© HYDROSTATIC PRESSURE TESTING OF DI PIPES the contractor shall review the required PRESSURE TESTING AND PROCEDURES according to the international standards for pipes and water system ‘After completing the installation of a water main, or a section of the line, and before the joints are covered, a hydrostatic test of the line shall be made by the Contractor. A sufficient time for the curing of conerete thrust blocks must be allowed before the test is made. All backfilling and compaction over and around the pipes and thrust blocks must be completed except for the pipe joints to be left open for observation of any leaks, before the test is made, The Contractor will receive already prepared Pressure Test Protocols (format) according to DIN EN80S from the Engineer's Representative. This detailed procedure for performing hydrostatic pressure tests of installed pipes, fittings and valves as instructed by the Engineer must be used. Procedures for performing the hydrostatic pressure test shall indicate the location and capacity of the test pump for each test section, test pressure at the pump, procedure for venting the air from the pipeline, procedure of filling the pipe with water, length of the pipe section, and procedure for discharging water after test, flushing, drying and cleaning of the pipeline. Primary pipes shall be tested to a maximum of 1,000 m each section. ‘Secondary pipes and tertiary pipes (ISO 63) shall be tested to a maximum of 500 m each section. The pressure tests must be performed with adequate pressure loggers or recorders. Duration of Pressure Test The preliminary pressure test shall be performed with pressure applied for a period of 24 hours before the main tests are assumed to begin, to allow for a soaking period. After that, all joints shall be carefully inspected for evidence of leakage.The test pressure for the main test shall be applied for at least three hours for pipe diameters up to DN200 and six hours for pipe diameter DN250 to DN600. The test pressure shall not be allowed to fall below 24 bars for PN16, below 37 bars for PN25 and 40 bars for PN4O for pipe lines. If and when it does during the test period, the pressure shall be increased to the stated value and a record kept of the additional water added Procedure ‘The pressure for the preliminary test will start with the working pressure, and shall reach the test pressure within the last 6 hours of the preliminary test. Test pressure to be taken at the lowest point of the pipelines to be tested and corrected to the elevation of the test gauge. ‘The test pressure of the main test is ( Max Design pressure +Sbar ) in the contractor shall be review the required according, to ternational standards_for the pipe, and shall not exceed the PFA, as per instruction of the Engineer's representative. The main tests in particular have to be carried out in the presence of the Engineer's Representative in accordance with the relevant standards for the pipe material applied. When filling the pipe system, the Contractor shall not exceed the amount of water charged into the system as follows: Up to DN200 diameter 1.5 litres/second Up to DN300 diameter 3.0 litres/second Up to DN400 diameter 6.0 litres/second Up to DNS00 diameter 9.0 litres/second Up to DN600 diameter 14.0 litres/second Up to DN800 diameter 22.0 litres/second The test pressure shall be applied by a suitable pump equipped with connection valves and gauges, etc. to the satisfaction of the Engineer's Representative. The gauges and meters shall be new and accompanied by a certificate for test and calibration. The results of the tests, specifying the layout of sections of system, pipes and fittings tested including all relevant data of testing as weather, time, duration, filling time, pressure, etc., shall be produced in the form of a report by the Contractor and signed by the Contractor's and the Engineer's Representative. This report shall not relieve the Contractor of his responsibility for care and maintenance of the system until the date of final acceptance of the completed work.Stop Ends A simple stop end consists of a section of steel pipe about 0.5 - 1.0m long onto which a closing plate has been welded, contai ing the necessary openings for accommodating ingoing water and out coming air. The stop end may also include an opening through which the test water may be pumped from the line, if necessary. The stop end may be jointed to the pipe to be tested by means of a standard coupling or other method approved by the Engineer’s Representative. Thrust blocks or a temporary anchorage must be provided to hold the stop end in place against the test pressure. Air Removal before Test Before applying the test pressure, all air shall be expelled from the pipe. After all the air has been expelled, all cocks shall be closed and the test pressure applied as specified above. The line shall be filled slowly to prevent possible water hammer. Examination during Test All exposed pipes, fittings, valves, hydrants and joints shall be carefully examined during the pressure test. All joints showing leaks shall be rejoined u ight, or the pipe material replaced, Any defective pipes or joints, fittings or valves discovered as a result of this pressure test shall be repaired or removed and replaced by the Contractor at his own expense with sound material and the test shall be repeated Until proved satisfactory to the Engineer’s Representative. Permissible Addition of Water Additional water is defined as the quantity of water that must be applied to the laid pipe, or any section thereof, to maintain the specified test pressure after the pipe has been filled with water and the air expelled. The quantity of additional water pumped into the pipe shall be measured accurately. No section of the water main will be accepted until the additional water calculated in litres per km per 24 hours for the test pressure is less than 0.3 D, where D is the nominal diameter of the pipe in mm. The specific test, length of the pipe tested, the pressure, the duration of the test, and amount of additional water igineer’s Representative shall prepare a written report of results of the leakage test that identifies the required. The report shall be signed by the Contractor and the Engine 5 Representative. Cost of Testing The Contractor shall provide a sufficient quantity of gauges, pumps, stop ends, and connections and all things necessary and suitable for the testing of all pipes as described herein. The Contractor shall also provide all necessary temporary works in connection with test, and shall remove the same on successful completion of the test. All tests shall be done in the presence of the Engineer’s Representative and the results of such tests shall be signed by the Contractor and handed to the Engineer’s Representative who shall prepare the required test reportsAll equipment, labour, materials, and water necessary for the carrying out of these tests to the complete satisfaction of the Engineer’s Representative shall be provided by the Contractor at his own expense. Shall any test fail, the Contractor shall, after repairing and making good any leaks, carry out further tests all as described above until such test meets the requirements contained herein. All such tests and retests shall be at the expense of the Contractor. & PRESSURE TEST OF HDPE PIPES Test pressure shall be (1.5 x nominal working pressure) or 16 bars whichever is greater in this regard the contractor shoud be review the required according to international standards. The service lines including joints, fitings and appurtenances shall be tested for water tightness in accordance with ISO 1167 as follows Allowable quantity of water required to restore pressure at the end of the test period : <3 litres/km/25 mm diameter of pipe / 3 bars / 24 hours. Hydrostatic testing shall be carried out at ambient temperature (20 °C) otherwise a correction factor shall be applied to the nominal pressure Test shall be applied on sections of length less than 800 m with uncovered joints. Before testing the trench shall be partially backfilled to maintain adequate support and anchoring and to avoid floating of pipes during testing. Test procedure with joints exposed and valves in the open position. The filling of pipes shall be at a rate giving a maximum water velocity of 0.5 m/s in the pipe to ensure no surge and to give the air the necessary time to be released by the installed temporary air valves or cocks. Leave to reach equilibrium, i.e, the same temperature as the pipe and the surrounding soil and to remove all existing air for the saturation of pipe material, if any Apply test pressure slowly to avoid surge and hold for one hour. The system shall be isolated from the test pump, i¢., no pumping during the one hour test period allowed. Test pressure shall be applied to service lines including all couplings and fittings in the open position, with consideration to temperature variation, Apply the equation to determine if the section under test satisfies the requirements of the above. Finally after completion of the testing, the line shall be emptied slowly to prevent shocks or sudden counteraction of pipes. Short Pressure Test The so-called “Short Test” may be used for pipelines up to approximately 30 m and nominal diameter not more than DN 50 mm = ISO 63The test pressure is applied to the pipe and the first reading taken after 30 minutes. Note that this pressure is usually slightly less than initial pressure due to the normal expansion of the pipeline under pressure, but no additional “top-up” pressure shall be applied. For the short test the results are deemed to be satisfactory when pressure loss from the HDPE pressure pipeline is < 0.1 bar per $ minutes, Short pressure test for testing the house connections can be applied when approved by the Engineer. Pressure Test for black steel Pipes After completing the installation of a water main, or a section of the line, and before the joints are covered, a hydrostatic test of the line shall be made by the Contractor. The system test pressure (STP) value as the followings: SURGE HAS BEEN CALCULATED STP=MDP+1Bar MDP: maximum design pressure SURGE Has NOT been calculated STP = MDP X 1.5 or STP = MDP+ 5 Bar (whichever is the least) The contractor must take the value of MDP from the designer /engineer officially All backfilling and compaction over and around the pipes and thrust blocks must be completed except for the pipe joints to be left open for observation of any leaks, before the test is made. Procedure: Step 1 requires the main to be Preliminary soaked & conditioned for a period of time prior to pressure Testing (I.e. Overnight for Cement lined pipe) Step 2 Take the new main up to its System Test Pressure STD and record the time taken to achieve STP and also record the actual STP (Is it necessary to record the time to reach STP Step 3 Maintain the STP, by pumping and adding water into the main / pipe as necessary Step 4 Record the volume of water used to maintain STP for a period of one hour by using a volumetric Container and accurately measuring the volume of water it takes to achieve this. Step 5 if the volumes of water recorded is in exces test is a fail. of the permissible / allowable water loss table, Step 6 if test fails, Check main / pipe for leaks for leakage and redo the test. Standard Allowable Volumes of leakage by diameter (Liters / Per Kilometer / Per Hour‘Nominal Leakage Rate Pipe Diameter mm | (Litres/KM/Hour) 100mm ous 150mm 0.42 200mm 0.72 250mm 113 300mm 1.62 350mm 2.21 400mm 2.88 4somm 3.65 500mm 4.50 600mm 6.48 700mm 3.82 300mm, 11.52 900mm 14.58 000mm 13.00 DISINFECTION OF PIPELINES After the completed pipeline is tested, approved and backfilled, disinfections shall be performed in the following manner: after flushing the pipes, the system shall be drained completely, all valves shall be closed carefully and the system filled with a chlorine solution. All pipes, fittings, valves and appurtenances shall be disinfected by the Contractor as specified herein unless otherwise directed by the Engineer's Representative. The Contractor is also responsible for conducting bacteriological test for all pipe laying through WAI laboratory. The cost of disinfection and the bacteriological test shall be borne by the Contractor. The attention of the Contractor is directed to the requirements of the Contract whereby he is responsible for preventing the entry of foreign material of any kind from entering the pipe. The Contractor shall take extreme care to keep the interior of the pipelines free of dirt and other foreign material. If in the opinion of the Engineer's Representative, dirt or other foreign material entered a pipe which cannot be removed by flushing, then the Contractor shall clean and swab the interior of the pipe with a five percent hypo-chlorite disinfecting solution to the satisfaction of the Engineer’s Representative. The Contractor shall, during the initial filling of the pipeline, simultaneously introduce feed of chlorine at the same point where the pipeline is being filled. The rate of filling and the feed rate of the chlorine shall be proportioned so that the initial concentration of the chlorine in the water in the pipeline is between 50 and 100 milligrams per litre. To assure that this concentration is maintained, the chlorine residual shall be measured at blow-off, combination air valves, or other locations during the filling operation. The following is the amount of chlorine required, if either liquid chlorine (gas at atmospheric pressure) or a one percent chlorine solution is used, to produce a 100 milligram per litre concentration in 100 meters of pipe for the various diameters of pipe to be disinfected under this Contract.Table 1.1: Title of the Table Goes Here The use of liquid chlorine shall only be permitted when suitable equipment consisting of a solution feed chlorinator together with a booster pump of injecting the chlorine gas-water mixture into the pipeline to be disinfected is used. Introduction of chlorine gas directly from the supply cylinder shall not be allowed. After completion of the disinfections operation for one pipeline section the Contractor may reuse this chlorinated water to di fect adjacent sections of the pipeline by adding additional chlorine as required to produce the specified concentration of chlorine. ‘The Contractor shall submit a detailed description of the procedure he proposes to use to disinfect the pipeline including a description of all equipment to be used for the Engineer's Representative approval priot to starting the disinfections operations. Payment for all labour, material, and equipment, including the cost of all water and chlorine required to disinfect the pipeline and appurtenances shall be included in the unit prices for pipe installation. The chlorinated water shall remain in each section of the pipeline for at least 24 hours and during this period all valves and blow-off shall be operated in order to disinfect these appurtenances. At the end of the 24-hour period, the water in the pip. ine shall contain no less than 25 milligrams chlorine per litre throughout the length of the pipeline. Shall the pipeline fail to have the specified chlorine concentration at the end of the 24- hour period, the Contractor shall repeat the operation as necessary to provide complete disinfections. ® FLUSHING OF THE PIPELINE. All pipelines shall be flushed by the Contractor after all hydrostatic pressure tests and disinfections operations have been performed and accepted by the Engineer's Representative. After draining the chlorine solution the pipe system shall be flushed with potable water until the free chlorine content is between 2 to 4 milligrams per litre.SPECIFICATIONS OF MATERIALS VALVES, PIPES AND FITTINGS 1. General : 1, Supply and Quality of Materials : Alll materials shall comply with those Standards and Specifications laid down by internationally recognized institutions, for the water industrial. Preference will be given to manufacturers that are quality certified to ISO. 9001 Al materials supplied to the site in Jordan shall be subject to acceptance tests carried out by the Royal Scientific Society and if these tests are not applicable in RSS, they shall be carried in similar approved Authority and has to get WAJ approval firstly All materials supplied shall be subject to the Engineer's approval Any or all materials and manufactured articles supplied by the Contractor for use in the works, shall if so required by the Engineer be tested in advance at the Contractor's expense, in accordance with the required specs. Inspection or approval by the Engineer of any equipment or materials shall not release the Contractor from any of his obligations under this Contract Al information and specifications relating to Products and materials proposed for this Contract, must accompany each Tender Submission. 2. Storage of Materials : The Contractor shall be responsible for the storage and well being of all materials purchased under this Contract, and any discrepancies found therein. ‘The Contractor shall manage and maintain stock - yards that can accommodate all materials purchased and approved by the Engineer under this Contract, stored either in the open or under cover as required by the Manufacture's / contractor's instructions , and shall be regularly inspected by the Engineer's staff and ‘maintained to the Engineer’ satisfaction 3. Scope : The Contractor shall furnish and deliver to the site, all kind of pipes, valves, fittings, closure pieces, flanges, bolts, nuts gaskets, jointing materials ...etc. and appurtenances as specified and required, All valves shall be flanged. Pipe fittings and valves shall be Suitable for buried installation. All tapers (reducers) required at tees and other locations to meet the specified diameters may be furnished in the manufacturer's standard lengths and diameters. 4, References : Reference to any national standard or publication ( as ISO, BS, DIN. ... ete. ) in these specifications is intended to indicate general configuration, type and quality. Goods may be furnished which meet other internationally accepted standard, provided that overall quality will be at least equal to that required by the standard specified. Supporting documents / certificates shall be submitted hereto, 5. Potable Water Certification All pipe and coating materials shall be certified for potable water use and shall contain no ingredients that may migrate into water in amounts that are considered to be toxic or otherwise dangerous for health. All pipes shall be certified as safe for transporting potable water by an independent testing laboratory.6. Materials and Standards : All materials shall be complying with ISO, BS, API & DIN. standard and shall be supplied from approved manufactures and country of origin. The Contractor is requested to submit a list of contractors that he intends to use together with his Tender bid. The Contractor shall also submit for the approval of the Engineer, before ordering: a)Type of materials to be used, dimensions, thickness, lengths, shape, weight, class, tolerance limits and quality. ) Standard to which the item is manufactured. ©) Details of specials, adapters, fittings and joint design. 4) Coating and lining methods. 7. Fittings : Fittings unless otherwise specified shall be furnished with a type of joint compatible with the pipe system at the contractor's option. Any adaptors necessary to joint fittings to the adjacent pipes, even of different materials, shall be provided by the Contractor at no extra cost. 8. Toxic Materials : The Contractor is prohibited to import or to use any of the "Acrylamide and N-Methylolarcylamide Grouts" or any other toxic or poisonous materials or submaterials used in piping, it's accessories, lining, coating, sealing ...etc, or in various kinds of concrete or in soil in any kind of usage. Any import or usage of the above mentioned materials by the Contractor, requires to be licensed in writing by the Employer, otherwise, the Contractor shall be subject to legal pursuance. 9. Submittals : The Contractor shall submit 1. Detailed manufacturer's proposals for pipes and fittings manufacture, coating & lining... etc. 2. Certified copies of manufacturers quality control test results and reports 3. Certified copies of compliance certificates for pipes, fittings and other components . “ This is to certify that the pipes and specials delivered in this consignment comply with the required specification No payment shall be made in respect of any consignment of pipes and specials in case it is not accompanied by above mentioned certificates 10. Payment of Taxes and Duties : The contractor shall take in his consideration that all materials in this Contract shall not exempted from customs duties, import duties, sale taxes and all other kinds of duties and taxes. 11. Tests After Delivery : The Employer & the Engineer have the right to take samples of the supplied materials, and the following tests shall be carried out in accordance with the relevant ISO, BS, DIN or regulations by an approved laboratory.1. Hydrostatic pressure test 2. Hardness test 3. Tensile strength test . 4, Elongation test S. Measurement and weight 6. Test of cement mortar lining All tests as mentioned or directed by the Engineer shall be bone by the Contractor and the costs shall be included in the Contract unit rates. 12. Third Party Control : The Contractor shall at his own expense provide a recognized independent third party control to monitor quality and witness testing during manufacturing process and to ensure that the products used in the works ( such as pipes , fittings , valves . various electrical and mechanical apertures , lap equipment ... etc.) are all manufactured in accordance with the specific standards in this Contract (or any other specifications approved by the Employer ) The third party control should also issue test certificates stating that they had witnessed all the tests performed on the products , and all materials are conforming to Specifications and they had checked and inspected all materials regarding the proper packing and shipment , and certifying the bill of lading Before signing the Contract , the Contractor shall inform the Employer of the name of the control party he intends to engage , and obtain the Employer’s approval The third party control should be selected from the following list which issued by the Central Tenders Directorate : 1) SGS - Societe General De Servwillance, 2) Tuboscope Verco International 3) OMIC - Overseas Merchandise Inspection Company LTD. 4) Baltic Control LYTD. 5) Inspecturate (suisse) S. A. 6) Control Union International 7) Socotec International Inspection. 8) Bureau Veritas - Messers. Red Sea Shipping Agency W.L.L Box. 1284— Amman —Jordan 2, Valves : GENERAL : “Materials used in valves shall be suitable for potable water. Alll valves, on any type of pipeline must be jointed to the pipe by flanges (unless otherwise specified) and shall have a testing pressure of 1.5 times the nominal pressure. All valves shall be of the non-rising stem type, and shall be capable with standing the sp without leaking, ied test pressureThe hand wheels of all valves (including those which incorporate gear shall be arranged for clockwise closing. All hand wheels shall have, in their periphery, the words OPEN and SHUT and appropriately positioned arrows, ‘When valves have inaccessible positions, extension spindles shall be fitted to suit the situation, The contractor shall submit a certificate from the manufacturer certifying that all valves have been mill tested and that they have successfully passed the tests prescribed by the relative standard specifications. ii. Gate Valves : GENERAL: I They shall comply with EN 1171 standard latest revision. For drinking water, valves from DN 50 to 200mm, PN (16 , 25, 40) bars, shall also comply with EN 1074-2 standard latest revision. 2.Alll accessories and fittings (gasket, hand wheel GG25 or carbon steel, bolt and nut of A2, flanges EN 1092- 1/2 Steel flanges type ( O1, 11, 12) shall be provided by the contractor, this is general requirements for all kinds of valve for each 3. The valves shall be complete with mechanical position opening indicator with hand wheel from ductile cast iron fusion bonded epoxy powder coated with spur gearbox for sizes above DN 300 4.The contractor shall provide four detailed repair manuals for the gate valves supplied; and a letter of certification from the contractor verifying that all requirements of EN Standard and these Specifications have been met. VALVE JOINT! All valves shall have, flanged ends, mechanical joint ends or screw joints to fit the pipe run in which they are used, except valves installed on push-on joint pipe shall have mechanical joint ends unless otherwise specified and the flange design on request. Flanges shall be raised face rated and drilled according to EN 1092-1/2 PN (16, 25, 40) Bars and face to face length according to DIN 3202 series F15 or ENSS8 Regarding all standards or technical characteristics described hereafter, the contractor is required to submit certificates from third party inspectors recognized by the governmental tender directorate, its latest issue, but limited to following internationally recognized and accredited companies 1) Bureau Veritas 2) Lloyds 3) SGS 4) WRAS 5) RSS MATERIALS. -Gate valve form size DNS0mm and greater shall be Body wedge and bonnet of the material for pressure range 16 to 40 bars shall be ductile iron as listed in table below.Material Today Previously Code Designation Standard Material No Code Designation Standard Ductile iron DIN ENOls woo 1g ENASIOB0 EN 1563, 5.3106 GGG-40 0.7040 (ae Ductile iron . DIN ENGIS.5007 EN-IS1050. EN 1563 5.3200 GGG-50 0.7050 Tease Ductile iron nn (EN-GIS-400- EN-IS1025 EN 1563 5.3103 GGG-40.3 0.7043, 1eLT) 1693-1 2. Valve stem (shaft) shall be stainless steel with minimum 13% chromium for water system, 17% chromium for waste water system as listed in table below. DESIGNATION Material no En standard Stainless steels 316 Lane EN10088-1,2 of 3 3. Body, wedge and bonnet shall be of ductile cast iron GGG 40 or $0 according to DIN 1693. And Nut shall be of bronze CuSn!2Ni Stem shall be of stainless steel 316 while stem sealing shall be of PTFE. O-Ring made of EPDM for water system, NBR for wastewater system. Bolting should be of stainless steel 316. . Hand wheel made of non wounding Steel or Ductile Cast Iron DESIGN 1. Resilient seat to EN 1074-2 and EN 1171 Wedge full lining with EPDM for water system and NBR for ‘wastewater system process for pressure range 16 bars only. 2. Wedge will be equipped with polyamide gliders to protect the gate and body guides coating from wearing. Gliders should be preferably directly fixed to the Iron Gate and protection against corrosion of the wedge shall be assumed by the system glider/rubber. 3, Metal seated to EN 1074-2 and EN 1171 non resilient seat, tapered wedge design Flexible wedge type ‘T0OHS or Split wedge=Type 700 JJ for pressure range greater than 16 bars. Fully guided wedge for resilient and non-resilient gate valves. 4 5. Body/bonnet junction can be either realized with or without bolts, to avoid corrosion. 6. All bolts and nuts shall be of stainless steel 316 or Bronze. 1. Face to face+ Face to face dimension for the pressure range up to 16 bars accordance to ENSS8-1 basic series 14 (previously DIN 3202 F4) ; * Face to face dimension for the pressure range 25 bars accordance to ENSS8-I basic series 15 (previously DIN 3202 F5); * Face to face dimension for the pressure range 40 bars accordance to EN 558-1 basic series 15 (previously DIN3202-F5,), 8. Gate valve shall be designed with flanged end on both sides rising face according to EN 1092-1/2 9. Fixed stem seal (O ring seal) with minimum double O-Ring stem sealing and replaceable seal under pressure according to ISO 10079. 10. With draining plugs for waste water system. 11, Optional prepare for bypass for pressure range 40 bars, 12. Up to DN 200 the valves shall have a maximum operating torque of(DN) Nm. A gear box will be added if necessary to reach a maximum operating torque of 300 Nm (The valve from size 200mm and grater shall mountain with gear unite for pressure rang 25 bar and grater). 13. Inside screw stem(NRS) 14, ‘The valves shall be complete with mechanical position opening indicator with hand wheel from ductile cast iron fusion bonded epoxy powder coated with spur gearbox for sizes above DN 300 15. Rotation of opening All valves shall open by turning to the left or counter clockwise, when viewed from the stem (clockwise closing). COATING 1. All internal and external ferrous metal surfaces shall be fully coated, blue color, holiday free, to a minimum thickness 250 microns at least with a hot epoxy powder coating or two part thermosetting epoxy coating. Said coating shall be non-toxic, impart no taste to water, and shall be in accordance with British, French or German drinking water national regulations, 2. The valves shall be shot blasted before coating according to specifications and shall be coated inside and ‘outside with fusion bonded epoxy powder minimum 250 microns in RAL 5015. 3. The valves shall be complete with mechanical position opening indicator with hand wheel from ductile cast iron fusion bonded epoxy powder coated with spur gearbox for sizes above DN 300. MARKINGS Markings shall be in accordance with EN 19 and shall include (size, working pressure, name of manufacturer, and year of manufacture). TEST 1. Final production tests in accordance with EN 1074-2 or EN 12266-1 (when EN 1074-2 not applicable). 2. Drinking Water use valves are in accordance W270 OR British, French German drinking water national regulations. 3. Life cycle testButterfly Valves GENERAL 1. Butterfly valves shall comply with EN 593 standard latest revision. For drinking water valves from DN 50 to 2000mm, PN (16 , 25 , 40)Bars shall also comply to EN 1074-2 standard latest revision. Butterfly valves shall be of the tight closing, metal seat type with recess-seat. Rubber gasket will be fixed on the butterfly and replaceable without removing the shafts. 2. Directions of flow shall be satisfactory for applications involving valve operation after long periods of inactivity. Valves being tight in the two ways will be preferred. 3. Valve discs shall rotate 90 degrees from the full open position to the tight shut position, Obturator disc will be of double accentuated type. 4, The valves shall have the possibility for horizontal and vertical installation by changing the lever position only. 5. the contractor is required to submit certificates from third party inspectors recognized by the governmental tender directorate, its latest issue, but limited to following internationally recognized and accredited companies: © Bureau Veritas * Lloyds * sGs © WRAS + RSS MATERIALS 1 butterfly valve form size DNSOmm and greater shall be Body wedge and bonnet for Pressure range (16 to40) Bars shall be ductile iron as listed in table below, Material Today Previously, Code Designation Standard MaaterialNo Code Designation Standard Ductile iron : DIN ENGIsu0n 1s ENISI030. EN 1563 5.3106 GGG-40 0.7040 Hea Ductile iron. DIN ENols-s00.7 ENUSI0SO EN 1563 5.3200 GGG-s0 0.7050 pega Ductile iron. a (EN-GIS-400- EN-JS1025 EN 1563 5.3103 GGG-403 0.7043 eet 18-LT') 3 2.Valve shaft shall be stainless steel minimum 13% chromium for water system 17% chromium for waste water system,Designation Material no En standard ___ Stainless steels 316 Laree EN10088-3 3.Sealing seat ring (metal sealing corrosion and wear resistance sealing surface) shall welded-on or rolled on the body and made of A. Stainless steel B. Chrome-nickel CC. Bronze for wastewater only, D. (EN 10088 -3/2,2.0975,2.1020,Ni) 4 Internal bolts shall be stainless stee! minimum A2 according to EN 10088-2/3. 5.O-Ring and seat gasket shall be made of EPDM used in Drinking Water system and will be in accordance with British, French or German national regulations for water system. DESIGN 1 Face to face to EN 558-1 basic series!4 and (previously DIN 3020 F4). 2.With Flanged end on both sides rising face accordance to EN 1902-Ior 2. 3. With gear box featuring position indicator (for non buried valves) and mechanical stops. 4, Bearing sealing with minimum double O-Ring on both sides. 5. Disk with close disk eyes. 6. Tight in both side, 7. Valves shall be suitable for installation in either horizontal or vertical position. 8. Double eccentric bearing of disk butterfly valve. COATING All internal and external ferrous metal surfaces shall be fully coated, blue color, holiday free, to a minimum thickness 250 microns at least with a hot epoxy powder coating or two part thermosetting epoxy coating. Said coating shall be non-toxic, impart no taste to water, and shall be in accordance to W270 OR British, French German drinking water national regulations. MARKINGS Markings shall be in accordance with EN 19 and shall include (size, working pressure, name of manufacturer, and year of manufacture). TEST 1. Final production tests in accordance with EN 1074-2 or EN 1226-1 (when EN 1074-2 not applicable); 2. Drinking Water use valves shall be in accordance with British, French or German drinking water national regulations. 3. Life cycle testiv. Air Valves : Single Air Valve DN 50 Air Valves shall be single automatic air valves, PN 16, PN25, PN40 and PNSO according to the final design performed by the contractor, with body/bonnet of Acetal with PE shield for UV protection, and shall be inside and outside epoxy powder coated complying in general with DIN 30677 part 2, coating thickness shall be minimum 250um, freedom from imperfections shall be tested by high-voltage method. Air Valves shall be either with DN 50 female threat or with Flange DN 80. Double Air Valve DN 100 Double orifice air valves shall be of the triple function type with a flanged inlet to EN 1092-2 PN 16, PN25, PN40 and PNSO according to the final design performed by the contractor (DIN 28605 / DIN 2501/BS 4504) and shall be suitable and approved for the use with potable water. Body and cover shall be of ductile iron EN-GJS-400-18 ace. to EN 1563 (GGG 400 - DIN 1693) and shall be inside and outside epoxy powder coated complying in general with DIN 30677 part 2, coating thickness shall be minimum 250ym, freedom from imperfections shall be tested by high-voltage method Orifice and float balls shall be of corrosion free material (stainless stee! or plastic), all seals shall be of EPDM or NBR suitable and approved for potable water, Automatic Air Valve, Single-Chamber Type ‘* Single-chamber valve directly operated by the medium; ‘+ Two-orifices venting system with 3 functions (supply and release of air as well as automatic venting during operation); ‘+ Safe operation even under high-volume, high-speed venting up to sonic speed; ‘+ With test and purge connection; ‘* Body and cap made of ductile cast iron EN-IS 1030 (GGG-40), ‘Inner parts made of stainless steel grade 316 (DN 50 float made of plastic); ‘+ Seal made of EPDM. ‘Equipped with inspection valve. Corrosion protection: Inside and outside with epoxy coating to GSK standards for heavy-duty corrosion protection to DIN 30 677- 2, coating thickness >250 pm, colour: RAL 5005 blue - Air valves shall be installed as follows: ‘A. For black steel main pipelines, the contractor shall cut a hole in the transmission Pipeline and install and weld a black steel pipe of suitable length and diameter provided with the appropriate slip - on flange with a neck to suit the flanged air valve. B. For ductile iron main pipelines, the contractor shall install a suitable flange tee (T) and install a pipe of suitable length and diameter in order to install the A.V provided with a neck to suit the flanged air valve.C. The Welding and the air valve pipes welded joints together with flanged joints, shall be properly protected in accordance with the specifications. D. Air valves with diameter 1 % “and larger shall be installed in concrete valve chambers according to the Standard Drawings. E. Air valves with diameter 1%“ and less shall be installed in the ground according to the Standard Drawings. vy. Wash-Outs : ‘The types of wash - out specified for this contract, whether in concrete chambers or buried type are as shown on the Standard Drawings. All wash - outs will be constructed as indicated on these Standard Drawings or as instructed by the Engineer. At places shown on the drawings or directed by the engineer, wash - outs shall be installed as follows: A. For black steel main pipeline; the contractor shall cut a hole at the lower part of the transmission main, install and weld a stee! pipe of suitable length and diameter provided with a slip - on welding neck flange to suit the flanged washout valve. B. For ductile iron main pipelines, the contractor shall install a suitable flanged tee (T) to install the flanged washout valve C. The welding and the W.O pipes welded joints together with flanged joints of the valves shall be properly protected in accordance with the specifications D. The wash - out pipes shall be extended to such a length and reach discharge area as is required for every particular site condition as not to flood the trenches or cause any damage to the surrounding area. The unit price of wash - out pipelines shall also include all concrete and other works at the end of W.O pipelines (outlet structure with riprap) as shown on the drawings, unless otherwise noted vi, WATER METERS : DIGITAL PROPELLER TYPE - MECHANICAL: The water meter shall be flange ended of the helical type and shall have a registration dial with six digit integrator calibrated to read in cubic meters and shall be of the straight reading type and shall have cover plate and a bank lid to be fitted in place of the lid fixed to the metering mechanism, in case the later is removed for repair. ‘The water meter shall be suitable for a working pressure as indicated on the Drawings and the Contractor shall supply the tapers and the necessary flanges required for the proper completion of the work. The length of the pipes connected to and from the water meter shall be at feast ten (10) times the diameter of each pipe away from fittings or valves. The Contractor shall supply install and operate these type of flow meters to measure the flow in water mains, it shall be installed as located on the Drawings. The nominal working pressure of these flow meters type shall be as indicated on the Drawings.vii, CHECK VALVES: The check valves shall be suitable for potable water and shall conform to ( BS.5153 ) for valves of working pressure up to 25 bars. They shall have cast iron bodies, hung single disc doors, the valves seating shall be gunmetal faced and the doors shall have facing of gunmetal For valves of maximum working pressures greater than 25 bars, the valves should be flange ended of lift type, designed for water works duty and comply with (BS 5160) or equivalent specification. ‘The Spindles shall be of solid forged manganese bronze or equivalent The bearings shall be designed to minimise hinge friction and be accessible for inspection and replacement from the outside of the valve. A soft packed gland shall be provided ‘A plugged pressure taping point shall be provided for the insertion of pressure monitoring devices during commissioning, The valves shall be suitable for operating either in the vertical or horizontal position as required, and shall be non-slam type. Pressure Gauges: ‘The pressure gauges shall be from an approved manufactures. All gauges shall have concentric dials of 150 mm. diameter ,or as approved by the Employer ‘The graduation of the pressure shall be in 0.5 bar: a) For suction pipes from 0.00 ~ 5 bar. b) For discharge pipes from 0.00 — 25 bar or from 0.00 — 40 bar. The cover of the facia shall not be less than 4 mm. glass. The gauge mechanism shall be of the Bourdon tube type, having stainless steel movments and shall comply with BS.1780 . It shall be sealed from the liquid being measured by means of a diaphragm or capsule and be filled with silicon oil. ‘The gauge shall be fitted with a pressure snubber, le. orifice, to dampen pressure pulsation . In addition to a small stopcock for venting Each gauge must have a test certificate stating that it is tested according to BS. 1780 and confirming that it is the required accuracy. Flexible Couplings and Flange Adaptors: For connection of the existing to the new pipeline system, flexible couplings shall be installed as indicated on the drawings or as directed by the Engineer. Couplings must be capable of adapting to different pipe materials Flexible couplings and flange adaptors shall be of mild steel and of an approved type suitable for making a ‘watertight flexible connection between plain-ended pipes, or between a plain-ended pipe and a flanged fitting (e.g. Viking-Johnson couplings as manufactured by the Victualic Co. Ltd. Or Dresser Couplings as manufactured by the Dresser Manufacturing Division in the U.S.A’ or equivalent approved by the Engineer. Unless otherwise specified, the external and internal surfaces of couplings and adaptors shall be cleaned down to a metallic finish, then primed and painted with epoxy resin paint, applied by an electro static process.x iS All mechanical couplings shall be of appropriate internal diameter and shall be capable of withstanding the maximum working test pressure specified for the pipes they are to connect, including a joint deflection of up to 3 degrees in any direction All mechanical couplings and flange adaptors shall be supplied complete with all necessary coupling rings, nuts, bolts, washers and rubber rings. Wedge joint rings shall comply with _BS.2494, and shall be made of nitrile rubber, ethylene propylene rubber (EPDM) or styrene butadiene rubber (SBR) or other approved materials, Bolts and nuts of galvanized steel shall be hexagonal with dimensions in accordance with BS. 4190 or DIN 601/555. Where a Harnessed Steel Flange Adaptor is shown on the drawings, the bolts connecting the flange of the Flexible Flange Adaptor to the Flange of the adjacent fitting shall be replaced by tie-bars threaded at both ends. One threaded end of each tie bar shall pass through holes in the abutting flanges and be anchored by two nuts to make the flanged joints in the normal way. The other threaded end shall be anchored by two further nuts in a corresponding boit-hole on the flange, soundly welded integrally onto the fitting which it is intended to harness to the adaptor. The integraily-cast flange on the flange-spigot shall be located such that, after the joint has been made and all nuts fully tightened, the integrally-cast flange is about 400 mm axially from the abutting flanges. The bolt circles on all the flanges shall comply with BS 4504 PN 16, as specified. The threaded tie bars shall be machined from steel at least equal to that specified for flange bolts of corresponding duty and threaded in the same way. The threaded length shall allow the nuts to be run forward sufficiently to permit complete withdrawal of the tie bars from the flange of the abutting fitting without requiring any other joint to be dismantled. The strength of the threaded tie-bars in both tension and compression shall be appropriate to the pressure rating of the flanged joints. Dismantling Joints: Dismantling joints shall be provided and installed with each valve as indicated on the Drawings for convenient installation of re-installation of valves or similar items. For prevention of any move of the pipe joints adjacent to closed valves, dismantling joints shall be provided in general by restrained dismantling pieces (short version) according to DIN. 2541 or DIN 2547 or flanged adapters as indicated on drawings or as directed by the Engineer. Body and glands of steel welded dismantling pieces shall be of pressure similar to the valve or pipeline connected to it, with bolts and nuts of stainless steel, Surface protection by epoxy resin coating or equivalent quality. Rubber sealing rings made of Perbunan material, nitrile rubber or equivalent quality, shall be used. ce Boxes Cast Iron surface boxes with round lid according to DIN. 4056 shall be suppli described. Surface boxes shall be suitable for a 100 KN load. for operation of valves as The surface box made of cast iron or ductile iron shall be situated at ground level on the road or pavement. The hinge of the lid shall be of non-corrosive material. Circular lids shall be used for valves (gate and butterfly).