LUSAIL DEVELOPMENT

District Cooling Distribution System

Design Guidelines for Supply of
Pre-Insulated Pipes for
Mega-development

Document No: LUS-CPALL-MAQ-SPE-UT-00001

REV REASON PREPARED CHECKED APPROVED
DATE DOCUMENT HISTORY STATUS
NO. FOR ISSUE BY BY BY
Muhammad Abdullah D. Reed
0 IFI 12-04-2012 A
Ali Abushaikha Phillips

REASON FOR ISSUE: STATUS

IFR Issued for Review/Comment(s) PFC Preliminary for Comment A Approved
IFI Issued for Information SS Superseded
IFA Issued for Approval
IFT Issued for Tender
IFC Issued for Construction

Marafeq Qatar L.L.C/ Capital QR 30 000 000

P.O. Box 5651 Doha - Qatar
T: 974 40120120 F: 974 40120121
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CONTENTS

1 INTRODUCTION 4
1.1 General 4

1.2 Tender documents package 4

1.2.1 Technical Requirements Supply of Pre-insulated Pipes – documents package 4

1.3 Scope of Supply 4

2 DEFINITIONS, ABBREVIATIONS AND REFERENCES 5

2.1 Definitions 5

2.2 Abbreviations 6

2.3 Reference documents 6

2.3.1 Codes, standards and specifications 6

2.4 Document precedence 7

3 TECHNICAL REQUIREMENTS AND SPECIFICATIONS 8

3.1 General 8

3.2 Basic design conditions 8

3.3 Distributed water quality 8

4 PRE-INSULATED PIPES 8
4.1 General 8
4.1.1 Chilled water service carbon steel pipes 9

4.1.2 Thermal insulation 9

4.1.3 Outer casing jacket pipe 10

4.2 Surveillance system 11

4.3 Outer casing pipe joints 12

4.3.1 Joint kit’s with heat shrinkable casing 12

4.3.2 Joint kit’s with electro welded casing 13

4.3.3 Special joints for on-site made branches 13

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4.4 Straight pipe lengths 13

4.5 Pipe elbows 13

4.5.1 Pre-insulated elbows 13

4.5.2 Steel pipe elbows 13

4.5.3 Mitred pipe ends 14

4.6 Branches and T-pieces 14

4.6.1 Pre-insulated branches 14

4.6.2 Site made branches 14

4.7 Reducers 14

4.8 Special fittings 15

4.9 Pre-insulated valves 15

4.9.1 Pre-insulated shut-off valves 15

4.9.2 Pre-insulated drain and venting valves 16

4.10 Plastic warning devices 16

5 MARKING, IDENTIFICATION AND TRANSPORTATION 16

5.1 Marking and identification 16

5.2 Transportation, delivery of material to the site 16

6 DESIGN, PREPARATIONS AND TRAINING ON SITE 16

7 QUALITY CONTROL 17

8 WARRANTIES 17

9 DOCUMENTATION 17

10 APPENDICES AND DRAWINGS 18

11 DRAWING / DOCUMENT LIST FORM 18

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1 INTRODUCTION

1.1 General

This document and the attached files define the technical requirements to furnish pipe
and materials for the portion of the district cooling system referred to as Mega-
Development. For ease in understanding, these documents are prepared as if the project
was broken into three separate contracts, but in fact they are all components of a single
contract between the Client and one contracting party.
In the end, the contracting party is responsible for all aspects of the project and that all
tools, equipment, and devices are suitable and reliable for the intended use and in the
ambient conditions expected at the construction site. He shall be responsible for all
documents and procedures requested by authorities for the official inspection and
acceptance of the works.
In general the technical tender documents are described as:
 LUS-CPALL-MAQ-SPE-UT-00001 Pre-insulated Pipes: The scope of supply is
described as pipe and materials including delivery to a lay down area designated by
Client, but the scope does NOT include fabrication or installation of pipe (mechanical
works) or trenches (civil works).
 LUS-CPALL-MAQ-SPE-UT-00002 Civil Works: The scope of supply is the civil
portion of the underground piping system and thus does NOT include pipe materials
or mechanical installation.
 LUS-CPALL-MAQ-SPE-UT-00003 Mechanical Works: The scope of supply includes
mechanical installation of pipe and materials, but does not include furnishing
materials or preparing the trenches.

1.2 Tender documents package

This document is part of the total tender package and ultimately will be incorporated into
the project Agreement.

1.2.1 Technical Requirements Supply of Pre-insulated Pipes – documents

package

This document specifies technical requirements for supply of pre-insulated district

cooling pipes and fittings and is a part of the total Technical requirements for Supply of
Pre-insulated pipes package.
The Scope of Supply is defined by:
- This document.
- Appendices and drawings in accordance with Drawings/Documents List form
(DLF).

1.3 Scope of Supply

The Supplier shall provide material and services necessary for a complete, safe and
prudent underground pipe system as described herein.

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Delivery shall be made in accordance with good industry practice, notwithstanding

certain essential items not being expressly stated in these requirements or elsewhere in
the Request for Proposal (RFP).
The Scope of Supply shall include, but not be limited to the supply and delivery of:
1. Pre-insulated carbon steel pipes intended for installing underground.
2. Pipe elbows, branches, and other fittings, valves and auxiliaries.
3. Surveillance system(s).
4. Outer jacket casing pipe joints.
5. Documentation.

Laying down pipes in the trench, installation and welding of the steel pipes will be carried
out by the Mechanical Contractor and is not a part of this Scope of Supply.

2 DEFINITIONS, ABBREVIATIONS AND REFERENCES

2.1 Definitions

The following expressions shall, where the context so permits, have the meaning hereby
respectively assigned to them.
Client The master developer - Lusail Real Estate Development
Company (LREDC) or its appointed representative.
Contractor The organization or its appointed representative,
responsible for execution of the works.
Customer The owner / sub-developer in-charge of the building.
Engineer Marafeq’s supervision engineer or its appointed
representative.
Marafeq The utility company which provides District Cooling, Gas
Supply and Waste Management services.
Mega-Developer The owner of the district.
Sub-Developer The owner of the building.
Vendor Any invited companies being fully eligible to submit the
Tender. The successful Vendor will be the
contractor/Supplier.
Works Means work, products, materials, computer software and
documentation, and other work as called for in the
Agreement.
Agreement Means the contract or other written agreement entered
into between the Client and a contracting party regarding
supply of the Works including appendices, amendments,
and additions agreed in writing.
For Information only Means information only is indicative and not under
responsibility of the Client. Vendor has to control, verify
and be responsible for any such information in the same
manner as other submittals.
Must This is a minimum requirement.

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Must This is a minimum requirement.

Shall Indicates a mandatory requirement.
Should Indicates a preferred method or material.
Request for Proposal Means the document prepared and issued by the client
who includes this document and other general and
particular requirements.

2.2 Abbreviations

DP Design pressure
ID Internal diameter
OD Outer diameter
WT Wall thickness
QCP Quality Control Plan
FAT Factory Acceptance Test
SAT Site Acceptance Test
RFP Request For Proposal
WPS Welding Procedure Specification

2.3 Reference documents

2.3.1 Codes, standards and specifications

Material supplied by the Supplier and work, methods, testing, and actions carried out by
the Supplier shall, at a minimum, conform to the requirements of the codes listed below.
When an edition date is not indicated for a code or standard, the latest edition in force at
the time of contract award shall apply.
EN253 Pre-insulated bonded pipe systems for directly buried hot water
networks.
EN448 Pre-insulated fittings for bonded pipe systems
EN488 Pre-insulated valves for bonded pipe systems
EN489 Joints and connections for pre-insulated bonded pipe systems
EN13941 Design and installation for bonded pre-insulated pipe systems.
EN14419 Surveillance systems for bonded pre-insulated pipe systems
EN10216-2 Seamless steel tubes
EN10217- 2, -5 Welded steel tubes
EN10253-2 Butt welded steel fittings
EN13480 Metallic industrial piping
P235GH Steel quality
EN 12517 Non-destructive testing of welds. Radiographic testing of
welded joints
EN12613 Plastic warning devices for underground cables and pipelines
with visual characteristics

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EN ISO 5817 Fusion welded joints in steel and alloys. Quality levels for
imperfections.
EN206-1 Concrete: Specification, performance, production and
conformity.
EN287-1 Qualification test of welders. Fusion welding – Part 1: steels.
E 287-3 Welding procedures tests.
EN288-2 Specification and approval of welding procedures for metallic
materials. Welding procedures specification for arc welding of
steels.
EN288-3 Specification and approval of welding procedures for metallic
materials. Welding procedures specification for arc welding.
EN ISO 9692-1 Welding and allied procedures – Recommendations for joint
preparation.
EN ISO 11970 Specification and approval of welding procedures for
production welding of steel castings.
ISO 12096 Submerged arc-welding steel tubes for pressure purposes –
Radiographic testing of the weld seam for the detection of
imperfections.
EN ISO 15607 Specification and qualification of welding procedure for metallic
materials. General rules.
EN ISO 3834 Quality requirements for fusion welding of metallic materials.
EN ISO 15614-1 Specification and qualification of welding procedures for
metallic materials -- Welding procedure test -- Part 1: Arc and
gas welding of steels and arc welding of nickel and nickel
alloys.
EN 10253-1,-2 Butt welding pipe fittings.
QCS Qatar Construction Specifications.
Kahramaa Water and Electricity Components.
QCD Qatar Civil Defense.
Other standards Mentioned or referred to in the complete package of Tender
documents.

2.4 Document precedence

The Contractor shall notify the Engineer of any conflict between this specification, the
related requirements and/or data sheets, the codes and standards and any other
specifications noted herein. Resolution and/or interpretation precedence shall be
obtained from the Engineer in writing before proceeding with the design or manufacture.
In case of conflict, the order of precedence shall be:
1. Material narrative specifications.
2. Project specifications and standards.
3. Industry and official codes and standards.

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3 TECHNICAL REQUIREMENTS AND SPECIFICATIONS

3.1 General

The piping system shall be supplied as pre-insulated bonded carbon steel pipes with
polyurethane foam insulation (PUR) and with high density polyethylene (HDPE) outer
casing jacket.
Works, pipes, and components shall meet the technical and environmental requirements
of the applicable directives and standards.
Health and safety requirements and the function of safety related systems must be
fulfilled.

3.2 Basic design conditions

Design pressure 1600 kPa

Operating temperature range 4.0 – 16°C
Soil temperature range 10 – 50°C
Ambient design temperature 50°C; maximum outdoor temperature during
installation
Water quality See table in paragraph 3.3.
Calculated life-time Pipes, works, and components shall be designed for
a calculated life-time of 40 years.

3.3 Distributed water quality

The Client intends to maintain the circulated water quality as noted in the table below.
Parameter Data
pH-value 8.0 +/-1.0
TH (°F) 2 - 20
Punctual TH (°F) 8 - 20
TAC (°F) 35 +/- 10
Total copper 0.2 +/- 0.1 mg/l
Total iron 2.0 +/- 0.5 mg/l
Conductivity 471 +/- 251 µs/cm
Chlorides 10 +/- 2 mg/l
CO2 > 30 mg/l
O2 1.0 +/- 0.1 mg/l

4 PRE-INSULATED PIPES

4.1 General

Pre-insulated bonded pipe systems for directly buried water networks. Pipes assembled
by carbon steel service pipe, polyurethane thermal insulation and outer casing of high
density polyethylene (HDPE).

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The pre-insulated bonded piping shall comply with standard EN253 as minimum.
Certification of testing from independent party to verify compliance with EN253 shall be
provided.
Pipe ends shall be delivered free from insulation for welding in the field. Insulation of the
free pipe joints and joining of the outer casing pipe shall be carried out with a proven
reliable method, as further described.
A surveillance system based on copper wires moulded into the pipes and components
foam insulation shall be included in the pre-insulated piping system as described in
greater detail in clause 4.2

4.1.1 Chilled water service carbon steel pipes

The service carbon steel pipe shall conform to dimensions in accordance with DIN 2458
and steel quality P235GH in accordance with standard EN10216-2, EN10217-2 and
10217-5.
Elbows, reducers, tees and other fittings shall comply with standard EN10253-2 type B.
Pipes shall be delivered from factory in 12 m or 16 m length sections.
Seamless steel tubes in accordance with EN10216-2 shall be used for dimensions up to
DN350.
Welded steel tubes in accordance with EN10217-2 (ERW) or EN10217-5 (SAW) shall be
used from dimension DN400 and larger.
Carbon steel pipe dimensions:
Nominal
Dimension Outer Diameter
Wall Thickness
DN100 114,3 mm 3,6 mm
DN125 139,7 mm 3,6 mm
DN150 168,3 mm 4,0 mm
DN200 219,1 mm 4,5 mm
DN250 273,0 mm 5,0 mm
DN300 323,9 mm 5,6 mm
DN400 406,4 mm 6,3 mm
DN450 457,0 mm 6,3 mm
DN500 508,0 mm 6,3 mm
DN600 610,0 mm 7,1 mm
DN700 711,0 mm 8,0 mm
DN800 813,0 mm 8,8 mm
DN900 914,0 mm 10,0 mm
DN1000 1016,0 mm 11,0 mm
DN1100 1120,0 mm 11,0 mm
DN1200 1220,0 mm 12,5 mm
DN1300 1320,0 mm 12,5 mm

4.1.2 Thermal insulation

The pre-insulated pipes and fittings shall be delivered with high density polyurethane
foam applied at factory. The polyurethane foam shall be bonded to the carrier pipe and
the outer casing jacket pipe. Minimum insulation requirements:

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Property Min. requirement

Closed cell content > 90,0 %
Size of cells < 0,3 mm
Core density ≥ 60 kg/m3 Note1
o
Thermal conductivity at 50 C
< 0,029 W/mK
(λ50)
Water absorption < 5 % (volume)
Compression strength > 0,30 MPa
Axial shear strength,
> 0,12 MPa
23 deg C new
Axial shear strength,
> 0,12 MPa
23 deg C aged
Note 1: Core density is currently not defined in EN253:2009. However, the specified density is required for
handling large diameter pipes. (It was included in the previous EN253:2003. Requirements are considered by
CEN/TC 107, to be included again in next EN253 standard version.)

Thickness of insulation varies depending on pipe size. See dimensions of outer casing
jacket pipe in paragraph 4.1.3.
Before insulation is applied, the external surfaces of the carrier pipe and the inner
surface of the casing pipe shall be cleaned and treated to maximize adhesion between
the insulating foam and the adjoining surfaces.

4.1.3 Outer casing jacket pipe

The outer casing jacket pipe functions as the vapour barrier (barrier against
condensation) and shall be manufactured in UV-stabilized HDPE in accordance with
EN253 or equal.
Materials High density polyethylene (HDPE) bimodal minimum PE80, ISO
12162
Density Min. 944 kg/m3
Pipe wall thickness According to EN253 or equal
Outer casing jacket pipe dimensions:
Minimum Casing
Outer Diameter
Dimension Wall Thickness
Casing Pipe
(mm)
DN100 200 mm 3,2
DN125 225 mm 3,4
DN150 250 mm 3,9
DN200 315 mm 4,5
DN250 400 mm 4,8
DN300 450 mm 5,2
DN350 500 mm 5,6
DN400 520 mm 5,7
DN450 560 mm 6,6
DN500 630 mm 7,2
DN600 780 mm 7,9
DN700 900 mm 8,7

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Minimum Casing
Outer Diameter
Dimension Wall Thickness
Casing Pipe
(mm)
DN800 1000 mm 9,4
DN900 1100 mm 10,2
DN1000 1200 mm 11,0
DN1100 1300 mm 11,8
DN1200 1400 mm 12,5
DN1300 1500 mm 15,9

4.2 Surveillance system

For detection and location of moisture in the insulation, a complete surveillance system
including main central computer, surveillance units, outside cabinets, cable connectors,
etc shall be included in the works.
Detailed design of the leak detection system for this specific project shall be carried out
by the Supplier and included in the delivery. Detailed design shall include, but not be
limited to, size and location of control loops, location of alarm units, commissioning and
documentation.
The surveillance system shall be specially designed for District Cooling systems. This
especially means, among other requirements, that the detection wires must be designed
in order to avoid problems caused by “natural condensation” in the foam insulation and
moisture from condensed ambient air.
The foam insulation naturally has a low non-detectable concentration of moisture equally
spread between steel pipe and outer casing jacket. In operation, the warmer atmosphere
outside the insulated pipe will create a process in which the natural moisture travels
towards the colder steel pipe and eventually will reach a high concentration. The
detection wires must be able to handle the consequences of such natural “moisture
travel” without giving any false alarms.
The detection wires shall be insulated copper wires mounted as 3 parallel wires at a fixed
distance between the conductors in a common cable conduit. The common cable conduit
shall be assembled directly to the media steel pipe.
The system shall detect moisture in the foam by measuring impedance along the
insulated copper wires. By detecting faults early, damage and degradation of the
insulation and/or corrosion of the service pipe can be minimized. The system shall also
be able to locate a break of the surveillance copper wires.
The system shall, beside copper wire and constant distance elements, include a
sufficient number of microprocessor based monitoring alarm units.
The surveillance units shall operate on a pulse reflection method and be able to survey
the entire system including straight pipes, bends, branches and other fittings. The system
shall also be capable of detecting more than one leak after acknowledgement of previous
or current leak.
Only pulse surveillance units (for use in district cooling systems) shall be supplied.
Resistance surveillance (commonly used for district heating systems) will not be
accepted.
The surveillance system shall work as a fully documented system taking measurements
of each increment of the entire sensor wires and storing the received data in a non-
volatile data base memory as start-up data. In monitoring mode, actual data and start-up
data shall be compared in order to detect deviations.

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System sensitivity shall be selectable in different levels in such a way that minor
irregularities from the installation phase can be detected and accepted as “zero-figures”.
Surveillance units shall be prepared for communication with a central system for
supervision of all alarm units in the system. Communication shall be possible via GPS,
signal or optic cables and 24/7 surveillance from a centralized control room shall be
possible.
In the tender, the Vendor shall completely describe the system he is proposing. Only
well-proven systems for district cooling applications with documented reliability from
experienced suppliers will be accepted.

4.3 Outer casing pipe joints

Supply and installation of joint kits for the outer casing HDPE pipe shall be delivered to
the amount specified in Bill of Quantity.
Delivery shall comply with the requirements in EN489 as minimum.
Not all joint kits will be installed at completely straight pipe joints so it is important that
joint kits are designed to accommodate small angles of deviation.
The Vendor shall in his tender specify all relevant data including:
1. Maximum allowed deviation-angle for a “standard” joint kit.
2. Special joint kits for deviation-angles larger than the standard joint kit.
3. Required education of fitters for each type of delivered joints.

4.3.1 Joint kit’s with heat shrinkable casing

A joint kit includes a tubular heat-shrinkable casing, sealant mastic’s, additional outside
sealing sleeves and polyurethane foam for applying on site.
Joint kit’s with heat shrinkable casing shall only be supplied for dimensions DN 150 and
smaller.

Tubular heat-shrinkable casing

The casing portion in a joint kit shall consist of an oversized tubular casing for application
on the pipe end prior to welding. The casing shall be manufactured of cross linked, high
density polyethylene layers.
The tubular casing shall be manufactured heat-shrinkable with a gas torch. Sealing plugs
for the insulation holes shall be included in the works.
Length of the casing shall minimum overlap 100 mm of adjacent pipe component’s
casing.

Sealant mastic and sleeves

Delivery of wide sealant mastics strips for installation on the pipe ends under the tubular
casing shall be included in the works.
Additional outside heat-shrinkable sealing sleeves for application after installation of the
tubular casing shall be included for double security.

Polyurethane foam insulation

Polyurethane foam shall be delivered in sets/kits for mixing and applying on site.

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Sets/kits shall be delivered with sufficient volume to seal each pipe size and based on a
calculated average application temperature.

4.3.2 Joint kit’s with electro welded casing

A joint kit includes a tubular casing, strips for electro welding, welding sleeves with
accessories and polyurethane foam for applying on site.
Joint kits with electro welding casing shall be used in dimensions DN 200 and larger.

4.3.3 Special joints for on-site made branches

For branches made on site in accordance with paragraph 4.5.2, special joints shall be
provided in the quantities listed in the Bill of Quantity.
Delivery shall comply with the requirements in EN489 as minimum.
Vendor shall present the design and specifications in his tender.

4.4 Straight pipe lengths

Straight pipes shall be delivered in standard 12 m and 16 m lengths, in the quantities

listed in Bill of Quantity.
Each pipe end shall be free of foam installation at a minimum length of 250 mm. Pipe
ends shall be bevelled as specified in standard EN ISO9692-1.
All pipes shall be delivered with plastic end caps in order to avoid debris in the pipes,
during transportation, storing and handling.
Delivery shall comply with the requirements in EN253 as a minimum.

4.5 Pipe elbows

Pre-insulated elbows shall be delivered in accordance with clause 4.5.1; in general for
directional changes greater than 10 deg.
Steel pipe elbows (uninsulated fittings) shall be delivered in accordance with clause
4.5.2; in general for directional changes from 0 to 10 deg.

4.5.1 Pre-insulated elbows

Pre-insulated elbows shall be delivered to the quantities listed in Bill of Quantity.

Delivery shall comply with the requirements in EN448 as minimum.
Each pipe end shall be free of foam installation at a minimum length of 250 mm. Pipe
ends shall be bevelled as specified in standard EN ISO9692-1.
All pipe components shall be delivered with plastic end caps in order to avoid debris in
the pipes, during transportation, storing, and handling.

4.5.2 Steel pipe elbows

Uninsulated steel pipe elbows are used for sizes larger than DN350 in small angles
between 0 to 10 degrees and shall be delivered in the quantities listed in Bill of Quantity.

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An uninsulated steel pipe elbow is welded in between two straight cut pipe ends to create
an angle of deviation. The elbow shall be designed in such a way that the inner arc
length exceeds 40 mm for DN400 - DN500. For larger dimensions shall the inner arc
length exceed 50 mm.
Field joints are insulated and sealed on site using standard or special joint kits (as
defined in paragraph 4.3.2, 4.3.3).

4.5.3 Mitred pipe ends

For directional changes from 0 to 10 deg for piping DN 350 and smaller, the Mechanical
Contractor will miter the pipe ends in the field.

4.6 Branches and T-pieces

Branches and T-pieces shall be delivered to the amount specified in Bill of Quantity.
Delivery shall comply with the requirements in EN448 as minimum. Pipe used for
branches shall comply with the requirements stated in clause 4.1.1.
Branches shall be supplied as pre-insulated branches or site made branches in
accordance with the table below:
Main pipe Pre-insulated branch Site made branch
DN500 DN250 and larger DN200 and smaller
DN600 and larger DN350 and larger DN300 and smaller

4.6.1 Pre-insulated branches

Each pipe end shall be free of foam insulation for a minimum length of 250 mm. Pipe
ends shall be bevelled as specified in standard EN ISO9692-1.
All pipe components shall be delivered with plastic end caps in order to avoid debris in
the pipes, during transportation, storing and handling.

4.6.2 Site made branches

Delivery of each site made branch shall, at a minimum, include:

- One 90 degree steel pipe elbow
- One steel pipe stub piece
- One special joint kit
- Detailed instructions for the welding contractor.
Cutting main pipe casing and insulation, cutting a hole in main pipe, installation and
welding of pipe stub and 90 degree elbow will be done by others.

4.7 Reducers

Reducers shall be delivered to the amount specified in Bill of Quantity.

Delivery shall comply with the requirements in EN448 as minimum. Pipe used for
reducers shall comply with the requirements stated in clause 4.1.1.

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Each pipe end shall be free of foam installation at a minimum length of 250 mm. Pipe
ends shall be bevelled as specified in standard EN ISO9692-1.
All pipe components shall be delivered with plastic end caps in order to avoid debris in
the pipes, during transportation, storing and handling.

4.8 Special fittings

Fittings and components of “special type” (other then described in this document) shall
fulfil all applicable codes and standards.
If the Vendor chooses to offer special fittings then all details must be clearly specified in
the bid.

4.9 Pre-insulated valves

Pre-insulated valves shall be delivered to the amount specified in Bill of Quantity.

Delivery shall comply with the requirements in EN488 as minimum. Pressure class for
valves is minimum PN16. Suppliers of certified pre-insulated ball valve shall use so
called S-valves (Strong).
Valves shall be designed for the extra large external forces created by thermal
contraction and friction forces exerted from connected pipes. Axial forces calculations
shall be based on ambient design temperature during installation and lowest operating
temperature in accordance with clause 3.2.
Stem shall be fitted with a position indicator.
Total delivery of valves shall include 1 (one) manoeuvre device per gearbox dimension
designed for operation from street level. Device shall be based on stem grip in
appropriate size(s), wrench extension, gearbox and manoeuvre wheel.
For valves buried deeper than 2 meters, provide hydraulic actuators, hoses, control
cabinet and auxiliaries as indicated on the drawings and Bill of Quantity.

4.9.1 Pre-insulated shut-off valves

Up to DN450, use steel ball valves with all-welded body and carbon reinforced Teflon
seals.
DN500 and larger, use butterfly valves.
For valves DN400 and larger, provide DN 50 pre-insulated by-pass valves.
For valves DN200 and larger, provide gear boxes.
Stem shall be provided with double sealing, minimum two O-rings and the upper one
shall be changeable from top.
Long stem ball valves where the extended stem is an integrated part of the valve is
preferred.
Valves for connection to plots shall be equipped with venting valves.
All valves shall comply with requirements in EN488 as minimum.
Number of valves and types of valves; in accordance with the Bill of Quantity.
All valves shall be delivered with plastic end caps in order to avoid debris in the valves,
during transportation, storing and handling.

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4.9.2 Pre-insulated drain and venting valves

Only steel ball valves with all-welded body and carbon reinforced Teflon seals are
accepted.
Ball valve shall comply with requirements in EN488 as minimum.
Stem shall be provided with double sealing, minimum two O-rings and the upper one
shall be changeable from top.
Venting valves shall be designed as straight T-pieces with valve on top, pointing
upwards. (Note that venting valves, when directly buried in the ground, if located at depth
that makes it hard to reach handle from street level, shall be arranged horizontally and
provided with a wrench extension (T-key).

4.10 Plastic warning devices

Plastic warning devices shall be delivered to the amount specified in Bill of Quantity.
Plastic warning devices will be rolled out and placed in the trench by the civil contractor,
see detail drawing: Typical trench section LUS-CPALL-MAQ-DWG-UT-10301

5 MARKING, IDENTIFICATION AND TRANSPORTATION

5.1 Marking and identification

As an addition to requirements specified in codes and standards, each piece shall be

marked in accordance with the Suppliers shop drawings and with a position number. The
position number will be given by the Engineer prior to ordering.
Position numbers shall be sprayed on the jacket pipe at minimum two sides of each
component for easy identification on site.

5.2 Transportation, delivery of material to the site

All delivery to the agreed site storage area shall be handled by and under the Supplier’s
responsibility.
In the event of damage caused under transportation or other defects in the material
delivered, The Engineer reserves the right to reject such material and have it replaced
with new material in good condition.
Unloading from trucks at the site will be carried out by others

6 DESIGN, PREPARATIONS AND TRAINING ON SITE

The high ambient temperature and bright sunlight must be considered during storage,
transportation, and installation.
Site work shall include:
- Design and preparation of “surveillance drawings” showing control loops layouts
including routings in branches and locations of circuit closings.

Project Name: Lusail Development District Cooling Distribution System

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 LUSAIL DEVELOPMENT

- Training of Contractor’s installing personnel and the Engineer in surveillance system

installation, testing and commissioning including issuing of certificates for persons
after the successful education.
- Training of Contractor’s installing personnel and the Engineer in outer casing pipe
jointing and testing for each type of delivered joints including issuing of certificates
for persons after the successful education.

7 QUALITY CONTROL
All quality control, inspection and testing shall be carried out in accordance with
applicable and specified codes and standards.
A quality control system in accordance with the international standard ISO 9001 is
preferred.
Products certified by independent body in accordance with official regulations are
preferred and will be considered as an advantage in the Client’s final evaluation of
received tenders.
Vendor shall provide his quality control manual as part of the tender submission.
Supplier shall be able to document and demonstrate that all the activities related to
quality throughout the process from confirmation of order to design, purchasing,
manufacturing and delivery have been carried out in a properly monitored and organised
fashion.
The Supplier shall give the Client at least 3 weeks notice of factory tests in order to give
the Client a possibility to witness the tests.

8 WARRANTIES

All pipe material and components shall be covered by the Supplier’s warranty for
duration of 5 years following acceptance, in the form of a global insurance policy,
covering damage of all types to the structure and with third party responsibility.

9 DOCUMENTATION
Supplier shall submit all documentation from quality control, inspection, and test reports.
Mill certificates for all steel shall be submitted and sorted in good order.
Welder’s qualification certificates from welding of pipe components shall be submitted.
Pipes and pipe components shall be marked for identification. Shop drawings with piece-
marks shall be submitted.
Complete documentation for the surveillance system including design documents,
commissioning documentation, and an instruction manual shall be delivered.
All documentation shall be delivered in minimum 5 sets hard copy plus 1 set soft copy.

Project Name: Lusail Development District Cooling Distribution System

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 LUSAIL DEVELOPMENT

10 APPENDICES AND DRAWINGS

Appendices and applicable drawings are listed in the Drawings/Documents List form
(DLF).

11 DRAWING / DOCUMENT LIST FORM

DRAWINGS/DOCUMENTS LIST FORM (DLF)

ITEM DRAWING/DOCUMENT NUMBER DRAWING/DOCUMENT TITLE Revision
01 LUS-CPALL-MAQ-DWG-UT-10301 DISTRICT COOLING-TYPICAL 0
TRENCH AND TUNNEL SECTION
02 LUS-CPALL-MAQ-DWG-UT-10302 DISTRICT COOLING-VALVE WITH 0
HYDRAULIC ACTUATOR

Project Name: Lusail Development District Cooling Distribution System

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GENERAL NOTES
1. THIS DRAWING SHOULD BE READ IN CONJUNCTION
WITH THE TECHNICAL REQUIREMENT FOR CIVIL WORKS.

2. DO NOT USE MECHANICAL COMPACTORS OR WHEEL OR

TRACKED VEHICLES FOR COMPACTION UNTIL A MINIMUM
OF 300mm OF COMPACTED SOIL IS ABOVE THE TOP OF
THE INSULATION JACKET.

LUSAIL REAL ESTATE DEVELOPMENT COMPANY

DISTRICT COOLING
TYPICAL TRENCH AND TUNNEL
SECTION
 HYDRAULIC ACTUATOR MANHOLE COVER
(BYPASS VALVE) CONCRETE COVERAGE SIDEWALK

A A

GENERAL NOTES
1. THIS DRAWING SHOULD BE READ IN CONJUNCTION
WITH THE TECHNICAL REQUIREMENT FOR CIVIL WORKS.
HYDRAULIC ACTUATOR
2. FOR TYPICAL TRENCH SECTION REFER TO DWG.
(HEAD VALVE) 8 HYDRAULIC HOSES
LUS-CPALL-MAQ-DWG-UT-10301.

CONTROL CABINET
MANHOLE COVER (BLOCK UNIT WITH NON RETURN VALVES AND
INDICATORS SHOWING OPEN/CLOSE AND
VALVE STATUS DURING OPERATION)

CONTROL CABINET
(BLOCK UNIT WITH NON RETURN VALVES AND
INDICATORS SHOWING OPEN/CLOSE AND
VALVE STATUS DURING OPERATION)

B B
HYDRAULIC ACTUATOR
(BYPASS VALVE)

HYDRAULIC HOSES

HYDRAULIC ACTUATOR
(HEAD VALVE)

LIMIT OF WORKS

PLOT LIMIT
VENTING VALVE WITH
END PLUG

WELD-ON END
LIMIT OF WORKS

PLOT LIMIT

PREINSULATED END FITTING

LUSAIL REAL ESTATE DEVELOPMENT COMPANY

D
SHRINK SLEEVE

C C

DISTRICT COOLING
VALVE WITH HYDRALIC ACTUATOR
D