ABU DHABI SEWERAGE SERVICES COMPANY (ADSSC)

GENERAL SPECIFICATION FOR MECHANICAL WORKS

DIVISION 15 MECHANICAL

SECTION 15010 PIPEWORK

ADSSC/GSMW

Division 15

Section 15010

Pipework

Rev: 02

Jan. 2011

Page 1 of 15

General Specification for Mechanical Works

Abu Dhabi Sewerage Services Company (ADSSC)

DOCUMENT CONTROL SHEET

Revision No. Date Revision Description / Purpose of Issue

01

April 2008

First Issue.

02

Jan. 2011

ADSSC new logo

03

04

05

06

07

08

09

10

ADSSC/GSMW

Division 15

Section 15010

Pipework

Rev: 02

Jan. 2011

Page 2 of 15

General Specification for Mechanical Works

Abu Dhabi Sewerage Services Company (ADSSC)

TABLE OF CONTENTS
1. PIPEWORK ..................................................................................................... 4 1.1 1.1.1 1.1.2 1.1.3 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 GENERAL ............................................................................................ 4 SUITABILITY OF PIPE MATERIALS FOR USE WITH SEWERAGE AND TREATED SEWAGE EFFLUENT ................................................ 5 GENERAL USE OF MATERIALS IN PIPELINES ................................. 5 SUMMARY OF PROPERTIES OF PIPE MATERIALS: ........................ 6 PRESSURE RATINGS ......................................................................... 9 DESIGN ............................................................................................. 10 VELOCITIES ...................................................................................... 11 FLANGE ADAPTORS ........................................................................ 11 CUTTING ........................................................................................... 11 JOINTING .......................................................................................... 11 PIPE SUPPORT WORK, HOLDING DOWN BOLTS & BOLTING ...... 11 INSULATION...................................................................................... 14 PIPELINE IDENTIFICATION .............................................................. 14 STEEL PIPES .................................................................................... 14 GALVANISED STEEL ........................................................................ 15 UPVC/ABS ......................................................................................... 15 FLEXIBLE HOSEWORK .................................................................... 15

ADSSC/GSMW

Division 15

Section 15010

Pipework

Rev: 02

Jan. 2011

Page 3 of 15

General Specification for Mechanical Works

Abu Dhabi Sewerage Services Company (ADSSC)

1.
1.1

PIPEWORK
GENERAL a) Materials and coatings used shall be unconditionally resistant to the conveyed fluids, and any gases derived from that fluid under all operating conditions. b) Pipework shall be as follows:i. ii. iii. iv. Pumped - GRP, MDPE, HDPE, Ductile Iron, coated steel Drainage - uPVC Sludge - Ductile Iron or Coated Steel or ABS Sampling - PVC or ABS, stainless steel

c) Air - Galvanised Mild Steel or ABS. d) Ductile iron for Potable/Water (including supernatant) shall be cement mortar lined. e) The following guidelines shall be followed: WRC Pipe Materials Selection Manual and EN 1295-1 Structural design of buried pipelines under various conditions of loading. f) General guidelines on the selection of pipe materials and the properties of pipe materials are given in the tables below.

g) This Specification shall be read in conjunction with Section 15001: General M and E Requirements. h) All pipework fabrications shall be protected against corrosion as specified in Section 15004 : Corrosion Protection. Pipework internals shall be protected to the same degree and specification as the pipework external structure.

ADSSC/GSMW

Division 15

Section 15010

Pipework

Rev: 02

Jan. 2011

Page 4 of 15

General Specification for Mechanical Works

Abu Dhabi Sewerage Services Company (ADSSC)

1.1.1

SUITABILITY OF PIPE MATERIALS FOR USE WITH SEWERAGE AND TREATED SEWAGE EFFLUENT
Class Sewerage Treated Sewage Effluent Relative Cost per m

Pipe Material

Manufacturing Base

Gravity Lined and coated RC DI Rigid No

Pressure No

Gravity Yes

Pressure No UAE, Saudi Arabia Medium

Semi rigid Flexible Flexible Flexible Flexible Rigid

No

Yes

No

Yes

Europe, USA

High

GRP HDPE MDPE uPVC VC

Yes Yes Yes Yes Yes

Yes Yes No No No

Yes Yes Yes Yes Yes

Yes Yes No No No

UAE UAE UAE UAE Saudi Arabia

Medium Medium Medium Low Low

1.1.2

GENERAL USE OF MATERIALS IN PIPELINES

Material Size

Trunk 300mm up to 2400mm dia

Distribution 50mm, generally300mm to 800mm dia GRP, HDPE, uPVC, VC ,

Services 50mm dia

Pumping Stations

Sewage

, DI, GRP, HDPE, VC

Not applicable

DI , Stainless Steel, Epoxy Coated Carbon Steel DI, MDPE, HDPE Stainless Steel, Epoxy Coated Carbon Steel

Treated sewage effluent

GRP, HDPE, MDPE, VC

HDPE,, uPVC, VC ,

HDPE, MDPE Stainless Steel Epoxy Coated Carbon Steel

ADSSC/GSMW

Division 15

Section 15010

Pipework

Rev: 02

Jan. 2011

Page 5 of 15

General Specification for Mechanical Works

Abu Dhabi Sewerage Services Company (ADSSC)

1.1.3

SUMMARY OF PROPERTIES OF PIPE MATERIALS:

DI GRP HDPE uPVC VC

Property

Specification

ISO 2531 ISO 8179

ASTM C128 ASTM D3262 AWWA C400 BS 486 BS 5480

ASTM D1447 ASTM D3035 DIN 8074 ISO 4427

ASTM D1784 ASTM D1785 ASTM D2241 ASTM D2665 BSEN 1452-2 ISO 11922-1 16 Bar

Coating BS EN 545 BS EN 548 Maximum operating pressure Structural type Semi rigid Maximum 25 Bar

ASTM C700, BS 65 BS EN 295 DIN 1230

Maximum 25 Bar

2.5 Bar to 30 Bar

10 Bar

Flexible

Flexible

Flexible

Rigid

Standard length

5/6m length

6m max

100m coil up to 110mm dia > 12m length above 110mm dia Butt fusion welding, Electrofusion , Flange

6m

2m

Jointing

Push fit spigot and socket, Flanged joints

Anchor blocks

Required

Push fit rubber gasket collar joint, Spigot and socket with gasket, Slip on collar flange Required

Push fit spigot and socket, Solvent welding

Push fit with rubber gasket

Not required on welded lines HDPE fabricated fittings, Standard mechanical joints

Required

Required

Fittings

DI fittings

GRP

PVCu

VC limited

ADSSC/GSMW

Division 15

Section 15010

Pipework

Rev: 02

Jan. 2011

Page 6 of 15

General Specification for Mechanical Works

Abu Dhabi Sewerage Services Company (ADSSC)

Property

DI

GRP

HDPE

uPVC

VC

Deflection allowed

Only on long length

Max 50

More than 50 35D

1 to 50

Up to 200mm 2.90 , For 1000mm 0.60

Trench required Installation

Wide trench

Wide trench

Narrow trench

Wide trench

Wide trench

Overground, Underground

Underground

Can be laid overground /underground on slopes Resistant to soil corrosion, Chemically inert Lightweight Easy handling, not easily damaged

Underground

Underground

Corrosion

Effected by certain soil chemicals Heavy Can be damaged by heavy handling

Weight Handling

Resistant to soil corrosion, Chemically inert Lightweight Careful handling, cracks if badly handled

Resistant to soil corrosion, Chemically inert Lightweight Careful handling because of brittle nature

Resistant to soil corrosion, Chemically inert Heavy Careful handling, can be easily damaged

Hydraulic properties

High frictional loss, High pumping cost

Low frictional loss, low pumping cost

Low frictional loss, low pumping cost

Low frictional loss, can be susceptible to fatigue, surge failures have been known Limited

Low frictional loss

Abrasion resistance

Lining suspect to abrasion

Good

Good

Good

Breakage

Damaged due to heavy impact loads

Impact loads cause cracks

Impact resistant, unbreakable

Damaged by impact

Damaged by impact

ADSSC/GSMW

Division 15

Section 15010

Pipework

Rev: 02

Jan. 2011

Page 7 of 15

General Specification for Mechanical Works

Abu Dhabi Sewerage Services Company (ADSSC)

Property Installation

DI Easy installation, larger sizes need craneage

GRP Careful installation, required

HDPE Easy installation, Less time required, Only very large sizes need craneage Selected as dug material, target 90% standard Proctor

uPVC Easy installation but subject to poor installation methods Selected as dug material or processed granular materials, target 90% standard Proctor

VC Easy installation, many joints due to small length

Bedding requirements

As dug material

As dug material, important to support along entire length must be self compacting

Selected as dug material or processed granular materials, target 90% standard Proctor Not applicable, Above ground installation not possible No maintenance Normal

Supports, clamps

Supports required

Not applicable, Above ground installation not possible Low maintenance Normal

No support required, frequent clamping No maintenance No Leakage

Not applicable, Above ground installation not possible No maintenance Normal allowances for push fit joints Medium surge pressure

Maintenance Leakages

Low maintenance Frequent if corroded High surge pressure

Surge head

Medium surge pressure

Water supply

Depending on water quality cement internal lining is provided

Common

Low wave velocity, Less surge pressure Recommend ed all over world

Not suitable for pumping

Commonly used in distribution

Not applicable

ADSSC/GSMW

Division 15

Section 15010

Pipework

Rev: 02

Jan. 2011

Page 8 of 15

General Specification for Mechanical Works

Abu Dhabi Sewerage Services Company (ADSSC)

Property Sewage

DI Common in pump mains

GRP Common in Middle East

HDPE New to UAE

uPVC Common in UAE

VC Common throughout World Air/gravity test

Test pressure

Design life

1.5 times operating pressure or 1.25 times max surge pressure, whichever is greater 35 years depending on environment

1.5 times operating pressure or 1.25 times max surge pressure, whichever is greater 50 years

1.5 times operating pressure or 1.25 times max surge pressure, whichever is greater 50 years minimum

1.5 times operating pressure or 1.25 times max surge pressure, whichever is greater 50 years (without brittle failures)

50 years

Deterioration with time

Corrosion encrustation etc

Joints deteriorate encrustation etc UAE

Nil

Joint deterioration

Joint deterioration

Availability

Imported

Local up to 1200mm dia UAE Stabilised

Commonly available up to 400mm dia Deteriorates in UV Low

Saudi Arabia

UV light

Not affected

Deteriorates in UV Moderate

Not affected

Cost

High

Moderate

Low

1.2

PRESSURE RATINGS a) Pipework and fittings shall be suitable for a safe working pressure equivalent to the maximum working pressure of the system. b) The safe working pressure of pumping mains shall be the closed valve head of the pump plus the maximum suction static head plus the maximum surge pressure. c) Pipework and fittings shall be suitably rated to withstand intermittent surge pressure transients specified in the technical schedules. d) Ductile iron pipework and fittings shall have a minimum pressure rating of 16 bar.

ADSSC/GSMW

Division 15

Section 15010

Pipework

Rev: 02

Jan. 2011

Page 9 of 15

General Specification for Mechanical Works

Abu Dhabi Sewerage Services Company (ADSSC)

e) Tests shall be carried out to ensure the pipework systems are correctly levelled. f) Upon completion of the installation, the whole of the pipework, valves etc shall be tested to 25% above the max. surge pressure.

1.3

DESIGN a) There shall be a sufficient number of mechanical joints to enable mechanical plant and valves to be disconnected from built-in pipework. Such joints shall be tied, and shall not be allowed to sustain the weight of any pipework. b) All machinery stations shall be provided with flexible joints, flange adaptors or unions such that upon renewal of plant minimal disturbance of pipework is required. c) Flanges shall be drilled off centres and shall be to BS EN1092-1. d) Pump suction bell mouths shall be standard castings in either cast iron or ductile iron. e) The use of gusseted bends shall only be permitted upon approval by ADSSC. f) All bends shall be even curvature manipulated bends where space allows and the use of carbon and alloy steel welding fittings to BS 1640 Part 3 or equivalent shall be permitted where short radius bends are required.

g) Carbon and alloy steel welding fittings to BS 1640 Part 3 or equivalent shall be permitted where short radius bends are required. h) Tee pieces on pump manifolds shall have a radial branch to enable a more streamline flow from branch to body. i) Short radius tee pieces are permitted where there are space limitations and the consequent head loss is insignificant. Due allowance shall be made for reinforcement in the vicinity of branches etc. Puddle flanges shall be provided on all pipes where they pass through pumping station walls and the Contractor shall provide and ensure a gas tight seal at the penetration.

j)

k) Pump suction and delivery manifolds shall be provided with a drain valve and a station isolating valve.

ADSSC/GSMW

Division 15

Section 15010

Pipework

Rev: 02

Jan. 2011

Page 10 of 15

General Specification for Mechanical Works

Abu Dhabi Sewerage Services Company (ADSSC)

1.4

VELOCITIES Allowable velocities shall be as stated in the Design Guidelines Document.

1.5

FLANGE ADAPTORS a) Thrust shall not be transmitted through the flange adaptor, but through suitable ties across the adaptor to the adjacent pipework an each side, and alignment shall be within the manufacturers tolerance. b) Where "tying" of flange adaptors is impractical fixed slip-on flanges are permitted.

1.6

CUTTING a) Pipes shall be cut by a method which provides a clean square profile, without splitting or fracturing the pipe wall, and which causes minimum damage to any protective coating. b) Where necessary, the cut ends of pipes shall be formed to the tapers and chamfers suitable for the type of joint to be used, and any protective coatings shall be made good to the original specification.

1.7

JOINTING a) Pipe jointing surfaces and components shall be kept clean and free from extraneous matter until the joints have been made or assembled. Care shall be taken to ensure that there is no ingress of grout or other extraneous material into the joint annulus after the joint has been made. b) Gaskets for flanged pipe joints shall be of the inside-bolt circle type. c) Flanges shall be properly aligned before any bolts are tightened. d) Jointing compounds shall not be used when making flanged joints, except that, to facilitate the making of vertical joints, gaskets may be secured temporarily to one flange face by a minimum quantity of clear rubber solution.

1.8

PIPE SUPPORT WORK, HOLDING DOWN BOLTS & BOLTING a) Pipework shall be designed and installed so that no dead weight loads are transmitted to machinery casings and pipes shall not be sprung into place. b) Riser pipework shall be supported independently of connected horizontal pipework.

ADSSC/GSMW

Division 15

Section 15010

Pipework

Rev: 02

Jan. 2011

Page 11 of 15

General Specification for Mechanical Works

Abu Dhabi Sewerage Services Company (ADSSC)

c) During site erection the Contractor shall take particular care to ensure that none of the component parts are stressed due to misalignment of the pipes or other items. d) The Contractor shall provide all fixing brackets and holding down bolts for the plant and pipework supplied within the scope of his works. e) Pipes shall be installed to provide a minimum spacing of 13mm between finished covering and adjacent work. f) Prior to tightening all bolt threads shall be treated with graphite paste or "copperkote".

g) Nuts shall be tightened evenly in diametrically opposite pairs. h) An expanding grout shall be used for grouting in any duck foot bends and the Contractor shall comply with the appropriate period stipulated by the manufacturer before any equipment is equipment is run on this grout and shall in any case not run any equipment for at least two weeks. i) The same stipulation shall apply for all other holding down bolts and brackets fixed by grout. All holding down bolts, pipe and support brackets within the works shall be sheradised or electro-galvanised before any painting is carried out of these items.

j)

k) Contact between dissimilar metals shall not be permitted. Suitable isolation washers/gaskets/ shims shall be used l) For auxiliary pipework, pipe hangers and supports shall be provided according to the following schedule:

ADSSC/GSMW

Division 15

Section 15010

Pipework

Rev: 02

Jan. 2011

Page 12 of 15

General Specification for Mechanical Works

Abu Dhabi Sewerage Services Company (ADSSC)

System

Pipe Size

Material

Features

Fire Protection Systems, Hydronic Systems, Refrigerant and Plumbing Systems

Hanger 9 mm rod 13 38 mm Malleable Iron /Carbon Steel, Stainless Steel Adjustable, swivel, split ring @ 2 meter maximum spacing, and at 1.8 m for uPVC pipe. Adjustable, Clevis @ 3 meter maximum spacing, and at 1.8 m for uPVC Steel channels with welded spacers and hanger rods spaced at: < 38 mm Dia- 2 meters > 38 mm Dia 3 meters and at 1.8 m for uPVC pipe Hook spaced at: < 38 mm Dia 2 meters > 38 mm Dia 3 meters Riser clamp Adjustable pipe saddle, lock nut, nipple, floor flange, and concrete pier or steel support. Adjustable Ring, spaced at < 38 mm Dia 2 meters > 38 mm Dia 3 meters New Hooked rod to concrete reinforcement. Refurbishment drill through concrete from below and provide through bolt, spaced at 3 meters, and 1.8 meters for uPVC Spaced at maximum spacing of 1.8 meters.

Hanger 9 mm rod

> 38 mm

Carbon Steel, Stainless Steel

Multiple or trapeze Hanger

All

Steel, Stainless Steel

Wall Supports

13 75 mm

Cast Iron, Stainless Steel

Vertical Support Floor Support

All All

Steel, Stainless Steel Cast Iron, Stainless Steel

Copper Support

All

Carbon Steel, copper plated Stainless Steel

Hanger > 100 mm diameter pipe

> 100

Galvanised Steel, Stainless Steel

Flanged uPVC & ABS Pipe Systems

All

uPVC proprietary systems, Stainless Steel

Accessories
Hanger Rods All Mild steel Galvanised, Stainless Steel Threaded

ADSSC/GSMW

Division 15

Section 15010

Pipework

Rev: 02

Jan. 2011

Page 13 of 15

General Specification for Mechanical Works

Abu Dhabi Sewerage Services Company (ADSSC)

1.9

INSULATION a) Where heat gain or heat loss affects process conditions, and where specified, pipework shall be provided with a flexible weather and vermin proof system of non-water absorbent closed cellular structure. b) The insulation shall be not less than 40mm thick with a thermal conductivity of 0.02 W/MC. c) The exterior of the lagging shall be Polyisobutylene suitable for colour coding. Other types of insulation may be approved by ADSSC. d) Valves and fitting shall be insulated using detachable moulded sections, and terminated ends shall be finished with a plastic disc taped hat, and all seams shall be joined underneath the pipe.

1.10

PIPELINE IDENTIFICATION All pipework shall be colour coded as stated in Section 15003: General M and E Specification.

1.11

STEEL PIPES a) Where fabricated steel pipework is offered then the fabricators and coating applicators shall have been approved by ADSSC or his nominated Representative. b) All pipework fabrications shall be protected against corrosion as specified in Section 15004 : Corrosion Protection. c) All materials shall have manufactures and mill test certificates, not letters of conformity. When specified, all procedure approval tests shall be witnessed by ADSSC. or his nominated Representative.

d)

e) The cost of carrying out any pre-qualifying trial shall be borne by the Contractor. f) The welding of steel pipework shall be in accordance with the appropriate standards as follows: i. ii. iii. BS 2633 BS 2971 BS 4677 Class I Arc Welding of Ferritic Steel Pipework for carrying Fluids. Class II Arc Welding of Carbon Steel Pipework for carrying Fluids. Arc Welding of Austenitic Stainless Steel Pipework for carrying Fluids.

ADSSC/GSMW

Division 15

Section 15010

Pipework

Rev: 02

Jan. 2011

Page 14 of 15

General Specification for Mechanical Works

Abu Dhabi Sewerage Services Company (ADSSC)

1.12

GALVANISED STEEL Where screwed joints are proposed then all joint threads shall be sealed with PTFE tape or hemp and paste and exposed threads shall be treated with galvafroid after assembly, and prior to the application of the final finish paintwork.

1.13

UPVC/ABS a) For uPVC and ABS pipework and fittings, consideration shall be given to pipe supports and the elimination of vibration transmission in order to reduce fatigue. Pipe support shall therefore be spaced at intervals not exceeding 1.8 m. b) Pipework shall be protected against degradation through exposure to sunlight.

1.14

FLEXIBLE HOSEWORK a) Flexible hosework shall be nylon reinforced PVC hose. b) Hoses used in the installation shall be of high strength, resilient and compatible with the contact chemicals. There shall be no joints which are out of sight of plant operatives, particularly where hoses are ducted underground. c) Hoses which are installed above ground and within the building shall be securely attached to adjacent walls and also be transparent. Where hoses are exposed to daylight they must satisfy the opacity test, set out in BS EN 1452-5 or equivalent. d) All dosing lines shall be non toxic and provided with a means of bleeding air from the pipework system. The latter is considered essential to ensure that the correct metered amount of chemicals is to be transferred to the injection point.

END OF SECTION

ADSSC/GSMW

Division 15

Section 15010

Pipework

Rev: 02

Jan. 2011

Page 15 of 15