ANNEX 2. Scope of Works 1.0. Introduction. The United. joint pipes and lengths, iv items. and testing. all tests and 2.0.
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- Mervyn Barnaby Watson
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1 ANNEX 2 Pre Shipment Inspectionn and Testing of Ductile Iron Pipes Scope of Works 1.0 Introduction The United Nation intends to procure ductile iron pipes, fittings and valves from China and Italy. The principal quantities are: i. 23,074m of DN600 K9 pipe in approximately 5.7m lengths, including restraint joint pipes and various corrosive protection systems, ii. 6,710m of DN300, 350 & 400 K9 pipe in approximately 5.7m lengths, iii pieces of flange / spigot or flange / flange specials, bends, wall castings, fittings etc. various diameters and pressure classes, iv. 117 valves of various sizess and pressure classes. See Bill of Quantities ( BoQ) for the full list of items. This Scope of Works (SOW) sets out the requirements for pre shipment inspection and testing of the items (see BoQ list) based on sampling in accordance with ANSI/ASQ Z (R2013). For the production of the DN600 (all joints and corrosion liners) the inspector should be at the factory during the whole process from pipe melt to pipe finish. Therefore, all tests and procedures during the manufacturing process should be witnessed. 2.0 Batch Production The pipes, fittings and valves will be manufactured and shipped in three batches; batch A, B & C. Batch A B C Category Pipes Pipes & Fitting Valves Location of Factory China China China / Italy Scope of Works Inspection and Testing Inspection and Testing (inspection only of fittings) Inspection only Batch A: Batch B: Batch C: 6,000m of DN600 K9 spigot / socket, All other items listed in Annex A except those included in Batch A and Batch C, All valves Therefore three reports are to be produced, one for Batch A, Batch B and Batch C. Each of the Batches will be ready at different times. 1 Page
2 3.0 Applied Standard The purpose of the inspection and testing is to ascertain whether the products being supplied to the UN meet the recognised international standards. The following standards are to be used: ISO 2531: 1998 ISO lso ISO ISO 4633 ISO 8180 EN EN 558 EN 1074 EN 593 DIN Ductile iron pipes, fittings, accessories and their joints for water or gas application. Centrifugal cement mortar lining. External zinc coating& bitumen coating. Metallic flanges Part 2: Cast iron flanges Rubber seals Joint rings for water supply, drainage and sewerage pipelines Specification for materials Ductile iron pipelines Polyethylene sleeving for site application Flanges and their joints. Circular flanges for pipes, valves, fittings and accessories, PN designated. Cast iron flanges Industrial valves. Face to face and centre to face dimensions of metal valves for use in flanged pipe systems Valves for water supply. Fitness for purpose requirements and appropriate verification tests. General requirements Industrial valves. Metallic butterfly valves External corrosion protection of buried valves; heavy duty thermoset plastics coatings. 4.0 Samples to be Inspected The sampling methodology will be used in accordance ANSI/ASQ Z (R2013). Samples will be selected from each category of pipe, fitting or valves. For example, a sample of DN300 will be inspected and tested as per requirements in Section 5.0. Batch A i. DN600 PE liner spigot / socket joint Batch B i. DN300 spigot / socket joint ii. DN350 spigot / socket joint iii. DN400 spigot / socket joint iv. DN500 spigot / socket joint v. DN600 PE liner (Polyethylene encasement) spigot / socket joint vi. DN600 PU liner spigot / socket joint vii. DN600 PE liner (Polyethylene encasement) R joint viii. DN600 PU liner R joint ix. DN800 spigot / socket joint x. spigot / flanged pipes (including wall castings) 2 P age
3 xi. xii. xiii. xiv. double flanged socket collars dismantling joints bends, tees/tapers/reducers Batch C i. Double Orifice Air Valve ii. Check Valve iii. Flanged motorized Gate Valve iv. Gate Valve v. Flanged motorized Butterfly Valves 5.0 Pre Shipment Inspection The following inspections should be undertaken prior to shipment: i. External diameter, wall thickness and length Batch A: Only required for DN600. Batch B: To be performed on samples from all the different diameters ranging from DN300 to DN800. ii. Straightness of pipes Batch A: Only required for DN600. Batch B: To be performed on samples from all the different diameters ranging from DN300 to DN800. iii. Cement mortar lining test Batch A: Only required for DN600. Batch B: To be performed on samples from all the different diameters ranging from DN300 to DN800. iv. Zinc coated test Batch A: Only required for DN600. Batch B: To be performed on samples from all the different diameters ranging from DN300 to DN800. v. Active Corrosion Protection with PE Liner (Polyethylene encasement) test Batch A: Only required for DN P age
4 Batch B: To be performed on samples from all the different diameters ranging from DN300 to DN800. Batch C: Valves, as per DIN or equivalent. vi. Passive Corrosion Protection with PU Liner test Batch A: Not required. Batch B: To be performed on samples from DN600 only. vii. Restraint Joints test Batch A: Not required. Batch B: To be performed on samples from DN600 only. viii. Quantity check TO BE PERFORMED AFTER THE OTHER INSPECTION AND TESTS Batch A: All pipes. Batch B: All pipes and fittings. Batch C: All valves ix. Marking check TO BE PERFORMED AFTER THE OTHER INSPECTION AND TESTS Batch A: All pipes. Batch B: All pipes and fittings. Batch C: All valves x. Correct Flange Alignment ISO & EN Batch A: None. Batch B: Flanged fittings only. Batch C: All valves xi. Material Test Certificates 4 P age
5 To be collated and reviewed for all pipes, fittings and valves (Batch A, B &C). These should include all hydrostatic / leaktightness certificates. 6.0 Witness of Tests at Factory The following tests should be taken from randomly selected pipes. There should be 3 from Batch A and 11 from Batch B. i. Hydrostatic test ii. Mechanical properties Tensile Strength iii. Brinell hardness test. These tests should be undertaken as per ISO 2531 and are only to be performed on the DN600 pipe in accordance with the following schedule: Category Hydrostatic Mechanical* Brinell* Batch A(DN600 spigot socket PE liner) Batch B (DN600 spigot socket PE liner) Batch B (DN600 R joint PE liner) Batch B (DN600 R joint PU liner) TOTAL NUMBER OF PIPE LENGTHS TO BE TESTED * assumes that the same pipe can be used for both tests. Therefore the total number of pipes needed for testing is For the Mechanical properties, Tensile Strength and Brinell, rings should be cut from the spigot end of the pipes. These rings will then be tested. If they pass the test, the pipes will be re chamfered so that the spigot socket can be re used. Any pipes damaged or which cannot be used by the UN should be disposed of by the manufacturer. They should not be shipped. 5 P age
6 7.0 Summary Table Inspection or test to be performed as per Section 4.0 & 5.0 Batch A (pipes) Batch B (pipes) Batch B (fittings) Batch C (valves) INSPECTION i. External diameter, wall thickness and length YES YES YES NO ii. Straightness of pipe YES YES iii. Cement mortar lining test YES YES NO NO iv. Zinc coated test YES YES NO NO v Active Corrosion Protection with PE Liner test YES YES NO NO vi Passive Corrosion Protection with PU liner test YES YES vii. Restraint Joints test NO YES NO NO viii. Quantity check YES YES YES YES ix. Marking check YES YES YES YES x. Correct Flange Alignment No No YES YES xi. Material Test Certificates YES YES YES YES TESTING i. Hydrostatic test YES YES NO NO ii. Mechanical properties YES YES NO NO iii. Brinell hardness test YES YES NO NO 6 P age
7 8.0 Report Three hard copies (via courier) and a soft copy (via ) of each report should be sent to the following: Jayne Ekema (Ms.) Procurement Officer Procurement Section United Nations Office at Nairobi (UNON) P. O. Box 67578, Nairobi Kenya Tel: +(254) Fax: +(254) Jayne.Ekema@unon.org Summary of the report should be sent immediately via after the inspection and testing highlighting any non conformities or discrepancies. Once this has been reviewed and accepted by the UN, a final report can be prepared that includes counting, marking and check packing, etc. The final report should be sent within 5 working days of each of the final tests. The report should also contain photographs of all testing processes and results. Where appropriate, screen grabs from computers should also be copied to the report. All report should detail any failures or incidences of non compliance/ discrepancy. 7 P age
8 ITEM DESCRIPTION QTY. UNIT BATCH A S1/1/1-1 Supply DUCTILE IRON PIPE socket-spigot conforming to ISO2531:1998 or equivalent international standard, K9 with internal and external lining, supply of rubber gaskets including 2% reserve, lubricating paste, in acc. with the Technical Specification Section 1.1, and as further specified below. S1/1/1-1.3 S1/1/1-1.1 S1/1/1-1.2 S1/1/1-1.3 S1/1/1-1.4 S1/1/1-1.5 S1/1/1-1.6 S1/1/1-1.7 Dia. 600mm, standard push on joint system, active corrosion protection with PE liner BATCH B Dia. 150mm, standard push on joint system, active corrosion protection with PE liner Dia. 500mm, standard push on joint system, active corrosion protection with PE liner Dia. 600mm, standard push on joint system, active corrosion protection with PE liner Dia. 600mm, standard push on joint system, passive corrosion protection with PU liner Dia. 600mm, restrained push on joint system marked "R" on the Bell Crest, active corrosion protection with PE liner Dia. 600mm, restrained push on joint system marked "R" on the Bell Crest, passive corrosion protection with PU liner Dia. 800mm, standard push on joint system, active corrosion protection with PE liner 6,000 m 26 m 64 m 14,859 m 200 m 1,050 m 965 m 47 m
9 S1/1/2-2 Supply Flanged pipes, conforming to ISO 2531:1998, K9 pressure rating, flange PN 10 with internal and standard external PE lining in acc. with the Technical Specification, Section 1.1 S1/1/2-2.1 Dia. 150 flange/spigot pipe, L=0.90m S1/1/2-2.2 Dia. 150 flanged pipe L=.10m 3 no S1/1/2-2.3 Dia. 200 flanged pipe L=.90m S1/1/2-2.4 Dia. 300 flanged pipe L=.70m S1/1/2-2.5 Dia. 500 flanged pipe L=1.50m S1/1/2-2.6 Dia. 500 flanged pipe L=2.25m S1/1/2-2.7 Dia. 500 flange/flange pipe, L=1.0m S1/1/2-2.8 Dia. 500 flange/flange pipe, L=0.40m S1/1/2-2.9 Dia. 500 flange/spigot pipe, L=1.0m S1/1/2-3 Supply Flanged pipes, conforming to ISO 2531:1998, K9 pressure rating, flange PN 25, with internal and standard external PE lining in acc. with the Technical Specification, Section 1.1 S1/1/2-3.1 Dia. 50 Flanged pipe (PN25), length 0.5m 7 m S1/1/2-3.2 Dia. 400 flanged pipe L=1.20m S1/1/2-3.3 Dia. 400 flanged pipe L=1.75m S1/1/2-3.4 Dia. 150 Flanged pipe (PN25) 6 m S1/1/3-4 Supply Flanged pipes, conforming to ISO 2531:1998 or equivalent international standard, K9 pressure rating, flange PN 40 and standard external PE lining in acc. with the Technical Specification, Section 1.1 S1/1/3-4.1 Dia. 400 flanged pipe L=1.20m S1/1/3-4.2 Dia. 400 flanged pipe L=1.75m
10 S1/1/3-5 Supply flanged pipes, conforming to ISO 2531:1998, K12 pressure rating, flange PN 40 with internal and standard external PE lining in acc. with the Technical Specification, Section 1.1 S1/1/3-5.1 Dia. 600 flanged pipe 135 m S1/2/1-1 Supply of DI fittings shall be made in accordance with international standard ISO 2531:1998 or equivalent international standard including rubber gaskets for push on joints with 2% reserve, lubricating paste, all accessories necessary for installation. All fittings shall be class K12 except T-pieces which shall be class K14. Corrosion protection shall be as defined in the Technical Specification S1/2/ Bends with double sockets, diameter and degrees as below S1/2/ Dia. 150 double socket - 90 degree bend S1/2/ Dia. 500 double socket - 45 degree bend S1/2/ Dia. 500 double socket - 90 degree bend S1/2/ Dia. 500 double socket - 90 degree bend S1/2/ Dia 600 double socket /4 degree bend 4 nos S1/2/ Dia 600 double socket /5 degree bend 10 nos S1/2/ Dia 600 double socket - 45 degree bend 10 nos S1/2/ Dia degrees double flange Duck foot bend, PN 40 S1/2/ Dia. 800 double socket - 90 degree bend S1/2/1-1.2 Bends with flange PN 10, flanges shall comply with ISO or equivalent international standard, diameter and degrees as below S1/2/ Dia. 500 flanged - 45 degree bend 3 no
11 S1/2/2-1.3 Blind flange PN 25 shall comply with ISO or equivalent international standard, diameter and degrees as below S1/2/ Dia 150 Blind Flange (PN25) S1/2/2-1.4 All Socket Collar. diameter as below S1/2/ Dia. 150 all socket collar 4 no S1/2/ Dia. 200 all socket collar S1/2/ Dia. 300 all socket collar S1/2/ Dia. 400 all socket collar S1/2/ Dia. 500 all socket collar 6 no S1/2/ Dia. 600 all socket collar 1 S1/2/ Dia. 600 all socket collar 10 no S1/2/ Dia. 600 all socket collar 30 no S1/2/2-1.5 Supply Flanged self restraint Dismantling Joint. Flanges shall comply with ISO or equivalent international standard, diameter and flange pressure rating as below S1/2/ Dia 150 flanged Dismantling Joint, PN25 S1/2/ Dia. 400 flanged Dismantling Joint, PN25 S1/2/ Dia. 400 flanged Dismantling Joint, PN40 S1/2/ Dia. 500 flanged Dismantling Joint, PN10 4 no S1/2/ Dia. 500 flanged Dismantling Joint, PN25 S1/2/ Dia. 600 flanged Dismantling Joint, PN25 5 no S1/2/ Dia. 600 flanged Dismantling Joint, PN40 6 no S1/2/3-1.6 Flanged Adaptor. Flange shall comply with ISO or equivalent international standard, diameter and flange pressure rating as below S1/2/ Dia. 400 flanged Adaptor, PN25 5 no S1/2/ Dia. 400 flanged Adaptor, PN40 6 no
12 S1/2/3-1.7 S1/2/ Flanged Concentric Taper. Flange shall comply with ISO or equivalent international standard, diameter and flange pressure rating as below Dia. 150x50 flanged Concentric Taper, PN25 S1/2/ Dia. 600x400 flanged Concentric Taper, PN40 S1/2/ Dia. 600x400 flanged Concentric Taper, PN25 S1/2/ Dia. 600x500 flanged Concentric Taper, PN25 S1/2/3-1.8 All Flanged Tee. Flange shall comply with ISO or equivalent international standard, diameter and flange pressure rating as below S1/2/ Dia. 600x150 flanged Reducing Tee, PN25 6 no S1/2/ Dia. 600x150 flanged Reducing Tee, PN40 5 no S1/2/ Dia. 600x400 flanged Reducing Tee, PN25 5 no S1/2/ Dia. 600x400 flanged Reducing Tee, PN40 6 no S1/2/ Dia. 600x600 flanged Equal Tee, PN25 S1/2/ Dia. 500x500 flanged Equal Tee, PN10 S1/2/ Dia. 600x150 flanged Reducing Tee, PN25 S1/2/4-1.9 S1/2/ S1/2/ S1/2/ Wall Casting (Flange/Spigot or Flange/Socket) with puddle flange shall comply with ISO 2531:1998 or equivalent international standard, type, diameter, length and flange pressure rating as below Dia. 150 flange/spigot Wall Casting, PN10, Dia. 150 flanged/spigot Wall Casting, PN25, Dia. 200 flange/spigot Wall Casting, PN10, 3 no
13 S1/2/ S1/2/ S1/2/ S1/2/ S1/2/ S1/2/ S1/2/ S1/2/ S1/2/ S1/2/ S1/2/ S1/2/ S1/4/1-1.1 S1/4/1-1.2 S1/4/1-1.3 Dia. 300 flange/spigot Wall Casting, PN10, Dia. 400 flange/spigot Wall Casting, PN10, Dia. 400 flanged/spigot Wall Casting, PN25, Dia. 400 flanged/spigot Wall Casting, PN40, Dia. 500 flange/socket - Wall Casting, PN10, Dia. 500 flange/spigot Wall Casting, PN10, Dia. 500 flanged/spigot Wall Casting, PN25, Dia. 500 flange/socket - Wall Casting, PN25, Dia 600 flange/spigot Wall Casting, PN10, length=1.0m Dia. 600 flange/spigot Wall Casting, PN25, Dia. 600 flange/spigot Wall Casting, PN40, Dia. 800 socket/spigot Wall Casting, PN10, Dia. 300mm, standard push on joint system, active corrosion protection with PE liner Dia. 350mm, standard push on joint system, active corrosion protection with PE liner Dia. 400mm, active push on joint system, standard corrosion protection with PE liner 5 no 6 no 6 no 27 no 24 no 1,230 m 1,770 m 3,710 m
14 BATCH C S1/3/1-1 Supply flanged Air Relief Valve, flange shall comply with ISO or equivalent international standard, details as defined in the Technical Specification Section 1.3 & Annex C-10, TS-HWA-0004, diameter and pressure rating as below S1/3/1-1.1 Dia 100 Double Oriface Air Valve (PN25) 6 no S1/3/1-1.2 Dia 100 Double Oriface Air Valve (PN40) 6 no S1/3/1-2 Supply flanged Check Valve, flange shall comply with ISO , details as defined in the Technical Specification, Section 1.3, diameter and pressure rating as below S1/3/1-2.1 Dia 150 Flanged Check Valve (PN10) 3 no S1/3/1-2.2 Dia 200 Flanged Check Valve (PN10) S1/3/1-2.3 Dia 300 Flanged Check Valve (PN10) S1/3/1-2.4 Dia 400 Flanged Check Valve (PN10) S1/3/1-3 Supply flanged Check Valve flange shall comply with ISO , defined in the Technical Specification, Section 1.3 & Annex C-10, TS-HWA-0006, diameter and pressure rating as below S1/3/1-3.1 Dia 300 Flanged Check Valve (PN40) 3 no S1/3/1-4 S1/3/1-4.1 S1/3/2-5 Supply flanged Flap Valve, flange shall comply with ISO , defined in the Technical Specification, Section 1.3, diameter and pressure rating as below Dia 400 Flanged Flap Valve (PN10) and assocated fittings Supply flanged Pressure Regulating Valve, flange shall comply with ISO as defined in the Technical Specification, Section 1.3, Annex C-10, TS-HWA-0008, diameter and pressure rating as below 1
15 S1/3/2-5.1 S1/3/2-6 Dia 50 Flanged Pressure Regulating Valve (PN25) and assocated fittings Supply flanged motorized Gate Valve, flange shall comply with ISO , with Electric Actuators local control, details as defined in the Technical Specification, Section 1.3, diameter and pressure rating as below S1/3/2-6.1 Dia 100 Flanged motorized Gate Valve, PN 40 S1/3/2-6.2 Dia 300 Flanged motorized Gate Valve, PN 40 3 no S1/3/2-6.3 Dia 400 Flanged motorized Gate Valve, PN 25 S1/3/2-6.4 Dia 400 Flanged motorized Gate Valve, PN 40 4 no S1/3/2-6.5 Dia 500 Flanged motorized Gate Valve, PN 25 S1/3/3-7 S1/3/3-7.1 S1/3/3-7.2 S1/3/3-7.3 S1/3/3-7.4 S1/3/3-7.5 Supply flanged motorized Butterfly Valves, double eccentric design, with Electric Actuators local control, details as defined in the Technical Specification, Section 1.3, diameter and pressure rating as below. Dia 150 Flanged motorized Butterfly Valves (PN10) with Electric Actuators local control and cabling Dia 200 Flanged motorized Butterfly Valves (PN10) with Electric Actuators local control and cabling Dia 300 Flanged motorized Butterfly Valves (PN10) with Electric Actuators local control and cabling Dia 400 Flanged motorized Butterfly Valves (PN10) with Electric Actuators local control and cabling Dia 500 Flanged motorized Butterfly Valves (PN10) with Electric Actuators local control and cabling 3 no 4 no 7 no
16 S1/3/3-7.6 S1/3/4-8 Dia 600 Flanged motorized Butterfly Valves (PN10) with Electric Actuators, local controls and cabling Supply flanged Gate Valve in accordance with Technical Specification, Section 1.3, diameter and pressure rating as below 4 no S1/3/4-8.1 Dia 50 Flanged Gate Valve, PN25 S1/3/4-8.2 Dia 150 flanged Gate Valve, PN10 S1/3/4-8.3 Dia 150 Flanged Gate Valve, PN25 S1/3/4-8.4 Dia 150 Flanged Gate Valve, PN40 2 S1/3/4-8.5 S1/3/4-8.6 S1/3/4-8.7 Dia 400 Flanged Gate Valve, PN25, with extended (ajustable up to 4m) spindle and assocated fittingss Dia 400 Flanged Gate Valve, PN40 including extension spindle (telescopic type, ajustable up to 4m) and cast iron surface box Dia 500 Flanged Gate Valve, PN25, including extension spindle (telescopic type, ajustable up to 4m) and cast iron surface box 5 no 6 no S1/3/4-8.8 Dia 600 Flanged Gate Valve, PN25, including extension spindle (telescopic type, ajustable up to 4m) and cast iron surface box 5 no S1/3/4-8.9 Dia 600 Flanged Gate Valve, PN40, including extension spindle (telescopic type, ajustable up to 4m) and cast iron surface box 6 no S1/3/4-9 S1/3/4-9.1 Supply flanged Flap Valves, flange shall the Technical Specification, Section 1.3, diameter and pressure rating as below Dia 700 Flanged Flap Valves, PN10 for overflow pipes END
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