Specifications

Volume-II Specifications

Contractor Witness Divisional Engineer (PH-2) Page 1 of 152

CHAPTER 1: Specification for Pipes & Laying

1.1 Scope

This specification covers the general requirements for manufacture, supply,

linings, coatings laying, jointing, testing and commissioning of spiral welded

Mild steel (MS) pipeline above / below ground including appurtenances and

associated civil works required for the same.

1.2 Materials

1.2.1 The mild steel pipes shall be manufactured by using Hot Rolled (H.R.) Coil

only either as per IS-10748 Grade III or as per IS: 2062 Grade B. The pipes

shall be manufactured confirming to IS 3589/2001, Grade: Fe-410 or higher

grade steel. The general requirements relating to supply of spiral welded pipes

and their process of manufacturing shall confirm to IS: 5504. The H.R. Coil

must contain brand name of manufacturer (engraved) at suitable interval.

1.2.2 Welding Consumables - such as electrodes, filler rods and wires shall conform

to IS: 814, IS: 3613, IS: 7280 and IS: 6419, 816.

1.2.3 Cement - The cement used for lining shall be the Portland cement conforming

to IS: 269 / IS: 8041 / IS: 1489 / IS: 8112. The minimum cement content shall

be 330 kg/m3 with 43 or higher Grade of cement.

1.2.4 Sand for lining shall conform to IS 2116 as per clause A-3.1 of IS : 3589-2001

1.2.5 Water - The water used in preparation of concrete mix shall be clear, colourless

and free from injurious quantities of organic matter, alkali, salt or other

impurities that might reduce strength durability or other desirable qualities of

mortar. It shall confirm to IS: 456.

1.2.6 Before fabrication of pipes and specials / fittings is commenced, the copies of

the mill sheets and the manufacturer's test certificates for materials required for

the fabrication shall be submitted by the Contractor to the Engineer-in-Charge

or his representative for his approval and record.



1.2.7 When requested by the Engineer-in-Charge or his Representative, the

Contractor shall supply free of charge to the Engineer-in-Charge, for testing

suitable samples of the materials to be used/used in the works. The cost of such

tests shall be borne by the Contractor and shall be included by him in his rates /

bid amount.

1.3 Inspection

1.3.1 All works and materials under the specification will be inspected during all

phases of manufacture and testing and such inspection shall not relieve the

Contractor of his responsibility to furnish materials and performed work in

accordance with this specification.

1.3.2 The Contractor shall notify the Engineer-in-Charge or his Representative in

advance of the production of materials and fabrication thereof, in order that the

Engineer-in-Charge may arrange for mill and shop inspection.

1.3.3 The Engineer-in-Charge or his Representative may reject any or all materials or

works that do not meet with any of the requirements of this specification. The

Contractor shall rectify or replace such rejected materials / performed work at

his own cost, to the satisfaction of the Engineer-in-Charge or his

Representative.

1.3.4 The Engineer-in-Charge or his Representative shall have free access to those

parts of all plants or any other premises and sites that are concerned with the

furnishing of materials or the performance of work under this specification.

1.3.5 The Contractor shall furnish to the Engineer-in-Charge's representative

reasonable facilities and space without charge for inspection, testing and

obtaining of any information he desires in respect of the quality of materials

used and the progress and manner of the work.

1.3.6 The Contractor shall provide 2 (two) sets of accurate 'Go' and 'No - Go' ring

gauges to measure the diameter of pipes, specials and fitting, gauges to measure



thickness of pipes & specials for the use of the Engineer-in-Charge or his

Representative at no extra cost.

1.4 Manufacture of M.S. Pipe

1.4.1 General

All pipes and specials shall be manufactured out of new mild steel Hot Rolled

(H.R.) coils only which shall be free from any cracks, surface flaws,

laminations, excessive pitting or any other defects. The pipes shall be mill

manufactured using spiral welding from coil either as per IS-10748 Grade III or

as per IS: 2062 Grade B. The Pipe should be procured from manufacturer

having in-house Plate / Coil rolling facility in the same name and style as pipe

manufacturer which should be in operation since last 5 Years. The pipe shall be

manufactured at a mill which can establish with authenticity having supplied

similar pipes in the last 3 years which are truly cylindrical, and straight in axis.

The ends shall be accurately cut and prepared for welding. No site-fabricated

pipes are allowed. The external circumference of the pipe pieces, which are to

be fixed adjacent to flange adopter with fixed outer diameter shall not deviate

from theoretical by more than 1 mm. The pipe shall be rolled several times, if

necessary, as pipe pieces should be truly cylindrical. The external

longitudinal/spiral welding of the pipe shall be ground smooth flush with

surface to the satisfaction of the Engineer-in-Charge or his Representative.

Nothing extra cost shall be charged by the Contractor for grinding work. No

negative tolerance is allowed in thickness of pipe.

Minor repair by welding or otherwise shall be permitted at the discretion of the

Engineer-in-Charge or his Representative but such repairs shall be done only

after obtaining the permission of the Engineer-in-Charge or his Representative.

Any pipe or part thereof which develops injurious defects during shop welding

or other operations shall be rejected.

1.4.2 Design

1.4.2.1 While designing the Steel Cylinder, it will be seen that no tension is taken

by the cement mortar lining / coating. The thickness of the pipe provided



shall be such that it will be able to cater to the maximum of the following

loading/pressures as given below: -

a) Class AA loading due to moving traffic + Weight of soil above the top

of the pipe + Self-Weight of the pipe and Water load in the pipe +

Internal pressure + Surge pressures.

b) Working pressure + Surge pressure.

c) It shall also be ensured by the Contractor that bending stresses do not

exceed the permissible limits when the pipes are placed on the pillars at

8.0 m centre to centre.

d) In addition to the above loads, load of water surrounding the pipe and

negative pressure due to partial vacuum shall also be considered.

e) Contractor shall also ensure that deflection shall not exceed the

permissible limits when laid under ground and when subjected to worst

loading conditions and also by placing the pipe filled with the water on

pillars at 7.0 to 8.0 m c/c.

f) Necessary precautions including providing stiffeners may be taken

against ovality in pipes under all load conditions as mentioned above.

g) The thickness of the pipe shall be maximum of designed thickness plus

corrosion allowance of 2 mm. The thickness to be adopted will be

maximum thickness of thickness as above and those specified in the

tender document.

1.4.3 Fabrication Specifications

1.4.3.1 The pipe shall be shop fabricated from a reputed manufacturer of pipes

through H.R coils only. The manufacturer should have arrangements for

testing all sorts of materials as per requirements of IS codes, etc. &

machining as well as lining by centrifugal process, out-coating etc. for

completing the work under the present contract within the contract period,

the factory shall be equipped with adequate number of various equipments

and plants such as:

o Machinery/equipments for manufacture of spiral welded pipes

o Automatic welding machines (suitable for circumferential welding)

o Facility to carry out ultra sonic testing of welds seam & body



o X-ray fluoroscopy of the weld seam

o Radiography of weld in pipe ends

o Radiography of joints at junctions of spirally weld and skelp-end weld.

o Extensive manual ultra sonic testing of weld seam & body

o Such other equipments necessary to check welding as per IS Codes

requirements

o Hydrostatic Testing Machines for carrying out tests as per relevant IS

Codes.

o Equipments for centrifugal mortar lining of pipes in factory.

o Equipment for mixing of concrete and mortar by weigh batching process

o Arrangements for curing to centrifugally applied mortar lining in shade

o Equipments/arrangements for testing of pipe shells and physical tests as

per clause of respective IS Codes

o Sand blasting equipments for cleaning the pipes to near white for

internal linings & external coatings

o Trained personals for the above jobs so that all the works could be

completed within the stipulated period

o Any other equipment required for manufacture/testing of material and

pipes even though not mentioned.

1.4.3.2 The factory shall have adequate area and shall also have stacking yard for

the stacking of plates, structural, fabricated pipes and scrap etc.

1.4.3.3 The hot rolled coil after decoiling shall be cut, straightened, and trimmed

on both sides, for cutting of mill edges and to have constant width. The

trimmed stripped edges shall be bevelled by planning tools and cleaned on

both sides by brushes for achieving good welding. The strap subsequently

shall be pressed through drive roll and pre-bending roll where edges are

bend slightly to eliminate the peaking effect in the region of weld seam. In

the pipe forming device the strip shall be formed to a pipe with high

dimensional accuracy by three rolled bending devices and outer roller cage.

The strip edge running together along with the formed pipe shall be welded

in side at the lowest pint by submerged are welding process. This shall be

followed by outside SAW welding t a phase of 1800. This welding process



shall be fully, automatic. Each pipe shall then be hydrostatically tested in

the plant/mill and subjected to ultrasonic and radiographic testing of weld

seam and body of the pipe

1.4.4 Standard Specification for Welding in shop and field

1.4.4.1 All components of a standard shell, either straight or bent etc. shall be

welded, wherever possible by use of automatic are welding machine by

Submerged Arc welding process with alternating current. Hand welding

shall not be permitted except for sealing runs and such other minor works

at the discretion of the Engineer-in-Charge or his Representative. The

strength of the joint shall be at least equal to that of the parent material.

1.4.4.2 Samples of welded joints shall be prepared and tested in the presence of the

Engineer-in-Charge or his representative. The values once determined shall

be maintained throughout the work and if any modifications are to be

made, a written permission of the Engineer-in-Charge or his Representative

shall be obtained. Welding shall be carried out inside as well as outside.

1.4.4.3 All the shop and field welding shall conform to the requirements of IS 823

and IS 4353, IS: 816, I.S:3600 (part I).

1.4.4.4 All longitudinal and circumferential joints shall be welded as per respective

IS Codes. End preparation for such welding shall conform to IS: 2825

1.4.4.5 All circumferential welds involving plates of unequal thickness shall be so

kept that the inside surfaces of plates match to provide stream lined joints

without alternation in the internal diameter. As far as practicable welding

of dissimilar thickness of shells shall be carried out in the shops.

1.4.4.6 The welding shall be of the best workmanship free from flaws, burns, etc.

and the electrodes at the desired temperatures and dry. In order to maintain

a good standard in welding, welders shall be tested by the Contractor

before they are entrusted with the job. Qualification standard for welding

procedures welders and welding operation shall conform to the



requirements of IS: 7307 and IS: 7310. Periodical tests as regards their

competence and efficiency shall also be taken at intervals of about 6

months and those found inefficient shall be removed from the job. Only

those who pass the test shall be posted on the job. If an incompetent welder

has already welded some pipes all welding done by him previously shall be

fully checked by X-ray in addition to the regular X-ray inspections. The

defects if any shall be set right to the satisfaction of the Engineer-in-Charge

or his Representative. All such check tests and rectification of defects shall

be entirely at the cost of Contractor. No pipe or steel sections shall be

erected unless the work of the welder concerned has been proved to be

satisfactory. Site welds shall be done by specially selected welders.

1.4.4.7 A record shall be maintained showing the names of welders and operators

who have worked on each individual joint. Hand-welding if necessary shall

preferably be carried out by a pair of welders so that by observing proper

sequence distortion can be avoided. A joint entrusted to a particular

individual or a pair shall be as far as possible completed by them in all

respects including sealing run. No helper or other unauthorized person shall

be permitted to do any welding whatsoever.

1.4.4.8 The welded joint after welding should not become brittle or sensitive to

blows and there should be no loss of toughness due to welding or heat

treatment. The material after welding and heat treatment is to be tougher

than the base metal and is to retain its original ductility. No allowance will

be made for thinning or weld and the weld should at no point be less than

the nominal thickness of plate. Final welding of closure gaps should be

carried out within a temperature range of average air temperature +/- 80 C

as per Clause 6.3 of IS: 5822.

1.4.5.9 Upon receipt of the order and prior to the start of fabrication, the

Contractor shall submit to the Engineer-in-Charge or his Representative for

his approval the welding procedure method statement, he intends to use

in the workshop. Similarly, prior to the start of the filed welding, procedure

for the field welding must be submitted to Engineer-in-Charge or his



Representative for his approval. Manual welding shall be adopted only

when machine welding is not possible

1.5 Radiography of Weld in factory and field joints

1.5.1 Soon after welding, 15% of total longitudinally/spiral and circumferential

welded length of the weld at random for each pipe shall be radio graphed to

deter welding defects (except for the mill situated in habituated areas) as

per requirements of IS : 4853 and as directed by the Engineer-in-Charge or

his representative. However in such inhabited area ultrasonic testing with

graph shall be done in lieu of radiography test. This sampling will be at

random to ensure 100% coverage of junctions of longitudinal, spiral and

circumferential joints. If the results of such radiography fail to conform to

the requirements, the Contractor shall carry out at his own expense 100%

radiography test for the pertinent pipe as directed and fully satisfying the

Engineer-in-Charge or his representative. The permissible percentage

breakdown of radiography shall be as per IS Codes/Engineer-in-Charge's

instructions. Also the welded joints shall be tested as per clause 6.2, 6.2.1

and 6.2.2 of IS: 5822

1.5.2 For Mild steel pipes manufactured in factory/workshop fabricated from Hot

rolled coil jointed in field, the 15% of the field welded joints shall be

subjected to Radiography/ultrasonic test. All cross or T joints shall be radio

graphically tested. In case of field joints, if any out of the 15% of the

number of joints and T joints at random fails in Ultrasonic and radiography

test respectively, thrice the number of field joints shall be put to

radiography/ UT. Even after such radiography test, if any of the joint fails,

the radiography/UT of the 100% of the joints shall be carried out in this

stretch. All these additional testing shall be done by the Contractor at his

own risk and cost. In inhabited areas ultrasonic testing with graph shall be

done in lieu of radiographic tests.

1.5.3 The weld ripples or weld surface irregularities and slag etc., on both inside

and outside shall be removed by any suitable mechanical process to a



degree such that resulting radiographic contact due to any remaining

irregularities cannot mark or be confused with that of objectionable defect.

The radiograph shall be made in strict accordance with the latest

requirements and as per the latest and most efficient technique either with

X-ray or gamma ray equipment. The safety requirements during

radiography shall be in accordance with IS : 2598.

1.5.4 The Photographs are to be marked in such a way that the corresponding

portion of the welded seam can be readily identified. All radiographs will

be reviewed by the Engineer-in-Charge or his Representative to identify the

defect and determine those which must be removed. Defects that are not

acceptable shall be removed by chipping, machining or flame gouging to

sound metal and the resulting cavities shall be welded. After rectification,

the joint is to be radio graphed again to prove the quality of the repair. The

radiographs will be judged as acceptable by the Engineer-in-Charge or his

Representative based on the latest standards prescribed by the relevant

Indian Standards specification.

1.5.5 All X-ray shall be made with equipment and by personnel furnished by the

Contractor. The films shall be developed within 24 hours of exposure and

be readily accessible at all times for inspection by the Engineer-in-Charge

or his Representative. The Contractor shall provide for the use of the

Engineer-in-Charge or his Representative suitable X-ray viewing

equipment X-ray films shall be properly maintained by the Contractor for

handing over finally to the department on completion of the Contract. All

films shall be identified by the No. and chart prepared indicating location

of the joint each X-ray photo represents. In the event of additional

radiographic inspections required of any work associated with the pipe

erection, such inspection shall be performed by the Radiographer at the

discretion of the Engineer-in-Charge or his Representative at no extra cost

to the Engineer-in-Charge.

1.6 Radiographic Inspection

Volume-II Specif ications


1.6.1 General

a) The Contractor shall certify that the welding of pipes has been done only

by qualified welders with approved quality of Electrodes and electric

current (Voltage and amperage). The Contractor shall also make available

to the Engineer-in-Charge or his Representative a certified copy of the

qualification tests of each welder and welding operator. The Engineer-in-

Charge or his Representative shall have the right at any time to call for and

witness tests of welding procedure or of the ability of any welder and

welding operator.

b) Radiographic Inspection of welded joints

c) All welded joints to be radio graphed shall be examined in accordance with

IS : 2595 Code of Practice for Radiographic Testing

IS : 4853 Recommended Practice for Radiographic Inspection of Fusion

Welded Butt joints in Steel Pipes.

IS : 1182 Recommended Practices for Radiographic Examination of

Fusion Welded Butt-Joints in steel plates.

IS: 2598 Safety Code for Industrial Radiographic Practice.

The reinforcement on each side of all butt welded joints shall not exceed

1.5mm

d) A complete set of radiographs and records as described in IS: 2595 Clause

14, for each job shall be retained by the Contractor and kept on file for the

contract period. After contract period all such records shall be handed over

to the Engineer-in-Charge or his Representative at no extra cost.

e) Final acceptance of radiographs shall be based on the ability to see the

prescribed penetrameter image and the specified hole.

f) Sections of welds that are shown by radiography to have any of the

following types of imperfections shall be judged unacceptable and shall be

repaired by the Contractor at his won cost.

any type of crack, or zone of incomplete fusion or penetration,

any elongated slag inclusion which has length greater than 6 mm,

any group of slag inclusion in line that have a aggregate length greater than

thickness in a length of 12 times thickness, except when the distance

between the successive imperfections exceeds 6L where L is the length of

the longest imperfection in the group,



Rounded indications in excess of that specified by the acceptance standards

given earlier.

1.7 Tolerance

Tolerance for pipes in respect of diameter and straightness shall be in

accordance with IS: 3589 however negative tolerance in pipe wall

thickness is not permissible.

1.8 Shop Testing

1.8.1 After fabrication, but before application of lining and protective coatings

all pipes and specials shall be subjected to a shop hydraulic test as per

IS: 3589. Standard lengths of pipes shall be directly subjected to test and

non-standard pipe and elbows can be tested as standard pipe before

being cut to size.

1.8.2 Each pipe shall be filled with water and the pressure slowly and

uniformly increased by the manufacturer at hisown cost until the

required test pressure is reached.

1.8.3 The pipe to be tested shall be given a serial no. which shall be painted on

its inside together with details such as pipe No. shell thickness, diameter,

length etc. It shall be entered in the register to be maintained by the

Contractor. A copy of results of the tests shall be sent every week on

Mondays and another copy shall be sent along with the lot sent to the

site for laying. The pipe shall also be given a certification mark as per

IS Code: 3589 - 2001.

1.8.4 Prior to testing, the pipe shall be inspected thoroughly and all the

apparent defects in welding such as porosity etc. shall be repaired by

gouge and re-welding.

1.8.5 The hydraulic test shall be carried out under cover at the fabrication

shop, in the presence of and to the satisfaction of the Engineer-in-Charge

or his Representative or the inspection agency appointed by the

Engineer-in-Charge.



1.8.6 For indicating the pressure inside the pipe an accurate pressure gauge of

approved make duly tested and calibrated for the accuracy of readings

shall be mounted on one of the closures which close the pipe ends.

1.8.7 The pipe shall withstand the test without showing any signs of

weakness, leakage, oozing or sweating. If any leak or sweating is

observed in the welded joints, the same shall be repaired by gouging and

re-welding after dewatering the pipe. The repaired pipe shall be re-tested

to confirm the specified pressure.

1.8.8 If any leak or sweating is observed in factory/mill made pipe shell, the

pipe under test shall be rejected temporarily. The Contractor shall stack

such rejected pipes separately in his yard. The Engineer-in-Charge or his

Representative shall inspect the same and after taking cuts if necessary,

shall determine the nature of repairs to be carried out there on and shall

then decide as to how and where they shall be used. No payment shall be

made for handling or carrying out repairs.

1.8.9 The Engineer-in-Charge or his Representative shall be supplied with two

copies of the results of all the tests carried out for which nothing shall be

paid.

1.9 Testing of Site Welded Joints

The welded joints shall be tested for Tensile test and bend test in

accordance with procedure laid down in IS No.3600 method of testing

fusion welded joints and weld metals in steel.

Test pieces shall be taken by the contractor from the welded joints at the

position on fabricated pipes pointed out by the Engineer-in-Charge or

his Representative.

The sample so taken shall then be cut to the exact shape and dimensions

and machined and handed over to the Engineer-in-Charge or his

Representative for testing. All the work upto and including machining

and arranging for test shall be done by the Contractors at his own cost.



1.10 Transporting of Pipe & Specials etc.

1.10.1 All pipes and specials fabricated in the factory shall be transported to the

site of laying after shop testing & cleaning them internally. The loading

in the factory shall be carried out by means of either a crane, gantry or

with shear legs, so as not to cause any damage to the finished material.

Similarly, while unloading and stacking, great care shall be taken to

ensure that the material is not damaged or dented. The equipments to be

used for unloading will be different in different situations and in each

case the one approved by the Engineer-in-Charge or his Representative

shall be adopted. The material stacked at site shall be jointly inspected

by the Engineer-in-Charge or his Representative and Contractor and

defect or damage notice shall be repaired to the satisfaction of the

Engineer-in-Charge or his Representative before payment is admitted /

released.

1.10.2 Props of approved designs shall be fixed to the pipes during transit to

avoid undue sagging and consequent distortion. After the pipes are

carefully stacked, props may be removed and re-used for subsequent

operations. The stacking ground, both in the Contractor's yard and at the

site of laying shall be levelled and shall be selected in such a way as not

to get waterlogged during monsoon. If this cannot be done, the pipes

shall be supported on sleepers to avoid contract with wet earth and

subsequent rusting. In order to prevent sagging during transit, savings of

steel plates can be utilized by cutting to the required length and tacking

the same to the pipe ends, in place of props, if approved by the

Engineer-in-Charge or his Representative.

1.10.3 As explained in earlier paragraphs, materials such as pipes & tapers etc.

may be transported to the site of laying as soon as the material is

finished in all respects with the permission of the Engineer-in-Charge or

his Representative to avoid congestion in the Contractor's yard.

However, materials such as expansion joints, manholes with covers

composite bends, 'T' branches and other complicated materials etc. shall



be stacked in the Contractor's yard under his security arrangements until

they are required for laying (and jointing) in the field. In view of this,

the work of fabrication of such materials shall be properly synchronized

as far as possible with the laying operations.

1.10.4 Fabricated materials such as man-hole covers to be provided & fixed in

each section between the sluice valves and an other required places and

as desired by the Engineer-in-Charge and his Representative,

appurtenances such as S.V.'s P.R.V's, air valves etc. bolts, nuts, distance

pieces, flanges, saddles, collars bypass arrangements etc. shall all be

transported to the site of laying from the fabrication shop according to

the needs of the laying/operations only. As regards access roads, the

Contractor shall note that access road may lead upto some points on the

alignment. Therefore, the Contractor shall have to make his own

arrangement for connecting approaches to transport the pipes and other

equipments & specials etc. across country to the actual site of laying at

his own cost. Whatever may be the mode of transport he uses it shall be

incumbent on the Contractor to carry and stack the pipes, specials and

fitting along the alignment as close as possible to the site of laying.

1.11 Procedure for Receiving Steel Pipes

1.11.1 General

To ensure that the work of erecting pipes is not held up at any stage and

place, the Contractor shall maintain an adequate stock of standard

specials, flange rings, expansion joints, manhole covers, etc. and short

lengths of pipelines, etc. at site in his field stores, in consultation with

the Engineer-in-Charge or his Representative. Wherever possible, the

Contractor shall arrange one full month's requirement of pipes, specials,

etc. stacked along the alignment in such a way that no obstruction is

caused to the traffic, residents, or for repairs to other utilities.

1.11.2 Stacking of Pipes, Etc. and Inspection

The Contractor shall keep in each section a responsible representative of

his own to take delivery of the pipes, specials and appurtenances, etc.

transported from the fabrication stockyard or received from any other



work site to the site of laying and to stack along the route on timber

skids. Padding shall be provided between coated pipes and timbre skids

to avoid damage to the coating. Suitable gaps in the pipes stacked shall

be left at intervals to permit access from one side to the other. The pipes

specials, appurtenances so received on site shall be jointly inspected and

defects recorded, if any, such as protrusions, grooves, dents, notches,

damage to the internal coating etc., shall be pointed out immediately to

the Engineer-in-Charge or his Representative at the site and in the

acknowledgment challans. Such defects shall be rectified or repaired to

the satisfaction of the Engineer-in-Charge or his Representative entirely

at the Contractor's risk and cost. Contractor should also note that watch

and ward of all materials is of the Contractor and if something is lost

from the site and is paid, its cost shall be recovered from the Contractor.

1.11.3 Handling of Pipes, Special Appurtenances Etc.

It is essential to avoid damage to the pipes, fittings and specials, etc. or

their coatings & lining at all stages during handling. The pipes and

specials shall be handled in such a manner as not to distort their

circularity or cause any damage to their surface treatment. Pipes shall

not be thrown down from the trucks nor shall they be dragged or rolled

along hard surfaces. Slings of canvas or equally non-abrasive materials

of suitable width of special attachment shaped to fit the pipe ends shall

be used to lift and lower the pipes to prevent damage to the coatings

provided. Great care shall be taken in handling the pipe right from the

first operation of manufacture until they are laid and jointed. The

Contractor will provide temporary props in order to prevent any sagging

of the pipes while they are stacked in their yard and while transporting

to the site of delivery, i.e. laying. The props shall be retained until the

pipes are laid. If at any time these props are found to be dislodged or

disturbed, the Contractor shall immediately reinstate them in such a way

that the true shape of the pipe shell or specials is maintained to the

satisfaction of the Engineer-in-Charge or his Representative. No

defective or damaged pipe or special shall be allowed to be used in the

work without rectification to the coating shall be repaired by the



Contractor at his own cost to the original shape and to the satisfaction of

the Engineer-in-Charge or his Representative.

1.11.4 Dents

Whenever any dent, i.e. a significant alteration of the curvature of the

pipe shell is noticed, the depth of the dent shall be measured between the

lowest point of the dent and the pipe shell curvature line. All dents

exceeding 2 percent of the outer diameter of the pipe shall be removed

by cutting out a cylindrical portion of the pipe and replacing the same by

an undamaged piece of the pipe. The Engineer-in-Charge or his

Representative may permit insert of patching if the diameter of the patch

is less than 25% of the nominal diameter of the pipe. Repairs by

hammering with or without heating shall not be permitted. Any damage

to the coating shall also be carefully examined and rectified fully by the

Contractor at his own cost as per IS: 5822.

1.11.5 Marking

1.11.5.1 The component parts of the pipes shall be carefully marked as per IS

Codes for identification in the field in such a way that these could be

located on the field.

1.11.5.2 The marking operation shall be conducted with full size rulers and

templates.

1.11.5.3 The plates used for fabrication of pipes shall be laid out in such a way

that when the shells are completed one set of original identification

markings for the material will be plainly visible. In case these markings

are unavoidably cut out, they shall be accurately transferred by the

Contractor to a location where these markings will be visible on the

completed work.

1.11.5.4 Two copies of these details shall be furnished to the owner free of cost.

1.11.5.5 No separate payment will be made for these markings and the rates

quoted shall be deemed to include the cost of such markings.

1.12 Laying of Pipeline

1.12.1 General



1.12.1.1 After having carried out excavation of trenches as is explained in these

specifications else ware the loose materials from the sides or the edges

of the trench shall be prevented from falling inside the trench. Properly

designed bedding as per site conditions for resting of the pipes shell then

be provided before starting with the laying. The excavation of trenches

for laying of M.S. pipe shall be as per Clause 4.2.1 of IS: 5822. Design

of bedding with respect to installation condition shall be submitted by

the Contractor for approval by the Engineer-in-Charge

1.12.1.2 When welding is to be carried out with pipes in the trench additional

excavation shall be provided all round the pipe at the position of the

joint for facilitating in the welding.

1.12.1.3 Unless specified otherwise, the M.S. pipeline shall be buried with

minimum cover of 1.0 meter above socket top as shown on drawings to

be submitted by the Contractor and approved by the Engineer-in-Charge.

No material shall be erected unless it has been previously passed by the

Engineer-in-Charge or his Representative.

1.12.1.4 Where pipes are to be laid to curves, the deflection at each joint shall not

exceed one degree. For sharper curves specifically made bends shall be

provided

1.12.2 Laying Programme

1.12.2.1 The Contractor shall submit a detailed bar chart for procuring and laying

of the pipelines, which shall be subject to the Engineer-in-Charges

approval. In preparing this bar chart, the Contractor shall plan his

activities such that the laying of pipes shall closely follow the

procurement schedule and no pipes shall remain stacked at site for a

period more than one month or as decided by the Engineer-in-Charge.

The Contractor shall also submit procurement schedule of pipes, specials

and fittings.

1.12.2.2 Together with the bar chart he shall also submit a methodology

describing how he will carry out this work within the contractual period

and the required resources in terms of construction equipments and other

facilities that shall be utilized to complete the works.



1.12.2.3 Before commencing the work of pipe laying, the Contractor shall study

the approved plan and L-section of the pipeline for the section

concerned. He shall also study the details of laying i.e. underground or

above ground. The under ground pipeline shall be laid on properly

designed bedding as shown in the drawing submitted by the Contractor

and approved by the Engineer-in-Charge or his Representative. The

difference in depth due to uneven excavations by the Contractor shall be

made up by sand cushioning / C.C. (M-10) as per direction of Engineer-

in-Charge. For laying of pipes below ground the Contractor shall also

follow specifications/instructions as are given in these specifications for

Excavation and Barricading etc. However, no pipeline shall cross

beneath the bed of nallahs/drains the width for the pipe line bridge shall

be such as to accommodate the pipes and facilities.

1.12.2.4 All M.S. pipe laying, welding and testing etc. shall be as per Clause

contained in IS:5822 and to the satisfaction of the Engineer-in-Charge or

his representative.

1.12.2.5 Erection of pipes/fabricated shells shall be carried out by the Contractor

who shall equip himself at his own cost, with all necessary tools,

machinery, equipments, generators, testing equipments, test plates and

piping etc. and labour required for the purpose. The pipeline shall be

constructed in lengths with a separate full time gang working on each

length/section.

1.12.3 Handling of pipes and specials

Coated pipes and specials that are to be stored / kept on supports shall

bear on the uncoated ends only. If bearing of coating is employed the

supports shall be not less than 20 cm (8 inches) wide and so arranged to

prevent damage to the coating. During handling of the pipes and fittings,

coating shall be protected not less than 20 cm wide and placing strips of

heavy belting or other approved sheet materials not less than 20 cm wide

under all ropes or fastening.

1.12.4 Sand Bedding (Wherever Required)



Where site situations require necessity of Sand beddings, the sand

bedding of minimum 200 mm thickness shall be provided below pipe,

prior to laying the pipe in trenches. It shall be completed with a light

hand rammer. Any reduction in thickness due to composition shall be

made up by adding sand during ramming. For the purpose of the

bedding under this item only screened fine sand or grain size not larger

than 2mm shall be used. The sand shall be clean, uncoated and free form

clay lumps, injurious amounts of dust, soft particles, organic matter,

loam or other deleterious substances. Nothing extra shall be paid for

sand bedding or any other type of bedding for resting the pipes in

trenches.

If the sand supplied is unclean it shall be washed. In no case shall sand

containing more than 3.5% by dry volume or 5% by wet volume of clay,

loam or silt be accepted. Tests specified for determining silt in sand and

organic impurities as described in IS:383 shall apply. Sieved and washed

sand shall be stored on the works in such a manner as to prevent

intrusion of any foreign matter, including coarser particles of sand or

any clay or metal or chips. Tests as indicated above shall be performed if

called for by the Engineer-in-Charge or his Representative at the

expense of the Contractor.

During the work of providing sand bedding and laying the pipeline over

it, loose material from the sides or edges of the trench shall prevented

from falling inside the trench, by providing shoring and taking other

measures. Also where necessary, trench shall be kept dry by pumping

out seepage leakage waters continuously at no extra cost to the

Engineer-in-Charge.

1.12.5 Lowering and Jointing

Before pipes are lowered the trenches shall be examined as per Clause

4.2 & 4.2.1 of IS:5822. Also pipe handling and inspection shall be done

as per Clause 5.1 to 5.2.5. Pipe laying below ground shall be as per

Clauses 8.1.1 to 8.1.2.1 and pipe laying above ground shall be as per

Clause 8.3.1 of IS:5822.



At places where shoring timbering is provided the pipe shall be lowered

into the trenches by removing only one or two struts at a time. It shall be

seen that no part of the shoring is disturbed or damaged and, if

necessary, additional temporary struts may be fixed during the lowering

operations. In case of laying of pipe is not damaged in any way during

the lowering operations. In case of laying of pipes and other situations

also it shall also be necessary to see that the coating of pipe is not

damaged in any way during the lowering and assembling. After the pipe

is lowered into the trench, it shall be laid in correct line and level by

using the leveling instruments, sight rails, theodolite etc. Care shall be

taken to see that the longitudinal joints of two consecutive pipes at each

circumferential joints are staggered by 300 as mentioned in Clause 8.1.2

of IS:5822. While assembling the pipes, the ends shall have to be

brought close enough to leave a uniform gap not exceeding 3mm. If

necessary a marginal cut may be taken to ensure a close fit of pipe faces.

For this purpose, only experienced cutters who can make uniform and

straight cuts shall be permitted to cut the faces of the pipes. No extra

payment shall be made for such marginal cutting. There shall be no

lateral displacement between the pipe faces to be joined. If necessary,

spiders from inside and tightening rings from outside shall be used to

bring the two ends in perfect contact and alignment. It may also be

necessary to use jacks for this purpose. In no case shall hammering or

longitudinal slitting be permitted. When the pipe is properly assembled

and checked for correct line and level, it shall be firmly supported on

wooden beams and wedges and tack welded. Some portion of the trench

may be refilled at this stage so as to prevent the pipeline from losing its

alignment. The tack welded circumferential joints shall then be welded

fully. Only experienced welders, who will be tested from time to time,

shall be permitted to carry out the welding work.

On Completion of the pipe jointing and external protection against

rusting the trench and the welding pits shall be cleaned filled and

compacted in 150mm layers as per direction of the Engineer-in-Charge.

1.12.6 Precautions against Floatation



When the pipeline laid underground in a long narrow cutting gets

submerged in water collected in the trench of cutting, it is subjected to

an uplift pressure due to buoyancy and is likely to float if completely or

partly empty. In the design of pipelines, provision is to be made to

safeguard against floatation, providing sufficient overburden or by

providing sufficient dead weight by means of blocks etc. Factor of safety

for calculation for check against floating shall be taken as 1.2.

In the case of works extending over one or more monsoon seasons,

however, special care and precautions shall be necessary during the

progress of work on this account. The Contractor shall close down pipe

laying operations well in time for the monsoon. The work of providing

blocks, refilling the earth to the required level, compacting the same, etc.

shall always be done as soon as the pipeline in the cutting has been laid.

The Contractor shall see that the water shall not be allowed to

accumulate in open trenches. Where work is in an incomplete stage,

precautionary work, such as blank-flanging in the open ends of the

pipeline and filling the pipeline with water etc. shall be taken up as

directed by the Engineer-in-Charge or his Representative.

Such works shall be to the Contractors account and no separate

payment shall be made for the same. The Contractors rate for pipe

laying shall be deemed to include such precautionary measures against

floatation.

Protection of the pipeline against floatation shall be suitably design and

adopted in the bid.

1.12.7 Refilling of trenches

On completion of the pipe laying operations in any section, for a length

of about 100m and while further work is still in progress, refilling of

trenches shall be started by the Contractor with a view of restricting the

length of open trenches. Pipe laying shall closely follow the progress of

Trench Excavation and the Contractor shall not permit unreasonably

excessive length of trench excavation to remain open while awaiting

testing to the pipeline. If the Engineer-in-Charge or his Representative

consider that the Contractor is not complying with any of the foregoing



requirements, he may prohibit further trench excavation until he is

satisfied with the progress of laying and testing of pipes and refilling of

trenches. Only soft earth and murrum of good quality free from stones

larger than 75mm in size and free from boulders, roots, vegetation etc.

shall be utilized after the lumps are broken for filing in around the pipes

for at least 30 cm all around for pipes less than 1200mm diameter and

d/4 for pipes greater than 1200 diameter. Filling shall be done in layers

not exceeding 150mm and compacted to 95 percent of the maximum dry

density as per part VII of IS: 2720. The excavated material nearest to the

trench shall be used first. Care shall be taken during backfilling, not to

injure or disturb the pipes, joints or coating. Filling shall be carried out

simultaneously on both sides of the pipes so that unequal pressure does

not occur. Walking or working on the completed pipeline unless the

trench has been filled to height of at least 30cm over the top of the pipe

except as may be necessary for tamping etc. during backfilling work.

The remaining portion of the trench may be filled in with a mixture of

hard and soft material free from boulders and clods of earth larger than

150mm in size if sufficient quantity of good earth and murrum are not

available. Filling in shall be done in layers not exceeding 150mm in

thickness accompanied by adequate watering, ramming etc. so as to be

compacted 95% of the maximum dry density as per part VII of IS:2720.

Water contents of the soil shall be as near the optimum moisture content

as possible. The trench shall be refilled so as to build up to the original

ground level, keeping due allowance for subsequent settlement likely to

take place.

To prevent buckling of pipe, pipes shall be strutted from inside while the

work of refilling is in progress, for which no separate payment shall be

made separately.

Strutting shall be done by means of strong spiders having at least 6 arms,

which shall be sufficiently stiff to resist all deformation of pipes. Spiders

shall be provided at a maximum interval of 2m. Strutting shall be done

in such a way that inside lining is not damaged.

Removal of all surplus will be the responsibility of contractor and the

same has to be removed immediately after completion of backfilling,



leveling and dressing etc. failing which it shall be removed at

contractor s cost.

If suitable material for refilling is not available from excavation the

Contractor shall bring good earth, murrum of approved quality as

directed by the Engineer-in-Charge. Nothing extra shall be paid for

bringing earth from outside for filing upto final ground level shown in

the approved L-section.

No mechanical plant other than approved compacting equipment shall

run over or operate within the trench until backfilling has reached its

final compacted level or the approval of the Engineer-in-Charge or his

Representative has been obtained.

Subsidence in filling in: should any subsidence take place either in the

filling of the trenches or near about it during the maintenance period of

12 months from the date of completion of the Contract, the Contractor

shall make good the same at his own cost or the Engineer-in-Charge

may without notice to the Contractor, make good the same in any way

and with any material that he may think proper, at the expense of the

Contractor. The Engineer-in-Charge or his Representative may also, if

he anticipates occurrence of any subsidence, employ persons to give his

timely notice of the necessity of making good the same, and the

expenses on this account shall be charged to the Contractor.

1.12.8 Welding

1.12.8.1 Unless specified otherwise all M.S. pipes and specials shall have butt-

welded joint. Where shown on drawings, flanged joints or collar sleeve

collar. Collar sleeve joints shall be provided.

1.12.8.2 The welding of pipes in the field should comply with IS: 816. Electrodes

for welding should comply with IS: 814. The welded joints shall be

tested in accordance with IS: 3600 (Part-1) and other relevant Codes.

One test specimen taken from at least one field joint out of 10 shall be

subjected to test as per Clause 6.2, 6.2.1, 6.2.2 and 6.3 of IS:5822 i.e. the

Contractor shall carry out all test for welding as are described under

Clause 6 of IS:5822.



1.12.8.3 Except for routine welding of joints, no other work shall be done in the

absence of Contractor s engineer, either during the day-time or at night.

1.12.8.4 Chipping shall not be kept in arrears for more than 15 joints.

1.12.8.5 Design for saddle pieces shall first be got approved from the Engineer-

in-Charge and then the saddle pieces shall be fixed in position as per

approved drawings after checking bolts holes, by means of templates.

Entire responsibility for proper design/shape for the saddles shall be of

the Contractor.

1.12.9 Preparation of Pipe faces

Preparation of pipe faces for welding shall be done as per Clause 5.2.5

of IS:5822.

1.12.10 Saddle Supports

Unless otherwise specified pipeline shall be underground. However in

certain reaches it shall be on R.C.C. or steel saddle supports spaced at

suitable intervals. The material and construction of R.C.C./ Steel

structures such as saddles, anchor blocks, crossings etc. associated with

the work of pipeline shall conform with the relevant I.S. Codes, good

engineering practice and as directed by the Engineer-in-Charge or his

Representative. The pipes to be laid at saddle supports shall be erected at

mean temperature. Saddle supports shall either be sliding type or fixed

type, detailed design and drawings including fabrication drawing for

which shall be supplied by the Contractor. In case of sliding support, the

pipe shall be allowed to slide freely over the plate embedded in the

saddle. Alternatively to achieve fixity, the pipe shall be anchored by

providing suitable anchor bases with steel clamps.

In such areas subjected to floods the contractor shall lay pipes on pillars

having unsettlable strong footings and the invert of the pipe shall

preferably be kept about 0.3 meter above HFL subject to approval of

Flood control department or any other concerned authority. Nothing

extra shall be payable or recoverable on account of change in the

proposed invert levels or location of the pipeline, if any.

The Contractor shall adopt these specifications for other pipes also

where the ground levels are low.



Below the pipes the Contractor shall provide necessary bedding/ saddle

supports required as per structural designs, which shall be got approved

from the Engineer-in-Charge or his Representative.

1.13 General Sequence of Operations

Anchor blocks shall be constructed before commencing the pipe laying

work in any section as per IS:5330. The construction of the thrust/

anchor blocks shall be carried out in 3 stages: in the first stage the lower

part upto 150mm below the invert of the pipeline including concrete

chairs to support it, shall be constructed in the second stage the pipeline

on this part of the block shall be laid; and lastly, the remaining block

around and over the pipeline with clamps shall be constructed.

1.14 Specials Fabrication

1.14.1 Generals

Specials, such as tees, Y-pieces, bends (single or composite), tapers,

tees, blank flanges and gap pieces, collars, expansion joints, man-hole

covers etc. shall necessarily be in steel and shall be manufactured as per

IS : 7322 standards and applicable codes and tested in the same manner

as the pipes. Small branches, single piece bends etc. may be fabricated at

the site. Care shall be taken to ensure that the fabricated fittings have at

least the same strength as the pipeline to which they are to be joined and

tested.

1.14.2 Bends

1.14.2.1 Bends shall be fabricated taking into account the vertical and horizontal

angles for each case.

1.14.2.2 The bends shall have welded joints and the upstream and downstream

ends of each bend shall have a straight piece of variable lengths as

required at site.

1.14.2.3 Bends shall be designed with deflection angle of maximum 10 deg

between segments.

1.14.2.4 When the point of intersection of horizontal angle coincides with that of

a vertical angle, or when these points can be made to coincide, a single



combined or compound bend shall be used, designed to accommodate

both the angles. The combined bend should have a pipe angle equal to

the developed angle, arrived at from appropriate formula.

1.14.2.5 All joints in bends and other specials shall be thermally stress relieved as

per Technical requirements / IS codes.

1.14.2.6 Details of thrust collars anchor bolts, holding down straps, saddle plates

shall be furnished by the Contractor which will have to be got together

with full specifications on contractor s fabrication drawing which will

have to be got approved from the Engineer-in-Charge or his

Representative before use at site.

1.14.3 Manholes

1.14.3.1 Manholes of sizes approved by the Engineer-in-Charge shall be

provided at locations generally 1 km apart, with additional manholes at

both the sides of butterfly vales/sluice valves. Manholes in the pipeline

above ground shall be placed in suitable position as agreed to with the

Engineer-in-Charge or his representative in the top quadrant.

1.14.3.2 The contractor shall fabricate different parts of manhole in conformity

with relevant IS specification, well-established practices and as directed

by the Engineer-in-Charge or his Representative. The Contractor shall

also submit designs / drawings of the manholes with covers.

1.14.4 Closing or Make Up Sections.

Closing or makeup sections shall be fabricated by the Contractor to

permit field adjustments in pipeline length to compensate for shrinkage

in field welded joints, differences between actual and theoretical lengths

and discrepancies in measurements. The Contractor shall initially plan

the positions of closing gaps and submit proper drawings showing the

materials/specials, which he shall be providing for closing of each gap at

his own cost.

1.14.5 Heads / Clousers

Two types of closures/ heads are used in pipelines depends on their

locations viz.:

a) Closures for manhole covers and



b) Blank flanges either of flat plate design of dished hemispherical

closures. These shall be properly designed and provided by the

contractor at his own cost depending on locations where to be used.

1.14.6 Flanges

Flanges shall comply with IS: 7322. The nominal pressure rating shall

be at least equal to the highest pressure rating of pipes or fittings to

which they are attached.

Flanges shall be properly designed and provided at the end of pipes or

special where sluice valves, blank flanges, tapers and other flanged

specials have to be introduced. The Flanges received from the

manufactures will have necessary bolt holes drilled to IS: 1538 (part VI).

The contractor shall assemble the flanges in the exact position by

marginal cutting, if necessary, so as to get the desired position of the

sluice valves and other specials and fittings etc. either vertical or

horizontal and shall then fully weld the flanges from both sides in such a

manner that no part of the welding protrudes beyond the flanges and if

the Engineer-in-Charge or his representative orders that such protrusions

shall be removed, the contractor shall file or chip them off. If required

and when ordered by the Engineer-in-Charge or his representative, the

contractor shall provide and weld gusset stiffeners, as directed on site.

The drilling pattern shall be matching with the drilling pattern of flanges

of valves and other fittings.

1.14.7 Blank Flanges

Blank flanges of suitable thickness shall be provided at all ends left

unattended for the temporary closure of work and also for

commissioning a section of the pipeline or for testing the pipeline laid.

For temporary closures, non-pressure blank flanges consisting of mild

steel plates, tack welded at the pipe ends may be used. For pipes

subjected to pressure, the blank flanges or domes suitably designed as

per site requirements shall be provided.

1.15 Linings and coatings of rising main



1.15.1 These specifications cover the requirements of providing materials and

application of cement mortar lining and coating at works applied by a

centrifugal spinning process as per IS: 3589 (Annexure-A). The

waterway of the M.S. pipes & fittings shall be completely covered with

specified mortar. The mortar lining & coating shall be completely free

from cavities or visible air bubbles and pinholes and shall be thoroughly

compacted throughout. The consistency of mortar and time and speed of

centrifuging of the pipe shall be so adjusted that the segregation of the

sand and cement is not there. The mix used for cement mortar lining

shall be 1:2 (1 Cement: 2 Sand), 25mm thick with 6 mm dia longitudinal

bars (24 Nos.) & 3.15 mm hard drawn wires @ 5 cm c/c up to 30 cm on

the inner surface on the both edges of pipe. The work shall be started

only after thorough cleaning of the pipes and sand blasting to near white

(SA-2.5 Swedish standard) and obtaining the written approval of the

Engineer-in-Charge or his representative in this respect. Before starting

the cement lining work, the Contractor shall also ensure that all related

works required are completed by him. Coating outside shall be in

cement mortar 1:3, 25mm thick including the cost of lining steel of 6

mm longitudinal bars (24 Nos.) and 3.15 mm hard drawn wire wound

circumferentially @ 4 cm centre to centre on the outer surface

throughout the length.

1.15.2 General

Engineer-in-Charge or his Representative shall have the right to inspect

the sources of materials, the operation of procurement and storage of

materials, Cement mortar batching and mixing equipment and the

quality control system. Such an inspection shall be arranged and the



Engineer-in-Charge or his Representative and approval obtained prior to

starting of lining or coating work.

1.15.3 Surface Finish

The surface of cement mortar lining and coating shall be uniformly &

perfectly smooth and shall be free from voids. The lining and coating

shall not have flaky areas. It shall not be crumbly and shall not have

waves or grooves and shall also conform to Clause IS specifications.

Pipe shall not be dispatched until 21 days have elapsed since the date of

lining.

1.15.4 Keeping Circulatory During Lining or coating.

During the processes of lining or coating the surface of the MS Pipes,

the Contractor shall ensure that roundness of the pipes is maintained.

1.15.5 Hand Application of Mortar Lining and coating for field joint

a) Hand placed mortar shall have a uniform and smooth surface

with smooth transitions to adjacent centrifugally placed linings.

b) Cement mortar lining and coating of bends, specials, areas

closely adjacent to valves and other such places where

centrifugal placing may not be practical shall be performed by

hand. The Engineer-in-Charge or his Representative may order

the correction for any defect by hand application.

c) Cement mortar for hand work shall be of the same materials as

the mortar for machine placed lining or coating.

d) The areas to be lined or coated shall be thoroughly cleaned as

specified earlier and, if necessary, shall be moistened with water

/ cement grout immediately prior to placing the hand-applied

mortar.

e) Steel finishing towels shall be used for the hand application of

cement mortar, except at bends the outer edge of hand trowelled

areas may be brushed in order to reduce the abutting offset.

1.15.6 Special Requirements at Laterals and Service Connections



Lateral and connections to the pipe that is being lined or coated shall not

be left obstructed by the lining operations.

Before the lining or coating is placed, the openings in the pipeline

leading to air valves, blow offs, manholes and appurtenances, as well as

to laterals and connections that transmit pressure to carry water from the

pipeline, shall be temporarily covered or plugged with suitable devices.

These shall be removed later without damaging the Cement mortar.

1.15.7 Responsibility of Engineer and Contractor

The entire procedure of applying cement mortar lining or coating shall

be subject to continuous inspection by the Engineer-in-Charge or his

Representative but such inspection will not relieve the Contractor of his

responsibility to furnish material and perform work in accordance with

this specification. All cement mortar linings or coatings not applied in

accordance with this specification shall be subject to rejection by the

Engineer-in-Charge. Lining or coating so rejected shall be removed and

replaced by the Contractor at his own expense. A manual visual

inspection of the lined / coated pipe shall be by means of CC TV to

determine the quality of the lining and to identify detective areas in

linings for repair. The contractor shall procure/hire suitable equipment

required for his purpose at his own cost.

1.15.8 Defective L ining

Defects in lining or coating including but not restricted to sand pockets

such as voids, over sanded areas, blisters, cracked and dummy areas, and

thin spots shall be removed, and the area shall be repaired by hand

application to the full required thickness of the mortar lining or coating.

Defective areas encompassing the full diameter of the pipe shall be

replaced by machine whenever practical. Defective lining or coating

rejected after initial set shall be replaced or repaired by the most

practical method as determined by the Engineer-in-Charge or his

representative.

1.15.9 Guarantee



If on examination, the Engineer-in-Charge or his Representative finds in

the cement-mortar lining work within defect liability period after final

completion and acceptance of the Contract work evidence of defective

materials or workmanship as defined in this specification, then the

Contractor shall perform the remedial work at his own expense in a

manner acceptable to the Engineer-in-Charge.

The inside coating shall also not contain any constituent soluble in

drinking water or any ingredient, which could impart any taste or

whatsoever to potable water after sterilization and suitable washing of

the mains.

1.16 Cleaning and Commissioning of the Pipeline

Upon completion of a newly laid main, the main shall be initially

flushed clean and then disinfected by the Contractor at his cost as

directed by the Engineer-in-Charge or his Representative.

It is expected from the Contractor that he will lay only thoroughly

cleaned pipes during the process of laying of pipes and shall not leave

any tool or brick bats etc. in the line. Also when laying is not being done

he will keep the open ends closed with temporary blank flanges so that

nothing can enter the pipe.

For final flushing and cleaning, the department will allow water from

one of its mains for two fillings only. For third filling if required,

Contractor will be charged at prevailing commercial rate at the time of

flushing/cleaning. The main shall be flushed prior to disinfection.

1.17 Distance indicators and Markings

The Contractor shall supply and fix indicators at all points of change of

direction, at all valves and at every one Kilometer intervals along the

buried pipeline. Indicators shall consist of 10 cm x 10cm precast

concrete post 1.25 meter long, set 0.75 meter into the ground and

painted white above ground level. The description shall be written in

blue at one face of the precast post.

In case of the pipeline laid above ground details such as chainages,

invert levels of pipe, appurtenance number, pedestal / saddle number etc.

shall be suitably marked either on the pipeline or the supporting



structure etc. in distinct colour. The Bidder/Contractor shall include the

cost of this in his rates for the other items.

1.18 Application Guideline for Liquid Epoxy certified for potable Water

application - Internal Lining of Drinking Water Pipeline

1.18.1 Scope:

This specification sets minimum standard requirement for shop and field

applied solvent free liquid epoxy lining used in Potable water supply

pipelines

1.18.2 Requirements:

1.18.2.1 Equipments: equipments for the blast cleaning, Airless machine for the

application of the coatings.

1.18.2.2 Quality and safety: Material furnished shall meet the specifications. All

necessary precautions shall be taken to protect personnel and property

from accidents due to falls, hazardous materials, fire explosion, and

other dangers.

1.18.2. 3 Coating System: Solvent free liquid epoxy coating will be used.

Coating should meet following physical and performance requirements.

Sr. No.

Product Property Minimum Value accepted

Test Method

1 Dry Film Thickness Min. 406 microns* SSPC PA 2 2 Adhesion to Steel > 1400 psi ASTM D-4541 3 Volume Solid 100% 4 Relative Humidity

during application of lining

< 85 %

5 Hardness Minimum 70 . Barcol Model GYZJ 925 Impressor.

ASTM D 2583

6 Impact Resistance Direct impact approx 2 Joules

ASTM D 2794

7 Suitability for drinking water

Certification for use with potable water according NSF / ANSI Standard 61 or Australian AS/NZ 4020 or BS 6920*. With certification for the manufacturing facility as well

8 Immersion No film defect after 8000 hrs of exposure

ISO 2812 Part 2 Determination of



resistance to liquids Deionised Water @ 40C

9 Abrasion Average of 130mg weight loss per 1000 cycles using CS10 wheels and a 1Kg loading.

ASTM D4060 - "Abrasion Resistance of Coatings via the Taber Abraser"

*As per standards AWWA C210 and IS 3689

1.18.2.4 Coating Application:

1.18.2.4.1 Surface preparation: Surface shall be blast clean with abrasive blasting

materials like sand or copper slag to SSPC SP Standard 10 or SA 21/2

with surface profile 50 75 microns. Surface should be free from dust,

oil, and other contaminations. Surface should be coated within 4 hours

of blasting.

1.18.2.4.2 Application of Coatings: Prior to application of the coatings surface

should once again clean with blowing dry air to ensure the removal of

all dust and other contaminants. The coating shall be applied with airless

machine as per the recommendation of the coating manufacturer.

Desired film thickness of the coating can be built up using wet on wet

application technique with help of wet film thickness gauge to check wet

film thickness. The dry film thickness of the coating should be minimum

406 as per AWWA C210 and IS 3589 standards. Coating should be

uniform and smooth in appearance and free from defect. Coated surface

shall not be touched at least for 4 hours. The wet coating shall not be

contaminated with particles such as blowing sand, insect, or other

foreign material.

In case small areas, coating can be applied using roller and brush.

Desired dry film thickness can be achieved using wet on wet application

technique or in number of coats.

1.18.2.4.3 Inspection of the Coating: The Coating system will be inspected

visually for uniformity, thickness, blister, pinholes etc. all imperfections

shall be identified and marked for repair.

1.18.2.4.4 Electrical inspection for continuity: After curing, but prior to

installation, the coating system applied to the pipe shall be tested for pin

holes according to the procedure and using the voltage setting outlined



in NACE RP0188-99 for the specified thickness. Any pinholes indicated

by the detector shall be marked with chalk to identify the area to be

repaired.

1.18.2.4.5 Repair of the Coating: All the damage areas requiring patching shall be

cleaned of coating by hand or power tool like surface grinders with

appropriate sanding disc. Steel surface area should be dry, cleaned.

Coating will be applied with the trowel or with roller if the surface area

is very small. Patches shall overlap the surrounding undamaged coating

by minimum 19 mm (). Repair shall be subject to inspection.

1.18.2.4.6 Testing: test panels shall be made following similar surface and coating

application procedure and send to reputed laboratory to check

performance parameters like adhesion, and other properties.



CHAPTER 2: Valves

2.1 SLUICE VALVE WATER APPLICATION

Up to 300 mm The sluice valves shall generally conform to IS 14846 / DIN 3352/BS 5163, with length over flanges as per PD of IS 14846 corresponding to BS EN 558 / ISO 5752 Basic Series 3:

Component Material of construction Body / Bonnet /Hand wheel Ductile Iron GGG 40 / IS 1865 Gr. 400/15 Wedge (fully rubber encapsulated)

Ductile Iron GGG 40 / IS 1865 Gr. 400/15 + EPDM

Spindle Non rising; Stainless Steel AISI 316/AISI 420 Spindle Nut (Replaceable) Aluminium Bronze, AB2 (Forged)/Brass Stem seal Multi-tiered NBR (Nitrile) O ring Fasteners High tensile steel, hot dip galvanized Flange Drilling BS EN 1092 2 PN 10 / 16 Painting / Coating Inside & Outside epoxy powder coated; DFT

minimum 250 micron, shade RAL 5005 (BLUE) 350 to 600 The sluice valves shall be Glandless and generally conform to IS 14846/BS 5163.

Component Material of construction Body / Door / Dome Ductile Iron GGG 40 / IS 1865 Gr. 400/15 Spindle Non rising; Stainless Steel AISI 316/420 Body seat / Door face (rings to be press fitted and riveted; no screws allowed)

Gun metal: IS 318 Gr. LTB 2/Resilient seat

Rivets Soft annealed brass Spindle Nut Gun metal: IS 318 Gr. LTB 2/Brass Stem seal (glandless) EPDM/NBR Fasteners Carbon steel, hot dip Galvanised Flange Drilling IS 1538 Table 4 & 6 or BSEN 1092-2 PN 10 / 16

Accessories: Ball thrust bearings Required: SKF or equivalent Enclosed spur gear box If Required: CI with IP 54 protection;

Make - MASTERGEAR INDIA / AUMA 700 to 1500 The sluice valves shall generally conform to IS 14846.



Component Material of construction Body / Door / Dome Ductile Iron GGG 40 / IS 1865 Gr. 400/15 or 500/7 Spindle Non rising; Stainless Steel AISI 316 / 410 Body seat / Door face (rings to be press fitted and riveted; no screws allowed)

Gun metal: IS 318 Gr. LTB 2

Rivets Soft annealed brass Spindle Nut Gun metal: IS 318 Gr. LTB 2

Stem seal Gland & Stuffing box type with hemp packing Fasteners Carbon steel Flange Drilling IS 1538 Table 4 & 6 PN 10 / 16

Accessories: Back Seat Bush Required: Halprene on bronze Ball thrust bearings Required: SKF or equivalent Enclosed spur / worm gear box Required: CI with IP 54 protection;

Make - MASTERGEAR INDIA / AUMA PAINTING & COATING (for 350 mm and above): Pre inspection: 1st Step Surface Preparation Blast cleaning to near white - SA 2 Grade

Post inspection, if applicable 2nd Step Application of Finish Coat One coat of epoxy coating (Shade: RAL 5005, Blue) Note: Liquid epoxy coating should be done by appropriate equipment

inside a proper paint booth, conforming to AWWA C 213. Manufacturer should be able to provide certificate from WRAS

(U.K.) stating suitability of the above paint in drinking water application.

The total DFT should not be less than 250 micron. Note: Manual operation by hand wheel (thru intermediate enclosed spur gear box, if applicable). Motorised operation by means of electrical actuator (thru intermediate gear box, if applicable). GENERAL

Volume-II Specif ications


1. Hydro testing:

PN 1.0 PN 1.6 Criterion Seat test (Kg/cm) 10 16 Drop - tight Body test (Kg/cm) 15 24 No leakage and deformation

2. Torque / Operating effort / Operating time: Manufacturer to furnish data and if

required supporting calculation for review / approval.

2.2 NON RETURN VALVES - WATER APPLICATION

The valves shall generally conform to IS 5312 Part 1 (Single Door Type) for sizes 50 to 1200 mm and IS 5312 Part II (Multi Door Type) for sizes above 1200 mm . The valve shall be suitable for mounting on a horizontal pipeline and flow direction shall be clearly embossed on the valve body. No spring loaded/ spring return action or external dampening arrangement is acceptable. Valves of multidoor type shall be additionally provided with a supporting foot. All faces and seat rings shall be riveted (350 NB & above) to the machined surface in the casting. The door shall be integral with the hinge and shall have a flat seating face. Minimum two (2) nos. suspension lugs shall be cast integrally on the diaphragm plate and shall be of adequate strength.

Component Material of construction Body / Door (& Diaphram)

Ductile Iron GGG 40 / IS 1865 Gr. 400/15 or 500/7

Hinge pin (single door ) / Stub pin (multidoor type )

SS AISI 410/SS AISI 420

Seat rings & Face rings / seal Resilient (EPDM) seal (upto 300 mm); Gun metal : IS 318 Gr. LTB 2 (350 mm and above)/Nickle weld overlay above 350 mm

Rivets Soft annealed brass Fasteners Carbon steel (galvanized) Flange Drilling IS 1538 Table 4 & 6/ BS En 1092 - 2 PN 10 / 16 By pass arrangement Optional Painting & Coating: Pre inspection:

1st Step Surface Preparation Blast cleaning to near white - SA 2 Grade

Post inspection, if applicable 2nd Step Application of Finish Coat One coat of epoxy power coating Note: Liquid epoxy coating should be done by appropriate equipment inside

a proper paint booth, conforming to AWWA C 213.



Manufacturer should be able to provide certificate from WRAS (U.K.) stating suitability of the above paint in drinking water application.

The total DFT should not be less than 250 micron. General 1. Hydro testing:


2.3 BUTTERFLY VALVE (GENERAL PURPOSE)

Up to 300 mm Flangeless wafer butterfly valve meeting the following

Bi directional shut off valve PN 10 / 16 Ductile body with fully vulcanized liner seat preventing corrosion between liner

and body Disc in SS CF8 For manual operation: Lever upto 200 ; above with Worm Gear box Suitable for easy installation between all kinds of flanges IS, BS No need of separate gasket for installation Motorised operation with Single / Three Phase electrical actuator.

All dimensions in mm NB 40 50 65 80 100 125 150 200 250 300 End to End 32 42 44 44 50 56 56 60 68 78 Top Flange F05 F05 F05 F05 F05 F07 F07 F07 F10 F10

350 and above The butterfly valves shall generally conform to BS EN 593, with length over flanges as per double flanged Long (BS EN 593 / BS EN 558 / ISO 5752 Basic Series 14), bubble tight shut off; resilient seal; integral body seat; double eccentric design. Nickeled weld overlay.

Component Material of construction Body / Disc Ductile Iron GGG 40 / IS 1865 Gr. 400/15 or 500/7 Stub Shafts SS AISI 431/420 Bearings Steel backed Teflon (co-efficient of bearing friction

not more than 0.1)/Bronze Body seat Integral Ni Cu alloy weld deposited, micro finished Disc seal EPDM



Disc seal retaining ring SS 304 / Ductile iron Shaft seal Halprene/EPDM Internal Fasteners SS Flange Drilling BS EN 1092 - 2 PN 10 / 16

Mandatory accessories: Enclosed worm gear box with additional spur gear boxes, if required

Required: CI/DI with IP 54 protection; Make - MASTERGEAR INDIA / AUMA/VAG

Mechanical Position Indicator Yes Limit stops Yes Operation Manual operation by hand wheel.

Motorised operation by means of electrical actuator.

PAINTING & COATING: Pre inspection: 1st Step Surface Preparation Blast cleaning to near white - SA 2 Grade

Post inspection, if applicable 3rd Step Application of Finish Coat One coat of epoxy coating (Shade: RAL 5005, Blue) Note: Liquid epoxy coating should be done by appropriate equipment

inside a proper paint booth, conforming to AWWA C 213. Manufacturer should be able to provide certificate from WRAS

(U.K.) stating suitability of the above paint in drinking water application.

The total DFT should not be less than 250 micron. General 1. Hydro testing:


2. Torque / Operating effort / Operating time: Manufacturer to furnish data and if required supporting calculation for review / approval.



2.4 AUTOMATIC AIR VALVES

KINETIC AIR VALVE (IS 14845) Body / Cover / Cowl DI IS 210 Gr. FG 200/ H.P. Orifice & Plug Bronze L.P. Seat ring Nitrile Rubber (Dexine) L.P. Ball Vulcanite Covered Timber H.P. Ball Rubber Covered Timber Isolating Sluice Valve CIDF as per IS 14846 with CI Cap Fasteners Carbon Steel PN 10

COMBINATON AIR VALVE Single chamber double orifice automatic triple function DI Air valves. L.P. & H.P. Chamber / Cover / L.P. seat retainer

Ductile Iron GGG 40 / IS 1865 Gr. 400/15 or 500/7

Cowl Carbon Steel H.P. Orifice EPDM L.P. Seat ring EPDM Floats (LP & HP Chambers) SS 304 Ferrule SS Isolating Sluice Valve with Cap

DIDF with resilient wedge

Fasteners Carbon Steel PN 10 / 16

GUIDELINE FOR USAGE

Valve size For Mains size 50 Upto 200 80 225 - 350 100 400 - 500 150 600 - 900 200 1000 - 1200

For mains size larger than 1200 NB, it is recommended tha

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Specifications