Excavation EarthWork fr Pipe

Trench Excavation

3.3.1 Protection of Affected Services, Structures, Pavements and

Vegetation
a) Owners of affected property, structures, services and other
pipelines (sewer, water, gas, electricity, telecommunications lines,
fuel lines, chemical pipelines) along or within 3 m of the excavation
shall be notified.

b) Services and other pipelines shall be protected, uncovered,

temporarily supported or temporarily relocated in accordance with
the conditions specified by the owner.

c) Where the shutdown of a service or pipeline cannot be avoided,

arrangements shall be made with the owner of the service or the
pipeline on the closure and reinstatement requirements.

d) Damages to any affected structure, service or pipeline shall be

avoided. e) Damage to any structure, service or pipeline shall be
informed to the owner and shall be repaired as quickly as possible
in accordance with the requirements of the owner.
f) Damage to vegetation (trees, bushes, gardens), paved areas
(roads, footways, kerbs), fences or other property within the
construction zone shall be minimised.

g) The length of time that any paved route is out of use shall be
minimised.

h) Not more than half the width of a roadway shall be disrupted at

any one time.

i)

j) Spoils shall not be placed on road surfaces. Where there is no

other approved storage area, spoil shall be carted away. Non-
reusable material excavated from roadways shall be disposed of in
an appropriate manner. Only fillings approved by the responsible
authority for the roads shall be used as refill.

k) Excavations shall be sufficiently clear of building foundations.

l) Excavations adjacent to roads shall be at least 1 m clear of the

road edge except when otherwise approved by the Commission.
Volume 3 Sewer Networks and Pump Stations 77 Construction and
Installation m) Trenches adjacent to roads, buildings and structures
shall be continuously supported until the trench is refilled. n) Page 1 of
Structures, services, vegetation, paving, or other property not 66
within the construction zone shall not be damaged.
o) Temporary fencing shall be provided where barriers such as
fences and walls are dismantled.

p) Warning signs and temporary fencing shall be provided at the

work site for excavation spoils, access routes, steep or loose slopes
resulted by excavation work.

q) Warning signs shall be in accordance with the relevant

Malaysian Standards.
Some of the relevant Malaysian Standards are:

i) MS 980 Specification for safety signs and colours: colorimetric

and photometric properties of materials
ii) MS 981 Specification for safety signs and colour: colour and
design
iii) MS 982 Specification for safety signs, notices and graphic
symbols

r) Adequate lighting and reflective signals, which can make clearly

visible the perimeter of the work site to pedestrians and traffic,
shall be provided.
s) Adequate lighting shall be provided for works undertaken in poor
lighting or at night. Lighting in confined spaces shall be explosion
proof.
t) Alternative means of access shall be provided to rights of way,
buildings and property where usual means of access are disrupted
by the excavation.
u) Soils shall not be taken out of the work site, put onto pavements
or flushed down to drains or water courses.
v) Road drains, gutters and channels shall not be obstructed.
w) Drains disturbed by works shall be rerouted to ensure continual
operation.
x) Sufficient top soil that will be used for surface reinstatement
shall be removed and stockpiled separately.
y) When dewatering, care shall be taken to ensure that the
adjacent structures, services and building foundations are not
affected.
z) Water removed from the excavation shall be disposed of without
damaging other property or causing a public nuisance.

3.3.2 Excavation Requirements

a) The required line of the sewer and manhole locations shall be set
out using accepted surveying practices. 78 Volume 3 Malaysian
Sewerage Industry Guidelines Construction and Installation
b) Manhole locations shall be pegged and the line of the excavation
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between manholes shall be maintained straight using one or more66
of pegs, chalk lines laser beam lines and string line.
c) Changes to the line, grade or level due to unforeseen
obstructions or proximity to services shall be approved by the
Commission prior to making the actual changes.

d) The trench shall be excavated precisely along the marked

alignment to ensure the sewer will be in the centre of the trench.

e) The trench shall be excavated to a depth so that the sewer can

achieve the specified level and grade when the specified bedding
depth is used.

f) Over-excavation of the trench depth shall be avoided.

g) For open excavation, depending on depth of sewer and soil

condition, sufficient slope protection must be provided and
supported by approved consultant drawings and design.

h) When the excavations are required to cross rivers, railway lines,

and any other obstructions, minimum soil cover requirements
specified by the responsible authorities shall be observed. In
extreme cases, inverted siphons may be necessary. Minimum
requirements for inverted siphons are shown in the standard
drawings in the Appendix, and they must be designed
individually based on actual locations.

i) When working with poor ground conditions, construction depth

shall be minimised. Reference shall be made to the approved
longitudinal and cross-sectional sewer profile drawings, which
give details of construction based on soil reports.

j) The base of the trench shall be trimmed carefully to level and

grade

k) Where sight rails are used to determine trench excavation

depth, at least three sight rails shall be used for each manhole
length.

l) Sight rails shall be fixed to a uniform height above sewer

invert.

m) Rocks that cause an uneven trench base shall be removed. The

resulting holes shall be refilled with the specified embedment
material.

n) The trench in the pipe zone shall be excavated to the minimumPage 3 of

width limits as given in the specification, except where a wider66
 trench is needed due to unsupportive soil adjacent to the pipe
zone.

o) The trench sides shall be vertical except where permitted

otherwise by the Commission.

p) To prevent trench wall from collapsing which may lead to

injuries and pipe damage, timber or steel support shall be
provided in the trench when the trench is deeper than 1.5 m.
These supports must be adequately designed for. Sewer
Networks and Pump Stations Volume 3 79 Construction and
Installation)
q) Where possible, spoil shall be placed only on one side of the
trench.
r) Spoil shall be placed at an appropriate distance away from the
edge of the trench (minimum 600 mm). This is to prevent the
spoil material from falling into the trench or to prevent the
weight of the spoil from collapsing the trench wall

s) Unsupportive (very soft, loose, spongy or puddly) soil in the

base of the trench (as determined by the Commission) shall be
removed and replaced. The replacement based shall be
sufficiently supportive and shall require approval from the
Commission

t) Excessive excavation shall be refilled with approved materials

to the specified compaction.

u) Where possible, the excavated trench shall be kept free of

water until sufficient backfill is placed above the sewer. This is
to prevent the base of the trench from becoming spongy and to
prevent the pipe from moving off line or grade.

v) Changes to the line, grade or level of the sewer shall be

properly recorded for incorporation in the as-constructed
drawings. All as constructed drawings, irrespective of whether
there are changes to the original design drawings, shall be
certified by consultants and shall include sufficient details,
including as-built sewer invert levels. These drawings shall be
submitted to the Commission.
w) Excavation shall not proceed too far ahead of pipe laying to
avoid damages from flooding or spoil.

x) Excavation shall not proceed too far ahead of the required

trench support placing to avoid trench wall from collapsing.

y) Excavation shall comply with the relevant Occupational Safety Page 4 of

and Health Act (OSHA) requirements for safety. 66
3.3.3 3.
Bored Excavation

a) The bore shall be on the line, level and grade and of sufficient
diameter to allow pipes to be inserted without over-stressing the
joints or damaging the pipes.

Pipe jacking

7.1 General

Pipe jacking shall be the process of installing precast reinforced

concrete pipes below a surface obstruction by driving them
successively through the in-situ soil from one pit (driving pit) to
another (the receiving pit) such that the finished pipe forms a
watertight continuous conduit between the pits on the desired
alignment for the laying of MS pipeline. Plans and details of the
equipment, materials and the method of construction to perform
and complete the work shall be submitted by the Contractor and
must be approved by the S.O. before commencing these operations.
Approval by the S.O. shall not relieve the Contractor of his sole
responsibility for the efficacy, reliability and soundness of the
method employed in completing the work in a satisfactory manner.
The Contractor shall satisfy himself as to the soil conditions along
the pipe jacking route and if he judges it to be necessary, he shall
carry out further soil investigations at his own cost. It shall be the
responsibility of the Contractor to maintain stable soil conditions at
the jacking face to prevent loss of ground above the jacking
operation and movement of the surrounding earth. The methods of
maintaining face stability and preventing ground movement and
subsidence shall be by means of compressed air or other plenum
methods where fluid slurry or earth pressure is applied to the
tunnel face. Alternatively, unstable ground ahead of the jacking
face may be stabilised by the injection of suitable chemicals.
Methods which require dewatering of the ground will not be
accepted, nor will methods which may lead to significant ground
loss. The Contractor's proposal must be submitted to the S.O. for
his approval. Movement or settlement of structures, utilities and
pavement shall be monitored by the Contractor during the jacking
operation and reported to the S.O.. If movement or settlement
occurs which in the opinion of the S.O. may cause damage, the
Contractor shall take immediate action to prevent further
movement, settlement or damage. He shall repair at his own cost
any damage and restore structures or pavements to the satisfaction Page 5 of
of the S.O. The Contractor shall be responsible for inspecting the 66
location and familiarising himself with the conditions under which
the work will be performed and with all necessary details as to the
orderly execution of the work. The omission of any details shall not
relieve the Contractor of full responsibility for the satisfactory
installation of the work in its entirety. No monetary or other claims
made by the Contractor on the grounds of want of knowledge will
be entertained.

7.2 Tender Submission

The tenderer shall submit with his tender the following particulars
relevant to his design and proposal for pipe jacking :-

(I) Four (4) copies of a detailed specification giving full particulars

of the jacking pipe, pipe joint and construction method proposed.

(II) Four (4) sets of calculations of his design and proposal.

(III) Four (4) sets of drawings showing in sufficient detail his design
and proposal.

The tenderer's design and proposal shall be based on the general

arrangements shown on the tender drawings which accompany the
tender document as far as possible to suit the tenderer's proposed
system.

7.3 Surface Reinstatement in Road Verges, Fields, etc.

Where excavation is in road verges, fields and grassed areas, the

turf previously removed will suffice for surface reinstatement
providing that the grass has not been killed during stacking and
that the surface is free from all loose stones. After refilling
excavation as specified, the Contractor shall replace all topsoil
previously removed and it shall be evenly distributed and levelled
over the full extent of the stripped area. The working space
occupied by the Contractor which was originally covered with grass
if destroyed during the course of construction shall be covered with
50mm of topsoil, close turfed and maintained until the new grass is
properly established at the Contractor’s expense. Other areas not
originally covered with grass shall be restored to their former
state. Road verges shall be restored to their original width and to a
minimum fall of 1 in 24 away from the road and towards the ditch
(if any). Restoration of the dip shall be carried out unless the fact
that no dip existed prior to pipelaying has been recorded in writing
and agreed to by the S.O. The Contractor shall restore all surfaces
in a condition not inferior to that which existed prior to
commencement of works. Any damage to the metalled road due to
pipejacking work alongside road verges or shoulders shall be Page 6 of
reinstated to the satisfaction of the authority concerned at no extra
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cost to Employer. For the purpose of determining the required
extent of reinstatements described above, the Contractor shall
jointly with the S.O. make assessment of the existing Conditions at
each work site before the work commences. The Contractor shall
produce two sets of photographs and other records of the existing
situation on site and they shall be jointly signed. One set shall be
kept by the Contractor and one set shall be submitted to the S.O.

7.4 Prospecting

The Contractor shall prospect for the position of buried or

otherwise hidden obstructions such as existing services, drains,
pipes, cables, culverts, etc. Trial holes and exploration trenches to
ascertain the exact positions of these shall be sunk, well ahead of
pipejacking and excavation, in places where they are known or
thought to be and elsewhere and these shall be backfilled with
approved materials immediately and in any case not exceeding 24
hours and subsequently reinstated. Approved marker posts shall be
erected to mark the position of all located services, drains, etc. and
these shall not be removed until reinstatements has been
completed. The S.O. shall instruct further prospecting if he is not
satisfied with the sufficiency of the Contractor’s prospecting.
Where necessary the Contractor shall make arrangements prior to
excavation of jacking and receiving pits and pipejacking proper for
the temporary or permanent support or diversion of services, rains,
etc. to the approval of the S.O. and the authority concerned. The
full cost of prospecting shall be deemed to be included in the
relevant Contract Rates. Attention is drawn to clauses concerning
the responsibility of the Contractor for the security of existing
services. The Contractor shall be deemed to have allowed for the
unavoidable delay of the Works due to any obstruction he may
encounter with the existing services and no claim for any extra
costs on account of this will be allowed.

7.5 Performance Requirements

The centre-line of the fully jacked pipes forming a continuous

sleeve shall at all points along its length be within 75mm of the
required alignment in the horizontal plane and 25mm in the
vertical plane. No movement, upheaval or settlement of soil which
in the opinion of the S.O. may cause damage to structures, utilities
or pavements shall be permitted. The pipeline laid in the jacked
pipe sleeves shall pass the watertightness test specified for the
pipelines in trench.

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7.6 Approval of Owner 66
 Before commencing preparations for pipe jacking the Contractor
shall obtain the written consent to his proposed procedures of the
Owner or Owners of the land, services and structures below which
(or close to which) the jacked pipeline will pass. Unless otherwise
stated, all costs, expenses, charges, rental, compensation etc.,
imposed by the Owner shall be deemed to be included in the
Contract Rates.

7.7 Jacking Operation

The Contractor shall be fully responsible for the materials,

equipment and facilities required in conjunction with jacking the
pipes. Before starting work, the Contractor shall submit to the S.O.
for approval, a detailed schedule of the entire jacking operation.
Approval of such schedule shall not relieve the Contractor of his
responsibility to provide a fully satisfactory installation. The
Contractor shall include with his submission evidence that he has
successfully completed a jacking installation using procedures
similar to those proposed. Where chemical stabilisation of soil is
used, a chemical grout shall be pressure injected into the soil over
and ahead of the pipe jacking to stabilise the soil. The chemical
grout used shall have a demonstrated history of success for
stabilising soils similar to that through which the pipe is to be
jacked. Where a mechanical shield is used, the Contractor must
provide proof that the particular model of shield has been used
successfully in soils similar to that on the site. The crew for the
operation of the shield must be specialist, with experience in the
use of that particular type of machine. After the jacking operations
has begun, the Contractor shall work continuously and
expeditiously in accordance to programme until the complete
length of jacked pipes is installed. This continuous work where
required shall not be construed as overtime work. During jacking
and excavation, the Contractor shall constantly ensure that the
internal lining of the jacking pipes is not damaged, and he shall
remove the excavated spoil to the jacking pit by conveyor to
minimise traffic on the invert. The pipes shall be jacked into place
true to line and level. The maximum tolerance allowable in the
displacement of the centreline of the jacked pipe from the design
centreline is 75mm in the horizontal plane and 25mm in the
vertical plane but there shall be no backfall at any point. The pipes
for the jacking operation shall not exceed 4m long. The pipe ends
shall be jointed by MS thrust collars/sleeves before the pipeline is
jacked. Details of how the pipes are to be lowered into the pit and
jointed shall be submitted to the S.O. for approval. The Contractor
shall be required to furnish and install and remove to the extent
required, thrust blocks or whatever provisions that may be
required for backing up the jacks employed in jacking the pipe Page 8 of
forward. The jacking pit shall also be equipped with steel rails or66
beams embedded in concrete for placement and alignment of each
pipe during the jacking operation. Other method may be used
subject to the approval of the S.O.. The Contractor shall be fully
responsible for the design and construction of the jacking and
receiving pits, thrusting wall, installation of jacking equipment,
sheeting, bracing, etc., and for the efficient execution of the jacking
operation. Full details of the proposals, including plant, shield
machine, equipment, operating procedures, jacking pit and
intermediate jacking stations etc., shall be submitted to the S.O.
and shall be fully satisfactory to him before construction. However,
review of the plans shall not relieve the Contractor from his
responsibility to provide a safe and satisfactory jacking pit. On
successful completion of the jacking operation, jointing of the
length of jacked pipes, jointing and installing of the MS pipeline,
hydraulic pressure testing of the pipelines and after the
connections at the extreme ends of the MS pipeline have been
made, the Contractor shall pressure grout the jacked pipes to fill all
the voids existing outside the pipe. Grouting shall be undertaken
through holes as specified herein. Then, the Contractor shall
remove complete the jacking pits and receiving pits together with
all the temporary works. He shall also backfill the pits with well
compacted suitable approved materials. The Contractor shall be
required to monitor closely the progress of the jacking operation.
Daily site records of thrusting pressures, rate of thrusting, the line
and level measurements of the jacking pipes and any movement or
settlement of existing structures shall be properly maintained and
shall be submitted to the S.O.. For the sections of the pipeline
crossing under roads, railway or structures along the pipeline
route, the Contractor shall be required to incorporate in his
tunnelling method measures to arrest settlement or upheaval of the
soil so as to safeguard the integrity of the structures and other
property. The Contractor shall ensure that the traffic flows along
railway lines and roads are not affected in any way by his work.

7.8 Safety

The minimum of plant shall be used in the pits, and any which
produces noxious gases or is operated by electricity at a greater
voltage than 240V shall be permanently outside the pit at ground
level. A ladder shall be fixed permanently in the receiving pit. Two
ladders shall be permanently fixed on opposite sides of the driving
pit, one on each side of the pipe jacking line. These ladders shall be
kept clear of obstructions to allow rapid exit in an emergency.
Excavated materials and plant other than small tools shall not be
passed via the ladder but shall be handled by crane. Pits shall be
securely fenced to prevent unauthorised persons from entering in.
All persons entering the pits shall wear safety helmets constantly,
and shall leave the pits for meal breaks, rests and the like. At the Page 9 of
beginning of each shift and after any break for refreshment or 66
other reason, the Contractor shall provide and use an approved
instrument to check for noxious gases before anyone re-enters
either pit. All costs associated with the provision of safety
equipment and measures shall be deemed included in the Contract
Rates

7.9 Design of the Jacking Pipes

The Contractor shall design the pipes to be jacked and the pipe
joints in accordance with the jacking procedure and operation
proposed by the Contractor. The design shall be submitted with full
detailed calculations to the S.O. for approval before construction
commences. The details of the jacking pipes are shown on the
Drawings and the design shall take into account the following
requirements: -

(1) The pipes for jacking operation shall be precast concrete pipes
manufactured by centrifugal or other equivalent process to be
approved by the S.O.

(2) All pipes shall be manufactured with two sets of grout holes.
Each set shall consist of three grout holes spaced at 120 degrees
on centres circumferentially located at quarter points from either
end of the pipe.

(3) The length of each pipe shall not exceed 4m and the pipe ends
shall have an external rebate suitable to accommodate a MS
joint/thrust collar. The collar shall be designed to take the jacking
load applied and transfer the load to the next pipe.

(4) The thrust collar shall be fitted onto the pipes with rubber rings
to prevent the ingress of water into the pipe from outside.

(5) The precast reinforced concrete pipes shall be sufficiently

reinforced with steel to withstand all stresses induced by handling,
jacking, earth and water pressure and all working loads at the
depth at which they are to be used without cracking, spalling or
distortion. The pipes shall be of at least strength Class ‘2Z’. A load
factor of not larger than 1.5 times shall be used in the calculations
to determine the strength of the pipes required. The strength of the
pipes shall be tested by the three edge bearing test. When subject
to the design load in such a test, the maximum crack width
developed on the pipe shall not exceed 0.25mm. All such tests shall
be carried out at the expense of the Contractor. (6) The Contractor
shall submit full details of his proposal for the pipes giving detailed
drawings showing sizes, reinforcement and joint details,
calculations, name and address of proposed manufacturer and the
manufacturing processes to the S.O. for approval. The proposal Page 10 of
shall be endorsed by a Professional S.O. The jacked pipes shall be 66
designed to withstand, in conjunction with the jacking load applied,
the following external loads: -

(i) Highway loading of 45 units of Type HB loading in accordance

with BS 5400, for pipe jacking under JKR roads.

(ii) Overburden load as shown on the Drawings.

The nominal diameter of the jacking pipe shall be as shown in the

Drawings for laying of the specified pipe.

7.10 Laying and Connections of Pipeline in Jacked

Reinforced Concrete Pipes Sleeve

The laying of the MS pipeline shall only commence after the full
completion of the jacking of the reinforced concrete pipes to the
approval of the S.O.. The MS pipes shall be in length of 4 metres or
less and to be jointed by welded split collars as specified in Clause
2.14. of this Contract. In addition all welded joints shall be tested
by ultrasonic examination in accordance with BS 3923 in the
presence of the S.O. or his representatives. The S.O.'s instructions
given as a result of the examination of ultrasonic results shall be
final. The Contractor shall submit his proposals to the S.O. for site
ultrasonic examination. The size, number and make of ultrasonic
equipment proposed shall be stated. The Contractor shall provide
adequate equipment and qualified and experienced personnel to
conduct the ultrasonic examination. The S.O. reserves the right to
carry out any independent ultrasonic examination of the welded
joints as he may deem fit. Such independent ultrasonic examination
shall be carried out by an Inspector appointed by S.O. and paid
through items in the Bill of Quantities. The Contractor shall provide
such assistance, labour, materials, electricity, supply ultrasonic
examination equipment and other apparatus as may necessary to
allow a thorough and extensive independent examination to be
carried out. After each section is jointed by welding and approved
by the S.O. or his representatives, the MS pipe shall be jacked or
pushed through the sleeve. The bottom of the MS pipes shall be
suitably supported on rollers or other means to prevent scouring of
the MS pipe external surfaces. Care shall be taken to ensure that
the internal concrete linings are not damaged during the operation.
The pipe ends shall be properly braced to prevent damage. The end
of the jacked reinforced pipe sleeve shall be grouted after the full
length of MS pipe has been jacked/pushed through. Connections at
the extreme ends of the MS pipeline shall be made only upon
successful completion of the hydraulic pressure test of the pipeline
as specified in Clause 2.17. of this Contract. The connections at the
two ends of the jacked pipeline will be made at the jacking or Page 11 of
receiving pits. The Contractor shall maintain and keep these pits 66
intact and in a safe condition to facilitate the connections. The
Contractor shall remove all other temporary works and any
concrete blocks including cutting and removing part of the walls of
the pits that are in the way of the pipework connections. When the
Contractor has completed the connections of the pipelines and has
completed the protection of these connections with sand or
concrete surround, he shall then backfill the pits with well
compacted suitable approved materials. The removal of the
temporary bracings and struttings shall be carried out
systematically together with the backfilling of the pits to prevent
collapse of the pit walls. The walls of the pits shall only be removed
when the backfill of the pits are completed.

7.11 Alternative Method of Pipe Jacking

Methods of pipe jacking other than described above may be

proposed by the Contractor and subject to the approval of the S.O.

Specification Nut&Bolt

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Welding Specification

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Welding Specification

welding

1.1 General

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1.1.1 Welding shall conform to the governing code.
1.1.2 For field run piping limits and locations of field welds, refer to piping drawings.
1.1.3 Where the closing dimensions at the beginning or end of a line cannot be
accurately determined at the time that drawings are issued for construction the
symbol ‘FFW’ (Field Fit Weld) is written next to the weld symbol. When this
occurs the Supplier is to ensure that the spool is 6” longer than dimensioned
length to allow field erection contractor to trim excess pipe and make final
closing weld. The pipe end is to be square cut.
1.1.4 Butt welds shall have full penetration
1.1.5 Storage, preparation and welding of stainless steel and other high alloy materials
shall be segregated from carbon steel fabrication to avoid contamination.

1.2 Weld Joint Preparation

1.2.1 Non-galvanized carbon steel may be cut by methods involving heating (i.e. flame
or arc cutting) provided the cut edge is machined or ground back sufficiently to
provide the proper preparation and fit-up for welding.
1.2.2 Flame cutting of stainless or alloy steels shall not be allowed but plasma cutting
of stainless steel shall be acceptable.
1.2.3 Galvanized pipe shall be cut by cold sawing or machining only.
1.2.4 Grinding wheels for stainless steel shall be resin bonded alumina or silicon
carbide. Rubber bonded wheels shall not be used. Wheels shall be dedicated to
a single material and the fabricator shall ensure wheels used on one material are
not subsequently used on another.
1.2.5 Wire brushes for stainless steel shall be stainless steel.
1.2.6 Wire brushes shall be dedicated for use on a single material and fabricator shall
ensure brushes used on one material are not subsequently used on any other.
1.2.7 All edges shall be accurate to design requirements with a smooth, even surface
and all cutting dross, slag, etc. shall be removed with special care taken to
ensure no foreign matter remains inside the pipe.

1.2.8 Inside diameters at the ends of components to be joined shall be aligned within
1/16”. Where misalignment is excessive, the thicker wall shall be taper bored at
30 deg. maximum in accordance with ASME B31.3 Figure 328.4.3. In no case
shall such trimming result in a net wall thickness less than the nominal wall
thickness specified minus the applicable mill tolerance.
1.3 Material Surface Defects
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1.3.1 Unless otherwise specified, surface defects shall be considered injurious if the
defect extends below the mill tolerance minimum wall thickness or is more than
1/16” in depth.
1.3.2 The Supplier shall not repair any injurious defects without prior approval of the
Buyer’s Engineer of the repair procedure and NDE requirements.
1.4 Weld Defects and Repairs
1.4.1 Weld defects shall be repaired in accordance with Process Piping ASME Code
B31.3 or Power Piping ASME Code B31.1 and the Supplier’s approved repair
procedure.
1.4.2 For Carbon Steel materials, the first and second repair of a weld can be made at
the Supplier’s discretion but shall be recorded. A third repair in the same
location shall have prior approval of the Buyer’s Engineer or Inspector.
For materials other than Carbon Steel, the first repair of a weld can be made at the Supplier’s
discretion but shall be recorded. The second repair in the same location shall have prior approval of
the Buyer’s Engineer or Inspector

fabrication

1.5 General
1.5.1 In addition to the requirements of the governing Codes and regulations the
following requirements shall be met unless otherwise noted on the piping
drawings.
1.5.2 Flange bolt holes shall straddle principle centerlines of equipment and piping,
unless otherwise shown on the drawings.
1.6 Threaded Connections
1.6.1 All threaded connections shall be gauge checked or chased after welding or heat
treating. Openings for thermowells and other inserts shall be drilled through the
connections and shall be free from obstruction.

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1.7 Socket Welding
1.7.1 A clearance of 1/16” is required between the male and female ends at the
bottom of the socket prior to welding. Pipe for socket welding shall be square
cut. The Supplier shall submit, for approval, socket welding procedure and
method to maintain the gap.
1.8 Orifice Runs
1.8.1 Weldneck orifice flanges shall have the same bore as the pipe. Orifice runs shall
not contain welds except at the flanges. Pipe ends and bevels at orifice flanges
shall be machine cut and shall be perpendicular to the axis of the pipe. Weld
penetrations at orifice flanges shall be ground smooth and flush inside. Pipe tap
connections on orifice flanges and directly on the pipe where so specified, shall
be drilled through the pipe wall and shall be finished smooth and flush inside.
1.8.2 Taps shall be oriented as shown on the piping drawings.
1.9 Bends
1.9.1 Unless otherwise noted, the centreline radius of bends shall be five (5) nominal
pipe diameters. Buttwelds in the arcs of bends or for the addition of pulling legs
shall not be permitted without written approval from the Buyer’s Engineer.
1.9.2 When bending welded pipe, the longitudinal weld shall be located in the neutral
axis of the bend.
1.10 Pipe Supports
1.10.1 Piping shall be supported as indicated on the piping drawings. When temporary
supports other than those shown on the piping drawings are required to
facilitate installation, they shall be of the removable type. Temporary supports
shall not transfer detrimental reactions to piping, structural members or
equipment. Welding to pipe and/or piping supports as a temporary support for
installation or hydrotesting is not permitted.
1.10.2 Temporary supports shall be painted bright red to ensure complete removal upon
completion of pressure testing and prior to commissioning.

Page 46 of
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1.11 Dimensional Tolerances
1.11.1 Dimensional tolerances shall be as recommended by the Pipe Fabrication
Institute – Standard ES-3.
1.11.2 Cold springing or forcing of piping for the purpose of joint make-up shall not be
permitted unless so specified on the drawings.
1.11.3 Except as noted in 7.7.2, piping components shall not be brought into alignment
through the use of mechanical force (i.e. come-a-longs) or heating unless
approved by the Buyer’s Engineer.
1.11.4 When connecting piping to equipment the Supplier shall ensure that the
manufacturer’s instructions are carefully observed for alignment and for
removal of external and internal protectives and that the opening is clean and
free from obstruction and foreign matter.
1.11.5 Mechanical clamps are preferred to welded fit-up lugs. Where welded fit-up lugs
are used, the weldment shall be ground out prior to removing the lug. The
remaining weld deposit is to be ground smooth and flush with the pipe. All
temporary attachment weld areas shall be visually inspected for carbon steel
and NDE for alloys. Areas where welded fit up lugs were installed must receive
the same heat treatment as the remainder of the pipe welds.
1.11.6 The use of welded alignment devices other than fit-up lugs shall not be
permitted.
1.11.7 All flange studs shall move freely in the flange bolt holes when piping is pushed
into place.
1.11.8 The flange faces of rotating equipment and piping shall be parallel within .010 in.
and mate without force. For compressor and turbine piping 6” NPS and below,
this tolerance shall be reduced to .005 in. The gap between flange faces shall
not be greater than 1/8” plus the gasket thickness.
1.11.9 Dial indicators, as used for driver aligning, shall be installed for checking casing
displacement during bolt-up. Consult with Rotating Equipment Specialist.
1.12 Flanges and Bolting
1.12.1 Flange faces shall be clean of protectives, etc. and checked for mechanical or
corrosion damage to the gasket contact surfaces. Damage shall be repaired
prior to installation. See Para 5.5.2.
1.12.2 Flange bolts shall be tightened evenly and diametrically opposite to impose even
pressure on the gaskets and to avoid distortion or overstressing of equipment.

1.12.3 Where hydraulic bolt tensioning is not required bolts shall be installed so as to
leave at least two threads exposed from each nut. Over long bolts shall not be
used.
1.12.4 Prior to flange joint assembly, bolts shall be lubricated with an approved
lubricant. .
Page 47 of
Note: Lubricating compounds containing copper are NOT allowed. 66
1.13 Gaskets
1.13.1 Gaskets shall not be reused. If a flanged joint must be opened, for example, for
system pressure testing, line flushing, removal of temporary blinds or strainers,
etc. the joint shall be re-made with new gaskets and with the bolt lubricant
replenished.
1.13.2 Flanged joints at equipment or valves employing tapped holes shall have the
thread depth checked prior to assembly to ensure that cap screws of the correct
length are used.
1.13.3 Connections to flat faced cast iron flanges shall use flat face mating flanges and
full face gaskets. Special care shall be taken to tighten bolts correctly.
1.13.4 No sealing compounds shall be applied to gaskets or flange faces.
1.14 Insulating Flange Kits
1.14.1 Where insulating flange kits are to be installed, care shall be taken not to damage
the bolt sleeves and gasket. The completed joint shall be tested with a
“Megger”, DVOM or similar device to assure electrical isolation. If both sides of
the flanges are grounded a reading of 1 to 20 ohms shall occur. If one or both
sides are not grounded, a reading of 1000 or more ohms shall occur.
Note: Welding grounds shall not be installed across insulation flanges.

1.15 Valves
1.15.1 Valves shall be installed with stems oriented as indicated on piping drawings
and/or models. In horizontal lines split disc wafer-type check valves shall be
installed with the shaft in vertical position. Globe valves shall be installed with
bottom of disc facing the flow direction.
1.16 Seal Welding
1.16.1 Where seal welding is required, the joints shall be made up without the
application of thread lubricant and threads thoroughly cleaned from grease and
oil. Welds on threaded fittings shall be the same size as for socket fittings and
shall cover the exposed threads completely.

Page 48 of
66
1.16.2 Seal welding shall be applied:
a) Between connections to columns, vessels, tanks and exchangers in
hydrocarbon service and the first valve.
b) Orifice flange taps in those systems where socket welding small piping is
specified.
c) Unvalved, plugged hydrostatic test vents in systems where socket welding
small piping is specified.
1.16.3 The following items shall never be seal welded:
a) Screwed Thermowells
b) Union Nuts
c) Screwed Ends of Gauge Glasses, Gage Cocks
1.17 Non-Metallic Pipe
1.17.1 Reinforced fibreglass and other non-metallic pipe shall be installed strictly in
accordance with the pipe manufacturer’s installation instructions. Personnel
doing this work shall be properly trained by pipe manufacturer’s representative
prior to doing this installation.
1.18 Threaded Joints
1.18.1 Threaded joints shall only be used where specified in the relevant Piping Classes.
All pipe threads shall be the NPS (threaded) type in accordance with either
ASME B1.20.1 or API 5B. Threads shall be cut after any required bending,
forming or heat treatment. Where this is not practical, suitable protection shall
be applied to protect the threads.
1.18.2 For instrument air, lube oil, seal oil, hydraulic lines and services over 400ºF, an
approved pipe dope shall be used. In other services and below 400ºF, a
temperature suitable tape may be used.
1.18.3 Where threaded flanges are specified, the pipe shall terminate 1/16” short of the
flange face.
1.18.4 Adequate unions shall be included in threaded assemblies to permit easy
assembly and dismantling without the need for rotation of long pipe legs. This
shall apply especially to pipework connecting to pumps, compressors, etc. where
routine servicing or replacement by a standby unit necessitates disconnection of
the pipe. This may be an add-on to details of the piping drawing.

Page 49 of
66
1.19 Shop Fabrication
1.19.1 Branch connections on shop fabricated piping shall include appropriate fittings or
groups of fittings, i.e. flanged thermowells connections, sockolets, threadolets or
pipe stubs for small field fabricated branch connections. NPS 2 and smaller pipe
stubs shall extend to the first weld but not more than 12” from the outside
surface of the header. NPS 3 and larger pipe stubs and branches shall extend to
the first flange or to the field weld point as indicated on the piping drawings or
as required for reasonable spool piece size.
1.19.2 Where reinforcement pads are required at branch connections which are to be
field welded they shall be fabricated by the Shop Fabricator and securely wired
to the spool for shipment.
1.19.3 A NPS ¼” (threaded) vent/tell-tale hole shall be drilled in each reinforcement pad
or reinforcement pad section.
1.19.4 Attachments shown as “loose” on isometric drawings shall be field installed.
Where pipe fabrication requires pre or post weld heat treatment then such
attachments shall be on pads or stubs to which the Erector can weld without
PWHT. Pads or stubs shall be installed by the shop fabricator and receive the
appropriate heat treatment.
1.19.5 All shop fabricated piping shall be hydro-tested unless otherwise specified in the
purchase order or contract.
1.20 Field Fabrication
1.20.1 All pipework, valves, piping specials shall be inspected before installation to
ensure that protective packing, covers, wrapping and internal protectives such
as silica gel bags are removed.
1.20.2 Protective covers of pipe, fittings, flanges and equipment shall not be removed
until immediately prior to installation.
1.20.3 All piping and valves shall be examined to ensure that no deterioration has
occurred in storage with particular note of valve internals. All manually
operated valves shall be cycled from fully open to fully closed and back again to
ensure operability.
1.21 Closure Welds
1.21.1 Closure welds on piping installed on shop fabricated pipe rack modules may be
field inspected for integrity by Alternative Testing in accordance with the
Specification for Piping Pressure Testing in lieu of hydrotesting.

Page 50 of
66
1.22 Alloy Cladding
1.22.1 All alloy cladding shall be performed in accordance with an approved
specification.

6.2 Fittings
6.2.1 The steel from which the fittings are made shall be in
accordance with 6.1 and 6.2 of SPAN TS 21827: Part 2.
6.2.2 Fittings shall be manufactured from tubes
manufactured in accordance with SPAN TS 21827: Part 2
or from plate or strip made from one of the steel grades
specified in Table 1 of SPAN TS 21827: Part 2.
6.2.3 All welds of fittings made from plate or strip and all
fabrication welds shall be arc welds and the preparation for
welding and the welding shall be carried out to qualified
procedures using competent welders. Procedures in
accordance with BS EN ISO 15607, BS EN ISO 15609-1
and BS EN ISO 15614-1 carried out by welders qualified in
accordance with EN 287-1 meet this requirement.
6.2.4 The NDT activities for fittings shall be in accordance
with 6.3.3 of SPAN TS 21827: Part 2.
7. Requirements for fittings
7.1 General Fittings, when inspected and tested in
accordance with clauses 9 and 10, shall comply with the
requirements of 7.2 to 7.8. In addition to the requirements
of this SPAN Technical Specification the general technical
delivery conditions specified in EN 10021 apply. Fittings
shall be designed to withstand a pressure of not less than
1.5 times the allowable operating pressure. NOTES It is
essential that the allowable operating pressure (PFA) is
stated in the enquiry and order (see 5.2.2.f).
7.2 Chemical composition Cast analysis and product
analysis requirement shall comply with the requirement of
7.2.1 and 7.2.2 of SPAN TS 21827: Part 2.
7.3 Mechanical properties
7.3.1 Tensile test The minimum yield strength, tensile
strength range and minimum elongation for fittings covered
by this SPAN Technical Specification shall be in accordance
with Table 3 of SPAN TS 21827: Part 2. For even curvature
bends and fittings made from plate or strip the tensile test
properties shall be determined after forming. Page 51 of
66
7.3.2 Weld bend test
7.3.2.1 The seam weld of fittings and fittings components
made from plate or strip shall pass a weld bend test in
accordance with 10.2.4 of SPAN TS 21827: Part 2 on the
root and face of the weld using a mandrel of diameter
specified in Table 3 of SPAN TS 21827: Part 2. No cracks or
imperfections shall be permitted in the weld metal, fusion
line, heat affected zone or parent metal, except as
permitted in 7.3.2.2.
7.3.2.2 The opening out of an imperfection due to
incomplete root penetration or lack of fusion shall not be
cause for rejection, provided that the imperfection has
sound metal at the back and on each side of it. Cracks
originating at the edges of the test piece which are less
than 6mm long and which do not penetrate through the
wall shall not be

7.4 Appearance Fittings shall be free from external and

internal surface defects which can be established by visual
inspection in accordance with this SPAN Technical
Specification. The outside surface condition, and where
practicable, the inside surface condition shall be such that
surface defects, and/or surface imperfections requiring
rectification, can be identified. It shall be permissible to
rectify surface imperfections by grinding or machining
provided that after so doing the wall thickness in the
rectified area is not less than the specified minimum
thickness. All ground or machined areas shall blend
smoothly in the contour of the fittings. Surface
imperfections which encroach on the minimum permissible
wall thickness shall be considered defects and shall not be
permitted. Rectification of such defects in fittings by
grinding or machining followed by welding shall be
permitted on the body of fittings unless Option 2 is
specified by the purchaser. Option 2 Rectification of the
body of SAW fittings by welding shall not be permitted.

7.5 Soundness
7.5.1 General Fittings shall meet the requirements for
soundness and freedom from internal imperfections
specified in 7.5.2 and 7.5.3. 7.5.2 Leak tightness All fittings
shall be leak tight. Leak tightness shall be demonstrated
either by a hydrostatic test in accordance with 10.3.2 of
SPAN TS 21827: Part 2 or by an electromagnetic test in
accordance with 10.3.3 of SPAN TS 21827: Part 2. 7.5.3 Page 52 of
Soundness of welds The welds of all fittings shall be shown 66
to be sound when tested in accordance with the
requirements of 10.4.
7.6 Types and dimension of fittings
7.6.1 General The fittings covered by the requirements of
this SPAN Technical Specification are even curvature
bends, gusseted bends, and tees, the dimensions shall be in
accordance with 7.6.2, 7.6.3 and 7.6.4 respectively.
7.6.2 Even curvature bends 7.6.2.1 For general
applications, the dimensions of even curvature bends,
formed by manipulation of tubes, for tubes with outside
diameters from 60.3mm to 323.9mm shall be as given in
Table 1 (see Figures 1 and 2). The purchaser shall specify
the outside diameter, wall thickness and angle of the bend
at the time of enquiry and order (see 5.2.2.e). NOTE 1
Tighter radius bends may be agreed between the purchaser
and manufacturer. NOTE 2 Bends are commonly specified
with angles of 11˚ 15’, 22˚ 30’, 45˚ and 90˚ but they may
be of any angle as required by the purchaser.
7.6.2.2 The bending radius R (see Figure 1 and 2) for tube
with outside diameters greater than 323.9mm up to and
including 1016mm shall be specified by the purchaser at
the time of enquiry and order (see 5.2.2.e). NOTE Even
curvature manipulated bends in diameters greater than
1016mm may be available by agreement with the supplier.

7.6.2.3 The length of straight S, specified in Table 1 shall

be the minima applicable to bends prepared for butt
welding. The lengths of straight S may be modified to suit
other types of joint but shall be not less than the values
specified in Table 1 or 1.5 D for tubes of diameter greater
than 323.9mm. 7.6.2.4 When bitumen lining is required on
even curvature manipulated bends of diameter greater than
168.3mm, the tube length in the bend shall be limited to
1800mm or a gusseted bend used.

Page 53 of
66
 Figure 1. Even curvature bend of 90o

Figure 2. Even curvature bend less than 90o

Table 1. Dimensions of even curvature bends: tube outside

diameters from sizes 60.3 mm to 323.9 mm inclusive

Tube Bend
Diameter Minimum thickness
R S mina
D T
(mm) (mm) (mm) (mm)
60.3 3.6 250 150
76.1 3.6 325 150
88.9 4.0 400 150
114.3 4.5 500 150
139.7 4.5 625 190
168.3 4.5 750 225
219.1 5.0 1000 300
273 6.3 1250 375
Page 54 of
323.9 7.1 1500 450 66
 a
See Figures 1 and 2.

7.6.3 Gusseted bends

Gusseted bends shall be of the general form shown in Figures 3 or

4 or 5 dependent on the angle of the bend. For bends with angle θ
greater than 45˚ in tubes of 457mm diameter and above, the bend
radius R shall be not less than 1.0 D. For other conditions the bend
radius R shall be not less than 1.5 D. The diameter, thickness, the
type (1, 2 or 3) and the angle θ shall be specified by the purchaser
and the dimensions L and R agreed between purchaser and
manufacturer at the time of enquiry and order (see 5.2.2.e).

Figure 3. Gusseted bend type 1, θ ≤ 30˚

Figure 4. Gusseted bend type 2, 31˚ < θ ≤ 60˚

Page 55 of
66
 Figure 5. Gusseted bend type 3, 61˚ < θ ≤ 90˚

7.6.4 Tees

Tees shall be supplied with plain ends (see Figure 6) or with ends
suitable for sleeve joints (see Figure 7) or with flanges attached to
the branch and/or the barrel (see Figure 8). Dimensions of standard
tees shall be given in Table 2. The purchaser shall specify the
diameter and wall thickness of the barrel and branch at the time of
enquiry and order (see 5.2.2.e). When sleeve joint tees or tees with
flanges on the branch and/or on the barrel are required the
dimensions C, E and F shall be as shown in Figures 7 and 8 as
appropriate

Table 2. Dimensions of tees : tube outside diameters from sizes

60.3mm to 2743mm inclusive.

Barrel Branch
Diameter G E H
D or D1 F (Min) (mm) (mm) (mm)
(mm) (mm)
(see Figure 6) 0.5 D plus

60.3 240 200 100 100

76.1 240 200 100 100

88.9 250 200 100 110

114.3 270 200 100 130

139.7 280 200 110 140

168.3 290 200 110 140

219.1 370 250 110 150

273 410 250 130 160

323.9 450 250 130 180

355.6 530 300 150 Page 56 of

200
66
406.4 600 300 150 230
457 to 711 300 230 300

762 to 914 380 300 300

1016 to 1.5 D1 but 380 380 380

2540 with minimum
of 0.5 D
2642 400 400 400

2743 420 420 420

Figure 6. Plain end tee for butt-welded joint

Figure 7. Sleeve joint tee for welding

Page 57 of
66
 Figure 8. Tee with flanged branch

7.7 Tolerance for Fittings

7.7.1 General

The ends of fittings (except for socketed or flanged tees) shall be

prepared to match those of the pipes to which they are to be joined.

7.7.2 Bends

Bends shall be supplied with plain ends cut nominally square to the
axis of the bend unless the purchaser specifies end preparation for
butt welding in accordance with 7.8 (option 3). The ends shall be
free from excessive burrs.

Option 3 The ends of fittings shall be prepared for butt welding.

NOTE Information on end preparation for jointing other than butt

welding is given in Clause 15 and may be agreed between the
purchaser and the manufacturer. Tolerance on the angle between
the end faces shall be within ±1 % of the specified bend angle θ
(see Figure 1 to 5). The radius R of the bend shall be within ±1 %
of the specified radius. The minimum wall thickness of even
curvature bends shall be not less than that permitted in the tube of
equivalent material to which it is intended to be connected. The
tolerance on leg length L1, L2 and L3 for gusseted bends (see
Figure 3 to 5) shall be ±35mm for outside diameters less than or
equal to 219.1mm and ±70mm for outside diameters greater than
219.1mm. When a fixed leg length is specified the tolerance on the
leg length shall be ±6mm.

7.7.3 Tees

Page 58 of
Plain end tees shall be supplied with the ends cut nominally square
to the axis of the barrel and the branch as appropriate unless the 66
purchaser specifies end preparation for butt welding in accordance
with 7.8 (option 3). The ends shall be free from excessive burrs.
Option 3 The ends of fittings shall be prepared for butt welding.
NOTE Information on end preparation for jointing other than butt
welding is given in Clause 15 and may be agreed between the
purchaser and the manufacturer. The tolerance on the angle of
branch relative to the axis of the barrel shall be ±1°. The tolerance
on the dimensions E, F, G and H see Figures 6 to 8) shall be ±6mm.
7.8 End preparation of fittings for butt welding 7.8.1 General The
purchaser may specify that the ends of fittings shall be prepared
for butt welding in accordance with 7.8.2 to 7.8.4. Option 3 The
ends of fittings shall be prepared for butt welding.

7.8.2 Diameter tolerance at fittings ends

The tolerance on the outside diameter of the fittings for a distance
to be agreed at each end shall be in accordance with Table 3. Out
of roundness shall be within the limits for the diameter tolerance
for fittings with D/T less than or equal to 100. For D/T values above
100 the out of roundness shall be agreed between the purchaser
and the manufacturer. Table 3. End tolerance on diameter (D)

Table 3. End tolerance on diameter (D)

Outside diameter
End tolerance
(mm)
≤ ± 0.5mm or ± 0.5% D whichever is the
219.1 greater
219.1 < D ≤ 2032 ± 1.6mm
>2032 ± 3mm

7.8.3 Squareness of ends The ends of fittings shall be at right

angles to the axis of the fittings within 1.6mm measured across the
diameter as shown in Figure 9.

Page 59 of
a) Bends 66
 b) Tees
Figure 9. Squareness of ends

7.7.1 Bevelled ends

7.8.4.1 The ends of fittings of thickness less than 3.2mm shall be supplied
without bevelled ends.

7.8.4.2 Fittings of thickness equal to or greater than 3.2.mm shall be

supplied with ends bevelled as shown in Figure 10 unless option 4 is
specified by the purchaser.

Option 4 An alternative bevel end preparation for butt welding shall be

provided; the purchaser shall specify the type of preparation required.

Figure 10. Butt-weld end preparation Page 60 of

66

Installation of fitting&valve
Fitting installation

All changes in pipe sizes on soil, waste and drain lines shall be
made of concentric reducers. All changes in direction shall be made
by the appropriated use of forty – five degrees (45°) wyes, or long
sweep bends, except that sanitary tees may be used on vertical
stacks. Short quarter bends or elbows may be used in soil and
waste lines where the change in direction is from the horizontal to
the vertical and on the discharge from the water closet.

Valve

2.0 Technical Requirement

2.1 General
The butterfly valves shall be of the double-flanged short in accordance
to BS EN 593+A1

2.2 Valve Size

Size of the valve shall be according to the PBAPP standard pipe
sizes as shown in Table 1 below:

Table 1 — PBAPP standard Nominal Sizes of pipes

Figure 10. Butt-weld end preparation

Materials used for the manufacture of the butterfly valve shall conform to the following:

Part Material
Body Spheroidal graphite iron according to BS EN 1563, material
number EN- JS 1030 Grade 420/12 or BS EN 1503
Shaft Stainless Steel 316 in accordance to BS970: PartPage 4 61 of
Internal fastener 66
Fasteners such as bolts, nuts or pins that are used to fasten or
secure any two or more parts from moving shall be of
 Stainless Steel 316 L
Disc Spheroidal graphite in accordance to BS EN 1563
Retaining Plate for disc Stainless Steel 316
and Sleeve Seat
Sealing Ring EPDM in accordance with MS 672 or BS EN 681
Coating Fusion Bonded Epoxy Coating

sealing ring is secured to the disc must be clearly shown in the engineering drawing.

5.2 Valve Design

5.3 Off- set Disc

The butterfly valve design shall be of double offset disc type.The

elastomer sealing ring be placed at circumference of the disc or on
the valve body.Technical details on how the elastomer sealing ring
shall is secured to the disc must be clearly shown in engineering
drawing

5.4 Operational Torque

Torque characteristics of the butterfly valve such as torque during

valve travel, at fully closed and opening shall be supplied by the valve
manufacturer.The normal operating torque shall be designed to 60 Nm
with the safety factor of at least 5 times of normal operating torque. This
shall apply to all sizes of butterfly valve. Safety pin shall be designed to be
failed at 4 times of normal operating torque or equivalent to 240 Nm

5.5 Flanges
Flanges shall be cast integral with the body.

5.6 Sleeve Seat for the Disc (Soft Seated Valve)

The part of the valve body that comes close or in contact with the
elastomer sealing ring during travel to close or when in closed
position shall be lined with stainless steel. This stainless steel
liner shall be Stainless Steel Grade 316.

The width of this sleeve shall be sufficient to ensure that the

elastomer sealing ring of the disc shall be protected from
damage by incrustations of the internal walls of the valve
(should this happen) during its travel between open and close
positions.

The method of securing the sleeve to the valve body shall be stated by the
manufacturer or clearly shown Page 62 of
66
5.7 Sealing Ring
 The sealing ring on the disc shall be fastened to the disc or the
internal side of the valve body such that it may be replaced when
worn or damaged.

5.8 Flow Characteristics of Butterfly Valve

Flow characteristics of the butterfly valves test in accordance
to Clause 4.2.3.1 and
4.2.3.2 of BS EN 593 + A1 shall be submitted
together with the tender.
5.9 Locking System to Disc
The disc shall be secured to the shaft by locking pins (<300mm) or
key & corresponding keyway (>300mm). Locking pin is
preferred not to pass through completely the whole disc.
Should it pass through completely, locking systems shall be in-
place to prevent the locking pins from being expelled by
hydrostatic pressures when the valve is in closed position.
The type of locking system shall be clearly shown on
engineering shop floor drawings.

5.10 Corrosion Protection Coating

All metal surfaces of the butterfly valve body and disc both
internal and external surfaces shall be coated with fusion bonded
epoxy coating. The coating material shall comply with BS 6920-
1:2014.

The thickness of the coating shall not less than 250µm when
measured on any part of valve and the disc.

Metallic surface preparation prior to application of the coating shall

conform to the requirement of ISO 8501-1:2007(E). Clause 4.2 of the
standard on Blast Cleaning to SA 2½ standard classified 'very
thorough blast - cleaning' shall be applicable.

Blasting to be done through grit blast to the roughness of between

2.0 G/S 76 to 3.0 G/S 76 using Keane - Tator Profile Comparator on
Grit blast disc for comparison.

Valve installation
Page 63 of
66
The valves are bi-directional and may be fitted in either direction
relative to the flow. The valve will control flow equally in either
direction. The recommended installation position is shaft horizontal
and the lower disc-edge opening down-stream. (Especially for
slurry service and media with a tendency for sedimentation). For
optimum valve control and smooth performance, it is recommended
to have a 10 to 20 pipe diameters of straight run inlet piping and 3
to 5 pipe diameters straight outlet piping. A valve is no crow-bar.
Do not use the valve to spread the flanges. Seat damage might be
the result. Notes • The valve can be installed in the pipe-line either
with or without the actuator mounted on top of the valve. Make
sure that you can turn the disc cautious so you can feel a mismatch
resulting from a disc touching the adjacent piping. • Do not use the
valve as a support of the pipe line construction. • Adjacent piping
must be positioned so that minimal piping stresses are transmitted
to the valve flanges during or after installation. • Handling and
lifting of the valves during installation MUST be performed
following the same instructions described in previous paragraph
“1.3 Handling”.

2.3.1. Existing system

1. Check whether the flange distance meets the valve face-to-face

dimensions. Spread with adequate tooling the flanges for easy
insertion of the valve.
2. In case of a wafer valve, insert some flange bolts in the pipe
flanges, to help you bear the valve after insertion.
3. Close the valve so far, that the disc-edge is at least 10 mm within
the body.
4. Insert the valve between the flanges, center the valve body and
insert all flange bolts. Tighten the flange-bolts hand tight.
5. Slowly open the valve completely. (The disc is in line with
parallel flats or keyway in stem head. Keyway points towards disc
edge).
6. Maintain the valve flange alignment while gradually removing
the flange-spreaders and tighten the flange-bolts hand tight.
7. Slowly close and open the valve to check for adequate disc
clearance.
8. Cross-tighten all bolting to the proper torque. Do not over
tighten.

2.3.2. New system

1. With the disc in near-closed position center each mating flange

with the valve body. Fix the body with some flange-bolts and
tighten the bolts.
Page 64 of
2. Use the flange-valve-flange assembly for fit-up and centering to 66
the pipe.
3. Tack-weld the flanges to the pipe.

4. Remove the bolting and remove the valve from between the
flanges.

5. Finish-weld the flanges to the pipe and allow the flanges to cool
completely.

6. Install the valve now according to the procedure for installing in

existing systems

Page 65 of
65