Testing shall be performed in accordance with the Finnish Standard SFS 3115:E and
the procedure described below. The Contractor shall supply all necessary fittings, equipment and
facilities required to undertake the testing.
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Phase 3
At the end of the second two hours release the pressure back down to the phase I level i.e. the
operating pressure or 5 bar, within a period of no more than 30 minutes and as quickly as is practical,
in a controlled manner.
Phase 3 – Case 1
If after one hour the pressure in the pipelines remains at or above the operational pressure, the test
is considered to be completed with the pipeline passing the hydrostatic test.
Phase 3 – Case 2
If after one hour the pressure in the pipeline has fallen below the operational pressure, water shall be
added to raise the pressure back to the operating pressure level, having first noted the low pressure
before adding any water.
Phase 3 – Case 2
Measure the added water by draining it off into a measuring cylinder. (i.e. reduce pressure to the
previously recorded low value and save the water bled off). The measured quantity is then compared
against the allowable quantity to determine if the pipeline passes the hydrostatic pressure test.
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Figure 2 Graphical Representation of the Hydrostatic Test Process
Case 2 – Water to be added to determine if the pipeline passes or fails
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Figure 3. Hydrostatic Test – Allowable Quantities of ‘Make Up’ Water
Hydrostatic Test
Pass
When ambient temperatures at the time of test are over 30 OC or higher and the test pressures exceed
the pressure rating of the pipe (after being derated in accordance with Annex A of ISO 4427-1) then it
is necessary to modify the test pressure according to the table below or as agreed with the pipe
manufacturer.
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Multiplier 0.9 0.85 0.8 0.75 0.7 0.65 0.6
Do not subject the line to prolonged over-pressure. Always aim to complete the procedure within
one working day.
During the summer make sure that the pipe is not subject to direct sunlight during testing.
During pressure testing pay full attention to the HSE aspects of the procedure. In particular keep
the general public away from high pressure test areas.
The test equipment must be capable of pressurizing the test length within a reasonable time. If the
procedure becomes protracted (beyond one working day) the test length may be modified or
reviewed. Extremely long test lengths may be subject to special procedures.
16.1 General
All water lines shall be disinfected by The Contractor to the satisfaction of the Engineer.
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shall be introduced and left for a further 24 hour period after which the free available chlorine
concentration shall be checked again. This procedure shall be repeated as necessary until the available
free chlorine taken after 24 hours exceeds 1 mg/l for all samples taken from the length of pipeline
under test. If the concentration of free available chlorine exceeds 5 mg/l at any point the after 48
hours the pipeline shall be flushed out until the concentration falls below this level.
After all testing and disinfection has been completed and the pipeline is ready for handing over in all
other respects including the installation of connections where appropriate, the new pipeline shall be
flushed out with potable water from the existing mains to which the new pipeline or network is or will
be connected. Flushing entry and exit points shall be designed to allow a minimum of 1.0m/s water
velocity in the main pipeline to remove any sand or other debris. The quantity of flushing water shall
be calculated as the equivalent to 3 times the volume of the pipeline to be flushed unless directed
otherwise.
It shall be a condition that the water in the existing network at the point of extraction shall register a
minimum of 0.4 mg/l of free available chlorine when tested with a site comparator prior to any
approval being given to commence flushing. If a reading of less than this is obtained the Engineer shall
be informed and the Contractor instructed accordingly.
Once flushed, the water in the new pipelines shall be allowed to stand for a further 24 hours. Samples
shall then be taken at locations instructed by the Engineer and immediately submitted for chemical
and bacteriological testing at approved laboratories. If available, chemical and bacteriological tests
shall normally be undertaken at the End Users laboratory and a charge may be made for testing. All
charges for water sample testing shall be paid by the Contractor.
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17 CONNECTION TO EXISTING WATER PIPELINES AND SERVICES
After successful completion of hydrostatic, chemical and bacteriological tests the Contractor may
apply for connection to existing pipelines, in advance of preparing the new pipeline or network for
handing over to the End User.
At least two weeks should be allowed for the application to be processed. The Contractor shall follow
strictly the timings and shutdown periods allowed by the End User for the means of connecting to the
existing system. A shutdown application shall also be completed by the Contractor and submitted to
the Engineer and End User if an existing pipeline needs to be shut down in order to make any
connection. Copies of the hydrostatic test results, together with the chemical and bacteriological test
certificates shall be attached to the application form. Connection works shall only proceed once the
End User, in response to the application, has issued a permit to work covering a particular connection.
The Contractor shall submit a detailed method statement setting out the means by which the
connection is to be made, together with highlighting what actions they believe will need to be
undertaken by the End User’s operational staff. The method statement shall identify the steps by
which the Contractor is going to minimise the contamination of the work area and disinfect all
pipework that shall be affected by the connection works.
The Contractor shall prepare all labour, plant and equipment well in advance of the proposed
shutdown date and shall make advance preparations at the site of the connection so as to minimise
the amount of work required during the limited period of shutdown allowed.
No cutting of existing pipework shall be allowed until representatives of both the Engineer and the
End User have officially given their authority for the work to commence. This shall only happen once
the End User’s operational staff have completed their work necessary to isolate the pipeline section
to which the Contractor is to connect.
After the successful completion of the connection works and if agreed by the Engineer and the End
User’s operational staff, the network shall be re-pressurise and brought back in to operation. If a valve
is installed at the subject connection it shall be maintained in a closed position and shall only be
opened for specific flushing requirements at the instruction of the Engineer.
18 PIPELINE COMMISSIONING
Unless otherwise approved by the Engineer the Contractor shall commission the pipelines only after
all hydrostatic pressure testing, disinfection, flushing and connections have been completed. The
Contractor shall prepare a detailed method statement describing the commissioning activities for
each section of the pipeline and these shall be subject to the Engineer’s approval. Once a method
statement has been approved, any change in procedure shall be subject to written approval of the
Engineer.
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compliance. On request, the Contractor shall provide objective evidence of their QA/QC surveillance
at all levels of their operation.
20 CONSTRUCTION RECORDS
20.1 General
The Contractor shall submit regular daily, weekly and monthly reports together with a project
completion report. The contents of these different reports shall, as a minimum, include the following
items:
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Any pipe welder certificates not previously submitted
Monthly safety report including details of any accidents or damages
List of site instructions and other project related correspondence issued by the Engineer
together with their revision, date of issue and approval status
Up to date list of confirmed Site Instructions issued by the Engineer
List of approved Vendors and Subcontractors and a brief description of the materials they are
supplying or work that they are undertaking.
List of equipment calibration and safe working certification submitted by the Contractor
together with their date of submission, status and date of expiry
List of permits and approvals requested and received by the Contractor together with their
revision, dates of submission and approval together with their status
Minutes of meetings with the Engineer and other relevant organisations over the last month
together with comments, if any
List of material certificates submitted by the Contractor, together with their revision, date of
submission and approval status
Receipts for materials received on site over the last month.
List of drawings submitted by the Contractor, together with their revision, date of submission
and approval status
List of method statements submitted by the Contractor, together with their revision, date of
submission and approval status
List of calculations and other technical submissions submitted by the Contractor, together with
their revision, date of submission and approval status
List of test reports submitted by the Contractor, together with their result, date of submission
and approval status
List of current ‘as-built’ drawings submitted by the Contractor, together with their revision, date
of submission and approval status
List of any other submissions made by the Contractor or issues that require action by the
Engineer and / or the project owner, their date of submission and status
Project progress photographs
20.5.1 General
The pipeline completion report shall comprise the final version of the information given in the
monthly progress reports together with the following
Details of all materials purchased by or supplied to the Contractor during the project together
with details of how these were consumed eg. incorporated in the works, disposed of as scrap
material, retained by the contractor and handed over
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Final as-built drawings
Operation and maintenance manuals
Detailed assembly drawings for all with keyed parts listed for each item of equipment
Two-year recommended spare parts list for all equipment
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