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DIVISION 15 MECHANICAL
ADSSC/GSMW
Division 15
Section 15010
Pipework
Rev: 02
Jan. 2011
Page 1 of 15
01
April 2008
First Issue.
02
Jan. 2011
03
04
05
06
07
08
09
10
ADSSC/GSMW
Division 15
Section 15010
Pipework
Rev: 02
Jan. 2011
Page 2 of 15
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
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
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
Pressure No
Gravity Yes
No
Yes
No
Yes
Europe, USA
High
Yes Yes No No No
Yes Yes No No No
1.1.2
Material Size
Pumping Stations
Sewage
Not applicable
DI , Stainless Steel, Epoxy Coated Carbon Steel DI, MDPE, HDPE Stainless Steel, Epoxy Coated Carbon Steel
HDPE,, uPVC, VC ,
ADSSC/GSMW
Division 15
Section 15010
Pipework
Rev: 02
Jan. 2011
Page 5 of 15
1.1.3
Property
Specification
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
Maximum 25 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
Anchor blocks
Required
Push fit rubber gasket collar joint, Spigot and socket with gasket, Slip on collar flange Required
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
Property
DI
GRP
HDPE
uPVC
VC
Deflection allowed
Max 50
1 to 50
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
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
Low frictional loss, can be susceptible to fatigue, surge failures have been known Limited
Abrasion resistance
Good
Good
Good
Breakage
Damaged by impact
Damaged by impact
ADSSC/GSMW
Division 15
Section 15010
Pipework
Rev: 02
Jan. 2011
Page 7 of 15
Property Installation
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
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
Not applicable, Above ground installation not possible No maintenance Normal allowances for push fit joints Medium surge pressure
Maintenance Leakages
Surge head
Water supply
Common
Low wave velocity, Less surge pressure Recommend ed all over world
Not applicable
ADSSC/GSMW
Division 15
Section 15010
Pipework
Rev: 02
Jan. 2011
Page 8 of 15
Property Sewage
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
Nil
Joint deterioration
Joint deterioration
Availability
Imported
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
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
1.4
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
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
System
Pipe Size
Material
Features
Hanger 9 mm rod
> 38 mm
All
Wall Supports
13 75 mm
All All
Copper Support
All
> 100
All
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
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
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