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LUSAIL DEVELOPMENT

Appendix 13 – Part 3, 3.1


Technical Requirements
Supply of Pre-Insulated Pipes

Document No.: LUS-[CP PKG]-MAQ-SPE-UT-10001

Project Name: Lusail Development Appendix 13 – Part 3, 3.1, Supply of Pre-Insulated Pipes
27-August-2013 Rev.0
LUSAIL DEVELOPMENT

Content

1 INTRODUCTION 4
1.1 General 4

1.2 Tender documents package 4


1.2.1 Technical Requirements Supply of Pre-insulated Pipes – documents package 4

1.3 Scope of Supply 4

2 DEFINITIONS, ABBREVIATIONS AND REFERENCES 5


2.1 Definitions 5

2.2 Abbreviations 6

2.3 Reference documents 6


2.3.1 Codes, standards and specifications 6

2.4 Document precedence 7

3 TECHNICAL REQUIREMENTS AND SPECIFICATIONS 7


3.1 General 7

3.2 Basic design conditions 8

3.3 Distributed water quality 8

4 PRE-INSULATED PIPES 8
4.1 General 8
4.1.1 Chilled water service carbon steel pipes 9

4.1.2 Thermal insulation 9

4.1.3 Outer casing jacket pipe 10

4.2 Surveillance system 10

4.3 Outer casing pipe joints 11


4.3.1 Joint kits with electro welded casing 12

4.3.2 Special joints for on-site made branches 12

4.4 Straight pipe lengths 12

4.5 Pipe elbows 12


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4.5.1 Pre-insulated elbows 12

4.5.2 Steel pipe elbows 13

4.5.3 Mitred pipe ends 13

4.6 Branches and T-pieces 13


4.6.1 Pre-insulated branches 13

4.6.2 Site made branches 13

4.7 Reducers 14

4.8 Special fittings 14

4.9 Pre-insulated valves 14


4.9.1 Pre-insulated shut-off valves 14

4.9.2 Pre-insulated drain and venting valves 15

4.10 Detectable warning devices 15

5 MARKING, IDENTIFICATION AND TRANSPORTATION 15


5.1 Marking and identification 15

5.2 Transportation, delivery of material to the site 15

6 DESIGN, PREPARATIONS AND TRAINING ON SITE 16

7 QUALITY CONTROL 16

8 WARRANTIES 16

9 DOCUMENTATION 16

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1 INTRODUCTION

1.1 General

This document and the attached files define the technical requirements to furnish pipe
and materials for the portion of the district cooling system referred to as [CP-PKG] . For
ease in understanding, these documents are prepared as if the project was broken into
three separate contracts, but in fact they are all components of a single contract between
the Client and one contracting party.
In the end, the contracting party is responsible for all aspects of the project and that all
tools, equipment, and devices are suitable and reliable for the intended use and in the
ambient conditions expected at the construction site. He shall be responsible for all
documents and procedures requested by authorities for the official inspection and
acceptance of the works.
In general the technical tender documents are described as:
 LUS-[CP PKG]-MAQ-SPE-UT-10001 Pre-insulated Pipes: The scope of supply is
described as pipe and materials including delivery to a lay down area designated by
Lusail, but the scope does NOT include fabrication or installation of pipe (mechanical
works) or trenches (civil works).
 LUS-[CP PKG]-MAQ-SPE-UT-10002 Civil Works: The scope of supply is the civil
portion of the underground piping system and thus does NOT include pipe materials
or mechanical installation.
 LUS-[CP PKG]-MAQ-SPE-UT-10003 Mechanical Works: The scope of supply
includes mechanical installation of pipe and materials, but does not include furnishing
materials or preparing the trenches.
 LUS-[CP PKG]-MAQ-BOQ-UT-10001 Bill of Quantity: The bill of quantity is relevant to
all because it summarizes the lengths, quantities, and sizes of materials.

1.2 Tender documents package

This document is part of the total tender package and ultimately will be incorporated into
the project Agreement.

1.2.1 Technical Requirements Supply of Pre-insulated Pipes – documents


package

This document specifies technical requirements for supply of pre-insulated district


cooling pipes and fittings and is a part of the total Technical requirements for Supply of
Pre-insulated pipes package.
The Scope of Supply is defined by:
- This document
- Appendices and drawings in accordance with Drawings/Documents List form
(DLF).

1.3 Scope of Supply

The Supplier shall provide material and services necessary for a complete, safe and
prudent underground pipe system as described herein.

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Delivery shall be made in accordance with good industry practice, notwithstanding


certain essential items not being expressly stated in these requirements or elsewhere in
the Request for Proposal (RFP)
The Scope of Supply shall include, but not be limited to the supply and delivery of:
1. Pre-insulated carbon steel pipes intended for installing underground.
2. Pipe elbows, branches, and other fittings, valves and auxiliaries
3. Surveillance system(s)
4. Outer jacket casing pipe joints
5. Documentation

Laying down pipes in the trench, installation and welding of the steel pipes will be carried
out by the Mechanical Contractor and is not a part of this Scope of Supply.
For each size, prices shall be individually stated in the tender for component material and
transportation. Quantities are described in LUS-[CP PKG]-MAQ-BOQ-UT-10001 – Bill of
Quantity DC Pipes and Fittings.

2 DEFINITIONS, ABBREVIATIONS AND REFERENCES

2.1 Definitions

The following expressions shall, where the context so permits, have the meaning hereby
respectively assigned to them.
Contractor means the organisation, or its appointed representative,
responsible for execution of the works as defined in
these technical tender documents
Engineer means Marafeq supervision engineer or its appointed
representatives
Client means the Master Developer (LREDC) or its appointed
representatives
Supplier means the organisation, or its appointed representative,
responsible to furnish the materials and/or services as
defined in these technical tender documents
Vendor means any of the invited companies being fully eligible to
submit the Tender. The successful Vendor will be the
Contractor/Supplier.
Works means work, products, materials, computer software and
documentation, and other work as called for in the
Agreement
Agreement means the contract or other written agreement entered
into between the Client and a contracting party regarding
supply of the Works including appendices, amendments,
and additions agreed in writing
For Information only means information only is indicative and not under
responsibility of the Client. Vendor has to control, verify
and be responsible for any such information in the same
manner as other submittals.
Must this is a minimum requirement
Shall indicates a mandatory requirement
Should indicates a preferred method or material
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Request for Proposal means the document prepared and issued by the client
who includes this document and other general and
particular requirements

2.2 Abbreviations

DP Design pressure
ID Internal diameter
OD Outer diameter
WT Wall thickness
QCP Quality Control Plan
FAT Factory Acceptance Test
SAT Site Acceptance Test
RFP Request For Proposal
WPS Welding Procedure Specification

2.3 Reference documents

2.3.1 Codes, standards and specifications

Material supplied by the Supplier and work, methods, testing, and actions carried out by
the Supplier shall, at a minimum, conform to the requirements of the codes listed below.
When an edition date is not indicated for a code or standard, the latest edition in force at
the time of contract award shall apply.
EN253 Pre-insulated bonded pipe systems for directly buried hot water
networks.
EN448 Pre-insulated fittings for bonded pipe systems
EN488 Pre-insulated valves for bonded pipe systems
EN489 Joints and connections for pre-insulated bonded pipe systems
EN13941 Design and installation for bonded pre-insulated pipe systems.
EN14419 Surveillance systems for bonded pre-insulated pipe systems
EN10216-2 Seamless steel tubes
EN10217- 2, -5 Welded steel tubes
EN10253-2 Butt welded steel fittings
EN13480 Metallic industrial piping
P235GH Steel quality
EN 12517 Non-destructive testing of welds. Radiographic testing of
welded joints
EN12613 Plastic warning devices for underground cables and pipelines
with visual characteristics
EN ISO 5817 Fusion welded joints in steel and alloys. Quality levels for
imperfections.
EN206-1 Concrete: Specification, performance, production and
conformity.
EN287-1 Qualification test of welders. Fusion welding – Part 1: steels.
E 287-3 Welding procedures tests.

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EN288-2 Specification and approval of welding procedures for metallic


materials. Welding procedures specification for arc welding of
steels.
EN288-3 Specification and approval of welding procedures for metallic
materials. Welding procedures specification for arc welding.
EN ISO 9692-1 Welding and allied procedures – Recommendations for joint
preparation
EN ISO 11970 Specification and approval of welding procedures for
production welding of steel castings.
ISO 12096 Submerged arc-welding steel tubes for pressure purposes –
Radiographic testing of the weld seam for the detection of
imperfections.
EN ISO 15607 Specification and qualification of welding procedure for metallic
materials. General rules.
EN ISO 3834 Quality requirements for fusion welding of metallic materials.
EN ISO 15614-1 Specification and qualification of welding procedures for
metallic materials -- Welding procedure test -- Part 1: Arc and
gas welding of steels and arc welding of nickel and nickel
alloys
EN 10253-1,-2 Butt welding pipe fittings
QCS Qatar Construction Specifications
Kahramaa Water and Electricity Components
QCD Qatar Civil Defense
Other standards Mentioned or referred to in the complete package of Tender
documents.

2.4 Document precedence

The Contractor shall notify the Engineer of any conflict between this specification, the
related requirements and/or data sheets, the codes and standards and any other
specifications noted herein. Resolution and/or interpretation precedence shall be
obtained from the Engineer in writing before proceeding with the design or manufacture.
In case of conflict, the order of precedence shall be:
1. Material narrative specifications.
2. Project specifications and standards
3. Industry and official codes and standards

3 TECHNICAL REQUIREMENTS AND SPECIFICATIONS

3.1 General

The piping system shall be supplied as pre-insulated bonded carbon steel pipes with
polyurethane foam insulation (PUR) and with high density polyethylene (HDPE) outer
casing jacket.
Works, pipes, and components shall meet the technical and environmental requirements
of the applicable directives and standards.
Health and safety requirements and the function of safety related systems must be
fulfilled.
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3.2 Basic design conditions

Design pressure 1600 kPa


Operating temperature range 4.0 – 16°C
Soil temperature range 10 – 50°C
Ambient design temperature 50°C; maximum outdoor temperature during
installation
Water quality See table in paragraph 3.3.
Calculated life-time Pipes, works, and components shall be designed for
a calculated life-time of 40 years.

3.3 Distributed water quality

The Client intends to maintain the circulated water quality as noted in the table below.

Marafeq
Parameters Unit Standard
pH -- 8.5 to 10.5
Total dissolved solids ppm < 2000
Conductivity µSiemens/cm < 3000
Total iron as Fe ppm < 1.0
Nitrite as NaNO2 ppm > 800
Total Suspended Solids ppm < 20
Chlorides as Cl- ppm < 150
Total Alkalinity as CaCO3 ppm < 250
Total Calcium hardness as CaCO3 ppm < 100

4 PRE-INSULATED PIPES

4.1 General

Pre-insulated bonded pipe systems for directly buried water networks. Pipes assembled
by carbon steel service pipe, polyurethane thermal insulation and outer casing of high
density polyethylene (HDPE).
The pre-insulated bonded piping shall comply with standard EN253 as minimum.
Certification of testing from independent party to verify compliance with EN253 shall be
provided.
Pipe ends shall be delivered free from insulation for welding in the field. Insulation of the
free pipe joints and joining of the outer casing pipe shall be carried out with a proven
reliable method, as further described.
A surveillance system based on copper wires moulded into the pipes and components
foam insulation shall be included in the pre-insulated piping system as described in
greater detail in clause 4.2
All temporary arrangement required for testing, flushing and commissioning of the
system shall be included in the contractor’s scope of work.

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4.1.1 Chilled water service carbon steel pipes

The service carbon steel pipe shall conform to dimensions in accordance with DIN 2458
and steel quality P235GH in accordance with standard EN10216-2, EN10217-2 and
10217-5.
Elbows, reducers, tees and other fittings shall comply with standard EN10253-2 type B.
Pipes shall be delivered from factory in 12 m or 16 m length sections.
Seamless steel tubes in accordance with EN10216-2 shall be used for dimensions up to
DN350.
Welded steel tubes in accordance with EN10217-2 (ERW) or EN10217-5 (SAW) shall be
used from dimension DN400 and larger.
Carbon steel pipe dimensions:
Nominal
Dimension Outer Diameter
Wall Thickness
DN100 114,3 mm 3,6 mm
DN125 139,7 mm 3,6 mm
DN150 168,3 mm 4,0 mm
DN200 219,1 mm 4,5 mm
DN250 273,0 mm 5,0 mm
DN300 323,9 mm 5,6 mm
DN400 406,4 mm 6,3 mm
DN450 457,0 mm 6,3 mm
DN500 508,0 mm 6,3 mm
DN600 610,0 mm 7,1 mm
DN700 711,0 mm 8,0 mm
DN800 813,0 mm 8,8 mm
DN900 914,0 mm 10,0 mm
DN1000 1016,0 mm 11,0 mm
DN1100 1120,0 mm 11,0 mm
DN1200 1220,0 mm 12,5 mm
DN1300 1320,0 mm 12,5 mm

4.1.2 Thermal insulation

The pre-insulated pipes and fittings shall be delivered with high density polyurethane
foam applied at factory. The polyurethane foam shall be bonded to the carrier pipe and
the outer casing jacket pipe. Minimum insulation requirements:

Property Min. requirement


Closed cell content > 90,0 %
Size of cells < 0,3 mm
Core density ≥ 60 kg/m3 Note1
o
Thermal conductivity at 50 C
< 0,029 W/mK
(λ50)
Water absorption < 5 % (volume)
Compression strength > 0,30 MPa
Axial shear strength,
> 0,12 MPa
23 deg C new
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Property Min. requirement


Axial shear strength,
> 0,12 MPa
23 deg C aged
Note 1: Core density is currently not defined in EN253:2009. However, the specified density is required for
handling large diameter pipes. (It was included in the previous EN253:2003. Requirements are considered by
CEN/TC 107, to be included again in next EN253 standard version.)

Thickness of insulation varies depending on pipe size. See dimensions of outer casing
jacket pipe in paragraph 4.1.3.
Before insulation is applied, the external surfaces of the carrier pipe and the inner
surface of the casing pipe shall be cleaned and treated to maximize adhesion between
the insulating foam and the adjoining surfaces.

4.1.3 Outer casing jacket pipe

The outer casing jacket pipe functions as the vapour barrier (barrier against
condensation) and shall be manufactured in UV-stabilized HDPE in accordance with
EN253 or equal.
Materials High density polyethylene (HDPE) bimodal minimum PE80, ISO
12162
Density Min. 944 kg/m3
Pipe wall thickness According to EN253 or equal
Outer casing jacket pipe dimensions:
Minimum Casing
Outer Diameter
Dimension Wall Thickness
Casing Pipe
(mm)
DN100 200 mm 3,2
DN125 225 mm 3,4
DN150 250 mm 3,9
DN200 315 mm 4,5
DN250 400 mm 4,8
DN300 450 mm 5,2
DN350 500 mm 5,6
DN400 520 mm 5,7
DN450 560 mm 6,6
DN500 630 mm 7,2
DN600 780 mm 7,9
DN700 900 mm 8,7
DN800 1000 mm 9,4
DN900 1100 mm 10,2
DN1000 1200 mm 11,0
DN1100 1300 mm 11,8
DN1200 1400 mm 12,5
DN1300 1500 mm 15,9

4.2 Surveillance system

For detection and location of moisture in the insulation, a complete surveillance system
including main central computer, surveillance units, outside cabinets, cable connectors,
etc shall be included in the works.

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Detailed design of the leak detection system for this specific project shall be carried out
by the Supplier and included in the delivery. Detailed design shall include, but not be
limited to, size and location of control loops, location of alarm units, commissioning and
documentation.
The surveillance system shall be specially designed for District Cooling systems. This
especially means, among other requirements, that the detection wires must be designed
in order to avoid problems caused by “natural condensation” in the foam insulation and
moisture from condensed ambient air.
The foam insulation naturally has a low non-detectable concentration of moisture equally
spread between steel pipe and outer casing jacket. In operation, the warmer atmosphere
outside the insulated pipe will create a process in which the natural moisture travels
towards the colder steel pipe and eventually will reach a high concentration. The
detection wires must be able to handle the consequences of such natural “moisture
travel” without giving any false alarms.
The detection wires shall be insulated copper wires mounted as 3 parallel wires at a fixed
distance between the conductors in a common cable conduit. The common cable conduit
shall be assembled directly to the media steel pipe.
The system shall detect moisture in the foam by measuring impedance along the
insulated copper wires. By detecting faults early, damage and degradation of the
insulation and/or corrosion of the service pipe can be minimized. The system shall also
be able to locate a break of the surveillance copper wires.
The system shall, beside copper wire and constant distance elements, include a
sufficient number of microprocessor based monitoring alarm units.
The surveillance units shall operate on a pulse reflection method and be able to survey
the entire system including straight pipes, bends, branches and other fittings. The system
shall also be capable of detecting more than one leak after acknowledgement of previous
or current leak.
Only pulse surveillance units (for use in district cooling systems) shall be supplied.
Resistance surveillance (commonly used for district heating systems) will not be
accepted.
The surveillance system shall work as a fully documented system taking measurements
of each increment of the entire sensor wires and storing the received data in a non-
volatile data base memory as start-up data. In monitoring mode, actual data and start-up
data shall be compared in order to detect deviations.
System sensitivity shall be selectable in different levels in such a way that minor
irregularities from the installation phase can be detected and accepted as “zero-figures”.
Surveillance units shall communicate with a central system for supervision of all alarm
units in the system. Communication shall be possible via GPS, signal and optic cables
and 24/7 surveillance from a centralized control room. Central monitoring system shall
have a built in OPC server in order to enhance further communication to central SCADA
or BMS systems.
In the tender, the Vendor shall completely describe the system he is proposing. Only
well-proven systems for district cooling applications with documented reliability from
experienced suppliers will be accepted.

4.3 Outer casing pipe joints

Supply and installation of joint kits for the outer casing HDPE pipe as per the project
requirement.
Delivery shall comply with the requirements in EN489 as minimum.

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Not all joint kits will be installed at completely straight pipe joints so it is important that
joint kits are designed to accommodate small angles of deviation.
The Vendor shall in his tender specify all relevant data including:
1. Maximum allowed deviation-angle for a “standard” joint kit.
2. Special joint kits for deviation-angles larger than the standard joint kit.
3. Required education of fitters for each type of delivered joints.

Polyurethane foam insulation


Polyurethane foam shall be delivered in sets/kits for mixing and applying on site.
Sets/kits shall be delivered with sufficient volume to seal each pipe size and based on a
calculated average application temperature.

4.3.1 Joint kits with electro welded casing

A joint kit includes a tubular casing, strips for electro welding, welding sleeves with
accessories and polyurethane foam for applying on site.
Joint kits with electro welding casing shall be used for all pipe dimensions.

4.3.2 Special joints for on-site made branches

For branches made on site in accordance with paragraph 4.6.2, special joints shall be
provided.
Delivery shall comply with the requirements in EN489 as minimum.
Vendor shall present the design and specifications in his tender.

4.4 Straight pipe lengths

Straight pipes shall be delivered in standard 12 m and 16 m lengths.


Each pipe end shall be free of foam installation at a minimum length of 250 mm. Pipe
ends shall be bevelled as specified in standard EN ISO9692-1.
All pipes shall be delivered with plastic end caps in order to avoid debris in the pipes,
during transportation, storing and handling.
Delivery shall comply with the requirements in EN253 as a minimum.

4.5 Pipe elbows

Pre-insulated elbows shall be delivered in accordance with clause 4.5.1; in general for
directional changes 10 degrees and greater.
Steel pipe elbows (uninsulated fittings) shall be delivered in accordance with clause
4.5.2; in general for directional changes between 0 to 10 deg.

4.5.1 Pre-insulated elbows

Pre-insulated elbows delivery shall comply with the requirements in EN448 as minimum.
Each pipe end shall be free of foam installation at a minimum length of 250 mm. Pipe
ends shall be bevelled as specified in standard EN ISO9692-1.
All pipe components shall be delivered with plastic end caps in order to avoid debris in
the pipes, during transportation, storing, and handling.

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4.5.2 Steel pipe elbows

Uninsulated steel pipe elbows are used for sizes larger than DN350 in small angles
between 0 to 10 degrees..
An uninsulated steel pipe elbow is welded in between two straight cut pipe ends to create
an angle of deviation. The elbow shall be designed in such a way that the inner arc
length exceeds 40 mm for DN400 - DN500. For larger dimensions shall the inner arc
length exceed 50 mm.
Field joints are insulated and sealed on site using standard or special joint kits (as
defined in paragraph 4.3.1, 4.3.2).

4.5.3 Mitred pipe ends

For directional changes between 0 to 10 deg for piping DN 350 and smaller, the
Mechanical Contractor will miter the pipe ends in the field.

4.6 Branches and T-pieces

Branches and T-pieces delivery shall comply with the requirements in EN448 as
minimum. Pipe used for branches shall comply with the requirements stated in clause
4.1.1.
Branches shall be supplied as pre-insulated branches or site made branches in
accordance with the table below:
Main pipe Pre-insulated branch Site made branch
DN500 DN250 and larger DN200 and smaller
DN600 and larger DN350 and larger DN300 and smaller

4.6.1 Pre-insulated branches

Each pipe end shall be free of foam insulation for a minimum length of 250 mm. Pipe
ends shall be bevelled as specified in standard EN ISO9692-1.
All pipe components shall be delivered with plastic end caps in order to avoid debris in
the pipes, during transportation, storing and handling.

4.6.2 Site made branches

Delivery of each site made branch shall, at a minimum, include:


- One 90 degree steel pipe elbow
- One steel pipe piece with weldolet
- One special joint kit
- Detailed instructions for the welding contractor.
Cutting main pipe casing and insulation, cutting a hole in main pipe, installation and
welding of weldolet, pipe piece and 90 degree elbow will be done by others.
The welded tangent piece or stub piece used for site made branches shall be sourced
from mills approved by engineer and shall be welded as per project approved WPS.

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4.7 Reducers

Reducers delivery shall comply with the requirements in EN448 as minimum. Pipe used
for reducers shall comply with the requirements stated in clause 4.1.1.
Each pipe end shall be free of foam installation at a minimum length of 250 mm. Pipe
ends shall be bevelled as specified in standard EN ISO9692-1.
All pipe components shall be delivered with plastic end caps in order to avoid debris in
the pipes, during transportation, storing and handling.

4.8 Special fittings

Fittings and components of “special type” (other then described in this document) shall
fulfil all applicable codes and standards.
If the Vendor chooses to offer special fittings then all details must be clearly specified in
the bid.

4.9 Pre-insulated valves

Pre-insulated delivery shall comply with the requirements in EN488 as minimum.


Pressure class for valves is minimum PN16. Suppliers of certified pre-insulated ball valve
shall use so called S-valves (Strong).
Valves shall be designed for the extra-large external forces created by thermal
contraction and friction forces exerted from connected pipes. Axial forces calculations
shall be based on ambient design temperature during installation and lowest operating
temperature in accordance with clause 3.2.
Stem shall be fitted with a position indicator.
Total delivery of valves shall include 1 (one) manoeuvre device per gearbox dimension
designed for operation from street level. Device shall be based on stem grip in
appropriate size(s), wrench extension, gearbox and manoeuvre wheel.
For valves buried deeper than 2 meters, provide hydraulic actuators, hoses, control
cabinet and auxiliaries as indicated on the drawings.
For valve buried up to 2 meters, spindle extension and gear boxe shall be provided
inside concrete protection chambers with diameter large enough for horizontal movement
of the pipe without contact between spindle extension and the protection chamber.
Maximum length of spindle shall not be more than 2 meters.
For the purpose of valve depth and spindle length, buried depth is measured from centre
of pipe to finished ground level.

4.9.1 Pre-insulated shut-off valves

Up to DN450, use steel ball valves with all-welded body and carbon reinforced Teflon
seals.
DN500 and larger, use butterfly valves.
For valves DN400 and larger, provide DN 50 pre-insulated by-pass valves.
For valves DN200 and larger, provide gear boxes.
Stem shall be provided with double sealing, minimum two O-rings and the upper one
shall be changeable from top.
Long stem ball valves where the extended stem is an integrated part of the valve is
preferred.
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Valves for connection to plots shall be equipped with venting valves.


All valves shall comply with requirements in EN488 as minimum.
Types of valves; in accordance with the specifications. Reduced bore valves are not
acceptable.
All valves shall be delivered with plastic end caps in order to avoid debris in the valves,
during transportation, storing and handling.

4.9.2 Pre-insulated drain and venting valves

Only steel ball valves with all-welded body and carbon reinforced Teflon seals are
accepted.
Ball valve shall comply with requirements in EN488 as minimum.
Stem shall be provided with double sealing, minimum two O-rings and the upper one
shall be changeable from top.
Venting valves shall be designed as straight T-pieces with valve on top, pointing
upwards. (Note that venting valves, when directly buried in the ground, if located at depth
that makes it hard to reach handle from street level, shall be arranged horizontally and
provided with a wrench extension (T-key).
Drain valve shall be installed at lowest point in the network.

4.10 Detectable warning devices

Detectable warning devices shall be delivered as per requirements.


Warning devices will be rolled out and placed in the trench by the civil contractor, see
detail drawing: Typical trench section LUS-[CP PKG]-MAQ-DWG-UT-10401.

5 MARKING, IDENTIFICATION AND TRANSPORTATION

5.1 Marking and identification

As an addition to requirements specified in codes and standards, each piece shall be


marked in accordance with the Suppliers shop drawings and with a position number. The
position number will be given by the Engineer prior to ordering.
Position numbers shall be sprayed on the jacket pipe at minimum two sides of each
component for easy identification on site.

5.2 Transportation, delivery of material to the site

All delivery to the agreed site storage area shall be handled by and under the Supplier’s
responsibility.
In the event of damage caused under transportation or other defects in the material
delivered, The Engineer reserves the right to reject such material and have it replaced
with new material in good condition.
Unloading from trucks at the site will be carried out by others

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6 DESIGN, PREPARATIONS AND TRAINING ON SITE

The high ambient temperature and bright sunlight must be considered during storage,
transportation, and installation.
Site work shall include:
- Design and preparation of “surveillance drawings” showing control loops layouts
including routings in branches and locations of circuit closings.
- Training of Contractor’s installing personnel and the Engineer in surveillance system
installation, testing and commissioning including issuing of certificates for persons
after the successful education.
- Training of Contractor’s installing personnel and the Engineer in outer casing pipe
jointing and testing for each type of delivered joints including issuing of certificates
for persons after the successful education.

7 QUALITY CONTROL
All quality control, inspection and testing shall be carried out in accordance with
applicable and specified codes and standards.
A quality control system in accordance with the international standard ISO 9001 is
preferred.
Products certified by independent body in accordance with official regulations are
preferred and will be considered as an advantage in the Client’s final evaluation of
received tenders.
Vendor shall provide his quality control manual as part of the tender submission.
Supplier shall be able to document and demonstrate that all the activities related to
quality throughout the process from confirmation of order to design, purchasing,
manufacturing and delivery have been carried out in a properly monitored and organised
fashion.
The Supplier shall give the Client at least 3 weeks’ notice of factory tests in order to give
the Client a possibility to witness the tests.

8 WARRANTIES

All pipe material and components shall be covered by the Supplier’s warranty for
duration of 10 years following acceptance, in the form of a global insurance policy,
covering damage of all types to the structure and with third party responsibility.

9 DOCUMENTATION

Supplier shall submit all documentation from quality control, inspection, and test reports.
Mill certificates for all steel shall be submitted and sorted in good order.
Welder’s qualification certificates from welding of pipe components shall be submitted.
Pipes and pipe components shall be marked for identification. Shop drawings with piece-
marks shall be submitted.
Complete documentation for the surveillance system including design documents,
commissioning documentation, and an instruction manual shall be delivered.
All documentation shall be delivered in minimum 5 sets hard copy plus 1 set soft copy.
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Appendix 13 – Part 3, 3.2


Technical Specifications
Mechanical Works

Document No.: LUS-[CP PKG]-MAQ-SPE-UT-10003

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Content

1 INTRODUCTION 5
1.1 General 5

1.2 Tender documents package 5


1.2.1 Technical Requirements Mechanical works – documents package 5

1.3 Scope of Works 5

2 DEFINITIONS, ABBREVIATIONS AND REFERENCES 6


2.1 Definitions 6

2.2 Abbreviations 7

2.3 Reference documents 7


2.3.1 Codes, standards and specifications 7

2.4 Document precedence 8

3 TECHNICAL REQUIREMENTS AND SPECIFICATIONS 9


3.1 General 9

3.2 Basic design conditions 9

3.3 Distributed water quality 9

4 PRE-INSULATED PIPES 9
4.1 General 9
4.1.1 Chilled water service carbon steel pipes 10

4.1.2 Thermal insulation 11

4.1.3 Outer casing jacket pipe 11

4.1.4 Surveillance system 12

5 Connecting and joining the alarm wires is the Mechanical


Contractor’s responsibility, but must be carried out by a
specialized sub-contractor. Connections shall be done to
existing cabinets.PIPE WORKS 12
5.1 Pipe works – underground pipes 12

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5.1.1 Temporary supports in trenches 12

5.1.2 Temporary supports – alternative 13

5.1.3 Lifting down and laying pipes in the trenches 13

5.2 Pipe works - valve chambers 13

5.3 Local storage and transportation of pipes 13

5.4 Applying jacket pipe joint casings 14

5.5 Welding of pipes and pipe systems 14


5.5.1 General rules 14

5.5.2 Contractor’s certification 14

5.5.3 Welding Procedures Specifications (WPS) 15

5.5.4 Welder’s qualification 15

5.5.5 Marking and identification 15

5.6 Pipe identification at sub-developer plots 15

5.7 Cutting of pre-insulated pipes 15


5.7.1 Cutting of pre-insulated fittings 15

5.8 Pipe angles and changes of direction 15


5.8.1 Pre-insulated elbow 16

5.8.2 Uninsulated steel pipe elbow 16

5.8.3 Mitered pipe ends 16

5.9 Branches and T-pieces 16


5.9.1 Pre-insulated branches 16

5.9.2 Site made branches 16

5.10 Reducers 17

5.11 Pre-insulated valves 17

5.12 Outer casing pipe jointing 17

5.13 Mounting of end-seals 17

5.14 Surveillance system 18

6 TESTING, CONTROL AND COMMISSIONING 18


6.1 Radiography tests 18

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6.1.1 Approval of welds 18

6.1.2 Weld quality failures 18

6.1.3 Costs for radiography inspections and tests 18

6.2 Initial Leak Testing 19

6.3 Hydrostatic Leakage Testing 19

6.4 Mechanical Cleaning 19


6.4.1 Pigging 19

6.4.2 Flushing, the Air-Water Cleaning Method 20

6.4.3 Dynamic Flushing 20

6.5 Chemical Cleaning 20

6.6 Passivation and Final Water Quality 20

6.7 Preventive Maintenance Program 21

7 DOCUMENTATION 21

Appendix 1: Criteria for Mechanical Cleaning and Chemical Flushing22

Appendix 2: Required Flushing Velocities 23

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1 INTRODUCTION

1.1 General

This document and the attached files define the technical requirements to furnish pipe and
materials for the portion of the district cooling system referred to as [CP-PKG] . For ease in
understanding, these documents are prepared as if the project was broken into three separate
contracts, but in fact they are all components of a single contract between the Client and one
contracting party.
In the end, the contracting party is responsible for all aspects of the project and that all tools,
equipment, and devices are suitable and reliable for the intended use and in the ambient
conditions expected at the construction site. He shall be responsible for all documents and
procedures requested by authorities for the official inspection and acceptance of the works.
In general the technical tender documents are described as:
 LUS-[CP PKG]-MAQ-SPE-UT-10001 Pre-insulated Pipes: The scope of supply is described
as pipe and materials including delivery to a lay down area designated by Lusail, but the
scope does NOT include fabrication or installation of pipe (mechanical works) or trenches
(civil works).
 LUS-[CP PKG]-MAQ-SPE-UT-10002 Civil Works: The scope of supply is the civil portion of
the underground piping system and thus does NOT include pipe materials or mechanical
installation.
 LUS-[CP PKG]-MAQ-SPE-UT-10003 Mechanical Works: The scope of supply includes
mechanical installation of pipe and materials, but does not include furnishing materials or
preparing the trenches.
 LUS-[CP PKG]-MAQ-BOQ-UT-10001 Bill of Quantity: The bill of quantity is relevant to all
because it summarizes the lengths, quantities, and sizes of materials.

1.2 Tender documents package

This document is part of the total tender package and ultimately will be incorporated into the
project Agreement.

1.2.1 Technical Requirements Mechanical works – documents package

This document specifies technical requirements for mechanical works and is a part of the total
Technical requirements for Mechanical works package.
The Scope of Works is defined by:
- This document
- Appendices and drawings in accordance with Drawings/Documents List form (DLF).

1.3 Scope of Works

Scope of works is defined as the design, detailed workshop engineering, fabrication, welding,
testing, transportation, handling, installation, site testing, commissioning and documentation for
carrying out mechanical works as defined in the tender documents.
The Contractor shall include in its scope all the works, material and services necessary for a
complete, safe and prudent underground pipe system as described herein.

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Works shall be carried out in accordance with good industry practice, notwithstanding certain
essential items not being expressly stated in these requirements or elsewhere in the RFP.
The Scope of Works shall include, but not be limited to:
1. Transportation and handling of pre-insulated pipes with HDPE outer jacket from the
local storage area to the trench.
2. Supply and placing out temporary supports on the prepared trench’s sand bed.
3. Lifting the pre-insulated pipes and pipe components down into the trench including
placement on the temporary supports.
4. Adjustment of pipes into final positions, preparation and welding of pipes, valves and
other pipe components together.
5. Removal of temporary supports.
6. Carry out cleaning, pigging, flushing, testing and control. (Separate quotation required,
work might be done at a later stage)
7. Installing, testing and commissioning the surveillance system in all pipe casing joints.
8. Jointing of outer casings including foaming.
9. Documentation

Civil works, supply of pre-insulated pipes and components will be carried out by other parties
and are not a part of this Scope of Works, for the Mechanical Contract.
Drawings showing the pipe route, dimensions and a typical trench section are attached.
Quantities are described in LUS-[CP PKG]-MAQ-BOQ-UT-10001 – Bill of Quantity to indicate
the extent of the mechanical works.
The Contractor is responsible for extra costs associated with any changes of plot connection
locations carried out without approval from the Engineer.

2 DEFINITIONS, ABBREVIATIONS AND REFERENCES

2.1 Definitions

The following expressions shall, where the context so permits, have the meaning hereby
respectively assigned to them.
Contractor means the organisation, or its appointed representative,
responsible for execution of the works as defined in these
technical tender documents
Engineer means Marafeq supervision engineer or its appointed
representatives.
Client means the Master Developer (LREDC) or its appointed
representatives.
Supplier means the organisation, or its appointed representative,
responsible to furnish the materials and/or services as defined
in these technical tender documents
Vendor means any of the invited companies being fully eligible to
submit the Tender. The successful Vendor will be the
Contractor/Supplier.
Works means work, products, materials, computer software and
documentation, as called for in the Agreement.
Agreement means the contract or other written agreement entered into
between the Client and a contracting party regarding supply of

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the Works, including appendices, amendments and additions


agreed in writing.
For Information only means information only is indicative and not under
responsibility of the Client. Vendor has to control, verify and be
responsible for any such information in the same manner as
other submittals.
Must this is a minimum requirement
Shall indicates a mandatory requirement
Should indicates a preferred method or material
Request for Proposal means the document prepared and issued by the client
which includes this document and other general and particular
requirements

2.2 Abbreviations

DP Design pressure
ID Internal diameter
OD Outer diameter
WT Wall thickness
QCP Quality Control Plan
FAT Factory Acceptance Test
SAT Site Acceptance Test
RFP Request For Proposal
WPS Welding Procedure Specification

2.3 Reference documents

2.3.1 Codes, standards and specifications

Material supplied by the Contractor or its sub-contractor, shall, at a minimum, confirm to the
requirements of the codes listed below.
Work, work methods, testing and actions carried out by the Contractor shall, at a minimum,
confirm the requirements of the codes listed below.
When an edition date is not indicated for a code or standard, the latest edition in force at the
time of contract award shall apply.
EN253 Pre-insulated bonded pipe systems for directly buried hot water
networks.
EN448 Pre-insulated fittings for bonded pipe systems
EN488 Pre-insulated valves for bonded pipe systems
EN489 Joints and connections for pre-insulated bonded pipe systems
EN13941 Design and installation for bonded pre-insulated pipe systems.
EN14419 Surveillance systems for bonded pre-insulated pipe systems
EN10216-2 Seamless steel tubes
EN10217-2, -5 Welded steel tubes
EN10253-2 Butt welded steel fittings
EN13480 Metallic industrial piping
P235GH Steel quality

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EN 12517 Non-destructive testing of welds. Radiographic testing of welded


joints
EN12613 Plastic warning devices for underground cables and pipelines with
visual characteristics
EN ISO 5817 Fusion welded joints in steel and alloys. Quality levels for
imperfections.
EN206-1 Concrete: Specification, performance, production and conformity.
EN287-1 Qualification test of welders. Fusion welding – Part 1: steels.
E 287-3 Welding procedures tests.
EN288-2 Specification and approval of welding procedures for metallic
materials. Welding procedures specification for arc welding of steels.
EN288-3 Specification and approval of welding procedures for metallic
materials. Welding procedures specification for arc welding.
EN ISO 9692-1 Welding and allied procedures – Recommendations for joint
preparation
EN ISO 11970 Specification and approval of welding procedures for production
welding of steel castings.
ISO 12096 Submerged arc-welding steel tubes for pressure purposes –
Radiographic testing of the weld seam for the detection of
imperfections.
EN ISO 15607 Specification and qualification of welding procedure for metallic
materials. General rules.
EN ISO 3834 Quality requirements for fusion welding of metallic materials.
EN ISO 15614-1 Specification and qualification of welding procedures for metallic
materials -- Welding procedure test -- Part 1: Arc and gas welding of
steels and arc welding of nickel and nickel alloys
EN 10253-1,-2 Butt welding pipe fittings
QCS Qatar Construction Specifications
Kahramaa Water and Electricity Components
QCD Qatar Civil Defense
Other standards Mentioned or referred to in the complete package of Tender
documents.

2.4 Document precedence

The Contractor shall notify the Engineer of any conflict between this specification, the related
requirements and/or data sheets, the codes and standards and any other specifications noted
herein. Resolution and/or interpretation precedence shall be obtained from the Engineer in
writing before proceeding with the design or manufacture.
In case of conflict, the order of precedence shall be:
1. Material narrative specifications.
2. Project specifications and standards
3. Industry and official codes and standards

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3 TECHNICAL REQUIREMENTS AND SPECIFICATIONS

3.1 General

The piping system will consist of two pipes (supply and return) parallel in the trench. The pipes
are pre-insulated bonded carbon steel pipes with PUR polyurethane foam insulation and with
HDPE outer jacket.
Works, pipes and components shall meet the technical and environmental requirements of the
applicable directives and harmonised standards.
Health and safety requirements and the function of safety related systems must be fulfilled.

3.2 Basic design conditions

Design pressure 1600 kPa


Operating temperature range 4.0 – 16°C
Soil temperature range 10 – 50°C
Ambient design temperature 50°C; maximum outdoor temperature during installation
Water quality See table in paragraph 3.3.
Calculated life-time Pipes, works and components shall be designed for a
calculated life-time of 40 years.

3.3 Distributed water quality

The Client intends to maintain the circulated water quality as noted in the table below.

Marafeq
Parameters Unit Standard
pH -- 8.5 to 10.5
Total dissolved solids ppm < 2000
Conductivity µSiemens/cm < 3000
Total iron as Fe ppm < 1.0
Nitrite as NaNO2 ppm > 800
Total Suspended Solids ppm < 20
Chlorides as Cl- ppm < 150
Total Alkalinity as CaCO3 ppm < 250
Total Calcium hardness as CaCO3 ppm < 100

4 PRE-INSULATED PIPES

4.1 General

Pre-insulated bonded pipe systems for directly buried water networks. Pipes assembled by
carbon steel service pipe, polyurethane thermal insulation and outer casing of high density
polyethylene (HDPE).

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The pre-insulated bonded piping will comply with standard EN253 as minimum.
The pre-insulated pipe system shall, for the main part, be directly buried in trenches without any
duct, concrete cover or similar. However, some drain valves and venting valves will be needed
to be installed in concrete valve chambers.
Civil work, excavation and backfill will be carried out by others and is not a part of this contract.
Pre-insulated pipes and fittings material will be supplied by others and is not a part of this
scope.
Installation works welding, lifting, handling and local transportation are included in the Scope of
Works. For installations in drainage & venting valve chambers is also supply of pipes, fittings,
flanges and other pipe components included in Scope of Works.
Pipe ends on straight pipe sections and fittings are delivered free from foam insulation at a
length of approx. 250 mm for welding in the field. For cutting of pipes and removal of foam
insulation, see clause 5.7.
Pipe ends or other openings in pipe sections shall always be covered in order to prevent inside
of pipes from debris and other foreign objects.
Insulation of the free pipe joints and joining of the outer casing pipe after welding and testing
are included in the Scope of Works.
A surveillance system consisting of copper wires is included in the pre-insulated piping system;
jointing of detection wires and installation of detection units shall be carried out by the
Mechanical Contractor in accordance with the supplier’s specifications.

4.1.1 Chilled water service carbon steel pipes

The service carbon steel pipes are a part of the pre-insulated pipe and fitting material scope.
The service carbon steel pipe will conform to dimensions in accordance with DIN 2458 and
steel quality P235GH in accordance with standard EN10216-2, EN10217-2 and 10217-5.
Elbows, reducers, tees and other fittings will fulfil requirements in accordance with standard
EN10253-2 type B.
Pipes will be delivered from factory in 12 m length sections.
Seamless steel tubes in accordance with EN10216-2 for dimensions up to DN350.
Welded steel tubes in accordance with EN10217-2 (ERW) or EN10217-5 (SAW) from
dimension DN400 and larger.
Following dimensions will apply for the service carbon steel pipe:
Nominal Wall
Dimension Outer diameter
thickness
DN100 114,3 mm 3,6 mm
DN125 139,7 mm 3,6 mm
DN150 168,3 mm 4,0 mm
DN200 219,1 mm 4,5 mm
DN250 273,0 mm 5,0 mm
DN300 323,9 mm 5,6 mm
DN400 406,4 mm 6,3 mm
DN450 457,0 mm 6,3 mm
DN500 508,0 mm 6,3 mm
DN600 610,0 mm 7,1 mm
DN700 711,0 mm 8,0 mm
DN800 813,0 mm 8,8 mm
DN900 914,0 mm 10,0 mm
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Nominal Wall
Dimension Outer diameter
thickness
DN1000 1016,0 mm 11,0 mm
DN1100 1120,0 mm 11,0 mm
DN1200 1220,0 mm 12,5 mm
DN1300 1320,0 mm 12,5 mm

4.1.2 Thermal insulation

The thermal insulation is a part of the pre-insulated pipes material scope. The pre-insulated
pipes and fittings will be delivered with hard polyurethane foam applied at factory. The
polyurethane foam is bonded to the service pipe and the outer casing jacket pipe.
Minimum insulation requirements
Property Min. requirement
Closed cell content > 90,0 %
Size of cells < 0,3 mm
Core density ≥ 60 kg/m3 Note1
o
Thermal conductivity at 50 C
< 0,03 W/mK
(λ50)
Water absorption < 5 % (volume)
Compression strength > 0,30 MPa
Axial shear strength,
> 0,12 MPa
23 deg C new
Axial shear strength,
> 0,12 MPa
23 deg C aged
Note 1: Not defined in present EN253:2009. However for securing the handling of pipes of large dimensions this is
required. (It was included in the previous EN253:2003. Requirements are considered by CEN/TC 107, to be included
again in next EN253 standard version.)

Thickness of insulation varies depending of pipe dimension, see dimensions of outer casing
jacket pipe in paragraph 4.1.3.

4.1.3 Outer casing jacket pipe

The outer casing jacket pipe works as the condenser barrier and is a part of the pre-insulated
pipes material scope. The outer casing pipe will be manufactured in UV-stabilized HDPE in
accordance with EN253 or equal.
Materials High density polyethylene (HDPE) bimodal minimum PE80, ISO 12162
Density Min. 944 kg/m3
Pipe wall thickness According to EN253 or equal
Following dimensions apply for the outer casing jacket pipe:
Minimum casing
Outer diameter
Dimension wall thickness
casing pipe
(mm)
DN100 200 mm 3,2
DN125 225 mm 3,4
DN150 250 mm 3,9
DN200 315 mm 4,5
DN250 400 mm 4,8
DN300 450 mm 5,2

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Minimum casing
Outer diameter
Dimension wall thickness
casing pipe
(mm)
DN350 500 mm 5,6
DN400 520 mm 5,7
DN450 560 mm 6,6
DN500 630 mm 7,2
DN600 780 mm 7,9
DN700 900 mm 8,7
DN800 1000 mm 9,4
DN900 1100 mm 10,2
DN1000 1200 mm 11,0
DN1100 1300 mm 11,8
DN1200 1400 mm 12,5
DN1300 1500 mm 15,9

4.1.4 Surveillance system

Surveillance system materials are supplied by the pre-insulated pipe supplier. All pre-insulated
pipes and fittings are delivered with three copper alarm wires moulded into the foam insulation.

5 Connecting and joining the alarm wires is the Mechanical


Contractor’s responsibility, but must be carried out by a
specialized sub-contractor. Connections shall be done to
existing cabinets.PIPE WORKS

5.1 Pipe works – underground pipes

Pipe works shall include following main phases and activities which are further described in
these Technical requirements.
- Transportation of pipes and components from the local storage to the working area
(trenches)
- Supply and install of temporary supports in the trenches.
- Lifting down pipes and components into the trench including adjustment of positions
including handling of temporary supports.
- Preparation and welding of pre-insulated steel pipe joints.
- Jacket pipe jointing including connections of surveillance wires.
- Insulation of joints.
- Carry out control, tests and inspection.
- Cleaning, pigging and flushing
- Documentation

5.1.1 Temporary supports in trenches

Contractor will be notified when civil works have been approved and the prepared sand bed is
ready for the pipes.
Contractor shall supply and put temporary supports on the sand bed in order to make the total
circumference of the pipe joint reachable for welding.

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For pipe DN400 and smaller, the supporting length shall be at least 200 mm and spaced no
farther than 5 m apart. For pipe DN450 and larger, the supporting length shall be at least 300
mm and spaced no farther than 3 m apart.
Temporary supports shall be fabricated from wooden timbers or sandbags. If the Contractor
prefers another material or type of temporary support, he shall describe it in the offer.
Before backfilling is started all temporary supports must be removed by the Contractor.

5.1.2 Temporary supports – alternative

As an alternative to temporary supports may local excavation being accepted, the Contractor is
allowed to use this alternative method only after a written approval from the Engineer:
Local excavation alternative
As an alternative for temporary supports described above, the Contractor may place pipes
directly on the sand bed and excavate a pit locally under each joint. The size of the pit must
allow room for welding, insulation and application of outer jacket pipe sleeves. Minimum length
is 2.0 m and minimum depth is 200 mm measured from the outer jacket.
Since this alternate method may require extra work for the Civil Contractor for embedment and
compaction, this alternate must be coordinated between the Mechanical and Civil Contractors
such that there is no variance to the Client.

5.1.3 Lifting down and laying pipes in the trenches

Pipes may be lifted into the trench only after the temporary supports are in place.
Pipe bends and other fittings are marked by others with a position number for individual
identification and these numbers must match with the drawings for each location.
Straight pipe sections shall be installed with the pre-fabricated leak detection wires on top of
the pipe.
Pipe position shall then be adjusted so the pipe ends are aligned. Pipes centre to centre
positions and distances from trench wall, etc shall be maintained in accordance with the
“Typical trench section” drawing.

5.2 Pipe works - valve chambers

Chilled water network piping system shall be provided with drain valves at all lowest locations
to facilitate draining when necessary. These valves shall be located in suitable accessible
chambers, with sump for collecting the drained water and to bring in and connect portable lifting
pumps. Drain valves shall meet specifications mentioned in Appendix 3.1.
Pre-insulated shut-off valves, drain valves and venting valves shall be installed in manholes in
accordance with the drawings. (If required)
Manholes are furnished and installed by the Civil Contractor and thus are not included in the
Scope of Works.
All mechanical installations, except the concrete manhole and manhole cover, shall be included
in the Contractors Scope of Works.

5.3 Local storage and transportation of pipes

Pre-insulated pipes and components will be locally stored in the area and shall be transported
by the Contractor to the trench.

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The Contractor will receive the material, providing written evidence of any defects detected
during visual inspection. After this inspection the Contractor will be held responsible for any
damages on the pipes.
The Contractor is responsible for protection of the pipes during storage, in local storages as
well as pipes in trenches/compartment. Sun protection is required; overheating by the sun will
lead to cracks in the jacket pipe casing and separation of the insulation foam from the carrier
steel pipe.
Damaged pipes and fittings will be rejected at the Contractor’s cost.
During loading, transport and unloading the material should be handled in such a way that
prevents damage, in accordance with pipe supplier’s recommendations.
Flat type fabric band straps shall be used for lifting, Chains, wires, ropes or other round lifting
equipment are not allowed. A fork lift can be used to lift fittings and components, provided that
flat forks are used.
T-piece branches shall not be lifted by the branch pipe only.
During transportation and handling the temporary end caps must be in place.
In any case shall instructions from the pipe supplier always be considered by the Contractor.

5.4 Applying jacket pipe joint casings

The tubular joint casings must be applied before the pipes are welded together.
Joint kits shall be supplied by the pipe material supplier. Joint kit shall include electro welded
band joint jacket and a foam kit.
Contractor shall slip on the tubular shell jacket on a pipe next to each joint before welding is
carried out.

5.5 Welding of pipes and pipe systems

Welding shall be carried out by certified contractor or certified sub-contractor with welder’s
qualifications as stated below.
Copy of certificate shall be submitted to the Engineer before the works are started.

5.5.1 General rules

The welding procedures shall follow EN ISO 15607 and EN 13480.


Welds quality levels shall be in accordance with EN ISO 5817 Grade B.
All welding of pipes shall be butt welding of pipe end against pipe end, no socket welding shall
be carried out. Preferred welding method is arc-welding or arc-welding combined with first pass
TIG-welding.
Preparation of pipe ends prior to welding, measurements, number of passes, etc are described
in standards referred to.

5.5.2 Contractor’s certification

The welding contractor shall be certified in accordance with EN ISO 3834 or equivalent to be
approved by the Engineer.

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5.5.3 Welding Procedures Specifications (WPS)

The Contractor shall submit to the Engineer for approval welding procedures (WPS) for each
method intended to use in this project.
The welding procedure inspection shall follow the EN ISO 15614-1.
Each welded joint shall also be marked with the welder’s name (initials) and the date for the
work, hand written marking with a permanent marking pen is sufficient

5.5.4 Welder’s qualification

Welder approval test shall be carried out in accordance with EN 287-1 before the actual welder
starts working in this project.
The first three (3) welds by each welder will be radiographed and judged by the Engineer’s
approved testing agent. The welder will be approved to work in this project only after
completing three successive welds.
All costs with re-testing, after the first three joints, until three successive welds have been
completed shall be at the Contractor’s cost. The Engineer has the right to reject a welder after
multiple tries.

5.5.5 Marking and identification

Each welded joint shall be marked with the welder’s name (initials) and the date for the work,
hand written marking with a permanent marking pen is sufficient.

5.6 Pipe identification at sub-developer plots

Chilled water supply and return pipes shall be marked clearly or colour coded at each branch
connection to sub-developers’ plots, to easily distinguish between supply and return pipe
branches. The proposal of colour coding or marking shall be proposed by the piping contractor
and approved by the Employer/ Engineer.

5.7 Cutting of pre-insulated pipes

The outer jacket PE-pipe shall be cut and foam insulation removed at a length of approx. 250
mm from the intended steel pipe end, it is most practical to cut a length of 2x250 mm with the
steel pipe cut in centre when cutting a pipe section.
At cutting of the outer jacket PE-pipe it is important to start with tangential cuts to avoid
scratches or damages in axial direction since a small crack tends to grow.
It is important to remove all foam insulation completely from the pipe end before welding starts.
Polyurethane foam insulation generates toxic fumes when heated.

5.7.1 Cutting of pre-insulated fittings

Normally, pre-insulated fittings shall not be cut. The Contractor shall receive approval from the
Engineer prior to cutting pre-insulated fittings.

5.8 Pipe angles and changes of direction

Pre-insulated elbows deliveries shall comply with the requirements in EN448.


Changes of direction are made in 2 different ways as described below.

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5.8.1 Pre-insulated elbow

For directional changes 10 degrees and greater, pre-insulated elbows will be furnished and by
others.
A pre-insulated elbow is made with two pipe ends for welding and shall be welded, by the
Contractor between other pipe components. The pre-insulated elbow requires two joint kits for
insulation.

5.8.2 Uninsulated steel pipe elbow

For directional changes between 0 to 10 deg for piping DN400 and larger, uninsulated fittings
will be furnished and delivered by others. An uninsulated steel pipe elbow is made from a
section of a bend and shall be welded, by the Contractor, between two perpendicular steel pipe
ends within a common casing pipe joint and requires one joint kit for insulation.

5.8.3 Mitered pipe ends

For field adjustments between 0 to 10 deg directional changes for DN350 and smaller, pipe
ends shall be mitered.
Contractor shall cut the two meeting pipe ends in equal angles and weld together as one weld;
thermal insulation plus HDPE jacket shall also be jointed together by the Contractor.
For field adjustments of plot connection service pipes in vertical direction, as shown on profile
drawings, pipe ends shall be mitered.

5.9 Branches and T-pieces

Branches and T-pieces deliveries will comply with the requirements in EN448.
Branches will be delivered as pre-insulated branches or site made branches in accordance with
the table below:
Main pipe Pre-insulated branch Site made branch
DN500 DN250 and larger DN200 and smaller
DN600 and larger DN350 and larger DN300 and smaller

5.9.1 Pre-insulated branches

Branches in larger dimensions (see table above) will be delivered as pre-insulated, by others.
Welding of a branch T-piece to the main pipe shall be carried out after careful adjustment of the
branch pipe vertical direction. Normally is the branch direction horizontal or slightly upwards but
this must be double checked.

5.9.2 Site made branches

Special site made branches are required in combinations as defined in paragraph 5.8.
Following branch details will be supplied by the pipe supplier:
- One 90 degree steel pipe elbow
- One steel pipe piece with weldolet
- One special joint kit
- Detailed instructions for the welding contractor.

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The Contractor shall cut main pipe casing and insulation and weld the branch pipe through
weldolet as a tie-in into to the main pipe.
Measurements and detailed drawings issued by the pipe supplier must be considered.

5.10 Reducers

Pre-insulated reducers will be delivered by the pipe supplier and shall be installed by the
Contractor.

5.11 Pre-insulated valves

All valves will be pre-insulated and put directly in the trenches. Pre-insulated valves will be
delivered by the pipe supplier and shall be installed by the Contractor in accordance with the
drawings.
The pre-insulated valves are designed for operation from the ground level. It is very important
that the valves are installed and welded with the stem in straight vertical position.
For valves buried deeper than 2 meters, the Contractor shall install hydraulic operators, hoses
and auxiliaries furnished by others.
Installation shall be done in accordance with the suppliers recommendations.

5.12 Outer casing pipe jointing

Installation of supplied joint kits is included in the Scope of Works.


Joint kits for the outer casing HDPE pipe will be furnished by others.
Delivery will comply with the requirements in EN489.
Joint kits of the following types will be supplied by the pipe material supplier:
- For pipe dimension DN150 and smaller: a tubular PE-shell jacket piece, sealing sleeves and a
foam kit.
- For larger dimensions: electro welded band joint jacket and a foam kit.
Not all joint kits will be installed at completely straight pipe joints, it is therefore of great
importance that joints kits are designed to overcome small angles of deviation.
Others will supply information on:
1. Maximum allowed deviation-angle for a “standard” joint kit.
2. Special joint kits for deviation-angles larger than the standard joint kit.
3. Training of fitters for each type of delivered joints.
No fitter will be allowed to perform casing joints without participating in pipe supplier’s training
program. Personal certificates of this education shall be issued for all fitters.

5.13 Mounting of end-seals

The pipe system will be constructed and finalized before the connection into the buildings are
ready for the DC pipe connection. The boundary of the delivery will then be a sectioning valve
and a welded end-cap after each valve.
Mounting of insulation end seals are included in the Scope of work.

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5.14 Surveillance system

All pre-insulated pipes and fittings are delivered (by others) with a surveillance system
consisting of 3 copper wires moulded into the foam insulation together with a sufficient number
of surveillance units.
Connections and jointing of the surveillance wires are included in the Contractor’s Scope of
works. The wires shall be jointed in accordance with the supplier’s specifications, creating loops
of pipe sections, each connected to a surveillance unit.
The works must be commenced by a special sub-contractor with documented experiences
within this field.

6 TESTING, CONTROL AND COMMISSIONING


All pipe systems shall be tested in presence of the Engineer or its representative.
Contractor shall repair all failures discovered and carry out re-tests after the repair.
A testing program shall be agreed upon before the starting the works. All temporary
arrangement required for testing, flushing and commissioning of the system shall be included in
the contractor’s scope of work.

6.1 Radiography tests

The Engineer intends to carry out non-destructive tests by visual examination and gamma ray
radiography (hereinafter referred to as “radiography”).
Welds quality will be checked by radiography inspection carried out by a company specialized
for the task and hired by the Client.
The Engineer will nominate the testing firm with approval from the Contractor and such
approval shall not be unreasonably withheld.
100% radiographic inspection of 100% of butt welds completed by each welder will be carried
out.

6.1.1 Approval of welds

Approval of welds will be in accordance with EN 12517 acceptance level 1, EN ISO 5817 grade
B
The testing firm will inspect all welds to assure the welds are proper.
The Engineer shall have the right to reject any weld not meeting the requirements of this
specification.

6.1.2 Weld quality failures

If tests of welds show disapproved welding all failed welds shall be repaired and tested after the
repair.

6.1.3 Costs for radiography inspections and tests

The Contractor shall pay for tests made for welder qualification purposes in accordance with
clause 5.5.4 and the 100% weld inspection.
The Contractor’s own costs shall be paid for by him and included in his work.

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All costs for additional testing, as stated in paragraph 6.1.2, shall be paid for by the Contractor.
This includes costs for the testing firm and the Contractor’s own costs.

6.2 Initial Leak Testing

All pipe systems shall initially be tested for leaks in pipes, pipe-joints, flanges and installed
components.
Leak detection shall be carried out with air as a first test before the pipe system is filled with
water for the pressure test.
Pipe sections shall be filled with slightly over pressured air (1-5 kPa), and joints treated with
soap water in order to locate possible leaks.
Air-pressure holding time is as long as it takes to inspect the welds.

6.3 Hydrostatic Leakage Testing

The pipeline shall be hydrostatically tested, but prior to starting the hydrostatic leakage test,
leak detection surveillance system shall be commissioned. Pressure test shall be carried out
with potable water which shall be provided by the Contractor at his cost. Contractor shall make
suitable arrangements for the drainage of water after test. Contractor shall install necessary
bypasses at all branch connections and main lines, fill-up the pipe system to be tested, release
air, and pump up pressure to the level stated below.
Test pressure, 23 bar (2300 kPa)
Pressure holding time, 6 hours before inspection of welds.

6.4 Mechanical Cleaning

Criteria for mechanical cleaning and chemical flushing are shown in Appendix 1. Contractor
shall follow these criteria for mechanical cleaning and chemical flushing of the entire network. A
sub-contractor with special competence in this field is required and a Method statement shall
be submitted to the Engineer for approval prior to starting the cleaning process.

6.4.1 Pigging

Pigging shall be carried out by running a foam type of plug covered with brush through the
pipeline system a sufficient number of times until the pipe is clean. The plug is pushed by
compressed air with a limited quantity of water added. The number of times and types of plug’s
to be used are dependent of the actual pipeline conditions. Butterfly valves must be removed
and temporarily replaced with spool pieces before pigging can be carried out.
Generally, pigging shall be carried out as briefly described below:
 Insertion of a soft type of plug in the pipeline launching end for the first run. Applying
compressed air mixed with a small quantity of water pushing the plug through the
pipeline and out at the receiving end.
 Examination of the used plug before decision about what type of plug (hardness,
coarse) to be used for the second run.
 Running the chosen plug through, the required number of times, until the added small
amount of water is clean and free from debris and loose material.

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6.4.2 Flushing, the Air-Water Cleaning Method

Where pigging is not possible flushing must be carried out. Due to the large pipe dimensions
flushing must be carried out with the Air-Water Cleaning Method. Air and water is mixed
proportionally in accordance to the pipeline dimension thus creating a turbulent flow in the
pipeline which removes dirt and debris from the pipeline.
The air-water mixture shall be injected in one end of the pipeline and the speed of the air-water
turbulent flow is controlled by the operator by the amount of air injected. The air-water cleaning
is considered finished when the outlet water at the other end is clean and do not show any
signs of debris and dirt as evidenced through dynamic flushing.

6.4.3 Dynamic Flushing

Where pigging or flushing with air-water mixture is not possible, dynamic flushing shall be
carried out at network design velocity plus 10% or mean flushing velocity equivalent to carry 25
mm particle size in largest diameter of pipe, whichever is greater. Refer to Appendix-2 for
flushing velocity.
The sample shall be visually clear before proceeding to the chemical cleaning phase. The
sample shall be approved by Marafeq Qatar in order to proceed with the chemical cleaning
phase. A minimum of 48 hours circulation shall be done during the dynamic flushing phase.

6.5 Chemical Cleaning

After primary flushing, chemical flushing shall be performed as mentioned in Appendix-1. At the
end of chemical flushing, pipe internal metal surface shall be clean and ready for passivation
film formation. During chemical flushing, velocity shall be maintained as mentioned in
Appendix-2.
The Iron level shall be less than 1.0 ppm and TSS shall be less than 20 ppm in order to
proceed to the passivation phase The sample shall be approved by Marafeq Qatar to proceed
with the passivation phase. A minimum of 48 hours circulation shall be done during the
chemical cleaning phase. Contractor shall provide the chemicals, and shall facilitate for water
analysis as and when required.

6.6 Passivation and Final Water Quality

If there is a delay of more than 24 hours between chemical cleaning and passivation, the water
shall be circulated for a minimum period of 3 hours at a velocity as per Appendix-2 and sample
analysis shall proceed after this. The Iron level shall be less than 1.0 ppm and TSS shall be
less than 20 ppm in order to proceed for the addition of passivation chemicals. A minimum of
48 hours circulation shall be done at a velocity as per Appendix-2 during the passivation phase.
The passivation phase is deemed as completed only once the final water sample is approved
by Marafeq Qatar. Contractor shall provide passivation program to achieve final water quality
as follows:

Marafeq
Parameters Unit Standard
pH -- 8.5 to 10.5
Total dissolved solids ppm < 2000
Conductivity µSiemens/cm < 3000
Total iron as Fe ppm < 1.0
Nitrite as NaNO2 ppm > 800

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Total Suspended Solids ppm < 20


Chlorides as Cl- ppm < 150
Total Alkalinity as CaCO3 ppm < 250
Total Calcium hardness as CaCO3 ppm < 100

6.7 Preventive Maintenance Program

For corrosion inhibitor programs that require the water to be circulated after final passivation,
the Contractor shall provide the provisions for pumping facilities, flushing connections,
chemicals, and corrosion testing stations.

7 DOCUMENTATION
The Contractor shall submit all documentation from quality control, inspection and test reports.
 The Welding procedure Specification (WPS) should be delivered 4 weeks before the
construction work of each system part.
 Welder’s qualification certificates from welding of pipe components shall be submitted,
2 weeks before each construction part.
 Pipes and pipe components shall be marked for identification.
 The as-built-drawings shall be delivered continuously during the progress of the
project.
 All documentation shall be delivered in minimum 5 sets hard copies and 1 set soft copy
as a minimum.

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Appendix 1: Criteria for Mechanical Cleaning and Chemical Flushing

Priority

OR Air-Water OR Dynamic Flushing at network


Pigging Mixture design velocity plus 10% or 25
mm steel particle size mean
flushing velocity (*)
Mechanical
Cleaning
Step 1

Dynamic Flushing Dynamic Flushing


at 5 mm steel at 5 mm steel
particle size mean particle size mean
flushing velocity flushing velocity
Chemical

Chemical Cleaning and Passivation


Flushing

Chemical Cleaning Chemical Cleaning


Step 2

and Passivation at 5 and Passivation at 5 at network design velocity plus


mm steel particle size mm steel particle size 10% or 25 mm steel particle size
mean flushing mean flushing mean flushing velocity (*)
velocity velocity
Notes:
1. (*) Whichever is greater
2. Pigging and air-water mixture can be used in combination
3. No method other than listed above is acceptable
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Appendix 2: Required Flushing Velocities

Nominal Pipe Size Mean Internal Particle Size (mm)


(mm) Diameter (mm) 5 mm 25 mm
100 107.1 1.21 2.62
125 132.5 1.24 2.68
150 160.3 1.27 2.75
200 210.1 1.31 2.84
250 263 1.35 2.92
300 312.7 1.37 2.98
400 393.8 1.41 3.06
450 444.4 1.43 3.10
500 495.4 1.45 3.15
600 595.8 1.49 3.22
700 695 1.51 3.28
800 795.4 1.54 3.33
900 894 1.56 3.38
1000 994 1.58 3.42
1100 1098 1.60 3.46
1200 1195 1.61 3.50
1300 1295 1.63 3.53
1400 1395 1.64 3.56
1500 1495 1.66 3.59
1600 1595 1.67 3.62
The flushing velocities stated above are based on BSRIA Guidelines AG 1/2001, but adapted for
larger pipe diameters and EN pipe dimensions.

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Appendix 13 – Part 3, 3.3


Technical Requirements
Civil Works

Document No.: LUS-[CP PKG]-MAQ-SPE-UT-10002

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Content

1 INTRODUCTION 4
1.1 General 4

1.2 Tender documents package 4


1.2.1 Technical Requirements Civil works – documents package 4

1.3 Scope of Works 4

2 DEFINITIONS, ABBREVIATIONS AND REFERENCES 5


2.1 Definitions 5

2.2 Abbreviations 6

2.3 Reference documents 6


2.3.1 Codes, standards and specifications 6

2.4 Document precedence 7

3 TECHNICAL REQUIREMENTS AND SPECIFICATIONS 7


3.1 General 7

3.2 Surface cutting or removal 7

3.3 Execution of excavation 7

3.4 Proximity to other, existing services 8


3.4.1 Proximity to sewer systems 8

3.4.2 Proximity to electrical lines 9

3.4.3 Special crossing and proximity to other services not detailed in this document 9

3.4.4 Special crossings 9

4 CIVIL WORKS 10
4.1 Work area 10

4.2 Breaking existing ground surfaces 10

4.3 Pre-insulated district cooling pipes (DC-pipes) 11

4.4 Trenches for DC-pipes 11


4.4.1 Excavated sand, soil and other masses 12
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4.4.2 Sand bed and embedding material requirements 12

4.4.3 Sand bed for DC-pipes 13

4.5 Mechanical works 13


4.5.1 Embedding (selected backfill around the pipes) 14

4.5.2 Remain backfilling 14

4.5.3 Surface layers and road foundation 14

4.6 Civil works for pre-insulated valves 14

4.7 Manholes 15

4.8 Communication cables - Option 15

4.9 Detectable warning devices 16

5 TRANSPORTATION, STORAGE AREA 16

6 QUALITY CONTROL 16

7 DOCUMENTATION 16
7.1 As-built drawings 17

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1 INTRODUCTION

1.1 General

This document and the attached files define the technical requirements to furnish pipe and
materials for the portion of the district cooling system referred to as [fill in project description
like; CP-07B; Road F3 – VIP Route]. For ease in understanding, these documents are
prepared as if the project was broken into three separate contracts, but in fact they are all
components of a single contract between the Client and one contracting party.
In the end, the contracting party is responsible for all aspects of the project and that all
tools, equipment, and devices are suitable and reliable for the intended use and in the
ambient conditions expected at the construction site. He shall be responsible for all
documents and procedures requested by authorities for the official inspection and
acceptance of the works.
In general the technical tender documents are described as:
 LUS-[CP PKG]-MAQ-SPE-UT-10001 Pre-insulated Pipes: The scope of supply is
described as pipe and materials including delivery to a lay down area designated by
Lusail, but the scope does NOT include fabrication or installation of pipe (mechanical
works) or trenches (civil works).
 LUS-[CP PKG]-MAQ-SPE-UT-10002 Civil Works: The scope of supply is the civil
portion of the underground piping system and thus does NOT include pipe materials or
mechanical installation.
 LUS-[CP PKG]-MAQ-SPE-UT-10003 Mechanical Works: The scope of supply includes
mechanical installation of pipe and materials, but does not include furnishing materials or
preparing the trenches.
 LUS-[CP PKG]-MAQ-BOQ-UT-10001 Bill of Quantity: The bill of quantity is relevant to all
because it summarizes the lengths, quantities, and sizes of materials.

1.2 Tender documents package

This document is part of the total tender package and ultimately will be incorporated into the
project Agreement.

1.2.1 Technical Requirements Civil works – documents package

This document specifies technical requirements for civil works and is a part of the total
Technical requirements for Civil works package.
The Scope of Works is defined by:
- This document
- Appendices and drawings in accordance with Drawings/Documents List form (DLF).

1.3 Scope of Works

Scope of works is defined as the detailed engineering, planning, demolition of existing


pavement where required, excavation, protection of exposed existing underground
structures, transportation, preparation of pipe-bed, backfilling, packing, putting cable hoses
in place, reinstatement of pavement, commissioning and documentation.

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The Contractor of Civil works shall include in its scope all the works, material and services
necessary for a complete, safe and prudent underground pipe system as described herein.
Works shall be carried out in accordance with good industry practice, notwithstanding
certain essential items not being expressly stated in these requirements or elsewhere in the
RFP.
The Scope of Works shall include, but not be limited to:
1. Mobilisation of all equipment, machinery, material and resources needed for the
successful completion of the works.
2. Fencing off the work areas in accordance with the authorities regulations. (where
necessary)
3. Demolition of existing pavement (where necessary)
4. Excavation for the new pipe system.
5. Protection of exposed existing underground structures.
6. Construction of concrete underground valve chambers. (Only if applicable)
7. Preparation of a sand bed for the pipes.
8. Transportation of excavated soil and new sand, from/to the site.
9. Backfilling and packing (for parts not located in utility tunnels)
10. Installation of hoses for cables (Only if applicable)
11. Supply and Installation of manholes including manhole’s covers (Only if applicable)
12. Reinstatement of pavement (where necessary)
13. Documentation

Mechanical works and the supply of pre-insulated pipes and components will be carried out
by others (the Mechanical contractor and the Pipe supplier) and is not a part of this Scope
of Works, for the Civil works Contract.
Drawings showing the pipe route, dimensions and a typical trench section are attached.
Quantities are described in LUS-[CP PKG]-MAQ-BOQ-UT-10001 – Bill of Quantity.

2 DEFINITIONS, ABBREVIATIONS AND REFERENCES

2.1 Definitions

The following expressions shall, where the context so permits, have the meaning hereby
respectively assigned to them.
Contractor means the organisation, or its appointed representative,
responsible for execution of the works as defined in these
technical tender documents
Engineer means Marafeq supervision engineer or its appointed
representatives.
Client means the Master Developer (LREDC) or its appointed
representatives.
Supplier means the organisation, or its appointed representative,
responsible to furnish the materials and/or services as
defined by in these technical tender documents
Vendor means any of the invited companies being fully eligible to
submit the Tender. The successful Vendor will be the
Contractor/Supplier.
Works means products, materials, works, computer software and
documentation, as called for in the Agreement.

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Agreement means the contract or other written agreement entered into


between the Client and a contracting party regarding supply
of the Works, including appendices, amendments and
additions agreed in writing.
For Information only means information only is indicative and not under
responsibility of the Client. Vendor has to control, verify and
be responsible for any such information in the same manner
as other submittals.
Must this is a minimum requirement
Shall indicates a mandatory requirement
Should indicates a preferred method or material
Request for Proposal means the document prepared and issued by the client
which includes this document and other general and
particular requirements

2.2 Abbreviations

DP Design pressure
ID Internal diameter
OD Outer diameter
WT Wall thickness
QCP Quality Control Plan
FAT Factory Acceptance Test
SAT Site Acceptance Test
RFP Request For Proposal
WPS Welding Procedure Specification

2.3 Reference documents

2.3.1 Codes, standards and specifications

Material supplied by the Contractor or its sub-contractor, shall, at a minimum, confirm to the
requirements of the codes listed below.
Work, work methods, testing and actions carried out by the Contractor shall, at a minimum,
confirm the requirements of the codes listed below.
When an edition date is not indicated for a code or standard, the latest edition in force at the
time of contract award shall apply.
EN12613 Plastic warning devices for underground cables and pipelines with
visual characteristics
QCS Qatar Construction Specifications
Kahramaa Water and Electricity Works and Components
QCD Qatar Civil Defense
Local standards All applicable standards, specifications and regulations issued
and/or referred to by Authorities, City Council, Civil Services
department or other parties.
Other standards Mentioned or referred to in the complete package of Tender
documents.

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2.4 Document precedence

The Contractor shall notify the Engineer of any conflict between this specification, the
related requirements and/or data sheets, the codes and standards and any other
specifications noted herein. Resolution and/or interpretation precedence shall be obtained
from the Engineer in writing before proceeding with the design or manufacture.
In case of conflict, the order of precedence shall be:
1. Material narrative specifications.
2. Project specifications and standards
3. Industry and official codes and standards

3 TECHNICAL REQUIREMENTS AND SPECIFICATIONS

3.1 General

The piping system will consist of two pipes (supply and return) parallel in the trench / over
pass compartment. The pipes are pre-insulated bonded carbon steel pipes with PUR
polyurethane foam insulation and with HDPE outer jacket.
Supply of pipes, installation and welding are carried out by the Pipe Supplier and
Mechanical Contractor but the Civil Contractor shall be aware of the sensitivity of the pipes
during his contract works.
The pre-insulated pipe system shall, for the main part, be directly buried in trenches without
any duct, concrete cover or similar. However some shut-off valves, drain valves and venting
valves shall installed in concrete valve chambers.
Works, materials and components shall meet the technical and environmental requirements
of the applicable directives and harmonised standards.
Health and safety requirements and the function of safety related systems must be fulfilled.

3.2 Surface cutting or removal

On special request from the Client, the demolition of roads and footpaths must be
performed in order to obtain a selection of their components in view of their re-use;
otherwise the components will be transported to a dump.
Paving stones and cobblestones must be removed carefully and stored on worksite
premises or transported to a storage area by the Contractor.
Hydrocarbon-binder based surfaces must be cut in a clean and rectilinear manner using
adapted equipment.

3.3 Execution of excavation

The Contractor will be responsible for taking all the precautions necessary to preserve
structures belonging to Public Services or private owners and will be responsible for
damage and deteriorations caused by himself or one of his workers.
The means used for the execution, shoring and closed or semi-closed sheeting of
excavations must be adapted to the type of land, dimensions and environmental constraints.
Unless a dispensation is granted, material extracted, even if intended to be reused, cannot
be stored on the site. It shall be evacuated progressively as the excavation is opened.
Material evacuation conditions shall be defined by the Contractor.

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Trench excavation sidewalls must be vertical. It is forbidden to dig under peripheral surfaces
that are maintained and under curbs. If necessary, the Contractor will have to execute all
sheeting even closed; these sheeting must be established so that the pipes can be lowered
and positioned.
All arrangements must be made to avoid the decompression of adjacent land as well water
run-off in the excavation. Route continuity for vehicles and pedestrians must be ensured.

3.4 Proximity to other, existing services

Contractor shall be aware of the occurrence of other existing services such as water and
sewer pipes, electrical, telephone and communication network cables, gas pipes, etc.
Shop drawing shall be developed in coordination with all other services and by maintaining
all proximity distance as per Marafeq specification and authorities regulations.
The work shall be carried out with minimum disruption to existing services. A minimum
distance of 250-500 mm (depending on pipe DN) should be respected between DC pipes
and other services crossing or parallel course, or more if the installation specification states
it should be so.
Before beginning work, the Contractor awarded the work should make contact with all the
service companies in order to obtain the relevant information and confirm the existence and
exact location of the existing services of each company.
You will find in this section the special conditions that should be complied with when
carrying out work next to:
 Sewer systems, potable water systems, drainage systems, irrigation systems
 Buried electrical lines
 Special crossing
The purpose of these minimum distances is to facilitate network maintenance operations
and ensure physical protection and integrity of equipment and workmen when faced with
possible impact from another service.
Whenever it is not possible to respect the previously indicated distances it will be necessary
to install sufficient protection. Similarly, the protection should be installed at the request of
the land owner’s representative.
In case the above mentioned distances cannot be maintained, the following procedure
should be followed:
 A protection system shall be placed between the two networks; it will be made of fibre-
cement protection measuring 10x600x300mm, either as a 100 mm board or using solid
blocks 40x300x150mm or solid bricks 50x300x150mm, laid side by side to each other;
 If the specific characteristics of the installation prevent this protection, making it difficult
to install, it is possible to use half struts made from fibre-cement 7 mm thick.
 In addition to this protection, if it is not possible to put a minimum of 20 mm layer of
sand between any tube and the protection system, rubber sheets (NBR) must be
installed. They must be 3 mm thick on both sides of the conductor to protect it and
avoid possible damages.

3.4.1 Proximity to sewer systems

When minimum distances to sewage systems cannot be avoided, the following procedure
should be followed:

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 The construction area close to the sewer shall be waterproofed by using an asphalt
sheet. The width of this sheet shall be the width of the pre-insulated conductor plus 500
mm on each side;
 Before putting the asphalt sheet in place, a layer of asphalt primer should be applied
first;
 A layer of mortar shall be laid to protect the asphalt sheet from the aggressions of the
ground that sits on it;
 As an alternative to the previous solution, DC-pipes can be installed inside a steel
sheath or a concrete protection slab of 150 mm thickness shall be placed in between
DC pipes and sewer system

3.4.2 Proximity to electrical lines

When laying DC-pipes next to electrical lines the work must be handled manually to avoid
short circuits and hot spots. The minimum distance indicated above must be respected to
avoid premature ageing of the pipes. The manual process described above shall be
followed with electric lines, placing special emphasis on the need to avoid the eventual
heating up or short circuiting of the electrical line that can affect the DC-pipes.
For the crossing of High Voltage Electrical lines the Contractor shall propose a tailored
procedure to ensure the safety of the works and the integrity of the pipe during the operation
phase.
For electrical cable proximity, follow Kahra-Maa specifications.

3.4.3 Special crossing and proximity to other services not detailed in this
document

When there is a special crossing or there are other services than above within minimum
distance, alternatives shall be proposed to the land owner’s representative and they must
also be approved by him.
In the proposal, the reason why the above mentioned procedures cannot be used must be
justified, in addition to the reason why the alternative procedure is the most adequate to
achieve the requirements described at the beginning of this section, which are:
 Allow for easy maintenance of the affected installations;
 Ensure integrity and protection of them.
 A special design will be discussed with the Property Owner in case of over-passing a
river inside a bridge under construction.

3.4.4 Special crossings

Here the document refers to special passes or crosses at sections of the network that have
to go under railway tracks or below a stream or river, and in general, due to certain
circumstances, the conductor requires special attention and/or it is not possible to dig a
trench.
The protection in this type of cross can be resolved using three types of solutions:
 Laying the pipes under a protective steel plate;
 Concrete covering;
 Underground water cross.

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3.4.4.1 Pipes under a protective steel plate

This type of protection consists of installing a steel plate and the pre-insulated pipes go
inside it. The steel plate shall be of sufficient resilience and shall absorb any forces that it
may receive, preventing the force from reaching the pipes inside.
Contact between the pipe and the steel plate should be avoided. The appropriate items
should be put in place to distance the pipes from the steel plate in relation to the pipe
diameter and should be made from polythene.

3.4.4.2 Reinforced Concrete block Conduction

This second method of protection for the DC-pipes consists of using a concrete covering
that provides the necessary mechanical resistance.

3.4.4.3 Underground water crossing

This type of solution will only be used when crossing rivers, marshes or areas prone to
flooding.
The underwater cross will weigh down the DC-pipes to prevent it floating or being dragged
by water.
 Concentric;
 Simple;
 With trestles.
The installation of underwater crosses will be studied separately in each specific case and
the pertinent calculations will be carried out in addition to the detailed plans.

4 CIVIL WORKS

4.1 Work area

The Vendor shall specify in his offer the width of needed work area on the sides of and
along the trench as well as needed areas for storage and machinery.
Local conditions of such nature which the Vendor will not take responsibility for shall be
clearly pointed out in his offer.
The Contractor should ensure that a sufficient space is reserved for correct and safe
excavation and installation.
The Contractor shall on his own responsibility inform himself about the local conditions and
any circumstances which can have influence on his work before starting the works.
The Contractor must remove all types of water of whatever origin which may lie in the
excavations, trenches, or which invade the site. The Contractor must carry out all of the
temporary works and structures necessary to ensure removal of this water and dry out the
excavations while they are open.

4.2 Breaking existing ground surfaces

Breaking and removal of existing ground surface structure shall be included in Scope of
works. In this project are existing surfaces mainly natural and consisting of gravel, soil etc,

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However, the Vendor shall on his own responsibility inform himself about the local
conditions and calculate with all circumstances affecting his price.

4.3 Pre-insulated district cooling pipes (DC-pipes)

The pre-insulated pipe system with a carrier carbon steel pipe, insulation foam and an outer
casing jacket pipe is shown on the drawings with the carrier steel pipe dimension indicated.
Following dimensions apply for the outer casing jacket pipe:
Minimum casing
Outer diameter
Dimension wall thickness
casing pipe
(mm)
DN100 200 mm 3,2
DN125 225 mm 3,4
DN150 250 mm 3,9
DN200 315 mm 4,5
DN250 400 mm 4,8
DN300 450 mm 5,2
DN350 500 mm 5,6
DN400 520 mm 5,7
DN450 560 mm 6,6
DN500 630 mm 7,2
DN600 780 mm 7,9
DN700 900 mm 8,7
DN800 1000 mm 9,4
DN900 1100 mm 10,2
DN1000 1200 mm 11,0
DN1100 1300 mm 11,8
DN1200 1400 mm 12,5
DN1300 1500 mm 15,9

4.4 Trenches for DC-pipes

The trench design should fulfil the following requirements:


 Sufficient trench open space (both length wise & width wise) for the correct installation
of DC-pipes and fittings.
 Sufficient space to compact filling materials in the trench;
 Necessary safety conditions for workers in the trench.
In any case shall the Contractor fulfil the specifications and follow the regulations issued by
the Authorities; such as the City Council or Civil Services department.
A table with the dimensions of the trenches within the different DC-pipe diameters is shown
at the “Typical trench section” drawing, LUS-[CP PKG]-MAQ-DWG-UT-10401.
The measures specified at the “Typical trench section” drawing have been adapted in order
to allow for the Mechanical Contractor to perform a professional and high quality work in
welding the steel pipes and sealing the outer casing joints.
Depth of the trench depends on DC-pipe dimension both also on the level of crossing
existing underground structures. Covering above top of the pipes shall not be less than
1500 mm measured from the highest point of the pipe to the ground surface.
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The two DC-pipes, supply and return, will be laid in parallel next to each other in the trench

4.4.1 Excavated sand, soil and other masses

Existing sand masses, excavated from the trenches may be re-used for sand bedding and
backfill under conditions specified in paragraph 4.4.2 and following:
For use in the sand bed
 Only washed material with low content of chlorides in order to not pollute the local
atmosphere during welding and keeping the steel pipes surfaces clean from corrosion
factors.
 No natural stones larger than dia. 32 mm
 No sharp stones from crossing material larger than 8 mm
 The sand shall have less than 2% content of organic material to avoid the material
decomposing over time and the support base being reduced.
For use as embedding (selected backfill)
From the sand bed and up to a level 200 mm above top of the pipe, following conditions
shall apply:
 No natural stones larger than dia. 32 mm
 No sharp stones from crossing material larger than 8 mm
 The sand shall have less than 2% content of organic material to avoid the material
decomposing over time and the support base being reduced.
For use as remaining backfilling
 The grain of the sand shall be less than 75 mm, pre-conditioned that the selected
backfill is secured up to a level of 200 mm above the top of the pipe.
 The sand shall have less than 2% content of organic material to avoid the material
decomposing over time and the support base being reduced.
Before any re-use of sand and other masses the Contractor must submit detailed
specifications of all materials he proposes to re-use. He must get a written approval from
the Engineer.

4.4.2 Sand bed and embedding material requirements

Detailed specifications of material approved for use as sand bed and embedding will be
issued prior to contract sign.
Under no circumstances will the following materials be approved for re-use as sand bed,
embedding or backfilling:
 materials likely to cause irregular future settlements such as peat, sludge, silt, clay or
unburned household refuse,
 compressible materials,
 materials containing components or substances likely to be dissolved, leached,
damage the networks or alter the quality of the water resources,
 unstable materials,
 industrial by-products

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4.4.3 Sand bed for DC-pipes

A sand bed for the DC-pipes shall be constructed on the bottom of the trench. The sand bed
shall be made in accordance with the “Typical trench section” drawing LUS-[CP PKG]-MAQ-
DWG-UT -10401.
Sand bed compacting shall be performed in order to obtain over the entire thickness of the
filling a dimensional weight higher than 95 % of the optimum Proctor normal.
When sand bed is finished for a section, this must be reported to the Engineer by Written
notice.
After approval, the pipes will be laid down in the trench by the Mechanical Contractor. The
pipes will be put on temporary supports in order to allow for welding and jointing of the outer
PE-pipe jackets.

4.4.3.1 Temporary supports in trenches

Temporary supports are put in place by the Mechanical Contractor and shall also be
removed by the Mechanical Contractor.
Temporary will be placed with a maximum interval of 5 m and each support will have a
minimum supporting length of 200 mm, for dimensions larger than DN400 the supports will
have a supporting length 300 mm or will be placed at a maximum interval of 3 m.
Temporary supports are fabricated of wooden logs or sandbags. .
Before backfilling is started must the Contractor make sure that all temporary supports have
been removed,

4.4.3.2 Temporary supports – alternatives

As an alternative for temporary supports described above, the Mechanical Contractor may
place pipes directly on the sand bed and then excavate a pit locally under each joint.
Since this alternate method may require extra work for the Civil Contractor for embedment
and compaction, this alternate must be coordinated between the Mechanical and Civil
Contractors such that there is no variance to the Client.
The Mechanical Contractor needs a written approval from the Engineer if he wants to use
this alternative method.
Local excavation alternative
The pipes are placed directly on the sand bed and the Contractor excavates a pit locally
under each joint. Size of the pit must allow for welding, insulation and application of outer
jackets pipe sleeves. Minimum length is 2.0 m and minimum depth is 200 mm measured
from the outer jacket.

4.5 Mechanical works

The Civil Contractor shall make room for the Mechanical Contractor’s works, including
testing and commissioning, in his planning. All temporary arrangement required for testing,
flushing and commissioning of the system shall be included in the contractor’s scope of
work.

After completion of the sand bed, following steps will be commenced by the Mechanical
contractor:
- Placing out temporary supports

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- Lifting down pipes and fittings, adjustment of pipes positions.


- Preparations and welding.
- Tests and inspection of welds
- Jacket pipe jointing
- Test and inspection of jacket pipe joints.
- Insulation of joints
- Removal of the temporary supports
- General inspection
- Interior cleaning of the pipe system by pigging.

4.5.1 Embedding (selected backfill around the pipes)

After written approval from the Engineer, work with embedding shall be carried out in steps
as follows:
1. Drain and/or clean the trench from water, dirt, debris, etc. remaining from the
pigging procedure.
2. Removal of all temporary pipe supports, this is best done by lifting the pipe with
straps so much that the temporary supports can be pulled out one by one.
3. Adjusting positions of the pipes to the right position and distance between.
4. Backfilling of first layer and careful filling under the lower pipe curve and between
the pipes. First layer material must be pushed and packed manually in order to
secure fill up the lower narrow gap between pipes and sand bed.
5. Packing and compacting with Forward soil plate.
6. Backfilling and embedding
7. Packing and compacting (and so on) up to level above top of the pipes, as shown at
the “Typical trench section” drawing LUS-[CP PKG]-MAQ-DWG-UT -10401.
Backfilling and packing shall be made in repeated layers not exceeding a thickness of 200
mm for each layer.
Duct for optic cables shall be installed in level with top of the pipes, in sections where
indicated on drawings.

4.5.2 Remain backfilling

Remaining backfilling from top of embedding to bottom of the surface layers, structure and
road foundation shall be carried out with the same method with repeated layers and
packing/compacting between layers.

4.5.3 Surface layers and road foundation

Surface layers and road foundation shall be carried out in accordance with separate
requirements issued by the City Council or Civil Services department.

4.6 Civil works for pre-insulated valves

Pre-insulated valves will be installed on locations as shown at the drawings. Embedding,


preparations, final adjustments, etc shall be included in Scope of works. The numbers of
valves are listed in LUS-[CP PKG]-MAQ-BOQ-UT-10001 Bill of Quantity Civil.
Detailed design of valve chamber is included in contractor scope of works.

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4.7 Manholes

Manholes for drainage and venting valves (pre-fabricated) shall be included in Scope of
works, in accordance with the drawings, specifications and complete scope of works.
Design of manholes is included in contractor scope of works.

4.8 Communication cables - Option

Installation of tubes for communication cables shall be regarded as an option. The Vendor
shall present optional prices for two different alternatives:

Optic fibres alternative


Installation of three ducts/hoses in parallel which shall located in the trench embedding
above the chilled water pipes.
Duct/hose in polyethylene PEL, with smooth inner surface aimed for blowing of optic fibre.
Size, DN 40 mm
Tube shall be installed seamless, joints are only allowed in pulling/connection chambers.
Maximum distance between pulling/connection chambers is 500 m, including branch
chambers.
Installation of optic fibre into the ducts/hoses will be carried out by others.

Copper cables alternative


Installation of three ducts in parallel which shall located in the trench embedding above the
chilled water pipes.
Hoses/tubes in polyethylene; PEL, PVC or PEAD.
Size, DN 100 mm
Minimum radius, 3 m
Maximum distance between pulling/connection chambers is 100 m, including branch
chambers.
The installation of copper cables into the ducts will be carried out by others.

Branches, both alternatives


Branches for customer connections
At branches for customer’s connections shall the three tubes follow each branch connection
back and forth with a pulling/connection chamber installed at each property border (six
tubes in parallel along the short branch connection trench)
Main pipes branches and T-pieces
No pulling/connection chambers are allowed to be installed in roads and streets, branches
for main pipes must be located elsewhere. Examples of locations accepted are in
roundabouts, planting areas or combined with customer connections chambers.
At main pipes branches shall the tree tubes be routed back and forth to the connection
chamber where it is located offset from the pipes branch.
Design of communication chamber is included in contractor scope of works.

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4.9 Detectable warning devices

Detectable warning devices with a width of 400 mm shall be rolled out in the trench
embedding above the chilled water pipes.
Two, three or four taps (depending on pipe dimension) shall be rolled out in parallel as
shown on drawings.
Warning devices are furnished by others and shall be installed by the Contractor.

5 TRANSPORTATION, STORAGE AREA


The Contractor shall prepare a site storage area for the received pre-insulated pipes. Pipe
Suppliers recommendations for storing shall be followed.
Size and location will be pointed out prior to contract sign.
Unloading from trucks is included in the Contractor’s Scope of works.
The Contractor is responsible for protection of the pipes unloaded and put into storage. Sun
protection is required; overheating by the sun will lead to cracks in the jacket pipe casing
and separation of the insulation foam from the carrier steel pipe.
Damaged pipes and fittings will be rejected at the Contractor’s cost.
During loading, transport and unloading the material should be handled in such a way that
prevents damage, in accordance with pipe supplier’s recommendations.
Flat type fabric band straps shall be used for lifting, Chains, wires, ropes or other round
lifting equipment are not allowed. A fork lift can be used to lift fittings and components,
provided that flat forks are used.
T-piece branches shall not be lifted by the branch pipe only.

6 QUALITY CONTROL
All quality control, inspection and testing shall be carried out in accordance with applicable
and specified codes and standards.
A quality system in accordance with the international standard ISO 9001 is preferred.
Vendor shall, in the tender, provide a quality manual in which the quality control system is
described.
A testing program shall be agreed upon before the starting the works.

7 DOCUMENTATION

The Contractor shall submit all documentation from quality control, inspection and test
reports.
All documentation shall be delivered in minimum 5 sets hard copies and 1 set soft copy as a
minimum.

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7.1 As-built drawings

As built drawings showing final location of pipes and components shall be delivered by the
Contractor minimum two weeks after finalisation of each pipe section phase.
Drawings shall include information of all measurements, levels and coordinates in X, Y and
Z directions. All valves, valve chambers and cable hose chambers shall be shown.

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