STATE OF KUWAIT تﯿوَـﻛﻟا ﺔـ َﻟو دَ MINISTRY OF PUBLIC

STATE OF KUWAIT یتوَ ـة الكـولَ دَ MINISTRY OF PUBLIC WORKS ةامَّ ال العَ زارة الأشغَ وَ

وجسورطرق وإنجاز وصیانة تصمیم وإنشاء ومجاري میاه امطار وخدمات أخرى وصرف صحي

یق الغزالي وشارع محمد بن القاسمبین الدائري الخامس وطر

266المناقصـة رقم ھـ ط / رقـة الطـھندس

Design Build and Maintain Roads, Bridges, Sanitary,

Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street

TENDER No. RA/266 Road Administration

DOCUMENT (III-2): Particular Specifications

Volume 2 – Appendix 1

المواصفات الخاصة )III-2المستند رقم (

Contracts and Documents Department إدارة الوثائق والعقود

الأشغال الكويت برقيا: 25380829فاكس 25385520 تليفون-13001 لكويتا-الصفاة 8ص.ب. P.O. Box: 8, 13001 Safat, Kuwait –Tel: 25385520 Fax: 25380829- Cable Works Kuwait

Contract RA/266



A. Water Pipelines Relocation B. Lighting and Electrical Works C. Telephone Works (PTT)

Contract RA/266



A - WATER PIPELINES RELOCATION

Table of Content

1 GENERAL ..................................................................................................................... 1-1

1.1 SCOPE ....................................................................................................................................................... 1-1

1.2 SCOPE OF THE CONTRACT .................................................................................................................. 1-1

1.3 GENERAL DESCRIPTION OF THE WORKS ........................................................................................ 1-2

1.3.1 Not Used ...................................................................................................................................... 1-2

1.3.2 Description of Water Utility Relocation Works (Contract 3) ......................................................... 1-2

1.3.3 DEFINITIONS AND INTERPRETATION. .................................................................................... 1-2

2 INSPECTION AND TESTING ................................................................................... 2-1

2.1 SCOPE ....................................................................................................................................................... 2-1

2.2 GENERAL ................................................................................................................................................. 2-1

2.3 SPECIALIST INSPECTION AND TESTING .......................................................................................... 2-1

2.4 ACCESS .................................................................................................................................................... 2-1

2.5 ENGINEER’S INSPECTION .................................................................................................................... 2-1

2.6 REJECTION AND RE-TESTING ............................................................................................................ 2-1

2.7 TEST CERTIFICATES ............................................................................................................................. 2-2

2.8 FACTORY WITNESS TEST AND INSPECTIONS ................................................................................ 2-2

2.9 VALVES ................................................................................................................................................... 2-2

2.9.1 Gate valves (sluice valves) .......................................................................................................... 2-2

2.9.2 Butterfly valves ............................................................................................................................. 2-2

2.9.3 Air valves ..................................................................................................................................... 2-2

2.9.4 Check valves ................................................................................................................................ 2-3

2.9.5 Non-Slam Air Valves .................................................................................................................... 2-3

2.9.6 Scope of Factory Inspections ...................................................................................................... 2-3

2.10 DUCTILE IRON PIPES AND FITTINGS ................................................................................................ 2-4

2.11 SITE TESTING ......................................................................................................................................... 2-5

2.11.1 Site Testing Proposals ................................................................................................................. 2-5

2.11.2 Programme and Notification of Tests .......................................................................................... 2-5

2.11.3 Site Laboratory (not required) ...................................................................................................... 2-5

3 PIPELINE TESTING, CLEANING, DISINFECTION AND COMMISSIONING ...................................................................................................... 3-1

3.1 METHOD & PROGRAMME OF PIPELINE TESTING AND CLEANING ........................................... 3-1

3.1.1 Water for Testing, Cleaning, Swabbing and Disinfection ............................................................ 3-1

3.2 VALVES ................................................................................................................................................... 3-1

3.3 TESTING PIPELINES .............................................................................................................................. 3-1

3.3.1 General ........................................................................................................................................ 3-1

3.3.2 Test Equipment ............................................................................................................................ 3-2

3.3.3 Anchors ........................................................................................................................................ 3-2

3.3.4 Procedure for Site Pressure Testing of Ductile Iron Pipelines for Water Supply ........................ 3-2

3.3.5 Test standard for Pressure Ductile Iron Pipelines for Water Supply ........................................... 3-3

3.3.6 Action Following Test Failures ..................................................................................................... 3-3

3.3.7 Working Pressure and Site Test Pressure .................................................................................. 3-3

3.4 CLEANING OF PIPELINES .................................................................................................................... 3-3

3.4.1 Water Pipelines ............................................................................................................................ 3-3

3.4.2 Cleaning of Cable Ducts .............................................................................................................. 3-3

3.5 SWABBING OF PIPELINES FOR WATER SUPPLY ............................................................................ 3-3

3.6 DISINFECTION OF PIPELINES ............................................................................................................. 3-4

3.7 COMMISSIONING ................................................................................................................................... 3-4

4 PIPELINES .................................................................................................................... 4-1

4.1 SCOPE ....................................................................................................................................................... 4-1

4.1.1 Materials ...................................................................................................................................... 4-1

4.2 DEFINITIONS .......................................................................................................................................... 4-1

4.3 SUBMISSIONS BY THE CONTRACTOR .............................................................................................. 4-1

4.3.1 Drawings and Data ...................................................................................................................... 4-1

4.3.1.1 DRAWINGS .................................................................................................................. 4-1

4.3.1.2 DATA ............................................................................................................................. 4-2

4.3.1.3 VALVES......................................................................................................................... 4-2

4.3.2 Products in Contact with Water for Drinking ................................................................................ 4-2

4.4 REFERENCE STANDARDS .................................................................................................................... 4-3

4.4.1 Introduction .................................................................................................................................. 4-3

4.4.2 Pipelines - General ...................................................................................................................... 4-3

4.4.3 Ductile Iron Pipelines ................................................................................................................... 4-4

4.4.4 Materials General......................................................................................................................... 4-4

4.4.4.1 DAMAGE ....................................................................................................................... 4-4

5 PIPES AND FITTINGS ................................................................................................ 5-1

5.1 SCOPE ....................................................................................................................................................... 5-1

5.2 DUCTILE IRON PIPES ............................................................................................................................ 5-1

5.2.1 General ........................................................................................................................................ 5-1

5.2.2 Ductile Iron Fittings ...................................................................................................................... 5-1

5.2.3 Thrust Flanges ............................................................................................................................. 5-1

5.2.4 Detachable Flexible Couplings and Flange Adapters .................................................................. 5-1

5.2.5 Marking of ductile iron pipes and fittings ..................................................................................... 5-2

5.3 CABLE DUCTS ........................................................................................................................................ 5-2

5.3.1 General ........................................................................................................................................ 5-2

5.3.2 HDPE Ducts ................................................................................................................................. 5-2

5.3.3 UPVC Ducts ................................................................................................................................. 5-2

6 VALVES......................................................................................................................... 6-1

6.1 SCOPE ....................................................................................................................................................... 6-1

6.2 REFERENCE STANDARDS .................................................................................................................... 6-1

6.2.1 Materials, Substances and Products ........................................................................................... 6-1

6.2.2 Painting and Protection ................................................................................................................ 6-2

6.2.3 Marking ........................................................................................................................................ 6-3

6.2.4 Tests 6-3

6.2.5 Flanges ........................................................................................................................................ 6-3

6.2.6 Bolts, Nuts and Washers ............................................................................................................. 6-4

6.2.7 Gaskets ........................................................................................................................................ 6-4

6.2.8 Operating Gear ............................................................................................................................ 6-4

6.3 ISOLATION VALVES ............................................................................................................................. 6-4

6.3.1 Operation ..................................................................................................................................... 6-4

6.3.2 Extension Spindles ...................................................................................................................... 6-4

6.3.3 Gate Valves (Sluice Valves) ........................................................................................................ 6-5

6.3.4 Butterfly Valves ............................................................................................................................ 6-5

6.3.4.1 RESILIENT-SEATED BUTTERFLY VALVES ........................................................ 6-6

6.4 AIR VALVES ............................................................................................................................................ 6-7

6.4.1 General ........................................................................................................................................ 6-7

6.4.1.1 SMALL-ORIFICE ......................................................................................................... 6-7

6.4.1.2 LARGE-ORIFICE ......................................................................................................... 6-7

6.4.2 Materials ...................................................................................................................................... 6-7

6.4.3 Non-slam Air Valves .................................................................................................................... 6-8

6.4.4 Check Valves (non-return valves, reflux valves) ......................................................................... 6-8

6.4.5 Single-door Swing Check Valves ................................................................................................. 6-9

6.4.6 Multiple-door Swing Check Valves .............................................................................................. 6-9

7 COATINGS AND PROTECTION .............................................................................. 7-1

7.1 PROTECTION OF DUCTILE IRON PIPES & DUCTILE IRON FITTINGS ......................................... 7-1

7.1.1 External Protection of Ductile Iron Pipes and Fittings ................................................................. 7-1

7.1.2 Internal Protection of Ductile Iron Pipes and Fittings................................................................... 7-1

7.1.3 Spigots and Sockets .................................................................................................................... 7-1

7.1.4 Protective Wrapping Tape Systems ............................................................................................ 7-1

7.1.4.1 OUTERWRAP PROTECTIVE TAPE ........................................................................ 7-2

7.1.4.2 PRIMER ......................................................................................................................... 7-3

7.1.5 Polyethylene Sleeving ................................................................................................................. 7-3

7.1.6 Heat-shrink Sleeving .................................................................................................................... 7-3

7.1.7 Fusion-bonded Epoxy Coating .................................................................................................... 7-3

7.1.7.1 REPAIRS ....................................................................................................................... 7-4

7.1.8 Two-part Epoxy Coating .............................................................................................................. 7-4

8 JOINTS AND ANCILLARIES .................................................................................... 8-1

8.1 SCOPE ....................................................................................................................................................... 8-1

8.1.1 Spigot and Socket Joints ............................................................................................................. 8-1

8.1.2 Mechanical (Bolted Gland) Joints ................................................................................................ 8-1

8.1.3 Anchored Joints ........................................................................................................................... 8-1

8.1.4 Joint Sealing Rings ...................................................................................................................... 8-1

8.1.5 Flanges and Flanged Joints ......................................................................................................... 8-1

8.1.6 Bolts, Nuts and Washers ............................................................................................................. 8-2

8.1.7 Gaskets ........................................................................................................................................ 8-2

8.1.8 Connections between Different Pipe Classes or materials ......................................................... 8-2

8.2 ANCILLARIES ......................................................................................................................................... 8-2

8.2.1 Marker Tape ................................................................................................................................. 8-2

9 CONSTRUCTION OF PIPELINES ............................................................................ 9-1

9.1 SCOPE ....................................................................................................................................................... 9-1

9.1.1 Setting Out ................................................................................................................................... 9-1

9.1.2 Trial Length of Pipeline ................................................................................................................ 9-1

9.1.3 Pipelines in the same Trench ...................................................................................................... 9-1

9.1.4 Pipeline Gradients and Cover ...................................................................................................... 9-1

9.1.5 Buried Pipes General ................................................................................................................... 9-1

9.1.6 Concrete Bed and Surround ........................................................................................................ 9-2

9.2 JOINTING ................................................................................................................................................. 9-2

9.2.1 Flanged Joints .............................................................................................................................. 9-2

9.2.2 Work Inside Pipelines .................................................................................................................. 9-2

9.2.3 Cutting of Pipes ............................................................................................................................ 9-3

9.2.4 Closing Lengths ........................................................................................................................... 9-3

9.3 EXTERNAL PROTECTION .................................................................................................................... 9-3

9.3.1 Sleeving of Ductile Iron Pipelines ................................................................................................ 9-3

9.3.2 Tape Wrapping with Outer wrap for Ductile Iron Pipelines .......................................................... 9-3

9.3.3 External Wrapping of Fusion-bonded Epoxy Coated Pipes and Fittings ..................................... 9-4

9.3.4 Protection of Buried Bolted Couplings, Adapters and Flanges ................................................... 9-4

9.4 CONNECTING TO EXISTING PIPELINES ........................................................................................... 9-4

9.4.1 Plugging of Dead Ends ................................................................................................................ 9-4

9.5 MARKER POSTS AND INDICATOR PLATES ..................................................................................... 9-4

9.6 CABLE DUCTS ........................................................................................................................................ 9-5

10 CHAMBERS AND THRUST BLOCKS .................................................................. 10-1

10.1 SCOPE ..................................................................................................................................................... 10-1

10.2 ANCHOR AND THRUST BLOCKS ...................................................................................................... 10-1

10.3 VALVE AND OTHER CHAMBERS ..................................................................................................... 10-1

10.3.1 Installation of Valves .................................................................................................................. 10-1

10.3.2 Pipelines Built into Structures .................................................................................................... 10-1

10.3.2.1 ROCKER PIPES ........................................................................................................ 10-1

10.3.2.2 EXCESS EXCAVATION ........................................................................................... 10-2

10.3.2.3 THRUST FLANGES .................................................................................................. 10-2

10.3.3 Pipeline Spacing at Structures ................................................................................................... 10-2

10.3.4 Pipework in Chambers ............................................................................................................... 10-2

10.3.5 Painting of Pipes, Fittings and Valves ....................................................................................... 10-2

10.4 DRAW PITS ............................................................................................................................................ 10-2

10.5 PIPES & FITTINGS SUPPLIER ............................................................................................................. 10-3

11 OPTICAL FIBRE CABLE ......................................................................................... 11-1

11.1 GENERAL ............................................................................................................................................... 11-1

11.2 CABLE ROUTE ...................................................................................................................................... 11-1

11.3 MATERIALS .......................................................................................................................................... 11-1

11.4 PRE-INSTALLATION TESTING .......................................................................................................... 11-1

11.5 INSTALLATION .................................................................................................................................... 11-2

11.6 ACCEPTANCE TESTING ...................................................................................................................... 11-2

Contract RA/266



PART - 1

GENERAL

Document III-2 - Particular Specifications Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 23/08/2015 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street (Contract RA/266) MEW Water Pipeline Relocation-Specification Part-1, General Specification

1 GENERAL

1.1 SCOPE This Part of the Specification gives a general description of the Works and covers the general duties of the Contractor in connection with the administration of the Contract.

The contractor shall undertake to perform all required works strictly in accordance with these specifications.

1.2 SCOPE OF THE CONTRACT

Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street.

The contract comprises the installation, construction, testing, commissioning and maintenance of Ductile Iron Pipelines complete with all connections as shown in the drawings.

Also forming part of this works is the connection of the relocated pipelines to the existing mains and recovery of the pipeline materials from the section replaced including transport to Ministry of Electricity & Water at Abrak Khaitan as well as demolishing existing reinforced concrete chambers.

Also included is land survey and site investigation of the route of each pipeline, provision of adjustment of the tender drawings as necessary in accordance to the site information gathered, preparation of construction drawing etc.

The Contractor shall provide all necessary supervision, engineering and technical expertise, obtain approvals and provide all necessary temporary and permanent facilities, supply materials, labour, construction equipment and temporary works and undertake everything necessary to complete the Works.

The Contractor shall provide all materials necessary for the relocation, completion and safe, reliable, efficient operation and maintenance of the Works whether specifically identified in the Contract or not.

The contractor should be familiar with the MPW Motorway construction specification especially for excavation, backfilling, concreting etc. In case of any conflict/or discrepancies between this specification and MPW specification, the MEW specification will prevail for waterworks only and contractor shall abide by the decision of the Engineer.

For the purpose of this contract, only a few relevant sections from Ministry of Electricity & Water specification for installation, testing & commissioning of steel and ductile iron pipelines. If any work under this contract is not covered by this specification, the contractor shall be referred to MEW specification for the same. The contractor shall obtain MEW approval for relocation of Water Pipelines.

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Document III-2 - Particular Specifications Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 23/08/2015 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street (Contract RA/266) MEW Water Pipeline Relocation-Specification Part-1, General Specification

1.3 GENERAL DESCRIPTION OF THE WORKS

1.3.1 Not Used

1.3.2 Description of Water Utility Relocation Works (Contract 3) The Works covered by this contract are as indicated on the drawings supplied.

Relocation of D.I. pipelines (various sizes as indicated) distilled water pipelines, and HDPE duct for fibre optic cable duct.

• Installation of air valves, washouts and isolation valves and construction of reinforced concrete chambers and thrust blocks for ductile iron pipes, recovery of existing pipes, demolition of existing chambers, making connection with the existing lines.

• The termination points and Limits of Work are shown on the Drawings.

1.3.3 DEFINITIONS AND INTERPRETATION.

In the Contract (as hereinafter defined) the following words and expressions shall have the meaning hereby assigned to them expect where the context otherwise requires.

a) The "Employer" means the Ministry of Public Works of the Government of Kuwait as

represented by H.E. the Minister of Public Works or representative thereof. It also includes the legal successors in title to the Employer. The terms "Owner", "Purchaser" and "Ministry" shall have the same meaning as "Employer" unless otherwise indicted.

b) The "Contractor" means the person or persons, firm or company whose Tender the

Employer has accepted and with whom a Contract has been signed and includes the Contractor's personal representatives, successors and permitted assigns.

c) The “Engineer" means the Chief Engineer for Roads Engineering Sector of the Ministry of

Public Works, or any other person appointed by the Employer and notified to the Contractor to act as "Engineer" for the purposes of the Contract.

d) "Works" means the works to be executed in accordance with the Contract.

e) "Contract" means the whole of the documents or any of the individual conditions and/or

clauses herein contained.

END OF SECTION

1-2

Contract RA/266



PART - 2

INSPECTION AND TESTING

Document III-2 - Particular Specifications Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street (Contract RA/266) MEW Water Pipeline Relocation-Specification Part-2, Inspection and Testing

2 INSPECTION AND TESTING

2.1 SCOPE This Part covers particular requirements for inspection and testing of the Works.

2.2 GENERAL The Contractor shall carry out all tests and inspections as required by the appropriate Reference Standard or as considered necessary by the Engineer. The Contractor shall submit details, for approval, of all proposed factory tests within 2 months of the Date of Enterprise. Inspections and test shall be carried out in the manufacturer's factory, or site or elsewhere.

If any tests are beyond the resources of the Contractor, supplier or manufacturer, then the Contractor shall arrange for the tests to be carried out elsewhere.

The Contractor shall ensure that all Sub-contractors, manufacturers and suppliers are given copies of the relevant specifications.

The costs of providing assistance and facilities to the Engineer or appointed inspectors for inspection and testing during the course of the Works shall be born by the Contractor.

Inspection, examination and testing shall not release the Contractor from any obligation under the Contract.

2.3 SPECIALIST INSPECTION AND TESTING The Employer shall employ one or more specialist third party Inspection Agencies or firms to witness test and undertake inspections of materials and workmanship at any stage during the execution and maintenance of the Works.

The third party Inspection Agency or Agencies, whose fees will be to the Employer’s account, will be appointed shortly after the Date of Enterprise and will be advised to the Contractor in Writing.

2.4 ACCESS The Engineer and/or Inspector shall be entitled at all reasonable times during the Contract to inspect, examine, and test materials on the Contractor’s or Manufacturer’s premises, in Contractor’s storage areas and compounds and any area of the Site at any time.

The Contractor shall provide all facilities and safety equipment necessary to allow the Engineer to inspect any part of the Works.

Manufacturers shall allow the Employers appointed Inspector or Inspection Agency free entry at all times and to all areas where work on the Contract is being performed and shall afford the Inspector, without charge, all reasonable facilities to satisfy him that the material/equipment is being manufactured in accordance with the Contract.

2.5 ENGINEER’S INSPECTION No work shall be covered until it has been inspected by the Engineer.

2.6 REJECTION AND RE-TESTING If the Engineer and/ or Inspector decides that any work material is defective or is not in accordance with the Contract, they shall give in writing notice of rejection, stating the grounds upon which the decision is based.

If any item or material fails or is rejected it shall be replaced or rectified and the item or its replacement shall be offered for re-testing and inspection. Any resulting additional expenses incurred by the Engineer, Employer or Inspector shall be borne by the Contractor.

2-1


The Contractor shall meet any extra costs that result from the failure of the Contractor to comply with the requirements for testing and inspection or which result from insufficient preparation taken by the Contractor before presenting work or materials for inspection or test.

Any item may be subject to random re-testing as directed by the Engineer.

2.7 TEST CERTIFICATES The Contractor shall submit test certificates giving a detailed record of all tests carried out within two weeks of completion of the tests. Test certificates shall certify that the item has been satisfactorily tested. They shall describe and give full particulars of the tests and shall attach copies of any test curves, test data and results.

Copies of test certificates for major items shall be included in the operation and maintenance manuals.

2.8 FACTORY WITNESS TEST AND INSPECTIONS The Contractor shall offer manufactured items for inspection examination and witness testing at all stages during manufacture.

Within 2 weeks of the Date of Enterprise the Contractor shall submit his proposed programme for factory tests and Inspections.

Detailed programmes shall be submitted monthly.

Wherever possible, inspections and tests will be conducted so as not to interfere unnecessarily with the operation of the factory.

Factory testing shall include pressure tests on all pressure pipes, fittings and valves, shall be hydraulically tested to the pressure specified in the Contract or in the appropriate Reference Standard.

2.9 VALVES Factory tests on valves and associated equipment shall be carried out as specified below:

2.9.1 Gate valves (sluice valves) Each gate valve shall be tested at the manufacturer's works in accordance with the requirements of BS 5163. Valve seat tests shall be made under open-end conditions, the test pressure being applied to each face of the valve in turn.

2.9.2 Butterfly valves Each butterfly valve shall be tested at the manufacturer’s works in accordance with BS EN 593.

2.9.3 Air valves Each air valve shall be tested hydrostatically in accordance with BS 6755: Part 1, except as specified below. Durations for tests shall be as given in Table 4 of BS 6755.

Seat tests shall be carried out at the lowest seating pressure specified and at four equal pressure increments up to 1.1 times the maximum permissible working pressure. The maximum permissible seat test leakage rate at each test pressure shall be rate A as defined in Table 1 of BS 6755. The back seat test shall not apply.

Two valves of each type and size incorporating large orifices shall be tested for exhaust of air at a differential pressure up to 1 bar in steps of 0.1 bar and for inflow of air at a differential pressure up to 0.5 bar in steps of 0.1 bar. During the tests the airflow rates shall be measured by orifice plates in accordance with BS 1042. Pressures (positive or vacuum) shall be measured by Bourdon tube gauges in accordance with BS 1780, or by means of mercury-in-

2-2


glass manometers. The temperature of the flowing air shall be measured in accordance with BS 1041: Part 1 and Part 2. The barometric pressure shall also be measured.

If the manufacturer provides results of independently witnessed airflow tests similar to those specified and the Engineer accepts these, the specified airflow tests shall be deemed to be completed.

2.9.4 Check valves Valves manufactured in accordance with BS 5153 shall be tested to that standard.

Valves manufactured to other standards shall be hydrostatically tested where applicable, in accordance with the manufacturing standard, providing that the testing requirements are at least as rigorous as those specified below for testing in accordance with BS 6755: Part 1. Otherwise, testing shall be in accordance with BS 6755: Part 1.

Pressure test durations for tests under BS 6755: Part 1 shall be as given in table 4 of that Standard. The maximum permissible seat test leakage rate shall be as defined in table 1 of BS 6755: Part 1 and shall be Rate B for metal-seated valves and Rate A for resiliently seated valves. The back seat test shall not apply.

Additionally, each valve shall be shown to control flows satisfactorily in accordance with the specified criteria throughout the full specified range of pressures and flows, to the satisfaction of the Engineer.

2.9.5 Non-Slam Air Valves All non-slam air release valves supplied shall be subjected to the following testing procedures in the order laid down:

i) A high pressure strength and leak test whereby the valve is filled with water and pressurized to twice the rated working pressure that shall be held for a period of 2 minutes. Any leaking, weeping or sweating shall be reason for rejection.

ii) A low head leak test whereby the valve is filled with water and pressurized to a maximum of 0.5 bar (7.3 psi) using a visible water column connected to the test rig. The valve shall be rejected if leak tightness is not maintained for 2 minutes.

iii) Every tenth air release valve of the same size and pressure rating must be subjected to a small orifice function test – “DROP TEST” – whereby the valve is filled with water, pressurized to above rated working pressure and isolated from the test rig by closure of an isolating valve. A chamber in the test rig immediately prior to the isolating valve must be filled with compressed air at a pressure equal to that being maintained in the air release valve. The isolating valve is the opened so as to allow the air to rise in the air release valve. The “DROP TEST” is then carried out by slowly bleeding off the pressure through a suitable cock until rated working pressure is reached and the float drops away from the orifice to allow discharge. Failure of the air release valve to function in the manner described will be reason for rejection.

2.9.6 Scope of Factory Inspections The following inspections will be performed or witnessed by the appointed Inspector/Agency and/or by the Engineer.

Visual inspection of all valve bodies and bonnets internally and externally after machining and prior to coating or painting.

Witness ultrasonic thickness inspection of 10 valves or 20% of the total quantity whichever is the greater for wall thickness of both body and bonnet.

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Witness dye-penetrate examination of all gates/discs and seat rings where hard facing is over laid.

Dimensional inspection of 10 valves or 20% of quantity whichever is greater. Dimensions will include face to face, PCD of flange bolt-holes, flange thickness, stem diameter and bonnet flange thickness.

Quality and thickness of internal and external epoxy coating.

Inspection of manufacturer’s material and test certificates for valve materials including body, bonnet, disc, stem, nut, body seat, disc seat, cap, hand wheel, bolts, nuts, washers and ensure that certificates are related to material by serial numbers.

Witness shell and seat pressure tests according to the applicable standard for 100% of valves. (No visible leakage shall be permitted during tests).

Witness all functional tests.

Check markings according to the applicable Reference Standard and the Specification.

Witness packing to ensure the following:

• All valves shall have tropical packaging;

• Each flanged end is effectively and securely sealed against the ingress of dust and water.

a. Valves are packed with the gate/disc in completely closed position.

b. For valves with actuators, the valve and the actuator are in fully assembled condition. Actuator openings/connectors are effectively and securely sealed against the ingress of dust and water.

c. All loose items are tagged with their part numbers and packing list reference numbers.

d. Each item is clearly identified in the packing list and carries the correct marking.

e. A copy of the packing list is included in each packing case or container.

f. The case is stamped or stencilled at a visible place by the appointed Inspection Agency to show that the packing has been inspected, and the contents tally with the packing list. (This is not required if materials are packed in shipping containers).

2.10 DUCTILE IRON PIPES AND FITTINGS The test and inspection of ductile iron pipes and fittings witnessed by the Inspection Agency shall include but not be limited to the following:

i) Audit of manufacturer’s quality programme.

ii) Check of drawings and specifications.

iii) Review of mill sheets.

iv) Document checks for materials received from sub-vendors.

v) Microscopic observation for graphite and annealing effect.

vi) Chemical examinations.

vii) Mechanical test (the dimensions of test bars and test method shall conform to standard specifications).

viii) Witnessing of factory hydrostatic test:

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- The hydrostatic test shall be carried out on pipes and fittings before application of

the coating.

- Leakage from the pipes and fittings shall be checked visually.

ix) Verification of dimensions (thickness and length):

- Checking of dimensions shall be carried out on the pipes and fittings using various limit gauges, measuring scale or callipers.

x) Mass verification:

- Checking of mass shall be carried out on pipes and fittings as standard.

- Weighing may be carried out after coating.

xi) Coating Inspection:

- Visual inspection shall be carried out on the coating surface of each pipe and fitting.

- The coating thickness of pipes and fittings shall be measured using a magnetic thickness gauge.

- Internal surface coating of socket and external surface coating of spigot of pipes and fittings.

- Review of all coating materials sheets.

xii) Cement Mortar Lining Inspection:

- Visual inspection shall be carried out on the lining surface of pipes and fittings.

- The lining thickness at both ends of the pipes and fittings shall be checked using a measuring scale.

xiii) Seal Coat Inspection

xiv) Shapes, Marking and Appearance Inspection

- Visual inspection shall be carried out on all pipes and fittings.

2.11 SITE TESTING

2.11.1 Site Testing Proposals Within three (3) weeks from the Date of Enterprise the Contractor shall submit his proposals for site testing and quality control.

The proposals shall include details of the Contractor’s proposed laboratory facilities including details of the tests he intends to conduct on site and those he proposes to sub-contract to an independent off-site laboratory.

2.11.2 Programme and Notification of Tests The Contractor shall programme site testing and shall ensure that all parties concerned are informed in advance and are present during any tests.

2.11.3 Site Laboratory (not required) The Contractor, if he desires may establish a Site Laboratory with the facilities and equipment necessary to undertake routine monitoring of site quality control such as determination of:

• Moisture content & Grading

• Concrete slump

• In-situ density tests.

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With the approval of the Engineer performance monitoring tests such as crushing of concrete cubes and compaction testing of soil samples may be undertaken either in an on site laboratory or at an independent off site laboratory.

The Engineer shall be permitted free unhindered access to all laboratories approved for use in any testing in connection with the Works.

END OF SECTION

2-6

Contract RA/266



PART - 3

PIPELINE TESTING, CLEANING

DISINFECTION AND COMMISSIONING

Document III-2 - Particular Specifications Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street (Contract RA/266) MEW Water Pipeline Relocation-Specification Part-3, Pipeline Testing, Cleaning & Disinfection

3 PIPELINE TESTING, CLEANING, DISINFECTION AND COMMISSIONING

3.1 METHOD & PROGRAMME OF PIPELINE TESTING AND CLEANING The Contractor shall submit for the approval of the Engineer details of his proposed methods and programme for pipeline testing, swabbing, disinfection and cleaning (including details of test and cleaning equipment).

All water pipelines shall cleaned, pressure tested and disinfected.

Cable ducts shall be cleaned and left stoppered with draw cords.

All chambers and draw pits shall be cleaned of all debris silt and sand, any mortar droppings on pipework or metalwork shall be removed and any damaged coatings made good. Valves shall be tested for operation, valve spindles shall be adjusted for correct alignment and chamber covers shall be cleaned and properly seated.

Records of all cleaning, testing and disinfection operations shall be submitted to the Engineer weekly

3.1.1 Water for Testing, Cleaning, Swabbing and Disinfection The Contractor shall provide all water required for testing and cleaning and disinfection of pipelines.

Wastewater shall be discharged only on to sites or into conduits that are suitable. Discharges shall not cause damage, create a nuisance or health hazard, or interfere with the work of others. The Contractor shall obtain the consent of the Engineer and relevant authority before discharging any water to a watercourse.

Where directed by the Engineer water may be re-used in testing or cleaning other parts of the Works or in works being executed for the Employer by other Contractors.

3.2 VALVES All valves shall be tested on completion of installation. Each installation shall be checked for water tightness. Valves shall be demonstrated to function satisfactorily under design maximum differential head conditions.

The Contractor shall carry out a final test and inspection of valves and associated equipment immediately before pressure testing the pipeline.

Where directed by the Engineer valves shall be internally inspected after testing to verify that the seals remain in a satisfactory condition.

3.3 TESTING PIPELINES

3.3.1 General All parts of pipeline systems shall be subjected to hydraulic pressure testing.

Testing shall be undertaken in sections as the work proceeds but the whole system shall be subjected to a final test.

Pipelines at road crossings and in other locations as may be directed by the Engineer shall be subjected to a hydrostatic pressure test immediately the section has been completed.

For the purposes of this final test, the pipeline system shall be divided into suitable sections as agreed with the Engineer. The length of pipeline tested at one time shall not exceed 10km without the approval of the Engineer.

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Testing shall not be carried out against closed valves.

All testing shall be witnessed and approved by the Engineer.

3.3.2 Test Equipment The Contractor shall supply water, pressure gauges, pressure recorders, meters, hoses, pumps, stop ends and all other equipment necessary for carrying out tests.

Pressure gauges shall be minimum diameter 100mm and shall have a full-scale reading of not more than twice the maximum pressure being tested. The Contractor shall provide the Engineer with a recent independent test certificate for each pressure gauge and pressure recorder.

3.3.3 Anchors The Contractor shall provide and install all necessary stop ends and temporary thrust restraints to carry out the tests. Pressure tests shall not be made against closed valves.

The Contractor shall satisfy himself and the Engineer that all temporary and permanent structures and thrust blocks are capable of withstanding the forces exerted from hydraulic tests with a sufficient factor of safety. Calculations shall be submitted to the Engineer for approval.

Thrusts from hydraulic test pressures shall not be exerted on any permanent structure that is located in saturated ground where the standing water level is above the lowest level of the foundation without the approval of the Engineer.

The Contractor shall provide any additional support or kentledge to structures as necessary to withstand the test pressures.

No loadings from testing shall be imposed on any structure without the approval of the Engineer. Notwithstanding any approval given by the Engineer, the Contractor shall be fully responsible for any consequences arising from the testing.

Where more than one pipe is laid in a common trench only one pipeline shall be pressurised at any one time.

3.3.4 Procedure for Site Pressure Testing of Ductile Iron Pipelines for Water Supply Before filling pipelines for pressure testing, the Contractor shall re-check pipes and valves for cleanliness and shall re-check the operation of all valves.

The ‘open’ ends of the pipeline (or sections thereof) shall be stopped off by blank flanges or cap ends secured by temporary struts, wedges and thrust blocks.

All permanent thrust blocks and valve chambers shall have been completed and backfilled and the concrete shall have attained its specified 28-day strength

All pipe straps and other devices intended to prevent the movement of pipes shall be securely fastened.

Joints including spigot and socket joints shall be left exposed for inspection during pressure testing and trenches between pipe joints shall be backfilled to the extent necessary to prevent movement of the pipeline.

The test section shall be filled with water and all air removed.

The pipeline shall stand full of water for at least 24 hours at the working pressure and all joints and restraints shall be inspected for leakage and movements.

The pressure shall then be raised by pumping in water until the specified test pressure is reached. The pressure shall be maintained at the test pressure by further pumping for a period

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of not less than 1 hour during which time the pipeline shall be again inspected for leakage or movement.

Pumping shall then cease and the time (T) for the pressure head to fall by 10m shall be recorded. If the pressure head has not fallen by 10m within three hours, then the fall in head at 3 hours shall be recorded. Pumping from calibrated container(s)shall then be resumed to restore the pipeline pressure to the test pressure. The quantity of water (Q) pumped into the pipeline shall be recorded.

The rate of loss shall be calculated as being the quantity (Q) pumped into the pipeline divided by the time (T).

3.3.5 Test standard for Pressure Ductile Iron Pipelines for Water Supply Testing of installed ductile iron pipelines shall be carried out according to Clause 29 of BS 8010:

Section 2.1: 1987.

3.3.6 Action Following Test Failures If the pipeline (or a section thereof) fails to pass the pressure test the Contractor shall locate the faults and shall uncover, repair, retest and reinstate the pipeline as may be necessary until all parts of the pipeline shall have passed the pressure test.

3.3.7 Working Pressure and Site Test Pressure The working pressure and test pressures of the different sections of pipeline, shall be as shown on the Drawings or as directed by the Engineer.

3.4 CLEANING OF PIPELINES

3.4.1 Water Pipelines Before commencing pressure testing, the Contractor shall clean out the part of the pipeline to be tested to the satisfaction of the Engineer.

Materials and equipment necessary for cleaning shall be provided by the Contractor.

After the whole pipeline has been successfully pressure tested (whether as a whole or in sections) and the Contractor has reconnected any parts temporarily removed from the pipeline, the Contractor shall finally clean out the whole pipeline and flush it through with clean water.

The Contractor shall be liable to the Employer for any damage caused to the pipeline or to pumps and other equipment of the Employer as a result of foreign matter of any kind not having been cleared out of the pipeline.

3.4.2 Cleaning of Cable Ducts Pipes laid as cable ducts shall be kept thoroughly clean and all pipe ends shall be kept stoppered off with expanding rubber plugs.

Ducts shall be proved by pulling through a train consisting of an approved badger and a circular rubber squeegee followed by a wooden ball.

The wooden ball shall not be smaller than 25mm less in diameter than the pipe.

After cleaning ducts shall be provided with draw cords.

3.5 SWABBING OF PIPELINES FOR WATER SUPPLY Water pipelines shall be swabbed after pressure testing and before disinfection by passing a foam swab through the pipeline.

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The swab shall be non-abrasive and shall fit compressed into the pipeline. Swab stiffness shall be selected to suit the pipe and lining material.

The swab shall be driven at a velocity of between 0.3m/s and 1.0m/s by the admission of treated water.

Sufficient passes of the swab shall be made to produce clear water.

Swabs and debris from the pipe shall be disposed of to suitable locations by the Contractor. Flushing water shall be disposed of as specified in Clause 3.1.1.

All materials and equipment, including temporary swab insertion and retrieval points and temporary connections to the source of water shall be provided by the Contractor.

3.6 DISINFECTION OF PIPELINES Disinfection of pipelines shall be carried out in accordance with AWWA C651.

The Contractor shall provide all materials and equipment & water necessary for disinfection.

Liquid chlorine, calcium hypochlorite or sodium hypochlorite may be used for disinfecting.

Liquid chlorine shall be used only in conjunction with proper equipment and under the supervision of qualified personnel who are familiar with the physiological, chemical and physical properties of this material and who are properly trained and equipped to handle any emergency that may arise.

Pipelines shall be disinfected by the continuous feed method. Water entering the pipeline shall be maintained at a minimum of 20mg/l available chlorine or such level as may be necessary to ensure that at the end of 24 hours the treated disinfecting water shall contain not less than 2mg/l of chlorine at all points in the pipeline being disinfected. The chlorine concentration shall be measured at regular intervals in accordance with AWWA M12 to ensure that the required concentration is maintained.

After the required retention period, the heavily-chlorinated water shall be flushed from the main using potable water until the chlorine concentration in the water leaving the main is no higher than that generally prevailing in the systems and not exceeding 0.1mg/l. Chlorine-residual determinations shall be made to ascertain that the heavily chlorinated water has been removed from the main.

De-chlorination shall be carried out if necessary and as instructed by the Engineer in order to achieve an acceptable low level of residual chlorine in the discharge.

After final flushing samples shall be collected from a sampling cock with a copper tube gooseneck located at the end of the pipeline that is remote from the source of supply and tested for bacteriological quality. The sampling cock shall remain in place upon completion of the test.

The samples shall show the absence of coli-form organisms.

Samples shall be collected directly from the sampling cock in sterile bottles treated with sodium thiosulphate. No hose or fire hydrant shall be used in the collection of the samples.

If the initial disinfection fails to produce satisfactory samples, disinfection shall be repeated until satisfactory samples have been obtained.

3.7 COMMISSIONING Commissioning and putting into service will be undertaken by the Employer and other Contractors working for the Employer. The Contractor shall provide attendance during the commissioning period and shall provide any assistance that may be required by the commissioning Contractor.

END OF SECTION

3-4

Contract RA/266



PART – 4 to 10

PIPELINES, CABLE DUCTS

AND

APPURTENANCES

Document III-2 - Particular Specifications Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street (Contract RA/266) MEW Water Pipeline Relocation-Specification Part-4, Pipelines Cable Ducts and Appurtenances

4 PIPELINES

4.1 SCOPE This Part covers general requirements for pipes, valves and fittings and cable ducts.

Water pipelines and fittings shall be of ductile iron. Pipe joints for DI pipes shall be spigot and socket push in joints. Valves shall have flanged joints.

Cable ducts, if required shall be high density polyethylene (HDPE) with push fit spigot and socket type joints.

4.1.1 Materials The Contractor shall supply all pipes, fittings, valves, couplings, jointing materials and all other items necessary for completion of the pipelines. Pipes and fittings shall be ductile iron with external and internal protection as specified. Pipes under this Contract shall comply with the requirements of the Specification.

The contractor shall purchase all pipes & fittings from the approved supplies of Ministry of Electricity & Water, attached with this specification.

4.2 DEFINITIONS The following terms shall have the meanings hereby assigned to them: -

‘Pipes’ Straight pipes, whether whole or cut and their joints. ‘Pipeline’ or ‘Pipework’ The whole pipeline inclusive of pipes, fittings, valves a

pipeline appurtenances. ‘Fittings’ All components fitted to a pipe for jointing, connecting

changing the direction or bore of a pipe (including bends, tee tapers, collars and couplings).

‘Valves’ Valves installed on the pipeline including isolation valves and valves.

‘Pipeline appurtenances’ All items additional to pipes and fittings required to complete pipeline including but not limited to internal and extern protection systems, supports and anchors, chambers, mark posts and any apparatus or construction required for testin cleaning, disinfecting or operating the pipeline.

‘Ducts’ High Density Polyethylene Pipeline inclusive of all fittings a appurtenances including draw pits and draw cords.

‘Accessories’ Nuts, bolts, gaskets, glands, adaptors, couplings. lubricants a all other items necessary to lay and joint the pipework.

4.3 SUBMISSIONS BY THE CONTRACTOR

4.3.1 Drawings and Data 4.3.1.1 Drawings

Submissions by the Contractor shall include but will not be limited to the following:

• Typical drawings of standard items;

• Detail drawings of special items;

• Shop drawings for valve chambers and draw pits including:

- Details of pipes and fittings.

- Foundation and support details for pipes, valves and fittings.

- Setting out dimensions. 4-1


- Reinforcement details.

- Metalwork and supports.

- Valve spindle details.

- Method of building pipes into structure walls.

• Pipeline plan and profile drawings;

• Details of supports to buried services;

• Temporary work details, including temporary supports.

4.3.1.2 Data

• Pipe, fittings and joint details including manufacturer, pressure/temperature ratings, material properties and thickness and lubricants;

• Design details of any flanges outside the range of Reference Standards;

• External and internal protection and lining system details;

• Method for control of line and level of pipeline during installation;

• Manufacturers’ calculations, catalogues and data sheets;

• Manufacturers’ installation instructions;

• Constituents and properties of materials used in non-homogeneous pipe wall construction;

• Contractor’s calculations for pipe and fitting design;

• Methods for pipe handling, installation and backfill;

• Details of pipeline insulation system.

• Works tests on pipes and fittings;

• Material tests;

• Inspection;

• Welder qualification tests (where applicable);

• Non-destructive tests on completed welds (where applicable).

4.3.1.3 Valves

• Materials of manufacture – chemical composition of alloys and quality of metals used;

• Sealing arrangements and seating designs;

• Performance data;

• Evidence of satisfactory performance.

4.3.2 Products in Contact with Water for Drinking

The Contractor shall submit for the Engineer's approval, a schedule of substances and products he proposes to use in the Works which may come into contact with water supplied for drinking. The schedule shall include:

• Item description;

• Substance or product in contact with water;

• Manufacturer of substance or product;

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• Location of point of use in the Works;

• Name of the regulatory body which has approved the substance or product for use in contact with potable water;

• Date of approval;

• Approval reference number;

• Details of any condition attached to the approval.

4.4 REFERENCE STANDARDS

4.4.1 Introduction Unless otherwise specified materials and workmanship shall comply with the relevant American, British or other Reference Standard as listed below or stated within the specification clauses.

Where pipelines or any parts thereof are outside the range of sizes covered by Reference Standards, the requirements of the Reference Standards shall still apply where relevant, unless otherwise specified.

4.4.2 Pipelines - General AWWA C651 Standard for disinfecting water mains. AWWA M12 Simplified procedures for water examination. BS 1377 Methods of test for soils for civil engineering purposes. BS 2494 Elastomeric seals for joints in pipework and pipelines. BS 2569: Part 1 Sprayed metal coatings. BS 3251 Indicator plates for fire hydrants and emergency water

supplies. BS 3927 Rigid phenolic foam (PF) for thermal insulation in the form

of slabs and profiled sections. BS 4190 ISO metric black hexagon bolts screws and nuts. BS 4320 Metal washers for general engineering purposes. Metric

series. BS 4504: Part 3 Circular flanges for pipes, valves and fittings (PN-

designated): steel, cast iron and copper alloy flanges. BS 5292 Jointing materials and compounds for water, low pressure

steam installations, 1st, 2nd and 3rd family gases. BS 6076 Tubular polyethylene film for use as protective sleeving for

buried iron pipes and fittings. BS 6105 Corrosion-resistant stainless steel fasteners. BS 6956: Part 5 Jointing materials and compounds: Jointing compounds

for use with water, low pressure saturated steam, 1st family gases (excluding coal gas) and 2nd family gases.

BS 7079: Parts O & A1 Preparation of steel substrates before application of paints and related produces: Introduction and visual assessment of surface cleanliness.

BS 8010: Part 1 Pipelines on land: general. BS 812: Part 103.1 Method for determination of particle-size distribution:

sieve tests. BS EN 1514 Flanges and their joints – Dimensions of gaskets for PN-

designated flanges. SIS 05-5900 Pictorial surface preparation standards for painting steel

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surfaces.

WIS 4-52-01 Polymeric anti-corrosion (barrier) coatings.

4.4.3 Ductile Iron Pipelines AWWA C.105 Polyethylene Encasement for Ductile Iron Pipe Systems AWWA C104/A21.4-95 Cement Mortar Lining for Ductile Iron Pipe and Fittings for

Water. AWWA C111/A21.11 Rubber Gasket Joints for Ductile Iron Pressure Pipes and

Fittings. AWWA C151/A21.51-96 Ductile Iron Pipe, Centrifugally Cast, for Water. BS 2789 Spheroidal graphite or nodular graphite cast iron. BS 3416 Bitumen-based coatings for cold application suitable for

use in contact with potable water BS 4027 Sulphate-resisting Portland cement. BS 8010: Section 2.1 Pipelines on land: design, construction and installation:

Ductile iron. BS EN 22063 Metallic and other coatings. Thermal spraying. Zinc,

aluminium and their alloys. BS EN 545 Ductile iron pipes and fittings. ISO 7005-2 Metallic Flanges – Part 2 ISO 2531 Ductile iron pipes, fittings and accessories for pressure

pipelines. ISO 8179 Ductile Iron Pipe – External Zinc Coating

4.4.4 Materials General All items shall be of the diameter detailed in the Drawings and shall be suitable for the test and working pressures specified or detailed on the Drawings. The class and pressure rating shall not be less than that specified.

The normal temperature of the water in the pipelines will be up to 50ºC. All materials that are close to or in contact with the water shall be suitable for long-term exposure to such temperatures.

4.4.4.1 Damage No pipes or fitting with significant damage to the internal or external coatings will be accepted. Where in the opinion of the Engineer damage to the coating is minor, it shall be repaired as far as possible in accordance with the manufacturers recommendations to the original coating system. Acceptance of repairs will be subject to the satisfaction and approval of the Engineer. The Contractor shall be responsible for any repairs to be carried out on pipes purchased by the Contractor. All such repairs shall be carried out in the presence of an approved representative of the manufacturer.

No crack shall be allowed in the cement mortar lining of pipes and fittings.

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Document III-2 - Particular Specifications Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street (Contract RA/266) MEW Water Pipeline Relocation-Specification Part-5, Pipes and Fittings

5 PIPES AND FITTINGS

5.1 SCOPE This part covers the supply of pipes and fittings.

5.2 DUCTILE IRON PIPES

5.2.1 General Ductile iron pipes shall comply with ISO 2531 and shall have cement mortar lining to AWWA C104. Pipes shall be manufactured by the centrifugal casting process with push-in socket and spigot joints The joints shall permit pipes to be deflected angularly by up to 2° axially for diameters up to 900mm and by up to 1.5° axially for diameters over 900mm. Pipes shall be Class K9, unless otherwise specified or otherwise required to withstand the specified pressures. Pressure ratings of pipes (and fittings) shall be determined in accordance with BS EN545. Pipes shall be capable of sustaining the pressures detailed in BS8010 Part 2.1 Where pipes are specified to be “gauged” or “sized” they shall be suitable for cutting on site. Such pipes shall have the tolerance required on the external diameter to suit the joint applicable over the full length of the barrel. Such pipes shall be clearly marked “Gauged for cutting on site”.

5.2.2 Ductile Iron Fittings Ductile iron fittings should comply with ISO 2531 to withstand the specified pressures. Fittings shall be Class K12. Tees shall be Class K14. Fittings shall be capable of sustaining the pressures detailed in BS8010 Part 2.1 Where indicated on the drawings spigot and socket joints shall be the mechanical (bolted gland) type supplied with rubber gasket and bolts. Glands should be ductile iron of the same quality as the fitting and shall be supplied with a bituminous coating of thickness not less then 100 microns. On a fixed spot on the outside of each gland the manufacturers name or identification mark, date of manufacture and nominal diameter shall be marked. Bolts for use with bolted gland joints shall be spheroidal graphite in accordance with BS 2789 Grade 500/7. Self-anchored couplings and flange adapters shall not be used for transmission of axial loads.

5.2.3 Thrust Flanges Thrust flanges shall be integral with the pipe and shall be designed to act in either direction and to transfer into the concrete surrounding the pipe and flange the thrust imposed on a blank flange fixed to the end of the pipe by an internal hydrostatic pressure equal to the factory test pressure.

5.2.4 Detachable Flexible Couplings and Flange Adapters Detachable flexible couplings or flange adapters shall only be used where shown on the Drawings or with approval of the Engineer.

Detachable flexible couplings shall be suitable for the angular deflections specified below without leakage. Flange adapters shall be suitable for half the angular deflection stated.

Nominal pipe diameter (mm) Angular deflection (degrees) Up to 600 601 to 750 751 to 900 901 to 1200

1201 to 1800 1801 upwards

5 4 3 3 2 1

5-1

Document III-2 - Particular Specifications Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street (Contract RA/266) MEW Water Pipeline Relocation-Specification Part-5, Pipes and Fittings

Flexible couplings for each size of pipe shall also be capable of withstanding the shear force applied by the weight of a 4m length of pipe of that diameter full of water suspended between two couplings.

Detachable flexible couplings shall be provided with central registers or location plugs only where specified or detailed in the Drawings.

Flange adapters shall have flanges as specified for flanged joints.

Bolts, nuts and washers shall comply with the requirements for bolts, nuts and washers for flanges.

The metal components of detachable flexible couplings and flange adapters shall be protected by thermoplastic polyamide or fusion-bonded epoxy coatings unless otherwise specified or detailed in the Drawings.

5.2.5 Marking of ductile iron pipes and fittings In addition to the requirements of ISO2531 each pipe and fitting shall be indelibly marked over any factory-applied coating with the letters M.E.W., the Contract number and a unique reference number to enable items to be correlated to works fabrication records, works test certificates, delivery notes and the like. Wherever possible, the marks shall be painted both on the inside and outside of pipes and fittings close to one end which, in the case of pies and fittings with socket and spigot joints, shall be the socket end.

Marking shall be at least 50mm high.

Where there is insufficient smooth surface area to accommodate the above information the marking shall be put on rust proofed metal tags secured to the item with galvanised wire.

Spigots shall have marks to ensure the correct register of the spigot in the socket (for example two white painted lines).

5.3 CABLE DUCTS

5.3.1 General Except where shown otherwise buried ducts if required shall be High Density Polyethylene (HDPE) pipes complying with ISO 8770/8772 or unplasticised PVC pipes complying with BS 2782, BS3505, BS3506 or DIN 62/8561. Draw cords shall be provided in all ducts. The draw cord shall be a polypropylene cord having a breaking load of not less than 5kN. Joints in the draw cord shall be kept to a minimum; they shall be at least as strong as the cord and shall be so made as not to cause any jamming in use.

5.3.2 HDPE Ducts Joints shall be spigot-and-socket solvent cement-welded or rubber-ring type or other approved.

5.3.3 UPVC Ducts The pipes shall be supplied in Grey colour and in 6 meters length. The pipes shall have a minimum of 80 mm internal diameter, minimum 4.5mm wall thickness and minimum 10cms expanded (socket) end. Tolerance allowed for pipe and socket are according to BS standards. The pipes shall not ignite or support their own combustion. The pipes shall be corrosion resistant and unaffected by water, oxidizing agents, aggressive soils, sand, fungi growth, and bacterial and electrolytic action. When UPVC pipes are procured, the Contractor shall make a thorough examination to ensure that the pipes are undamaged. All damaged pipes shall be rejected and promptly removed from the site of work.

5-2

Document III-2 - Particular Specifications Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street (Contract RA/266) MEW Water Pipeline Relocation-Specification Part-6, Valves

6 VALVES

6.1 SCOPE This Part covers the supply and testing of valves.

6.2 REFERENCE STANDARDS Valves shall be designed fabricated, tested and installed in accordance with the appropriate American, British or other Standard. Appropriate standards are listed below and are referred to within the particular clauses.

AWWA C502 Dry-barrel fire hydrants. AWWA C504 Butterfly Valves BS 1780 Bourdon tube pressure and vacuum gauges. BS 1041 Temperature measurement. BS 1042 Measurement of fluid flow in closed conduits. BS 1400 Copper alloy ingots and copper alloy and high conductivity copper

castings. BS 1452 Flake graphite cast iron. BS 2789 Spheroidal graphite or nodular graphite cast iron. BS 2874 Copper and copper alloys rods and sections. BS 3416 Bitumen-based coatings for cold application, suitable for use in contact

with potable water. BS 4147 Bitumen-based hot-applied coating materials for protecting iron and

steel, including suitable primers where required. BS 4504 Circular flanges for pipes, valves and fittings. BS 4999 General requirements for rotating electrical machines. BS 5156 Diaphragm valves BS 5163 Predominantly key-operated cast iron gate valves for waterworks

purposes. BS 6755 Testing of valves BS 970 Wrought steels for mechanical and allied engineering purposes: Part 1.

General inspection and testing procedures and specific requirements for carbon, carbon manganese, alloy and valve steels.

BS EN 593 Industrial valves – Metallic butterfly valves. EN 1092-2 Flanges an their joints – circular flanges for pipes, valve, fittings and

accessories. ISO 7005 –2 Metallic Flanges - Part 2

6.2.1 Materials, Substances and Products Valves shall be manufactured to the requirements specified hereunder. All valves shall be suitable for use with water at the temperatures and pressures specified or detailed on the Drawings.

Where the Contractor proposes to use dissimilar metals either in contact or close enough for the gap between them to be bridged by an electrolyte the Contractor’s design shall include provisions to prevent corrosion.

Gate valves (sluice valves) and butterfly valves shall be suitable for flow in either direction.

Valves shall be suitable for frequent operation as well as for operation after long periods of idleness in any position.

Rubber used in valves shall be ethylene propylene rubber (EPDM or EPM) or styrene butadiene rubber (SBR). It shall comply with the requirements of Appendix B of BS 5155, be

6-1


suitable for making a long-term flexible seal and be resistant to mechanical, chemical or bacteriological attack leading to deterioration of the flexible seal.

Valve components shall be of materials not inferior in strength or resistance to corrosion to those listed below.

Component Material

Bodies, covers, cowls and plungers Spheroidal graphite iron to BS 2789 grade 500/7 or 420/12

Pistons, sleeves, liners, guides, bushes, sea seat rings and seal holders

Gunmetal to BS 1400 grade LG2

Hinge bushes and pins Bronze to BS 2874 grade PB 102

Valve stems, spindles other than extensi spindles and pins

Stainless steel to BS 970: Part 4, grade 431 S29 or grade 316S16

Aluminium Bronze to BS 2874 CA104

Extension spindles (plain ends) Galvanised mild steel to BS 970: Part 1, grade 220 MO7

Except where otherwise specified all valves shall be suitable for continuous use in the range - 0ºC to +60ºC.

The pressure rating of all valves shall not be less than the maximum working and test pressure of the pipeline in which the valve is to be installed.

Valves shall be supplied with all necessary accessories such as hand wheel, extension shaft, couplings, caps, bolts, nuts, washers and 3mm cotton reinforced rubber gaskets for each flange.

Valves shall close clockwise.

All copper alloys which may come into contact with raw, treated or potable water shall contain not more than 4% zinc.

6.2.2 Painting and Protection Except where otherwise specified and except for stainless steel valve parts, all valves shall be fusion-bonded epoxy coated externally and internally to a thickness of at least 150 microns.

Fusion-bonded epoxy coatings shall be suitable for application to ductile iron based material used in contact with fresh water, brackish water or distillate in any soil conditions or in chamber applications. The coating shall consist of a polymeric anticorrosion barrier.

The coating system requirements, performance testing and factory applied coating requirements and practice shall be in accordance with the Water Industry Specification (WIS) 4-52-01.

The method of surface preparation and cleaning shall be in accordance with the Contractor’s specification which shall be no less than the minimum requirements specified by the coating material manufacturer and the following requirements:

a) The pre-coating surface shall be blast-cleaned to a minimum standard of Grade B Sa 2½ in accordance with BS 7079: Part A1;

b) The surface shall be tested for soluble salts and re-blasted if soluble salts are found to be present;

c) All oil, grease and other

d) All oil, grease and other contaminants shall be removed;

e) All slivers and scabs made visible by blast cleaning and detrimental to the coating process shall be removed;

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f) Welds shall be fettled smooth;

g) Edges and corners shall be smoothed to a 3.0mm minimum radius;

h) Any pre-treatment prior to coating shall not be permitted without the written approval of the Engineer.

The shot-basted surface shall have a roughness RZ between 40µm and 80µm inclusive.

Raised flange faces shall be dressed after coating to remove coating runs.

Unless otherwise specified, each item shall be checked for holidays over all of the coated surfaces. A valve with two or more holidays per 3m2 of surface area shall be rejected for subsequent stripping and re-coating. All holidays detected shall be repaired and on completion the item shall be re-examined for holidays. After repair the coating shall be holiday free to Class A.

All coatings shall be treated with a UV-inhibitor to prevent chalking or loss of colour.

Materials and instructions shall be supplied for repair of coating damaged in transit and on site. Repair materials shall be compatible with the coating in colour and adhesion and shall be suitable for site application.

6.2.3 Marking Each body will be marked by Cast-on or stamped figures as follows: - Size of Valve - Year of Manufacturing - Working Pressure - Type of Casting

6.2.4 Tests Each valve shall be tested according to the standard specification and the Employer shall be supplied with the records of all tests.

6.2.5 Flanges Flanges shall be ductile iron NP16 or NP25 as defined in the Bill of Quantities and shall have the following metric dimensions:

NP16 Flanges

Nominal Diameter

Flange O.D. (mm)

Bolt Circle Dia. (mm)

Bolt Hole Dia. (mm)

Bolt Number Bolt Dia.

200 340 295 23 12 M20

300 455 410 28 12 M24

800 1025 950 40 24 M36

1200 1485 1390 49 32 M45

NP25 Flanges

Nominal Diameter

Flange

O.D. (mm)


Bolt Hole Dia. (mm)


200 360 310 28 12 M24

300 485 430 31 16 M27

800 1085 990 49 24 M45

1200 1530 1420 56 32 M52

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6.2.6 Bolts, Nuts and Washers

Bolts nuts and washers shall be galvanized to BS729.

Nuts and bolts shall be manufactured to BS 4190 ISO metric black hexagonal bolt screws and nuts. They shall be threaded in accordance with BS 3643 par 2 ISO metric series threads.

Each bolt shall be provided with a nut and two 3mm thick washers.

Each bolt shall be of sufficient length to show two threads past the nut when installed.

6.2.7 Gaskets Gaskets shall be suitable for use with both flanges with raised faces and between flanges with fully machined faces.

Gaskets shall have a minimum thickness of 3mm rubber incorporating two layers of cotton fabric. The gaskets shall be suitable for use at pipeline pressures up to 25 bars.

Gaskets shall comply with the relevant sections of BS 5292 and their dimensions shall be in compliance with BS 4865.

6.2.8 Operating Gear Valves shall be clockwise closing and shall include on indicator to show the valve position.

Valves shall be capable of being opened and closed manually by one person, when the specified maximum unbalanced pressure is applied to the valve in use. The force required to open the valve from the closed position should not exceed 125N at each of two diametrically opposite points on the rim of a 0.4m diameter hand wheel.

Operating gear shall be watertight under an external head of 10.0m of water.

6.3 ISOLATION VALVES Isolation valves include:

• Line valves (located on the main pipeline)

• Washout valves

• Isolation valves at air valves

6.3.1 Operation Isolation valves will be manually operated and installed in chambers.

Valves shall be clockwise closing and shall include an indicator to show the valve position.

Valves shall be capable of being opened and closed manually by one person, when the specified maximum unbalanced pressure is applied to the valve. The force required to open the valve from the closed position should not exceed 125N at each of two diametrically opposite points on the rim of a 0.4m diameter hand wheel.

Operating gear shall be watertight under an external head of 10.0m of water.

6.3.2 Extension Spindles Line valves and washout valves shall be installed with extension spindles, spindle caps, spindle supports, protection tubes and surface boxes to permit operation of the valve from outside of the chamber.

The Contractor shall design, supply and install suitable extension spindles for all line and washout valve installations including for those valves supplied by the Employer. Spindles including fixing, mountings and couplings shall be designed for the maximum operating torque with a factor of safety of two.

Spindles shall be circular in section and provided with suitable bearings rigidly held on brackets spaced no more than 1500mm apart.

6-4


Couplings shall be robust and provided with adequate pinning to carry the shear and prevent pullout.

One T key shall be supplied for every five valves installed, with a minimum requirement of two keys in any one size.

6.3.3 Gate Valves (Sluice Valves) Gate valves up to and including 600mm nominal diameter shall conform to the requirements of BS 5163 for copper alloy faced with a solid wedge.

The valves components shall be manufactured from the following materials:

Body, bonnet, stuffing box, cap Ductile Cast Iron to BS 2789 Grade 420/12 Grade 500/7

Stem Aluminium bronze to B.S.2874 CA 104 Wedge Ductile Cast Iron to BS 2789 Grade 420/12

Grade 500/7 Facing rings Gunmetal to B.S.1400 LG2 Hand wheel (where required) Cast Iron to B.S.1452, Grade 17 min.

Valve spindles shall be of the internal non-rising type. The valve spindle seal shall be replaceable with the valve fully open and the main under pressure.

The valve stem shall be made in one piece and shall be able to withstand without permanent distortion all stresses, compressive, tensile and torsional, to which it could be subjected. The stem diameters above and below the collar shall comply with the dimensions given in table (4) of BS5163/86 (Type B, for A1 Bronze to B.S.2S74 CA 104 material).

Except where otherwise shown, gearbox spindles, for hand wheel/tee key or for connecting with an extension spindle shall be vertical when the valve is installed. Gate valve shall be manually operated and shall be closed clockwise.

Valves shall not contain any brasses, which have more than 5% zinc.

The length over flanges for Gate Valves (Sluice Valves) shall be as specified below:

Size (mm.) Face to Face Dimension (mm.) 200 400 300 500

6.3.4 Butterfly Valves Butterfly valves shall comply with BS EN 593 or AWWA C504, except as specified herein. Valves shall be suitable for mounting in any position and shall be designed to be used as a regulating valve and closing valve.

Valves shall be mounted with shafts horizontal unless otherwise specified or shown on the Drawings. Valves over 350 mm bore shall be provided with bevel gearing.

Valves shall be fitted with indicators to show the position of the disc.

The Contractor shall provide details of the materials of manufacture and of the valve design, including the access route to repair or replace seals and shall provide evidence to show that the proposed materials and seating designs for the sealing and seating arrangements have given satisfactory performance in similar conditions to those applying under the Contract.

Flanges and hubs for shaft bearing housings shall be integrally cast with the valve body. All bearings shall be maintenance-free of a self-lubricating or sealed-for-life type.

Disc edges shall be machined with rounded corners and shall be polished to a smooth finish. The valve disc shall rotate through an angle of 90 degrees from the fully opened to the fully closed position and the seat shall be designed so as to close at an angle normal to the axis of the pipe. Hollow discs and any other castings with voids shall be fitted with watertight threaded plugs.

6-5


Discs shall be capable of maintaining their fully open and fully closed positions with the gearbox removed. Limit stops shall be capable of absorbing full operating torque with a minimum design safety factor of 5.

Shafts shall be fabricated of stainless steel grade 316 S16 to BS 970 part 4. Body-seats shall be fabricated of stainless steel grade 316 S16 to BS 970 part 4 or made of back-up welded nickel face (nickel weld overlay).

The shaft and disc fixing shall be capable of absorbing the full operating torque with a minimum design safety factor of 5 and will safely sustained maximum differential pressure across the closed valve. Shaft seals, when used, shall be of the resilient O-ring type. Packing shall be either of the resilient 0-ring or of the self-adjusting chevron type.

The sealing ring shall be replaceable without the need to remove the valve body from the pipework in which it is fitted.

The valve body and disk shall be of ductile cast iron of quality not less than BS 2789 grade 500/7. In general the materials chosen shall be corrosion resistant to the source water referred to in the Specification. All bolts, nuts and other fixings, which will be in contact with the flow or with the ground shall be of stainless steel type 316-S16.

Bolts retaining the removable seal cover and the body seat ring shall be of stainless steel type 316-S16 to BS 970 Part 4.

Valves shall be suitable for submergence below water.

The valves shall be capable of being seated and unseated under the most adverse conditions appropriate to its rating.

The gearbox spindle for hand wheel/tee key or for connecting with the extension spindle shall be vertical when the valve is installed.

Valves greater than 600mm diameter shall be provided with suitable support feet.

Butterfly valves shall be resiliently seated.

The face-to-face dimensions of butterfly valves shall be as detailed below: -

Size (mm.) Face to Face Dimension (mm)

1200 630

1000 550

800 470

600 390

Each valve shall be tested in accordance with the requirements of BS EN593, for body test, seat test and disc strength test. Seat tests shall be carried out in each direction and the valve shall be drop tight. Disc strength tests shall also be carried out in each direction.

6.3.4.1 Resilient-seated Butterfly Valves Service application for resilient-seated valves shall be “tight shut-off”. The valve seal shall be EDPM, EPM or SBR, durable and replaceable. The rubber sealing ring shall be made of nitrile synthetic rubber (or equal) suitable for permanent contact with Fresh or Brackish water at a permanent temperature of at least 50°C.

The valve seal shall be securely clamped to the edge of the disc by seal-retention members or other equivalent retention device in such a manner as to prevent leakage of water under the seal and to hold the seal securely in position during opening and closing of the valve disc. The seal-retention members shall be of stainless steel and shall be securely fastened to the body or disc with stainless steel fasteners. Stainless steel shall be Grade 316-S16.

The seal and its retention members shall be adjustable to ensure water tightness and to minimise the seating and unseating friction forces. When all the seal retention members are in place the finished edges of the seal shall fit closely and the surface shall be smooth with all

6-6


fastenings set flush in the water passage so as to offer the least resistance possible to the flow of water through the valve.

Valve seats which extend over the face of the flanges to secure the seat in place, or which require surface grinding and/or hand fitting of the disc, or designs which require the adjoining pipe flange to retain the seat in place and resist line pressure, are not acceptable.

6.4 AIR VALVES

6.4.1 General Air relief valves shall be double air valves designed to meet the following conditions:

(a) Discharge air during charging of the pipework; (b) Admit air during emptying of the pipework;. (c) Discharge air accumulated at local peaks along pipelines under normal operating

conditions. Conditions (a) and (b) shall be met by the employment of a large orifice capable of handling large volumes of air at a high flow rate, and condition (c) by a small orifice capable of discharging small quantities of air as they accumulate.

6.4.1.1 Small-orifice The small-orifice for relief of air under pressure and/or in bulk shall automatically open and exhaust accumulated air from a pipeline and shall automatically close when all air has been exhausted from the pipeline. The valve shall function properly at all pressures up to maximum working pressure.

Each valve shall be fitted with a test cock in the valve body to permit easy verification that the valve is operating properly and that its orifice is not blocked.

Valves shall be capable of discharging not less than 0.5m3/min of free air when the pressure in the pipeline is at the maximum working pressure for which the valve is designed.

6.4.1.2 Large-orifice The large-orifice shall automatically open to allow air into a pipeline as it is drained of water or ventilate air out from a pipeline as it is filled with water. The large-orifice shall close automatically when all air has been exhausted from the pipeline on filling. Valve shall be constructed so that the air flow actively holds the valve open during air flows in both directions up to the design discharge.

The large orifice shall, when coupled to its respective isolating valves, be capable of admitting air to and exhausting air from the pipeline at 200m3/min without the pressure differential across the combined air valve and isolating valve exceeding 0.25 bar.

6.4.2 Materials The valve components shall be manufactured from the following materials:

Body, Bonnet, Cover Ductile Iron to BS.2789, Gr.420/12 or Gr.500/7. Float Vulcanised rubber or stainless steel Gr.316-S16 to BS 970/4

high impact polypropylene. Float Guide Gunmetal to BS 1400 LG2

Cock Gunmetal to BS 1400 LG2

Valves shall have approved screening arrangements, made of stainless steel, to prevent the ingress of foreign matter.

Floats shall be in one part without any welding or Fusion processes. Floats with centre guide shall not be accepted. Floats and seats shall be designed so as to minimise the risk of adhesion of the ball to the seat. They shall be of a type proved by experience to be suitable for

6-7


the specified duties. Floats of air valves shall seat against its orifice or cause the orifice to close without leakage of water at all pressures measured at the valve between 0.1 bar and the maximum working pressure. Orifices shall be nylon, bronze or stainless steel.

The valve body shall be fitted with Gunmetal guides (to BS.1400-LG2) for the Floating balls.

Vulcanised rubber and any other rubber parts shall be suitable for use with Distillate or Brackish water and withstand to a temperature not less than 50°C.

All air release openings shall be directed downwards.

6.4.3 Non-slam Air Valves Non-slam air valves shall be double air valves as specified above except that the air valve shall be fitted with a vented non-return valve or other device which permits air to enter the pipeline freely on low pressures caused by surges within the pipeline, but which controls the expulsion of any air drawn into the pipeline under surge conditions in order to minimise ‘slam’ as the air is finally expelled from the pipe.

The non-slam air release & vacuum break valve shall be of the compact single chamber design with solid cylindrical H.D.P.E. control floats housed in a tubular stainless steel body with epoxy powder coated cast iron or steel ends secured by means of stainless steel tie rods. The valve shall have an integral ‘Anti-Shock’ Orifice mechanism which shall operate automatically to limit transient pressure rise or shock induced by closure to 2 x valve rated working pressure.

The intake orifice area shall be equal to the nominal size of the valve. Large orifice sealing shall be effected by the flat face of the control float seating against a nitrile rubber ‘O’ ring housed in a dovetail groove circumferentially surrounding the orifice. Discharge of pressurised air shall be controlled by the seating and unseating of a small orifice nozzle on a natural rubber seal fixed into the control float.

The valve construction shall be such that leaking or damage of any kind does not occur by submission to twice the designed working pressure. Valves shall not exhibit leaks or weeping of liquid past the large orifice seal at operating pressures of 0.5 bar to twice rated working pressure.

The valve design shall incorporate an over pressure safety feature that will fail without an explosive effect, such as is normally the case when highly compressed air is released suddenly. The feature shall consist of easily replaceable components such as gaskets, seals or the like.

The valve shall be designed such that prior to the ingress of liquid into the valve chamber, as when the pipeline is being filled, valves shall vent through the large orifice when water approach velocities are relative to a transient pressure rise, on valve closure, of < 2 x valve rated pressure. At higher water approach velocities, which have a potential to induce transient pressure rises > 2 x valve rated pressure on valve closure, the valve shall automatically discharge air through the Anti Shock Orifice and reduce water approach velocity, so that on closure a maximum transient pressure rise of < 2 x valve rated pressure is realised.

Valves shall respond to the presence of air by discharging it through the small orifice at any pressures within a specified design range, i.e. 0.5 bar to 16 bar, 25 bar or 40 bar dependent upon the location of the valve. The valve shall remain leak tight in the absence of air.

Valves shall react immediately to pipeline drainage or water column separation by the full opening of the large orifice so as to allow unobstructed air intake at the lowest possible negative internal pipeline pressure.

6.4.4 Check Valves (non-return valves, reflux valves) Check valves may be of single/multiple door or tilting disc type, suitable for installation in the required position. Other types of valves may be acceptable, subject to the approval of the Engineer,

Check valves shall be designed for rapid closing without slamming no later than the moment of cessation of forward flow.

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6.4.5 Single-door Swing Check Valves

Single-door swing check valves hall have a single port sealed by means of a gate with hinges offset outside the area of the port. The gate shall open automatically on start of flow in one direction and close automatically on flow reversal. Closure of the gate may be assisted by weights or weighted levers.

Unless otherwise specified, valves shall conform to BS 5153 and shall be double-flanged.

6.4.6 Multiple-door Swing Check Valves Multiple-door check valves are swing check valves except the valves shall have two or more parallel ports each with separate hinged gates.

Unless otherwise specified, valves shall conform to the general requirements for swing type valves as specified in BS 5153.

6-9

Document III-2 - Particular Specifications Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street (Contract RA/266) MEW Water Pipeline Relocation-Specification Part-7, Coatings and Protection

7 COATINGS AND PROTECTION This part covers the coating and protection systems to pipes, fittings and valves.

7.1 PROTECTION OF DUCTILE IRON PIPES & DUCTILE IRON FITTINGS

7.1.1 External Protection of Ductile Iron Pipes and Fittings Ductile iron Pipes and fittings shall be factory coated externally with a layer of metallic zinc of minimum thickness 20 microns. Application methods shall be in accordance with BS EN 545 or ISO 8179. Pipes and fittings shall be further protected externally with an approved bitumen-based coating pigmented with aluminium of thickness not less than 100 microns.

The external surfaces of spigot ends up to 250mm from the end shall be coated with an approved 2-pack solvent free epoxy resin of thickness not less than 100 microns, applied in accordance with the manufacturers instructions.

No pipes with significant damage to the external coating will be accepted. Where, in the opinion of the Engineer damage to the coating is minor, it shall be repaired as far as possible in accordance with the original coating system, subject to the approval of the Engineer.

7.1.2 Internal Protection of Ductile Iron Pipes and Fittings Pipes and fittings shall be lined in accordance with AWWA C104/A21.4-95 with cement mortar lining (double thickness) and a seal coat. The lining thickness shall be to Section 4.7.2 as specified below and the seal coat shall comply with Section 4.11. Cement shall be ASTN C150 Type II Portland cement.

Pipe diameters (mm) Lining thickness (mm)

60 to 300

350 to 600

700 and greater

3.2

4.8

6.4

Tolerance on linings shall be as specified in AWWA C104 Table 8. Cement mortar linings shall be machine-applied. There shall be no cracks in the cement mortar lining.

Subject to the approval of the Engineer fittings may be coated wholly internally and externally with epoxy paint of thickness not less than 150 microns and suitable for drinking water at temperatures up to 50°C. No pipes with significant damage to the internal coatings will be accepted. Where in the opinion of the Engineer damage to the coatings is minor it shall be repaired as far as possible in accordance with the original coating system. The repair shall be subject to the approval of the Engineer.

7.1.3 Spigots and Sockets The internal surfaces of sockets (and external surfaces of spigot ends up to 250mm from the end) shall be coated with an approved 2-pack solvent free epoxy resin of thickness not less than 100 microns, applied in accordance with the manufacturers instructions.

7.1.4 Protective Wrapping Tape Systems The protective wrapping tape for the external protection of pipes and fittings shall comprise a thick PVC tape coated on one side with a heavy self-adhesive bituminous or butyl rubber compound.

The release paper shall be a minimum of 5mm wider each side of the tape edges and the tape shall have a guide-line printed to indicate 55% overlap.

The product shall achieve the following minimum performance values when tested as per methods indicated below.

7-1


Performance Value Test Method

Total tape thickness Compound thickness PVC thickness

1.6mm 0.85mm 0.75mm

-

Tensile Strength 12N/mm ASTM D1000

Elongation of non- strengthen tape

250% ASTM D638

Tear Resistance 45Newtons ASTM D1004

Impact Resistance (double layer 15 (Joules) ASTM G13

Adhesion 2.00N/mm ASTM D1000

Dielectric strength 20Kv

Insulation resistance 1,000,000 Mega ohms/Sq. cm

Operational temperature range -20 to + 80 deg. C

Water vapour permeability 0.6 g/Sq.m/24hrs ASTM E96

Water absorption 0.25% at 23 deg. C/ 24 hrs ASTM D570

Holiday test voltage 10/15/ kV

Note: Elongation for tapes strengthened with approved inert fibres may be reduced to 25%. However all tapes must be sufficiently deformable to ensure close wrapping of all joints and fittings.

7.1.4.1 Outerwrap Protective Tape The outer wrap to the bituminous protective wrapping tape shall comprise a PVC carrier coated with a pressure sensitive adhesive Wrapping Tape. The product shall achieve the following minimum systems performance values: -

Performance Value Test Method

Total tape thickness 0.2 mm -

Tensile strength 2.6N/mm ASTM D1000

Elongation 180% ASTM D638

Tear Resistance 8 Newtons ASTM D1004

Dielectric Strength 10KV -

Operational temperature range 0 to 75 ºC.

All tapes must be sufficiently deformable to ensure close wrapping of all joints and fittings.

7-2


7.1.4.2 Primer

The wrapping system for pipes shall, unless otherwise approved by the Engineer, include a bituminous based quick drying surface primer which shall be compatible with the wrapping tape and external pipe coating. The primer shall be as recommended by the tape manufacturer and be fast drying and suitable for cold application by brushing and spraying and be compatible with the factory applied pipe coating.

7.1.5 Polyethylene Sleeving Buried ductile iron pipes, fittings and joints shall be double sleeved with site applied polyethylene sleeving. Factory applied sleeving shall not be used.

Polyethylene shall be in accordance with BS 6076 or 'C' of AWWA C.105, except as otherwise specified.

Suitable adhesive PVC tape shall be used to fix the sleeving in position and to make joints between adjacent sections.

Sleeving shall be black Class C.

7.1.6 Heat-shrink Sleeving Heat-shrink sleeves for use at pipe joints to complete fusion-bonded epoxy coatings shall be manufactured from heavy-duty radiation cross-linked polyolefin sheet material, coated on one side with high shear strength hot-melt adhesive,

7.1.7 Fusion-bonded Epoxy Coating Fusion-bonded epoxy coatings shall consist of a polymeric anti-corrosion barrier applied at a factory approved by the Engineer.

The coating system requirements, performance testing and factory applied coating requirements and practice shall be in accordance with the Water Industry Specification (WIS) 4-52-01.

The method of surface preparation and cleaning shall be in accordance with the Contractor’s specification which shall be no less than the minimum requirements specified by the coating material manufacturer and the following requirements:

• The pre-coating surface shall be blast-cleaned to a minimum standard of Grade B Sa 2½ in accordance with BS 7079: Part A1;

• The surface shall be tested for soluble salts and re-blasted if soluble salts are found to be present;

• All oil, grease and other contaminants shall be removed; • All slivers and scabs made visible by blast cleaning and detrimental to the coating

process shall be removed; • Welds shall be fettled smooth; • Edges and corners shall be smoothed to a 3.0mm minimum radius; • Any pre-treatment prior to coating shall not be permitted without the written approval of

the Engineer • The shot-blasted surface shall have a roughness RZ between 40µm and 80µm

inclusive. The minimum and maximum thickness of coatings for pipes and fittings shall be as in the table below: -

Location Minimum Maximum Pipe walls

Fittings including flanges Inside bolt holes

300 microns 300 microns 300 microns

1.6mm 2.0mm 2.0mm

7-3


All thickness-critical surfaces shall be coated to the thickness specified and within the tolerances identified. Raised flange faces shall be dressed after coating to remove coating runs.

Unless otherwise specified, each item shall be checked for holidays over all of the coated surfaces. A fitting with two or more holidays per 3m2 of surface area or a pipe with thirty or more holidays per pipe length shall be rejected for subsequent stripping and recoating. All holidays detected shall be repaired and on completion the item shall be re-examined for holidays. After repair the coating shall be holiday free to Class A.

All coatings on pipes and fittings shall be treated with a UV-inhibitor to prevent chalking or loss of colour.

External protection to pipes to be surrounded in concrete over part of their length shall extend at least 150mm within the concrete.

7.1.7.1 Repairs Materials and instructions shall be supplied for repair of coatings damaged in transit and on site. Repair materials shall be compatible with the coating in colour and adhesion and shall be suitable for site application.

In the event of a fusion-bonded epoxy coating being damaged after leaving the factory the item shall be returned to the factory for repair or, with the consent of the Engineer, be repaired at Site. Site repairs will not be permitted where the total area of damage to be repaired on a single pipe or fitting exceeds 6cm2 for pipes and fittings up to and including 600mm diameter and 12cm2 for pipes and fittings in excess of 600mm diameter. Repairs shall be effected in accordance with the manufacturer’s recommendations. Notwithstanding such recommendations the repair shall meet the following minimum requirements:

• Repair materials shall be compatible with the original factory-applied coating materials and, where applicable, they shall comply with Clause 5.2.4;

• The edges of the original factory-applied coating shall be ground off to a taper or feather edge;

• Exposed metal shall be cleaned and prepared as specified in Clause 10.1.7 • The relative humidity of the atmosphere in which the repair is to be effected shall be

maintained (if necessary by the use of hot-air blowers and tenting) at less than 85%, a wet/dry thermometer being provided during repairs to demonstrate humidity;

• The surface temperature of the exposed metal shall be raised to at least 3oC above dew point and the coating shall then be applied in stages, as recommended by the manufacturer, so as to achieve a total thickness in accordance with Clause 10.1.7

• All repairs shall be checked with a holiday detector and any holidays shall be repaired, after which the repairs shall rechecked.

7.1.8 Two-part Epoxy Coating Two-part epoxy coating shall be applied in accordance with the manufacturer’s recommendations and shall meet the minimum requirements as follows: Surface preparation of exposed metal shall be as specified for fusion-bonded epoxy coating. The coating shall be applied in two or more layers to a minimum thickness of 300 microns. The relative humidity shall be maintained at less than 85% during application of coating material. The surface temperature of the metal during application shall be raised to at least 3°C above dew point. All surfaces shall be checked with a holiday detector following application. All holidays found shall be repaired. Adequate ventilation shall be provided during application and curing of the material.

7-4

Document III-2 - Particular Specifications Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street (Contract RA/266) MEW Water Pipeline Relocation-Specification Part-8, Joints and Ancillaries

8 JOINTS AND ANCILLARIES

8.1 SCOPE This part covers joints to pipes, fittings and valves.

8.1.1 Spigot and Socket Joints Push-in socket and spigot joints shall permit pipes to be deflected angularly by up to 2° axially for diameters up to 900mm and by up to 1.5o axially for diameters over 900mm.

8.1.2 Mechanical (Bolted Gland) Joints Spigot and socket joints to fittings shall be the mechanical (bolted gland) type supplied with rubber gasket and bolts. Glands should be ductile iron of the same quality as the fitting and shall be supplied with a bituminous coating of thickness not less then 100 microns. On a fixed spot on the outside of each gland the manufacturers name or identification mark, date of manufacture and nominal diameter shall be marked. Bolts for use with bolted gland joints shall be spheroidal graphite in accordance with BS 2789 Grade 500/7.

8.1.3 Anchored Joints Self-anchored couplings and flange adapters shall not be used for transmission of axial loads.

8.1.4 Joint Sealing Rings Joint sealing rings shall be obtained from the manufacturer of the pipe or joint.

Joint sealing rings shall comply with the relevant requirements of BS EN 681 or AWWA C111/21.11, shall be rubber, suitable for making a long-term flexible seal between the pipes and shall be suitable for the ambient and climatic conditions in Kuwait, for water temperature of 50°C and be resistant to mechanical, chemical or bacteriological attack leading to deterioration of the flexible seal. Rubber for sealing rings shall be ethylene propylene rubber (EPDM or EPM), acrylonitrile butadiene rubber (nitrile) or styrene butadiene rubber (SBR) which complies with the above requirements.

Lubricants used during jointing shall have no deleterious effects on either the sealing ring, pipes or pipe coating and shall be unaffected by the liquid to be conveyed.

8.1.5 Flanges and Flanged Joints Flanges shall be compatible with the flanges on materials supplied by the Employer. Back faces of flanges shall be machined. The Contractor shall ensure that flanges are compatible in all cases, including where connections are to be made to existing pipe flanges. Where flanges are coated with paint, fusion bonded epoxy or other materials, the coated surfaces of mating faces shall, whilst maintaining minimum coating thickness, be prepared as necessary to ensure suitable regular surfaces for mating. Bolt holes shall be reamed out as necessary to allow insertion of bolts whilst maintaining minimum coating thickness. Flanges shall be ductile iron NP16 or NP25 to ISO 2531 and drilled to ISO 7005-2 as follows:

Dimensions NP16 Flanges

Nominal Diameter

Flange

O.D. (mm)


Bolt Hole Dia. (mm)


200 340 295 23 12 M20

300 455 410 28 12 M24

800 1025 950 40 24 M36

1200 1485 1390 49 32 M45

8-1

Document III-2 - Particular Specifications Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street (Contract RA/266) MEW Water Pipeline Relocation-Specification Part-8, Joints and Ancillaries

Dimensions NP25 Flanges

Nominal Diameter

Flange

O.D. (mm)


Bolt Hole Dia. (mm)


200 360 310 28 12 M24

300 485 430 31 16 M27

800 1085 990 49 24 M45

1200 1530 1420 56 32 M52

8.1.6 Bolts, Nuts and Washers Bolts nuts and washers shall be galvanized to BS729.

Nuts and bolts shall be manufactured to BS 4190 ISO (ISO 4014) metric black hexagonal bolt screws and nuts. They shall be threaded in accordance with BS 3643 part 2 ISO metric series threads.

Each bolt shall be provided with a nut and two 3mm thick washers.

Each bolt shall be of sufficient length to show two threads past the nut when installed.

8.1.7 Gaskets Gaskets shall be suitable for use with both flanges with raised faces and between flanges with fully machined faces. Gaskets shall be inside bolt circle type to BS EN 1514-1 of materials complying with BS EN 681.

Gaskets shall comply with the relevant sections of BS 5292 and their dimensions shall be in compliance with BS 4865.

Gaskets shall have a minimum thickness of 3mm rubber incorporating two layers of cotton fabric.

Gaskets shall be one piece EPDM rubber of hardness 80, of minimum thickness 3mm and of such physical properties as to be capable of forming permanent watertight joints against pressures up to the maximum test pressure. The use of jointing paste, adhesive tape or grease on gaskets will not be permitted.

8.1.8 Connections between Different Pipe Classes or materials Where different types or classes of pipe material or of different materials are jointed together, the Contractor shall supply special fittings or stepped couplings designed and manufactured to suit the ends of pipes to be jointed. Stepped couplings shall comply with the requirements for detachable flexible couplings and flange adapters where applicable.

8.2 ANCILLARIES

8.2.1 Marker Tape Marker tape shall be 50mm wide and 0.1mm nominal thickness coloured polythene or similar approved system boldly printed with the word ‘CAUTION’ and words to identify the particular service throughout its entire length, in accordance with the following coding: -

Types of service Tape Colour Service Identification Wording

Water supply pipe Blue WATER MAIN BELOW

Instrumentation, telephone telemetry cables

Red CONTROL CABLE BELOW

8-2

Document III-2 - Particular Specifications Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street (Contract RA/266) MEW Water Pipeline Relocation-Specification Part-9, Construction of Pipelines

9 CONSTRUCTION OF PIPELINES

9.1 SCOPE This part covers the installation of buried pipelines.

9.1.1 Setting Out Pipelines shall be accurately installed to even grades and to the lines and levels shown on the Drawings so that the barrel of the pipe is continuously supported throughout its length by the bedding material. The line and level of the pipeline shall be as shown on the Drawings or as directed by the Engineer.

The Contractor shall submit details of the methods he proposes to use for control of the accuracy of pipe laying. The position of any pipe shall be within ±25 mm of the specified level and within ±100mm of the horizontal alignment.

Strong sight rails marked the centre line and the level to which the pipeline is to be laid shall be fixed and maintained at each change of gradient and at as many intermediate points as necessary not more than 40m apart. Alternatively the Contractor may use laser techniques.

Horizontal curves and changes in grade of the pipeline shall be carried out smoothly by making use of the permissible deflection at joints.

9.1.2 Trial Length of Pipeline At the commencement of the Works the Contractor shall construct a trial 1000m length of pipeline and carry out soils testing and a successful pressure test to demonstrate the acceptability of his proposed construction methods.

The trial length may form part of the permanent works providing that it complies with the specification.

9.1.3 Pipelines in the same Trench The minimum clear spacing between barrels of adjacent parallel pipes shall be 600mm. Unless otherwise shown the crown levels of the pipelines shall be at the same level.

9.1.4 Pipeline Gradients and Cover Pipelines shall be laid to a minimum cover below the natural ground level of 1.20m. The maximum cover below final ground level shall not exceed 4.0m unless otherwise directed by the Engineer.

The minimum rising gradient in the direction of flow shall not be less than 0.2% and the minimum falling gradient in the direction of flow shall not be less than 0.33%.

9.1.5 Buried Pipes General Trench excavation and backfill shall be co-ordinated with the construction of the pipeline as a whole so as to ensure expeditious completion of the whole operation.

Flexibly-jointed socket and spigot pipes shall normally be laid with sockets leading. Where the gradient exceeds 5%, installation shall proceed on an ascending grade with sockets leading. Pipes shall be installed singly and shall not be jointed until after they have been laid. After laying and jointing, the level of each pipe shall be checked before the next pipe is laid.

Pipe bores shall be kept clean and free from water, dirt, stones and other foreign matter.

When installation is not proceeding a suitable stopper shall be installed to seal the open ends of pipes.

The Contractor shall take such precautions as are necessary to prevent pipes from floating.

9-1


9.1.6 Concrete Bed and Surround

Where shown on the Drawings or directed by the Engineer concrete bedding haunches and surround shall be provided in accordance with the typical details shown on the Drawings. Concrete shall be un-reinforced of the class shown on the Drawings. Any formwork required shall be Class F1.

Each pipe shall be supported on at least two purpose-made pre-cast concrete blocks, which shall be left in place. In-situ concrete shall be placed after the joints at each end of the pipe have been completed and the pipeline has been checked and adjusted for alignment. The concrete shall be placed and carefully worked and compacted beneath and around the pipe. Unformed surfaces shall be of spade finish. The pipe shall be prevented from floating or otherwise moving during concreting.

The continuity of concrete bed, haunch or surround to pipes with flexible socket and spigot joints shall be broken at each flexible joint by 25mm thick fibreboard, placed against the face of the socket. The concrete bed, haunch or surround shall be discontinued at detachable flexible couplings, leaving a clearance of 75mm each side of the coupling.

Where two or more pipelines are laid in the same trench, the joints shall coincide at the joints in the largest diameter pipeline where the continuity of the concrete bed, haunch or surround shall be broken. Any intermediate joints in the smaller diameter pipelines shall be surrounded in concrete.

9.2 JOINTING Before making any joint the Contractor shall ensure that the interior of each pipe or fitting is clean and shall prepare the ends for jointing as necessary. All mechanical joints shall have their coating made good before assembly in accordance with the coating manufacturer’s recommendations.

Only the proper jointing parts as specified and obtained from the suppliers of pipes or fittings shall be used.

Joints shall be made in accordance with the manufacturer’s instructions.

Unless otherwise specified or detailed in the Drawings the deflection of a flexible joint shall not exceed 50% of the maximum value specified by the manufacturer.

Bolts for flanged and other mechanical joints shall show two threads clear of the nut after tightening.

Stainless steel nuts and bolts shall be lubricated before assembly with an anti-galling lubricant. Nuts shall be tightened to the torques recommended by the joint manufacturer. Torques shall not exceed values at which there is risk of galling.

After completing the joint any protective or other coating shall be made good and the joint protection and sleeving completed without delay.

9.2.1 Flanged Joints Joint rings for flanged joints may be fastened to the bolts with cotton thread. The use of jointing paste, adhesive tape or grease will not be permitted.

The bores of abutting pipes or fittings and the joint gasket shall be concentric; no joint material shall be left protruding into the bore. Nuts shall first be tightened by hand and nuts on opposite sides of the joint circumference shall then be alternately and progressively tightened with a spanner so as to ensure even pressure all round the joint.

9.2.2 Work Inside Pipelines The Contractor shall maintain adequate safety and monitoring systems, access, lighting and ventilation to any part of a pipeline where work is undertaken inside the pipes.

9-2


9.2.3 Cutting of Pipes

Pipes shall not be cut until after adjacent pipes have been laid and jointed and accurate measurement of the length and the required angle and shape of the cut can be made.

The cut shall be neatly performed by an experienced skilled man using tools or machinery appropriate for the type and diameter of pipe to be cut. The cut ends of the pipes shall be shaped up and trimmed so as to ensure an accurate joint. Any damage to wrapping, coating or lining shall be made good.

The unused part of any cut pipe shall be disposed of off the Site unless, with the Engineer's approval, it can be used elsewhere in the Works or it is required to be returned to the Employer.

9.2.4 Closing Lengths Pipes for closing lengths or for inserting into pipelines already laid shall be cut to allow a gap of at least 20mm between adjacent pipe ends. Otherwise, the gap shall be as recommended by the manufacturer of the coupling. The closing joints in pressure pipelines shall be made with bolted gland collars unless otherwise shown on the Drawings.

9.3 EXTERNAL PROTECTION

9.3.1 Sleeving of Ductile Iron Pipelines Double layer polyethylene sleeving shall be installed on ductile iron pipelines such that it is continuous over joints and fittings in accordance with the following procedure:

Immediately before lowering the pipes into the trench they shall be cleaned of all soil and foreign matter and any damage made good.

The sleeve shall be slipped over the pipes and secured in place using adhesive PVC tape. The sleeving shall be pulled tight against the bottom invert of the pipe and the excess girth shall be gathered at the top of the pipe and folded. The sleeve at the ends of the pipes shall be left loose until after jointing and any wrapping of the joint. The loose sleeving shall then be carefully pulled over the joints so that it is continuous. The overlaps shall be secured with PVC tape at not more than 600mm centres. Bends, tees and similar fittings shall be protected similarly.

Any sharp edges such as at bolted gland or flanged joints shall be padded with four thicknesses of sleeving material before the sleeve is pulled over them.

Care shall be exercised during handling, installing and backfilling to prevent damage to the sleeving. Any minor damage to the sleeving shall be repaired by wrapping a sheet of material cut from the sleeving material right round the pipe and so that it provides an overlap of at least 200mm past each side of the puncture; all edges being taped to the sleeving.

Sleeving shall be omitted from the sections of pipes and fittings which are embedded in concrete chambers. Before placing the concrete, the end of the sleeving shall be folded back clear of the concreting operations and a run of adhesive PVC tape not less than 50mm wide shall be affixed around the pipe barrel so that the centre of the tape is aligned with the eventual position of the concrete face. After concreting is completed, the sleeving shall be pulled over the pipe up to the concrete face and secured to the pipe barrel with PVC tape such that the end of the sleeving overlaps the tape previously placed around the pipe and so that no part of the pipe remains exposed. The termination of the sleeving shall be completed by placing a further run of adhesive PVC tape around the pipe, spanning between the end of the sleeving and the face of the concrete.

Sleeving shall be continuous around fittings (bends and tees) at thrust blocks.

9.3.2 Ductile Iron Pipelines & Fittings The contractor shall obtain all D. I. Pipes & Fittings from MEW approved Supplies, a list for approved supplies is attached with this

.

9-3


9.3.3 External Wrapping of Fusion-bonded Epoxy Coated Pipes and Fittings

Field joints of fusion-bonded epoxy coated pipes shall be protected by heat-shrink sleeves. The sleeve shall be pre-cut to size and wrapped around the pipe or fittings before it has cured. The completed sleeve shall conform to the pipeline shape, show no blisters or sign of air entrainment and the hot-melt adhesive shall be visible as a flow from all edges.

9.3.4 Protection of Buried Bolted Couplings, Adapters and Flanges After jointing and testing, corrosion protection shall be applied to all buried detachable couplings, adapters, flange adapters, mechanical (bolted gland) joints and flanged joints. All such joints shall be thoroughly cleaned and wrapped with tropical grade petroleum jelly impregnated open weave cotton, synthetic fibre or glass fibre tape. The tape shall be suitable for use in the prevailing climatic and soil conditions and be applied in accordance with the manufacturer’s instructions. Profiling putty shall be used as required to provide a regular surface for wrapping. The tape shall extend at least 200mm over the adjacent pipe barrel.

All bolts shall be rechecked for tightness before wrapping tape is applied.

9.4 CONNECTING TO EXISTING PIPELINES Before starting any connection into an existing pipeline the Contractor shall verify the exact dimensions and the materials necessary. The Contractor shall excavate trial pits, prepare designs, and obtain the Engineer’s approval and liase with the authority responsible for the operation of that pipeline.

The Contractor shall prepare a detailed method statement for the completion of the connection, clearly indicating the period for which it will be necessary for the existing pipeline to be taken out of service The period of planned shut-down shall be kept to the minimum practicable in the circumstances.

The statement shall also detail the methods and plant to be employed, standby plant to be made available and the measures that will be taken to prevent contamination of the existing pipeline.

The statement shall be subject to the approval of the Engineer and of the operating authority.

Unless otherwise agreed in writing the operation of valves necessary to isolate the section of the existing pipeline and subsequently to restore it to service shall only be undertaken by staff of the operating authority. If so instructed by the Engineer the Contractor shall assist the authority in carrying out any activities necessary to facilitate the efficient completion of work on the connection.The contractor shall be responsible for any unforeseen connection found during execution of works.

The new pipeline and, where practicable, the existing pipeline at the connection shall be tested for leakage. Any existing pipe, fitting or joint leaking due to damage occurring during the connection operation shall be removed and replaced by the Contractor at no extra cost to the Employer.

9.4.1 Plugging of Dead Ends The dead ends of pipes and fittings shall be plugged and concrete anchors shall be provided.

9.5 MARKER POSTS AND INDICATOR PLATES Route marker posts shall be installed along all pipelines at every field and property boundary, at all chambers, valves, bends and the like at positions determined by the Engineer but at not more than 500m centres. Marker posts shall be installed only after the Engineer has approved their location.

Posts and indicator plates shall be as shown on the Drawings. The marker posts shall be set up as soon as practicable after trench excavations have been backfilled.

9-4


9.6 CABLE DUCTS

Where ducts are detailed as being laid in large radius curves in either the horizontal or vertical planes these shall normally be not less than 50m radius, unless a smaller radius is specifically detailed. In no case shall a curve of less than 25m radius be installed. Ducts shall be laid in regular curves of the required radius by bending the pipe during installation. Curves shall not be formed with angular deviations at flexible joints.

Joints in the draw cord shall be kept to a minimum; they shall be at least as strong as the cord and shall be so made as not to cause any jamming in use.

9-5

Document III-2 - Particular Specifications Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street (Contract RA/266) MEW Water Pipeline Relocation-Specification Part-10, Chambers and thrust Blocks

10 CHAMBERS AND THRUST BLOCKS

10.1 SCOPE This part covers the installation of valves and fittings and the construction of chambers and thrust blocks.

10.2 ANCHOR AND THRUST BLOCKS Unless otherwise detailed in the Drawings thrust blocks shall be constructed with the bottom, thrust and side surfaces bearing against undisturbed ground.

If blinding concrete is required or allowed to be placed beneath any horizontal thrust block shear keys shall be formed on its upper surface.

The surfaces of concrete thrust blocks not cast against undisturbed ground shall be waterproofed with two coats of bituminous paint.

Where steel beams for resisting the thrust of pipelines are installed under this Contract for future pipelines they shall be protected with a wrapping of petroleum jelly impregnated tape and outer wrapped with polyethylene sheet and adhesive tape.

10.3 VALVE AND OTHER CHAMBERS The thrust-bearing surfaces of pipeline chambers which are designed to carry thrusts shall be constructed against undisturbed ground as shown on the Drawings.

If undisturbed ground has not been maintained the gap shall be backfilled with C35/40 mass concrete.

Pipes shall project from the external faces of the chambers by the amounts stated for ductile iron pipes in Clause 10.3.2 unless otherwise shown on the Drawings or instructed by the Engineer.

Top surfaces of walls supporting pre-cast concrete cover slabs shall be to true line and level. Lifting holes or eyes in pre-cast components are to be provided as shown on the Drawings or as directed by the Engineer.

The outer surfaces of concrete chambers shall be waterproofed as detailed on the drawings and Specified in Specification Clause 6.15.

Where pipes are built into chambers for connection in the future the buried exposed end shall be plugged with a timber stopper and wrapped with petroleum jelly impregnated tape and outer wrapped with polyethylene sheet and adhesive tape.

10.3.1 Installation of Valves Valves shall be installed and commissioned in accordance with the manufacturer’s instructions. After installation valves shall be cleaned. Gates, discs, seats and other moving parts shall be closely inspected and all foreign matter removed and the valve shall be checked for ease of operation. Moving parts shall be lightly greased or otherwise treated as the manufacturer instructs to bring them into a good operating condition. Valves within chambers or other structures shall be protected from damage and dirt with suitable approved covering until commissioning.

Butterfly valves shall be fixed with the disc spindle horizontal and installed so that when the valve is opening the lower portion of the disc moves in the direction of the main or normal flow.

Except where shown otherwise in the Drawings gate valves shall be fixed with their spindles vertical.

10.3.2 Pipelines Built into Structures 10.3.2.1 Rocker Pipes

Where Ductile Iron pipes are built into structures rocker pipes comprising a short length of spigot and socket pipe shall be provided as shown on the Drawings. Unless otherwise shown

10-1

Document III-2 - Particular Specifications Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street (Contract RA/266) MEW Water Pipeline Relocation-Specification Part-10, Chambers and thrust Blocks

the first joint shall be not more than one pipe diameter or 500mm, whichever is the smaller, from the outside face of the structure and the length of pipe between the flexible joints shall be equal to two pipe diameters or 1000mm, whichever is the greater.

10.3.2.2 Excess Excavation Any excavation beneath the formation line of a pipe trench adjacent to a structure shall be backfilled to the formation line with concrete Class 20/40. The concrete shall extend at least 500mm beyond the extremities of the pipe on each side.

10.3.2.3 Thrust Flanges Ductile iron pipes passing through the walls of chambers shall be provided with thrust flanges where shown on the Drawings.

10.3.3 Pipeline Spacing at Structures Where it is necessary to increase the spacing of pipelines at structures such as chambers and thrust blocks the deviation shall be made by deflecting the pipe joints. Deflections shall be limited to 50% of the maximum allowable stated by the manufacturer.

10.3.4 Pipework in Chambers Pipework systems shall be complete and checked for correct position and alignment before being concreting in.

The Contractor shall ensure that no excessive loads or stresses are imposed upon the pipework or structure and shall adequately support the pipework during installation until permanent supports and anchorages are completed.

Where pipe fittings are cast into in-situ concrete walls and where a puddle flange is not required to resist forces rubber sealing rings shall be installed.

10.3.5 Painting of Pipes, Fittings and Valves Factory-applied coatings on pipes, fittings and valves in chambers and other exposed areas shall be made good on completion of construction of the chambers as necessary to return the items to the appearance on leaving the factory. Where specified exposed pipes, fittings and valves and their joints shall be over-painted to a colour to be agreed with the Engineer. Paint systems for over-painting shall be compatible with any factory coatings including coatings made good on site. Bitumen coated items shall be primed with two coats of aluminium sealer to a total dry-film thickness not less than 30 microns. Top coats of approved colour of alkyd chlorinated rubber finish shall be applied sufficient to give a total over-paint dry-film thickness of 80 microns. Where shown on the drawings or specified FBE or epoxy-coated items shall be lightly rubbed down with emery to provide a key and painted with two coats of alkyd or epoxy finish coats of approved colour.

10.4 DRAW PITS The Contractor shall submit details for the draw pits for cable ducts which shall be either pre-cast or in-situ concrete class C35A. The roof slab shall be pre-cast concrete with lifting hooks to enable it to be removed.

The cover shall be bedded and sealed as for the pipeline chambers, as detailed on Drawing.

The external faces of buried walls shall be painted with 2 coats of bitumen paint.

Where ducts are built into the walls the openings shall be sealed and made good.

10-2

Document III-2 - Particular Specifications Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street (Contract RA/266) MEW Water Pipeline Relocation-Specification Pipelines and Fittings Suppliers

10.5 PIPES & FITTINGS SUPPLIER

10.5.1 DUCTILE IRON PIPES

The following is a list of the Ministry of Electricity and Water’s Prequalified Suppliers of Ductile Iron Pipes.

COMPANY NAME ADDRESS LOCAL AGENT

American Cast Iron Pipes Co. (up to 1200 mm only)

2930 North 16th Street Birmingham Alabama, 35207, USA

ASIA Electro Mechanical Co. Lt PO Box 24354, Safat 13104 Kuwait Tele. 965 2401320 Fax : 965 2404527

Stanton (Export) Ltd (For fitting only)

Lows lane Stanton by Dale Ilkeston, Derbyshire DE7 4QU , England

Mhd. Khalid Zeid Al Khalid Tradi & Contracting Company PO Box 29465, Safat 13155 Kuwait Tele: 2429951/2, Fax 965-24409

Kubota Corporation (up to 1200 mm only)

International Operations Departme Ductile Iron Pipe Division 1-3 Nihombashi-Muromachi 3-cho Chuo-ku Tokyo 103-8310, Japan

Al-Masat Al-Thalatha Trading Co. (Mitsubishi) KSC. PO Box 2444, Safat 130 Kuwait Tel.: 965 2446399, Fax.: 9 2447189 Email:[email protected]

Schalker Verein Rohrsysteme Gmbh (up to 1200 mm only)

Am Schürmannshütt Postfach 23 47441 Mo Nordrhein-Westfalen Germany

Ahmad F.Al-Fahad Trading Contracting Co. PO Box 79 13001, Kuwait Tel: 2466888 Fax:2436410

Buderrus Guss Gmbh ((up to 1000 mm only)

Export Dept. RV/3 PO Box 1240 D-35573 Wetzlar Germany

Ferrodyne Trading Co.WLL. PO Box 3653, Safat 13037 Kuw Tel. 965 4768993 /4768164 Fax- 965 4768165

Pont-A-Mousson SA (up to 1200 mm only)

91, avenue de la Libération 54076 Nancy Cedex France

Abrar General Trading & Contracting Co. PO Box 315, Safat 13004, Kuw Tele. 965 2411545 / 2407794/5 Fax: 965 2407793

Saudi Arabian Ductile Iron Pipe Co. Ltd. (SADIP) (up to 600 mm only)

Export Division Sales PO Box 589, Dammam 31421 Tel: +966 3 857 1160 Fax: +966 3 857 9771 Telex: 801084 AMIDAM SJ

F.B.S. International Trading Co Salhiya, PO Box 27173 Safat 13132 Kuwait

Biwater Industries Ltd Coney Gree, Clay Cross,

Chesterfield, Derbyshire S45 9NE Tel: 0044 1246 861617 Fax: 0044 1246 866449

Arabi Co.

10-3


10.5.2 VALVES

The following is a list of the Ministry of Electricity and Water’s Prequalified Suppliers of Valves. Suppliers of Valves will also be required to supply Air Valves and Actuators.

Company Name Address Local Agent Glenfield & Kennedy Ltd. (For BFV, SV & FH only)

Glenfield Works Queens Drive Kilmarnock KA1 3XF, United Kingdom

Arabi Company WLL PO Box 4090, Safat 13041, Kuwait Tele. 965 4724057/58, Fax. 965 4724059

RMI Holland (For all Valves and Hydrants)

Havendijk 6 PO Box 26 4600 AA Bergen Op Zoom, Hollan

Gulf Suppliers Group Co., P.O. B 4018, Safat 13041, Kuwait

Guest & Chrimes Ltd UK (For all Valves and Hydrants)

Lows Lane Stanton-by-Dale Ilkeston, Derbyshire DE7 4QU, United Kingdom

United Engineering & Trading PO Box 12036, Shamiya -71651, Kuwait Tele. 965 2434160 , Fax. 965 241248

Pont-A-Mousson SA (For all Valves and Hydrants)

91, avenue de la Libération 54076 Nancy Cedex France

Abrar General Trading & Contracting C PO Box 315, Safat 13004, Kuwait Tele. 965 2411545 / 2407794/5 Fax: 965 2407793

Kubota Ltd., (For all Valves and Hydrants)

International Operations Departme Ductile Iron Pipe Division 1-3 Nihombashi-Muromachi 3-cho Chuo-ku, Tokyo, 103-8310, Japan

Al-Masat Al-Thalatha Trading Co. (Mitsubishi) KSC. PO Box 2444, Safat 13025, Kuwait Tel.: 965 2446399, Fax.: 965 2447189

Kuriomoto Ltd., Valve Division (For all Valves and Hydrants)

1-9 Shimbasi 4-chome, Minato-ku, Tokyo 105-004, Japan. Tel: 0081 3 3436 8191 Fax: 0081 3 3436 8026

Kuwait Marine Trading Co.

Ohtori Manufacturing Co Ltd (For all Valves and Hydrants)

2-7 Osumi 1-chome, Higashi-Yodogawaku, Osaka, Japan. Tel: 0081 6 6327 1820, Fax: 0081 6 6327 8084

Al Thuwainy Trading Co.

Popp & Reuther Armaturen Gmb (VAG) (For BF valves only)

Carl-Reuther Str.1 68305 Mannheim, PO Box 310140 68261 Mannheim, Germany Tel: 0621 7 490 , Fax: 0621 7 49 1 10

Al-Arfaj Engineering Co., PO Box 391, Salmiya -22004, Kuwait Tele. 4817448/950 Fax : 4817442/3

Ham Baker (For all Valves and Hydrants)

Simon Hartley, Garner Street Etruria, Stoke on Trent, Staffordshire ST4 7BH Tel; 0044 1782 202300, Fax: 0044 1782 260534

Marine Sevices Trading & Contract Co.

10-4


Company Name Address Local Agent Saudi Valves Manufacturing Co. (AVK SVMC) (For SV and FH only)

Jeddah Industrial C Phase 4, Street no. LO 4 P.O. Box 108 KSA-21443 Jedd Kingdom of Saudi Ara Tel: +966 263715 Fax: +966 26379380

F.B.S. International Trading Co. Salhiya, PO Box 27173 Safat 13132

Duvalaco BV (For BF Valves Only)

PO Box 5, 3300A Dordrecht, T Netherlands. Tel: 0031 78 654 5250 Fax: 0031 78 654 5260

Al-Arfaj Engineering Co., PO Box 3 Salmiya -22004, Kuwait Tele. 4817448/950 Fax : 4817442/3

END OF SECTION

10-5

Contract RA/266



PART-11 FIBRE OPTIC CABLE

11-1Document III-2 - Particular Specifications Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street (Contract RA/266) MEW Water Pipeline Relocation-Specification Part-11, Fiber Optic Cable

11 OPTICAL FIBRE CABLE (IF REQUIRED)

11.1 GENERAL The Contractor shall supply, test and install a single optical fibre cable system associated with the relocation of MEW Pipeline at chainages between 46+000 and 63+474.91.

The cable shall be laid inside a HDPE cable duct, running along side with pipeline route.

The duct material shall be High Density Polyethylene (HDPE). Each cable shall incorporate a minimum of eight optic fibre cores.

The cable construction components comprising inner and outer sheaths, strength, protection and support members shall be entirely non-metallic. Metallic armouring and also integral support wires for suspended cable installation shall not be used. Cable outer sheaths shall provide cable protection from the effects of continuous exposure to direct sunlight.

Cable shall be provided and installed in accordance with Fibre Optic Industry Code of Practice for the installation of Fibre Optic Cabling British Standard BS7718: 1994 or equal.

11.2 CABLE ROUTE The Contractor shall conduct a survey of the routes, shown on the Contract Drawings, to verify suitability and identify any impediments or hazards.

The Contractor shall ensure that the environmental conditions within the cable routes and the installation methods to be used shall be suitable for the optical cable to be installed.

11.3 MATERIALS The optical cable will be exposed to elevated air temperature due to the local climate. The Contractor shall ensure that all materials within the cable construction are stable and able to resist negative effects under these conditions. Flammable sheathing shall not be used within buildings.

The Contractor shall confirm the compatibility of the cabling components before delivery to site. Cables shall be procured and installed so as to minimise the number of joints. All joint components shall be of the same manufacturer.

Fibre optic cable and connectors shall be tested according to BS 9230.

The proposed cable shall be same or similar to match the existing Fibre Optic Cable

11.4 PRE-INSTALLATION TESTING The optical cable shall be physically inspected and tested for conformance with its optical specification prior to delivery to site. The tests shall include optical time domain reflectometry measurement for testing length and attenuation coefficient. Details of the measurement procedure shall be provided together with type, serial number and proof of calibration of the measurement equipment.

Pre-terminated components shall be certified as tested for insertion loss and return loss, where relevant.

11-1


11.5 INSTALLATION

The proposed materials and equipment for cable installation, detailed method statement for installation and an installation programme shall be submitted to the Ministry of Energy (Electricity and Water) for approval.

The Contractor shall install communications cable following the recommendations of the manufacturer and the relevant standards.

The Contractor shall be fully responsible for the installation of the cable and shall provide suitably qualified staff for supervision.

All fittings and accessories shall be provided and employed which allow installation in accordance with the cable manufacturer’s recommendations.

A sufficient length of cable shall be allowed at each closure to provide for subsequent access, cable management and acceptance testing.

Joints shall in general be fusion bonded. All splice joints shall be protected by suitable sleeves or splints and sufficient strain relief shall be provided. All joints shall be supported.

11.6 ACCEPTANCE TESTING The tests shall include optical time domain reflectometry measurement for testing length and attenuation coefficient. For runs of over 100 metres measurements for length shall be made at both ends and the two measurements compared. Differences greater than those that could be caused from instrument resolution, shall be investigated and resolved.

Attenuation coefficient shall be measured to ensure compliance with the design specification and to detect the presence of localised losses following installation. The cause of localised losses shall be determined and corrected.

Tests for signal-to-noise ratio, bandwidth and phase jitter shall be conducted for each line, where applicable and recorded.

All test equipment shall be provided by the Contractor and shall include as a minimum an optical power source, power meter and time domain reflectometer.

All communications components shall be tested and confirmed for correct operation individually and as a system. The diagnostic capabilities of the systems shall be demonstrated including self-test and fault notification.

All tests shall be fully documented and submitted to the Engineer. Documentation shall include procedures and results.

SINGLE MODE OPTICAL FIBER SPECIFICATIONS (G-652 C)

PARAMETER SPECIFICATION

Fiber Type Matched Clad Single Mode Step Index Fiber w Dual Layer primary Coating

Optical Characteristics

Attenuation Change (dB/km)

1310 nm

1550 nm

<0.34

<0.20

Attenuation Change (dB/km)

1285 nm to 1330 nm

1525 nm to 1575 nm

<0.05 (1310 nm reference)

<0.05 (1550 nm reference)

Point Discontinuity at 1310, 1550nm (dB) <0.1

11-2


Chromatic Dispersion (ps/nm, km)

1285 – 1330 nm

1550 nm

<3.5

<18

Zero Dispersion Wavelength (nm) 1300 to 1322

Slope at zero Dispersion (ps/nm2 <0.092

Polarization Mode Dispersion (ps/sqrt(km)) <0.2

Mode field Diameter (μm), at 1310nm 9.3 + 0.7 (Peterman II)

Mode field Diameter (μm), at 1550nm 10.5 + 1.0 (Peterman II)

Fiber Cutoff Wavelength (nm) 1100 to 1330 nm

Cable Cutoff (nm) < 1260

Geometrical Characteristics

Coating Diameter (μm) 245 + 10

Cladding diameter (μm) 125 + 1

Core/Cladding Concentricity Error (μm) < 0.8

Coating Concentricity Error (μm) <12.5

Cladding Non-circularity (%) <2

Fiber Curl Radius (mts) <4

Mechanical Characteristics

Proof Test (GPa) 0.7 (100 kpsi)

Macro Bend Test (dB)

Loss Increase at 1550 nm, 32 nm, oneturn

< 0.5

Macro Bend Test (dB)

Loss Increase at 1310 nm & 1550 nm, 100 tur wound on 60 nm diameter mandrel

<0.05

Coating Strip Force (N) 1.0 to 5.5

Environmental Characteristics

Temperature test at 1310nm & 1550 n Attenuation increase (dB),-600 c to +85

<0.05

Water Immersion Test at 1310nm & 1550 m Attenuation increase 230 c ,30 days

< 0.05

Effective Group Refractive Index 1.467 at 1310nm

1.468 at 1550 nm

Standard Delivery Lengths (km) 8.8km, 10.5km, 12.6km, 25.6km, and multiples 2.2km.

Packaging Fibres are shipped on standard fiber shippi spools having Flange Diameter 235 m and Bore Diameter : 25.4mm

Compliance Test Procedures All the test methods followed comply with ITU-T Rec. G 650, EIA /TIA Standards and IEC Publication 60793

NB: Cable specification may change, if required.END OF SECTION

11-3


Contract RA/266



PART-12 GEOGRAPHICAL INFORMATION SYSTEMS

Ministry of Public Works- Roads Administration

Document-2-III

Tender No. : RA/266 Technical Specification, Part-12, GIS

Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between

5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street Water Pipeline Re-locations

Design Build and Maintain Roads, Bridges, Sanitary, Storm water drainage, and other utility works between 5th Ring Road, Ghazali Road and Mohamed Bin Al-Qassim Street

Geospatial Information Systems

CAD Drawings Submittal Guidelines

1-Water Pipelines Relocation

12-83 Tenderer Signature & Stamp


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TABLE OF CONTENTS

1. Purpose and Scope ......................................................................................................................................... 11-4

2. Introduction ...................................................................................................................................................... 11-4

3. Spatial Information Submittals Policy ................................................................................................................. 6

4. AutoCAD Standard Specifications ...................................................................................................................... 8

4.1. Spatial Reference ...................................................................................................................... 8

4.2. Organize Data by CAD Layer .................................................................................................... 8

4.3. Consistent Geometry ............................................................................................................... 12 4.4. Symbology ............................................................................................................................... 12

4.5. Snapping .................................................................................................................................. 14

4.6. Polygon Representation .......................................................................................................... 14

4.7. XData Water Tool .................................................................................................................... 14

5. AutoCAD Drafting Rules .................................................................................................................................... 14

5.1. Fittings ..................................................................................................................................... 14

5.2. Valves ...................................................................................................................................... 16

5.3. Other Junctions .................................................................................................................... 11-1

6. Encoding Attributes for AutoCAD Objects .................................................................................................... 11-1

6.1. Terms of Use ........................................................................................................................ 11-1 6.2. Installing the XDataWater Tools ........................................................................................... 11-2

6.3. Applying and Working with AutoCAD XDataWater Tools .................................................... 11-4

7. Updating Attributes Information ..................................................................................................................... 11-8

8. Summary .......................................................................................................................................................... 11-8




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TABLE OF FIGURES

Figure 1: Sample of Acceptable Point Symbology .......................................................................... 13 Figure 2: Point Style Library in AutoCAD 2010 ................................................................................ 13

Figure 3: Case of Fitting Splitting Pipe (Connecting Two Different Pipes) ................................... 15

Figure 4: Case of Reducer Fitting Connecting Two Pipes of Different Diameters ....................... 15

Figure 5: Case of Fitting NOT Splitting the Pipe .............................................................................. 15

Figure 6: Case of End Cap Fitting Installed at End of Pipe ............................................................ 16

Figure 7: Case of Tee Fitting Connecting to Three Pipes ............................................................... 16 Figure 8: Valves Split the Pipes to which they Connect ................................................................. 16

Figure 9: Case of Washout System Valve Located on Free End of One Pipe .............................. 17

Figure 10: Installing the XDataWater Tools ................................................................................... 11-2

Figure 11: Loading the XDataWater Tools in AutoCAD ............................................................... 11-3

Figure 12: Sample XDataWater Tool Palette ................................................................................. 11-4

Figure 13: Choosing the Appropriate XData Button to Match the Active Layer ........................ 11-5 Figure 14: XData Water Tool Palette Attribute Form .................................................................... 11-6

Figure 15: Customizing the Icons of the XDataWaterWells Tool Palette ................................... 11-7

Figure 16: Select Image file dialog for the Button Image ............................................................. 11-7




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Purpose and Scope

This document provides an overview of the standard developed by MEW for the exchange of Spatial Information (GIS) with external third parties. This standard provides drawing specifications (in AutoCAD) to streamline the process of capturing network schemes and assets information, and thereby easing the conversion of CAD files into GIS data format on ESRI’s ArcGIS 10 platform. This will maximize the usability of the information between MEW and other external parties (such as consultants and contractors).

As such, MEW requires that all spatial information submitted to the Ministry be structured according to the guidelines specified herein. The contractor, for example, is required to adhere to the drawing strategy suggested in CAD in order to help improve the structure of the data, create GIS-ready data and reduce the time required for the conversion into MEW's GIS. The contractor is asked to submit all network schemes and projects' Shop drawings and As-built drawings in accordance with the requirements in this document.

The document is intended for AutoCAD users and stresses on CAD conversion tools and techniques, suggested methods, and level of effort required to perform each conversion task. Users of Bentley’s Microstation are required to structure their drawings (DGN files) in the same way as explained for AutoCAD drawings (DWG files). The document will focus on the guidelines for building data that can easily be collected as assets information and used as GIS content.

Introduction AutoCAD has the ability to draw lines, points or polygons (closed polylines) representing components in the Water Network (e.g. a Main Distribution Pipe can be represented as line/polyline and a Pump as a point). CAD can be used to model sophisticated sketches in the Water Wells and Water Networks by means of coded standards in Symbology that can be applied to a layer. It can also be used in the context of ArcGIS by maintaining CAD standards, in order to organize CAD data efficiently and collect valuable asset information from the CAD drawings. The usability of the CAD drawings for network layouts as a source of asset information and GIS content can be improved dramatically, and with minimal effort, during the CAD drafting process. As such, the contractor is required to comply with the guidelines presented in this document as these will be enforced as part of MEW's Spatial Information Submittals Policy and Standards.




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The goal of the document is to provide a simple procedure for the CAD operator to follow during the original design effort. This document covers what is required to structure an AutoCAD drawing in order to use it as a source of asset information and as GIS content. It also emphasizes the standard specifications that the contractor should follow in order to accomplish the aforementioned goals.

The features that are not covered by this document should continue to be drafted by the contractors as per their current methods and processes. This document addresses some additional specifications to be followed while drafting certain Water Network features in AutoCAD, because these will be later converted into GIS.

Furthermore, this document does not affect the submission process of Shop drawings and As-built drawings, which will still follow the same procedure that has been observed in the past. This standard will simply address the format of the network layout drawings which have to be delivered according to the set CAD specifications.




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Spatial Information Submittals Policy

The contractor is required to adhere to the following when submitting deliverables to MEW related to Water Network Layout Drawings:

a) The contractor shall obtain the latest CAD Drawings Submittal Guidelines document from MEW. b) The contractor shall obtain the latest (most updated) Kuwait Base Map used at MEW, to be used as the Key

Map of all network layout drawings. c) The contractor shall accompany the deliverables with spatial and attribute information in digital format

according to the standards described herein. The digital format shall be in Write-Once media (DVD, CD). d) The contractor shall make use of the latest MEW WaterWellsCADTemplate (Template for the Water Wells) or

WaterNetworkCADTemplate (template for the Water Network) drawings, described later in this document, as the basis of all network drawings.

e) The contractor shall ensure that any submitted network drawings contain a Key Map and properly measured dimensions from the road centre line or edge of a parcel.

f) The contractor shall use the following Spatial Reference as the projection system for all spatial information:

• Kuwait Utility Data Management System (KUDAMS) Datum, Kuwait Traverse Mercator KTM, GRS 1980

g) The contractor shall submit all data structured according to MEW's Data Models described hereafter in this document that are in accordance with the industry standard data models, including:

• MEW Water Network Physical Data Model for Water networks (distilled, brackish and fresh).

• MEW Water Wells Physical Data Model for Water Wells networks (brackish). h) The contractor shall ensure that physical connectivity of the water network assets is upheld and shall model

all edge-junction related rules, described later in this document, in the submitted drawings. i) The contractor shall adhere to the following general AutoCAD Standard Guidelines, which are elaborated

further in this document:

• Create Objects with Consistent Geometry

• Do Not Create Symbols using Cross Lines, Cross Lines and Circle combinations…

• Snap Lines at their Intersection

• Create Polygons using Closed Polylines only

• Create and Save Attributes in the CAD Drawing File Using the Corresponding “XDataWater” or "XDataWaterWells" Tool

j) MEW shall verify the compliance, completeness, and accuracy of the submitted information. The contractor shall make all necessary modifications to achieve compliance with MEW Standard.




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k) The acceptance of the work executed by the contractor shall not be considered complete until all information

is submitted and approved by MEW.




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AutoCAD Standard Specifications MEW will implement these CAD standards to improve the quality of the CAD data and its usefulness as a source of asset information and GIS content. The most important aspect is the use and enforcement of the CAD standard. The output will be CAD files organized in a better way, and containing valuable asset information. The following are the standard specifications that MEW has set for contractors to follow while capturing data in CAD software.

Spatial Reference Standardization of spatial references associated with any dataset play a vital role in data conversion because it provides a common drawing area for all layers involved in any project. For this reason, CAD files must be drawn in real-world coordinates and must adhere to the specification for spatial reference described next.

KUDAMS/KTM, or Kuwait Utility Data Management System / Kuwait Transverse Mercator, is a projected Coordinate Reference System (CRS) which is used in Kuwait. This geodetic coordinate system uses the KUDAMS geographic 2D CRS as its base reference system and the Kuwait Transverse Mercator as its projection. The associated geodetic reference system is the GRS 80, or Geodetic Reference System 1980, and consists of a global reference ellipsoid.

As such, all layout drawings, which should comply with the CAD Specifications set in this document, are required to be geo-referenced or have a physical geographical projection using the coordinate system: KUDAMS/KTM, GRS 1980.

Organize Data by CAD Layer When drafting the Water Wells Distribution Pipes in any given area, for example, one can decide to draw all these pipes in a single CAD layer called Well Distribution Pipe. However, these pipes may represent the Suction, Bypass, Main, Outlet, etc. distribution pipes. Thus, the need to distinguish between all of these different types of water well distribution pipes will necessitate matching each type to its corresponding subtype in MEW's GIS. At times, MEW may even recommend the use of different layers for each subtype of a specific Water Network Asset in order to have a structured and organized CAD drawing. Layers that are not distinguished by their subtypes will have a subtype field as an attribute in their Extended Data (XData) records in order to distinguish between their various subtypes. During the automated conversion, a migration tool will load each layer to its corresponding feature and according to its subtype field.




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Layers in MEW's WaterNetworkCADTemplate and WaterWellsCADTemplate AutoCAD drawings are defined in the following tables. It is crucial to note that the AutoCAD Layer Names supplied in these tables must be followed and as such must not be changed. The contractor can use the templates as the basis of his/her network drawings and may choose to add any other layers he/she feels are needed; however, only the layers listed in the following tables will be converted into MEW's GIS Networks.

Layer # GIS Feature Class Name Subtype AutoCAD Layer Name Feature Type

1 GravityChannel OpenChannel Gravity Channel Polyline

2 GravityPipe All Gravity Pipe Polyline

3 ServicePipe All Service Pipe Polyline

4 WellDistribution All Well Distribution Pipe Polyline

5 WellGathering None Well Gathering Pipe Polyline

6 WellTransmission None Well Transmission Pipe Polyline

7 AirValve All Air Valve Point

8 PressureControlValve All Pressure Control Valve Point

9 ServiceValve All Service Valve Point

10 FlowControlValve Flow Control Flow Control Valve Point

11 SystemValve All System Valve Point

12 Fitting All Fitting Point

13 FillingPoint Filling Point Filling Point Point

14 FlowMeter All Flow Meter Point

15 Hydrant All Hydrant Point

16 Junction None Junction Point

17 PressureSensor None Pressure Sensor Point

18 Pump Centrifugal Pump Point

19 Reservoir Ground Reservoir Point

20 Source None Source Point

21 WellAndSubmersiblePump WellAndSubmersiblePump Submersible Pump Point

22 SurgeVessel All Surge Vessel Point

23 WServicePoint Service Point Water Service Point Point

24 AnodeProtection None Anode Protection Point

25 CathodicProtection None Cathodic Protection Point




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26 MeasurementPost None Measurement Post Point

27 CasingLine All Sleeve Polyline

28 Manhole None Manhole Point

29 PipeElevation None Pipe Elevation Point Point

30 SCADASensor None SCADA Sensor Point

31 WarehouseLocation None Warehouse Location Point

32 WaterChamber None Water Chamber Boundary Polygon

33 WaterStructure All Water Structure Boundary Polygon

Table 1: Water Wells Network CAD-GIS Layer Mapping Table




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1 TransMainPipe None Transmission Main Pipe Polyline

2 DistMainPipe All Distribution Main Pipe Polyline

3 DistSubMainPipe All Distribution SubMain Pipe Polyline

4 ServicePipe All Service Pipe Polyline

5 GravityPipe All Gravity Pipe Polyline

6 GravityChannel OpenChannel Gravity Channel Polyline

7 AirValve All Air Valve Point

8 PressureControlValve All Pressure Control Valve Point

9 ServiceValve All Service Valve Point

10 FlowControlValve Flow Control Flow Control Valve Point

11 SystemValve All System Valve Point

12 Fitting All Fitting Point

13 FillingPoint Filling Point Filling Point Point

14 FlowMeter All Flow Meter Point

15 Hydrant All Hydrant Point

16 Junction None Junction Point

17 PressureSensor None Pressure Sensor Point

18 Pump All Pump Point

19 Reservoir Ground Reservoir Point

20 Source None Source Point

21 TankerFillingPoint Tanker Filling Point Tanker Filling Point Point

22 SurgeVessel All Surge Vessel Point

23 WServicePoint Service Point Water Service Point Point

24 ROMembrane None RO Membrane Point

25 ROTank All RO Tank Point

26 InjectionPoint All Injection Point Point

27 Filter All Filter Point

28 MonitoringPoint All Monitoring Point Point

29 BlendingChamber None Blending Chamber Point

30 AnodeProtection None Anode Protection Point

31 CathodicProtection None Cathodic Protection Point




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31 MeasurementPost None Measurement Post Point

32 CasingLine All Sleeve Polyline

33 Manhole None Manhole Point

34 PipeElevation None Pipe Elevation Point Point

35 SCADASensor None SCADA Sensor Point

36 WarehouseLocation None Warehouse Location Point

37 WaterChamber None Water Chamber Boundary Polygon

38 WaterStructure All Water Structure Boundary Polygon

39 GeneralPoint Chemical Dosing Pump Chemical Dosing Pump Point

40 GeneralPoint Air Blower Air Blower Point

41 GeneralLine Chemical Injection Line Chemical Injection Line Polyline

42 GeneralLine Air Blowing Pipe Air-Blowing Pipe Polyline

43 BlendingPlant None Blending Plant Boundary Polygon

44 ROSite None RO Site Area Polygon

Table 2: Water Networks CAD-GIS Layer Mapping Table

Consistent Geometry Contractors are expected to create all objects with a single data system using a consistent geometric type. For example, when drawing linear pipes, only use linear features and avoid using objects that will be interpreted by ArcGIS as points or areas. The previous tables outline the geometric type for each layer in the column labeled "Feature Type".

Symbology An essential factor in the CAD Specifications is the type of the objects to be drawn in the specified layers. Thus, contractors should not create a point symbol using crossed lines, or combinations of crossed lines and circles because the symbol will be interpreted as two lines or two lines and a polygon, instead of a simple point. As an example, drawing a polyline in a layer with “point” feature type is restricted. Since popular point objects are drawn in CAD as shapes that represent those objects, the CAD Specifications accept shapes in case they are of type point. Figure 1 shows the different types of the same shape, where the first shape (on the left) is of type polyline (and as such has more than one point, 4 points) while the second shape (on the right), which is the one to be followed, is of type point.




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Figure 1: Sample of Acceptable Point Symbology

In addition, the use of built-in symbols from AutoCAD’s list of point styles for point symbols is acceptable. The point style library in AutoCAD 2010 is displayed, as an example, in Figure 2.

Figure 2: Point Style Library in AutoCAD 2010

Contractors are also free to place any symbology they need in additional layers in the CAD file, as long as the point representing the feature to be imported into GIS is in its associated Point Layer. For instance, if the contractor wants to




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sketch a System Valve, the contractor must, first, choose the System Valve AutoCAD Layer to sketch in. Next, the contractor must draw a single point to resemble the System Valve in question. The contractor is then free to create an additional AutoCAD Layer (e.g. Symbology), and use it to draw the symbol of the System Valve over the point that was drawn to resemble the valve. Moreover, trenches and channels should be represented in CAD as a single line. This means that it is not allowed to draw two parallel lines to represent a trench or one pipe.

Snapping Contractors are expected to connect lines at their intersections using Snapping Tools and in accordance with the AutoCAD Drafting Rules listed in the following section of this document. For example, when drawing a Distribution Main Pipe, all lines should be snapped together at the valves, junctions and intersections, in order to ensure that they are going to be snapped in ArcGIS; otherwise the flow of Water will stop at any unsnapped location.

Polygon Representation To represent a Polygon, create closed polygons using AutoCAD snapping and closed polylines, since this need to be interpreted as areas by GIS.

XData Water Tool Use the supplied XDataWater and XDataWaterWells Tools to define attributes for the various CAD objects being drafted. The procedure or method that should be followed to add attributes to assets is outlined in Section 6 - "Encoding Attributes for AutoCAD Objects" - of this document.

AutoCAD Drafting Rules While drafting features in CAD drawings, contractors are asked to follow the specifications and drafting rules herein, upon CAD drawing. The examples given are meant to be indicative of the desired drawing methods and drafting rules to be followed and, as such, do not cover all the drawing cases.

Fittings

When fittings are placed on the pipes, there are a few standard drawing rules that need to be observed, as listed in the following table and illustrated in the figures that follow:




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No. Fitting Type Proper Use of Feature

1 Flange Adapter Joins two different pipes; pipes need to be split at the fitting (refer to Figure 3)

2 Collar Joins two different pipes; pipes need to be split at the fitting (refer to Figure 3)

3 Hydrant Duck Foot Joins two different pipes; pipes need to be split at the fitting (refer to Figure 3)

4 End Cap Placed at the end of one pipe (refer to Figure 6)

5 Reducer Joins two pipes of different diameters; pipes need to be split at the fitting (refer to Figure 4)

6 Tee May connect to up to three different pipes; pipes need to be split at the fitting (refer to Figure 7)

7 Coupling Joins two different pipes; pipes need to be split at the fitting (refer to Figure 3)

8 Saddle Does not split the pipe (refer to Figure 5)

9 Dismantling Joint Joins two different pipes; pipes need to be split at the fitting (refer to Figure 3)

10 Bend Joins two different pipes; pipes need to be split at the fitting (refer to Figure 3)

Table 3: Types of Fittings in Water Networks

Figure 3: Case of Fitting Splitting Pipe (Connecting Two Different Pipes)

Figure 4: Case of Reducer Fitting Connecting Two Pipes of Different Diameters

Figure 5: Case of Fitting NOT Splitting the Pipe




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Figure 6: Case of End Cap Fitting Installed at End of Pipe

Figure 7: Case of Tee Fitting Connecting to Three Pipes

Valves

Generally, it is required to split the pipes at the connection to almost all valve point features as shown in Figure 8 below.

Figure 8: Valves Split the Pipes to which they Connect

There is one instance in which the pipe does not need to be split; which is the case of the System Valve of subtype Washout. The Washout valve can sometimes be located at the free end of one pipe, and as such, no splitting is required as shown in Figure 9 below.




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Figure 9: Case of Washout System Valve Located on Free End of One Pipe




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Other Junctions

There are additional rules for junctions like Hydrants, Flow Meters and Tanker Filling Points in the Water Networks that need to be observed. These are listed in the following table, and follow the same drafting rules described in sections 5.1 and 5.2:

No. Junction Proper Use of Feature

1 Hydrant Either joins two different pipes; pipes need to be split at the Hydrant (refer to Figure 3), or can be placed at the free end of one pipe (refer to Figure 9)

2 Flow Meter Should split the pipe (refer to Figure 3)

3 Tanker Filling Point Joins two different pipes; pipes need to be split at the fitting (refer to Figure 3)

Table 4: Rules Regarding Other Junctions in the Water Network

Encoding Attributes for AutoCAD Objects A tool was developed to enable using the CAD XData simply and easily. XData, or Extended Entity Data, is a property of any CAD object. It is a way to link external data to an AutoCAD object. The Xdata tool provides a user-friendly interface to set and store values of Xdata for every CAD object that the user drafts. It encodes any required attribute for a drawn object inside the CAD file itself. Thus, the drawing and the related attributes of each object in the drawing will be stored in a single CAD File. This “XDataWater" Tools provide a simple interface to the CAD Xdata including the needed attributes of each object, as well as its subtype. The interface also supports domain values in drop-down lists, which are lists of valid and possible values for a specific attribute or element.

Terms of Use

The XDataWater Tools may be used for the ad hoc reasons provided by MEW. However, MEW has the right to distribute the tools to its contractors as long as they sign with MEW a licensing agreement stipulating that they cannot copy the tools outside the scope of their projects and cannot recompile and/or reproduce the tools.




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Installing the XDataWater Tools

The XDataWater Tools Setup files will be provided with the CAD Drawings Submittal Guidelines Document.

Contractors are asked to follow the outlined procedure to setup the tools on their systems:

1. Install the tools by following the simple setup wizard steps

Figure 10: Installing the XDataWater Tools

2. Load the XDdataWater Tools palettes inside AutoCAD by browsing to the Tools Menu > Palettes > XDataWater or XDataWaterWells Tools.




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Figure 11: Loading the XDataWater Tools in AutoCAD

3. Once loaded, the tools will be accessible from any AutoCAD drawing file, however, are only compatible with the AutoCAD Layer naming convention specified in the associated Water and WaterWells AutoCAD Templates. It is very important to keep the layer names as specified in order for the tools to function. Additional layers can be created, but will not be accessible by the tools and as such will not be converted into MEW GIS. A sample XDataWater Tool Palette is shown in the following figure.




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Figure 12: Sample XDataWater Tool Palette

Applying and Working with AutoCAD XDataWater Tools




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To start working with the XDataWater Tools, follow the steps below:

1. Draw an object in its corresponding layer (e.g. if drawing a gravity pipe in the Water Wells Network, you need to choose the Gravity Pipe CAD Layer).

2. Press the button in the XDataWaterWells Tool palette related to the active layer.

Figure 13: Choosing the Appropriate XData Button to Match the Active Layer

3. As you are prompted to select an object, or objects, select the drawn object(s) for which you would like to set the attributes. You can select as many objects of the same layer as you need, provided they will be sharing the same attributes.

4. The form in the following figure will popup, showing the required attribute fields that need to be filled by the contractor. Note that some attributes may be already filled with predetermined default values.




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Figure 14: XData Water Tool Palette Attribute Form

5. Press the “Start an Edit Session” button on the top left corner of the form to start editing the attributes of the selected object(s)

6. Complete encoding the attributes 7. Press the “Save” button and then the “Exit” button to close the form 8. Repeat steps “2” to “7” to edit the encoded attribute values 9. Press the “Undo Edits” buttons to undo the edits and stop the edit session 10. To simply view/read the stored attributes, if any, of an element, you will need to ensure that the current

active layer is set to the layer in which that CAD element is present, and then press the associated button of that element. Any saved attributes will be immediately visible in the form

The users can also customize the appearance of the icons attached with the layers in the Palette Toolbar to ones of their choice to make it easier for them to identify. They may choose to change the tool's icons to suit their corresponding layers’ colors and symbology. This will help users customize the tool palette in a manner that will expedite their work and helps in identifying the appropriate buttons quickly. The steps to achieve this are outlined as follows:

1. Open the Palette toolbar in an AutoCAD Drawing file 2. Right click on the button in the tool palette that you want to customize, e.g. Gravity Pipe 3. Select the “Specify Image” option from the list, as shown in the following figure




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Figure 15: Customizing the Icons of the XDataWaterWells Tool Palette

4. A dialog box, "Select Image File", will show up for the selected command/button, where you can choose predefined icons

Figure 16: Select Image file dialog for the Button Image

5. Choose the image icon you want to use for the tool palette command button then click 'Open'. 6. The icon of the selected command button will be changed in the tool palette and set to the chosen

image.




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Updating Attributes Information

During the installation of the XDataWater Tools, MS Access Data Configuration databases will also be automatically installed on the system. These configuration databases store all the required data fields and domain values of all the Water Network and Water Wells Network CAD Templates' features. Since changes and updates on the data structure happen frequently, the configuration files can be easily synchronized with the updates and changes to keep the tools up-to-date with the physical models and functioning properly. By replacing the existing configuration databases with newly synchronized databases and simply running the tools again, the new updates will be directly reflected.

Summary

This document has provided the contractors with additional specifications to be followed when drafting network features in Shop-drawings and As-built drawings in AutoCAD. These specifications, along with the use of the XDataWater Tools, will ensure that asset information can be collected easily and efficiently from CAD drawings and that it can be converted easily from these CAD drawings into GIS format.



Contract RA/266



B - LIGHTING AND ELECTRICAL WORKS

SECTION 14: LIGHTING AND ELECTRICAL WORKS

SUPPLIMENTAL SPECIFICATIONS (RA/266)

1401.13.3.1 Refurbishing and Relocating Existing Lighting Units

The Contractor shall refurbish and relocate the existing lighting masts and columns as indicated on the drawings and as specified in the Contract Specifications. All existing high masts and lighting columns shall be carefully dismantled and transported to contractor's workshop for refurbishing.

The refurbishing work of the existing lighting units shall include, but not be limited to the following:

1. Thorough cleaning of the exterior and interior of each lighting unit and components therein.

2. Repairing damage to paint work as specified in Clause 1401.13.3. For galvanized masts and columns, treating of any damage with cold galvanizing materials.

3. Reconditioning of the hoist assemblies and control equipment for high masts.

4. Furnishing and installing of new street lighting luminaires, lamps and controlgears for all resited lighting units.

5. Rewiring the installation of new component parts where specified and/or when directed and the rectification of all deteriorated and damaged parts.

6. Furnishing and installing new grounding and lightning protection systems for high masts.

7. Furnishing new grounding systems for all lighting units.

8. Furnishing and replacing gaskets on mast and column doors.

9. Furnishing and replacing locking arrangements on mast and column doors as and where required.”

1401.13.3.3 New Foundations for Lighting Masts and Columns

The Electrical Subcontractor shall construct new foundations at each relocated lighting unit. All such foundations shall conform to the requirements of Clause 1403 of the General Specifications. The Contractor shall furnish and install new anchor bolts, to match existing anchor bolts being removed. New bolts shall be of the same material, diameter, dimensions and configuration of the existing bolts and shall be as approved by the Engineer. The new foundations for refurbished units shall be the same size as those being provided for new installations.

1401.13.3.4 Removal of Electric Cable

The Contractor shall hand excavate, remove and salvage existing redundant underground cables under the supervision of and to the satisfaction of the MEW and as directed by the Engineer.

The Contractor shall furnish and utilize pulleys or other approved devices to prevent any damage to existing cables being removed and salvaged. The Contractor shall recover intact each full length of existing redundant cable unless otherwise directed by the Engineer. Salvaged cables shall be cut at either end of the length removed and no intermediate cuts will be permitted unless approved by the Engineer. The Contractor shall furnish drums upon which he shall wind the salvaged cable. Each reel shall be tagged or marked to identify the cable voltage, type and length wound on their respective drums.

The Contractor shall carefully handle the salvaged cable, cable cover tiles and all other appurtenances and other materials to prevent any damage to same. All excavation and backfill in removal and salvage of existing electrical material shall comply with the applicable requirements of Section II of the General Specifications.”

2-RA-266 Supplimental Particular Specs. for Street Lighting Page 1

1413 - LIGHTING SYSTEM FOR UNDERCROSSINGS

1413.01 SCOPE

Page 14-54: At the end of this clause –

Add the following paragraphs:

“The Contractor shall supply and install hot dip galvanized steel junction boxes embedded in abutment walls with circuit breakers, galvanized steel raceway with all accessories, galvanized steel conduits and high pressure sodium undercrossing luminaires all of the types and sizes shown in the Bills of Quantities.

The Contractor shall allow for the supply of all material, plant and labour and perform all activities as necessary to complete the works as specified and instructed by the Engineer.”

Page 14-56: After clause 1413.07.2 –

Add the following clause:

“1413.08 LIGHTING SYSTEMS FOR UNDERPASSES “The lighting systems for the tunnels/underpasses shall be in full compliance with the CIE Publication No. 88 and the general requirements as specified for undercrossing lighting system shall apply. The Contractor shall submit all lighting and other required calculations and lighting control schematics for approval by the MEW Engineer. No works shall be started for the lighting systems of the tunnels/underpasses until and unless MEW approval is gained on all shop drawings and material submissions.”

1414 - LIGHTING SYSTEM FOR OVERHEAD GUIDE SIGNS



“1414.09 ALTERATION OF EXISTING OVERHEAD GUIDE SIGNS “The Contractor shall supply and install complete lighting systems for the overhead signs as listed in the Bills of Quantities and as specified and instructed by the Engineer.

The Contractor shall allow for the supply and installation of heavy duty rain-tight safety switches complete with poles and fuses, wire sign lighting installations complete with cables and steel conduits. Pedestrian Bridge and Bridge Mounted sign lighting installations complete with cables and steel conduits, and metal halide sign luminaires.

The Contractor shall allow for the supply of all material, plant and labour and perform all activities as necessary to complete the works as specified and instructed by the Engineer.

Where existing sign gantries are to be retained but the sign face panels replaced, the Contractor shall disconnect the existing luminaires and shall install new luminaires in the locations indicated on the Drawings. The Contractor shall include for the provision of all necessary trunking, junction boxes, conduit, cabling etc. from the existing safety switch to provide a complete lighting installation for the new sign face panels. The Contractor shall inspect and test, in the presence of the Engineer, the existing electrical circuitry to be retained and shall carry out any required repair work to the existing installations.


The Contractor shall prepare, for the approval of the Engineer, the necessary drawings, indicating all components, fixing details and cabling arrangements etc. All proposals and materials shall be in accordance with the requirements of the relevant Clauses of the Specifications. Any damage to the galvanized finish of the sign gantries resultant from the Contractor's operation shall be made good by the Contractor in accordance with Clause 1401.13.3 of the General Specifications. The existing installations (luminaires, conduit, etc.) shall be abandoned unless their removal is necessitated by installation of the new lighting facilities.”



“1423 - REINSTATEMENT OF POWER SUPPLIES 1423.01 GENERAL The Contractor shall reinstate power supplies to any existing lighting installations which are interrupted by the removal of redundant installations. This work, which shall include the installation of through joints and the extension of existing cables as required, shall not be measured or paid for separately but will be considered as a subsidiary obligation of the Contractor.”

(End of Section)


SECTION 14: LIGHTING AND ELECTRICAL WORKS

PARTICULAR SPECIFICATIONS (RA/266)

14.1 GENERAL A. In addition to MEW Amendment No. 1 - April 2013 to Section 14 - Lighting and Electrical

Works in of the Appendix B, Volume 3 to this Document, the following Particular Specifications shall also apply.

Should there be any difference between the General Specifications, Amendment No.1, Contract Drawings and the Supplemental Specifications, then the requirements of the Particular Specifications shall prevail.

B. The Contractor shall note that the street lighting system for the project shall be provided with energy saving features for all street lighting units except for the high mast lighting units with 1000W HPS luminaires.

C. BOQ Pay Items are under 26 56 19.

14.2 APPROVAL STAGE B – MATERIAL APPROVAL Submittal Schedules:

The Technical Schedules referred to in Clause 1401.09 (B) of the General and Supplemental Specifications required for the items of this Contract and included at the end of this section are as follows:

Item Submittal Schedules

35M High Lighting Masts & Units A1, B1, C1

30M High Lighting Masts & Units A2, B2, C2, E1, E2

25M Rigid Lighting Columns & Units A3, B3, C3

16M Rigid Lighting Units A4, B4, C4, E3,

12M Rigid Lighting Columns & Units A5, B5, C5, E4

1000 & 400 Luminaires D1, D2

1000 & 400 W. HPS Lamps/Control Gears F, G, H, I

Control Cabinet J

14.3 LUMINAIRES FOR 25 m to 40 m MOUNTING HEIGHT

14.3.1 General Requirements

The Ministry of Electricity & Water reserves its full right to ask the Contractor to provide M/s. GE, USA manufactured 1000W high pressure sodium high mast luminaire, Type- HMAA01SYA1GMC3143 (with IP65 degree of protection) for the 35m and 30m high mast lighting units under the project and he must provide this luminaire for all units without raise of any question.


14.3.2 1000 Watt High Pressure Sodium Lamps

A. The 1000 watt high pressure sodium lamps for the 35 & 30 metre high lighting masts shall be suitable for operation in conjunction with an auto-regulator ballast manufactured by General Electric (G.E.) U.S.A., having the following operating characteristics:

1000 Watts HPS 1. Ballast ANSI Code S 52 2. Rated Voltage 240 Volts 3. Voltage input Range + or - 10% 4. Rated Frequency 50 Hz 5. Lamp Regulation spread 20-30% 6. Power Factor 90+ to 65% 7. Starting Current (Variation from operating Current) Lower 8. Input Voltage Dip 35-10% 9. Ballast losses Medium

10. Crest Factor for Lamp .6 - 1.8 current.

B. The Contractor shall submit a guarantee from the lamp manufacturer stating that the offered lamps will correctly and fully satisfactorily operate with an auto-regulator ballast (GE Make) having operating characteristics as specified above.

C. The lamps shall be manufactured to the best modern practice and shall fully comply with the latest relevant ANSI specifications.

D. The Contractor shall maintain with him a minimum stock level of 20% of the total lamps from each type under the contract to replace any failed or burnt out lamps within maximum two (2) weeks of a written intimation. In case he fails to replace the lamps within the specified time period, a penalty @ KD.2.000/Lamp/Day will be imposed on him.

E. The Ministry of Electricity & Water reserves its full right to ask the Contractor to provide M/s. GE, USA manufactured 1000W. High Pressure Sodium Lamp, Type-LUCALOX LU1000 for the 30 Metre lighting units under the project and he must provide this lamp for all the 35 & 30 Metre units without raise of any question.

14.4 LUMINAIRES FOR 6 m to 22 m MOUNTING HEIGHT

14.4.1 600 Watt High Pressure Sodium Street Lighting Cut-off Luminaires

A. 600 Watt HPS Lamp

The Contractor shall maintain with him a minimum stock level of 20% of the total lamps from each type under the contract to replace any failed or burnt out lamps within maximum two (2) weeks of a written intimation. In case he fails to replace the lamps within the specified time period, a penalty @ KD.2.000/Lamp/Day will be imposed on him.

B. Control Gear

Control Gear Panels:

The Contractor shall maintain with him a minimum stock level of 20% of the total energy saving ballasts and switching devices from each type under the contract to replace any failed or burnt out items within maximum two (2) weeks of a written intimation. In case he fails to replace the items within the specified time period, a penalty @ KD.10.000/Ballast or Switching Device/Day will be imposed on him.





B. Control Gear

The Contractor shall maintain with him a minimum stock level of 20% of the total energy saving ballasts and switching devices from each type under the contract to replace any failed or burnt out items within maximum two (2) weeks of a written intimation. In case he fails to replace the items within the specified time period, a penalty @ KD.10.000/Ballast or Switching Device/Day will be imposed on him.




B. Control Gear

The Contractor shall maintain with him a minimum stock level of 20% of the total energy saving ballasts and switching s from each type under the contract to replace any failed or burnt out items within maximum two (2) weeks of a written intimation. In case he fails to replace the items within the specified time period, a penalty @ KD.10.000/Ballast or Switching Device/Day will be imposed on him.

14.5 PERFORMANCE REQUIREMENTS FOR LIGHTING SYSTEMS The performance requirements for lighting systems installed under the Contract shall be as follows:

Project Area Average Maintained Road

___________ Surface Luminance/lluminance Mainline Roads at Grade & Elevated 2.0 cd/m2 All Interchanges 30 Lux Service Roads 1.5 cd/m2

The above levels of lighting are the maintained values of the average road surface luminance and illuminance. In order to maintain these levels, depreciation (maintenance factor) as approved by the Engineer shall be used.


14.6 PENALTIES AND VIOLATIONS A. Notwithstanding other penalties specified elsewhere in the Contract Documents, the

following penalties shall apply and deducted from the Contractor’s payments:

1. In the event of absence of the Electrical Subcontractor’s engineer or supervisor, KD.100/- (Kuwaiti Dinars one hundred only) shall be deducted per each day of absence. In the event of absence or delay of any of the required manpower mentioned in the schedule of manpower approved by the Ministry, the daily wage shall be deducted according to the daily wages of the manpower stated in the schedule.

2. In the event where the Electrical Subcontractor does not provide a first aid kit to any of the teams, an amount of KD.100/- (Kuwaiti Dinars one hundred only) shall be deducted. The penalty shall be doubled in the event of repetition.

3. In the event of leaving waste at the work site after completion of the installations works, an amount of KD. 100/- (Kuwaiti Dinars one hundred only) shall be deducted. The penalty shall be doubled in the event of repetition.

4. In the event where it was proved that the Electrical Subcontractor used manual compactors to compact the soil at any site, the Engineer shall have the right to deduct KD.100/- (Kuwaiti Dinars one hundred only). The penalty shall be doubled in the event of repetition.

5. In the event where the Electrical Subcontractor appoint any manpower for the completion of the Contract works, not approved by the Engineer/MEW supervising engineer, these manpower shall be registered in the file of manpower as rejected, with the deduction of KD.100/- (Kuwaiti Dinars one hundred only). The penalty shall be doubled in the event of repetition.

6. In the event where it was proved that the Electrical Subcontractor’s engineer or supervisor works on any other contract, the concerned person shall be rejected from the Contract’s works, deducting his wage of 6 months according to the schedule of manpower.

7. In the event where the Electrical Subcontractor uses invalid cars and vans or the same are not conformant to that required for the performance of the installations works, the Engineer shall have the right to reject these teams (until replacement of the vehicles as required). This shall also be applied in the event of not placing

a sticker indicating the name of the company and the number of the contract onsuch vehicles, deducting KD.50/- (Kuwaiti Dinars fifty only) per each case. The penalty shall be doubled in the event of repetition.

8. In the event where any worker of the installation teams do not wear the uniform provided by the Electrical Subcontractor, his daily wage shall be deducted according to the schedule of manpower. The penalty shall be doubled in the event of repetition.

9. In the event where the installation works do not start on the time agreed upon with the Engineer, an amount of KD.100/- (Kuwaiti Dinars one hundred only) shall be deducted. The penalty shall be doubled in the event of repetition.

10. In the event where it was noticed that on performing the installation works of the columns, the Electrical Subcontractor leaves a lighting column without completion of internal grounding, or leaves a lighting column with loose wires (control gears, cut-outs), KD.100/- (Kuwaiti Dinars one hundred only) shall be deducted. The penalty shall be doubled in the event of repetition.

11. In the event of fixing any internal parts of the lighting control cabinets or lighting columns with tools other than those specified therefore, an amount of KD.100/- (Kuwaiti Dinars one hundred only) shall be deducted. The penalty shall be doubled in the event of repetition.


12. In the event of accumulation of waste and trash near and under the site offices of the Electrical Subcontractor or in the event of non-observation of cleanliness, an amount of KD.100/- (Kuwaiti Dinars one hundred only) shall be deducted. The penalty shall be doubled in the event of repetition.

13. In the event where it was proved that the Electrical Subcontractor’s engineer or supervisor does not operate the mobile phones or does not respond to the calls of the Engineer’s employees or MEW’s supervising engineer without prior excuse and convincing reason, the daily wage of the concerned person shall be deducted according to the schedule of manpower. In the event of repetition, he shall be subject to interrogation.

B. The total sum of above noted penalties, as well as other penalties listed under this section shall not exceed five percent (5%) of the Total Exterior Lighting (Street Lighting) amount listed in in Division 26 (Electrical) of the BOQ.


SCHEDULE – A1 TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS

35 METRE HIGH MAST

No. Item Specified Submitted 1. Nominal Length 35 metre 2. Shaft a) No. of sections 4 max. b) Length of each section c) Overlap at joints 1.5 x dia. of female section 3. External diameter at the * bottom of each section 4. External diameter at the * top of each section 5. Base/Flange plate a) Diameter * b) Thickness 60 mm min. 6. Foundation bolt frame a) Bolt length * b) Diameter of bolt * c) No. of bolts * d) Bolt circle diameter * 7. Base-compartment door openings * 8. Thickness of sheet steel of column * Signed: ___________________________ Signed: ________________________ Manufacturer Electrical Subcontractor Name: ___________________________ Name: _________________________ Address: _________________________ Address: _______________________ * Not specified


SCHEDULE - A2 TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS

30 METRE HIGH MAST

No. Item Specified Submitted 1. Nominal Length 30 metre 2. Shaft a) No. of sections 3 max. b) Length of each section c) Overlap at joints 1.5 x dia. of female section 3. External diameter at the * bottom of each section 4. External diameter at the * top of each section 5. Base/Flange plate a) Diameter * b) Thickness 50 mm min. 6. Foundation bolt frame a) Bolt length * b) Diameter of bolt * c) No. of bolts * d) Bolt circle diameter * 7. Base-compartment door openings * 8. Thickness of sheet steel of column * Signed: ___________________________ Signed: ________________________ Manufacturer Electrical Subcontractor Name: ___________________________ Name: _________________________ Address: _________________________ Address: _______________________ * Not specified



25 METRE RIGID LIGHTING COLUMN

No. Item Specified Submitted 1. Nominal Length 25 metre 2. Shaft a) No. of sections 3 max. b) Length of each section c) Overlap at joints 1.5 x dia. of female section 3. External diameter at the bottom of each section 4. External diameter at the top of each section 5. Base plate a) Diameter 660 mm b) Thickness 40 mm min. 6. Foundation bolt frame a) Bolt length 750 mm b) Diameter of bolt 24 mm c) No. of bolts 16 d) Bolt circle diameter 570 mm 7. Base-compartment door openings 1660 mm x 190 mm 8. Thickness of sheet steel of column 5 mm. Signed: ___________________________ Signed: ________________________ Manufacturer Electrical Subcontractor Name: ___________________________ Name: _________________________ Address: _________________________ Address: _______________________ • Not specified



16 METRE RIGID LIGHTING COLUMN

No. Item Specified Submitted 1. Nominal Length 16 metre 2. Shaft a) No. of sections 2 max. b) Length of each section * c) Overlap at joints 1.5 x dia. of female section (min.) 3. Top spigot a) Arm length 600 mm b) External diameter of arm 60 mm c) Arm tilt 50, 100, 150,or 200 4. Internal diameter at the top of the column 98 mm 5. External diameter at the bottom of the column 320 mm 6. Base plate a) Size 580 mm x 580 mm a) Thickness 40 mm b) Foundation bolt-holes diameter 44 mm 7. Foundation bolt frame a) Bolt length 1700 mm b) Diameter of bolt 38 mm c) No. of bolts 4 d) Bolt circle diameter 460 mm 8. Base-compartment door openings 600 mm x 180 mm 9. Thickness of sheet steel of column 5 mm Signed: ___________________________ Signed: ________________________ Manufacturer Electrical Subcontractor Name: ___________________________ Name: _________________________ Address: _________________________ Address: _______________________ • Not specified


SCHEDULE - A4

TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS 12 METRE RIGID LIGHTING COLUMN

No. Item Specified Submitted 1. Nominal Length 12 metre 2. Top spigot a) Arm length 600 mm b) External diameter of arm 60 mm c) Arm tilt 50, 100, 150,or 200

3. Internal diameter at the top of the column 66 mm 4. External diameter at the bottom of the column 220 mm 5. Base/Flange plate a) Size 400 mm x 400 mm a) Thickness 30 mm b) Foundation bolt-holes diameter 30 mm d) Bolt circle diameter 360 mm 6. Foundation bolt frame a) Bolt length 1250 mm b) Diameter of bolt 24 mm c) No. of bolts 4 7. Base-compartment door openings 650 mm x 150 mm 8. Thickness of sheet steel of column 5 mm. Signed: ___________________________ Signed: ________________________ Manufacturer Electrical Subcontractor Name: ___________________________ Name: _________________________ Address: _________________________ Address: _______________________


SCHEDULE - B1

TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS STEEL QUALITY - 35 METRE MAST

1. Table (1) : Chemical Composition of Steel

Material Type and Classification C% Minimum Maximum Si% Minimum Maximum Mn% Minimum Maximum S% Minimum Maximum P% Minimum Maximum

2. Table (2) : Mechanical Properties

Material Type and Classification Tensile Strength, N/mm2

Yield Stress, Min. N/mm2 Elongation Min. Bend Test (180 degrees bend)

3. Maximum Stress allowed in Column ....................... N/mm2 Signed: ___________________________ Signed: ________________________ Manufacturer Electrical Subcontractor Name: ___________________________ Name: _________________________ Address: _________________________ Address: _______________________


SCHEDULE – B2

TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS STEEL QUALITY - 30 METRE MAST








SCHEDULE – B3

TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS STEEL QUALITY - 25 METRE RIGID LIGHTING COLUMN








SCHEDULE – B4


1. Table (1) Chemical Composition of Steel





3. Maximum Stress allowed in Column ....................... N/mm2

Signed: ___________________________ Signed: ________________________ Manufacturer Electrical Subcontractor Name: ___________________________ Name: _________________________ Address: _________________________ Address: _______________________


SCHEDULE – B5


1. Table (1) Chemical Composition of Steel





3. Maximum Stress allowed in Column ....................... N/mm2



SCHEDULE – C1 TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS

DEVIATIONS FROM TECHNICAL SPECIFICATIONS - 35 METRE MAST

Item No. in BOQ Precise Details of Minor Deviations Included in the Submittal Signed: ___________________________ Signed: ________________________ Manufacturer Electrical Subcontractor Name: ___________________________ Name: _________________________ Address: _________________________ Address: _______________________



DEVIATIONS FROM TECHNICAL SPECIFICATIONS - 30 METRE MAST




DEVIATIONS FROM TECHNICAL SPECIFICATIONS - 25 METRE RIGID LIGHTING COLUMN



SCHEDULE – C4

TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS DEVIATIONS FROM TECHNICAL SPECIFICATIONS - 16 METRE RIGID LIGHTING COLUMN




DEVIATIONS FROM TECHNICAL SPECIFICATIONS - 12 METRE RIGID LIGHTING COLUMN



SCHEDULE – D1

TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS 1000 WATT HIGH PRESSURE SODIUM (H.P.S.)

STREET LIGHTING CUT-OFF LUMINAIRES

Ser. No.

Description Particulars

1. Manufacturer 2. Country of Origin 3. Type of luminaire & Manufacturer’s Reference Number 4. Full details of Alloy/Material used for luminaire body 5. Type of reflector and full details of material 6. Type of glass cover used and full details 7. Wattage, Volts, phase 8. Total lumen output Lumens 9. Total flux in lower hemispheres Lumens

10. Downward light output ratio 11. Total flux above 85 degree 12. Peak intensity 13. Luminous intensity, I800 & I880 14. Flashed area of luminaire 15. Total weight Kgs. 16. Overall dimensions, L x W x H (mms.) 17. Total wind area Sq.M. 18. Is the luminaire having cut-off light distribution fully in

accordance with the relevant IEC/BS/CIE standard? Yes/No

19. Is the luminaire having Class-I protection with adequate insulation to IEC:60598? Yes/No

20. Is the luminaire having a degree of protection IP 65 to IEC:60529? Yes/No

21. Will the luminaire fit on to spigot having 60 mm outer diameter ? Yes/No 22. Name of testing laboratory where Tenderer is prepared to

conduct tests.

Note: The Ministry of Electricity & Water reserves its full right to ask the Contractor to provide M/s. GE, USA

manufactured 1000W. High Pressure Sodium High Mast Luminaire, Type-HMAA01SYA 1GSC3 for the 30 Metre high mast lighting units under the project and he must provide this luminaire for all such lighting units at no extra cost without raise of any question.



SCHEDULE – D2

TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS 400 WATT HIGH PRESSURE SODIUM (H.P.S.)

STREET LIGHTING CUT-OFF LUMINAIRES

Ser. No.

Description Particulars

1. Manufacturer 2. Country of Origin 3. Type of luminaire & Manufacturer’s Reference Number 4. Full details of Alloy/Material used for luminaire body 5. Type of reflector and full details of material 6. Type of glass cover used and full details 7. Wattage, Volts, phase 8. Total lumen output Lumens 9. Total flux in lower hemispheres Lumens

10. Downward light output ratio 11. Total flux above 85 degree 12. Peak intensity 13. Luminous intensity, I800 & I880 14. Flashed area of luminaire 15. Total weight Kgs. 16. Overall dimensions, L x W x H (mms.) 17. Total wind area Sq.M. 18. Is the luminaire having cut-off light distribution fully in

accordance with the relevant IEC/BS/CIE standard? Yes/No

19. Is the luminaire having Class-I protection with adequate insulation to IEC:60598? Yes/No

20. Is the luminaire having a degree of protection IP 65 to IEC:60529? Yes/No

21. Will the luminaire fit on spigot having 60 mm outer diameter & min. 120 mm. long and spaced at 600 mm centres? Yes/No

22. Name of testing laboratory where Tenderer is prepared to conduct tests.



SCHEDULE – E1 TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS

30 M. HIGH LIGHTING MASTS WITH 6 X 1000 W. HIGH PRESSURE SODIUM (H.P.S.) CUT-OFF LUMINAIRES

Ser. No.

Description

Required

Guaranteed

1. No. of luminaires in each unit 6 2. Mounting height of luminaire array 30 Metres 3. Width of carriageways 22.2 Metres 4. Number of lanes per carriageway 6 Lanes 5. Width of centre reservation (median) 2 Metres 6. Siting of lighting units Centre line of median 7. Bracket Projection 0.60 Metre 8. Elevation of Bracket 50, 100, 150 or 200 9. Type of light source H.P.S.

10. Wattage of lamp 1000 Watt 11. Lumen output of each lamp 130000 Lumens 12. Maintenance factor 0.75 13. Total lumen output of complete unit Lumens 14. Total flux in lower hemisphere of complete unit Lumens 15. Total flux in the Zone 90 degree above horizontal of

complete unit Lumens

16. Total flux in the zone of 60 degree to 70 degree of complete unit

Lumens

17. Intensity at 80 degree cd/1000 lumens Lumens 18. Average luminance (L ave) for above installation Not less than 2.0 cd/sq.m 19. Uniformity Overall (U o): L min / L ave Not less than 40% 20. Uniformity Longitudinal (U long): L min / L max (in

longitudinal direction, i.e., parallel to axis of carriageway) Not less than 70%

21. Threshold Increment Maximum 10% 22. Surrounding Ratio Minimum 0.5 23. Recommended spacing “S” between two lighting units for the

above values and installation (See note below).

S = Metres

24. No. of lighting units “N” in one kilometre of road (See note below).

1000 N = ------- S

N =

NOTE: Spacing ‘S’ and No. of Lighting Units ‘N’ must be expressed as whole numbers (i.e. without fractions) and must be

rounded to the next whole number for fractions of 0.5 & above and to the same whole number for fractions less than 0.5.



SCHEDULE – E2 TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS

30 M. HIGH LIGHTING MASTS WITH 4 X 1000 W. HIGH PRESSURE SODIUM (H.P.S.) CUT-OFF LUMINAIRES

Ser. No.

Description

Required

Guaranteed

1. No. of luminaires in each unit 4 2. Mounting height of luminaire array 30 Metres 3. Width of carriageways 18.5 Metres 4. Number of lanes per carriageway 5 Lanes 5. Width of centre reservation (median) 2 Metres 6. Siting of lighting units Centre line of median 7. Bracket Projection 0.60 Metre 8. Elevation of Bracket 50, 100, 150 or 200 9. Type of light source H.P.S.




Lumens





S = Metres


1000 N = ------- S

N =





SCHEDULE – E3

TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS 16 M. SINGLE ARM LIGHTING UNITS WITH

2 X 400 W. HIGH PRESSURE SODIUM (H.P.S.) CUT-OFF LUMINAIRES (3-LANE ROADS)

Ser. No.

Description

Required

Guaranteed

1. No. of luminaires in each unit 2 2. Mounting height of luminaire array 16 Metres 3. Width of carriageways 11.1 Metres 4. Number of lanes per carriageway 3 Lanes 5. Setback of lighting unit 3 Metres 6. Siting of lighting units Single Sided 7. Bracket Projection 0.60 Metre 8. Elevation of Bracket 50, 100, 150 or 200 9. Type of light source H.P.S.




Lumens





S = Metres


1000 N = ------- S

N =





SCHEDULE – E4

TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS 12 M. DOUBLE ARM LIGHTING UNITS WITH

2 X 400 W. HIGH PRESSURE SODIUM (H.P.S.) CUT-OFF LUMINAIRES (2-LANE ROADS)

Ser. No.

Description

Required

Guaranteed

1. No. of luminaires in each unit 2 2. Mounting height of luminaire array 12 Metres 3. Width of carriageways 8 Metres 4. Number of lanes per carriageway 2 Lanes 5. Width of centre reservation (median) 6 Metres 6. Siting of lighting units Centre line of median 7. Bracket Projection 0.60 Metre 8. Elevation of Bracket 50, 100, 150 or 200 9. Type of light source H.P.S.




Lumens





S = Metres


1000 N = ------- S

N =





SCHEDULE - F

TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS STRET LIGHTING LAMPS

Type of Lamp 1000 W HPS Lamps

400 W HPS Lamps

Manufacturer Country of Origin Manufacturer's Cat. No. Shape of Lamp Tubular Tubular Cap. Mogul E-40

Overall Length Nominal Required mm. 383 285 Offered mm.

Bulb Diameter Nominal Required mm 79 48 Offered mm.

Initial Lumen Output 100 Hrs.

Minimum Required mm. 130000 48000 Offered Lumens

Other Particulars to be indicated.

Average life to burn out, Hrs.

Required 16000 16000 Offered

Lumen output at half life as % of initial lumens

Required 75% 75%

Offered

Lamp Voltage Lamp Current

Ballast Impedance Required, at 220 V at 240 V

Lamps suitable for 240 V mains supply and + 6% or – 6% variation

Yes/No Yes/No

Lamps lumens life, etc., guaranteed are for 240V Main supply.

Yes/No Yes/No



SCHEDULE – G TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS

CHOKES

Ser. No. Description 1. Manufacturer 2. Country of origin 3. Manufacturer's Catalogue No. 4. Type 5. Wattage 6. Voltage 7. Phase 8. Voltage of Tappings 9. Overall dimensions (in mm) 10. Guaranteed Life in Kuwait conditions 11. Weight (in Kg.) 12. Place of the Inspection


For 1000 watt For 400 watt H.P.Sodium H.P. Sodium Lamps Lamps


SCHEDULE – H TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS

CAPACITORS

Ser. No. Description 1. Manufacturer 2. Country of origin 3. Manufacturer's Catalogue No. 4. Type 5. Capacity (in micro farad) 6. Type of container 7. Overall power factor of the control gear after correction 8. Overall dimensions (in mm) 9. Place of the Inspection


For1000 watt For 400 watt H.P.Sodium H.P. Sodium Lamps Lamps


SCHEDULE - I TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS

IGNITORS

Ser. No. Description 1. Manufacturer 2. Country of origin 3. Manufacturer's Catalogue No. 4. Type 5. Wattage 6. Voltage loss during lamp operation 7. Max. distance from lamp for reliable operation 8. Time for re-ignition of hot lamp following interruption to supply 9. Type of container 10. Overall dimensions (in mm) 11. Guaranteed Life in Kuwait conditions

12. Place of the Inspection


For 1000 watt For 400 watt H.P.Sodium H.P. Sodium Lamps Lamps


SCHEDULE – J

TECHNICAL SCHEDULE AND GUARANTEED PARTICULARS STREET LIGHTING CONTROL CABINETS

Ser. No. Description Unit

Particulars 12-Way, 200A

18-Way, 300A

24-Way, 400A

1.

Main MCCB: i) Make ii) Type & Cat No. iii) Standard Max. Cont. Rating iv) Max. Cont. Rating under Kuwait’s worst temperature

condition (52 degree Cent. Ambient) v) Temp. derating curves submitted ? vi) Rated Service Short Circuit Breaking Capacity at 415 volts

as per IEC:60947-2. vii) A.S.T.A. or equivalent certificate submitted ?

Amps Amps K.A

Yes/No Yes/No

Yes/No Yes/No

Yes/No Yes/No

2.

Branch MCCB / MCB: i) Make ii) Type & Cat No. iii) Standard Max. Cont. Rating at 40 Deg. Cent. Ambient

temperature. iv) Max. Cont. Rating under Kuwait’s worst temperature

condition (52 degree Cent. Ambient) v) Temp. derating curves submitted ? vi) Rated Service Short Circuit Braking Capacity at 240 volts

as per IEC:60947-2. vii) A.S.T.A. or equivalent certificate submitted ?

Amps Amps K.A.

Yes/No

Yes/No

Yes/No


SCHEDULE – J (CONT’D)



18-Way, 300A

24-Way, 400A

3.

Contactor: i) Make ii) Type & Cat. No. iii) Utilization category AC-3 or not iv) Rated operational current for Ut. category AC-3 v) Class of duty

Amps

Yes/No

Yes/No

Yes/No

4.

Bus-Bars: i) Size of Bus-bars - Phase - Neutral - Earth ii) Max. continuous Rating under Kuwait’s worst temp.

Condition (55 deg. Cent. Ambient).

iii) Max. symmetrical short circuit through fault current capacity

MM x MM MM x MM MM x MM Amps K.A.

5

Photo-Cell: i) Make ii) Type & Cat. No. iii) Switching on level iv) Switching off level v) Electrical Rating

vi) Contactor closes in case of failure of photo-cell ?

Lux Lux Amps





18-Way, 300A

24-Way, 400A

6.

Astronomical Time Switch: i) Make ii) Type & Cat. No. iii) Electrical Rating

7.

Incoming Cable Gland: i) Make & Cat. No. ii) Size iii) Material

Yes/No

Yes/No

Yes/No

8.

Outgoing Cable Glands: i) No. of Glands for (3x35+2x16) sq. mm. cables. ii) Make & Cat. No. iii) No. of Glands for (2x16+1x10) sq.mm. cables. iv) Make & Cat. No.

Nos. Nos.

9.

35 sq. mm. Terminal Blocks : i) Make & Cat ii) Terminal Material iii) Max. continuous working temperature

Degr. Cent





18-Way, 300A

24-Way, 400A

10.

Control Wires: i) Make/ Size ii) Insulation Type iii) Voltage Grade

11.

Housing:

i) Housing Material

ii) Overall length iii) Overall width

iv) Overall depth

v) Thickness of sheet steel

vi) Details of galvanization / electro-plating

vii) 350 mm (H) x 200 mm (W) empty space for future

installation of a Kilowatt-hour Meter provided ?

viii) Power Socket provided? ix) 24-hour MCB's provided?

x) M20x400 Anchor bolts as specified provided ?

MM MM MM MM

Yes/No Yes/No Yes/No Yes/No



11. Manufacturer's Drawing Number


(End of Section)


1

G.4 INSTALLATION OF 11 KV & 132 KV UTILITIES

G.4.1 Description

Under this section, the Contractor shall provide all resources including material, equipment, plant and labour and perform all activities necessary for installation of road crossing ducts of the EHV/HV/LV cables and the protection of any existing ones at Site including the removal of existing ducts and structures and the installation of new diversions as shown on the Drawings.

The scope of works under this section is described as follows:

G.4 1.1 Laying of 11 KV Electrical Ducts

The Contractor shall manually or mechanically excavate trench bed, supply and lay 150 mm UPVC pipe ducts, 4-way configuration and backfill trench and in accordance with the Specifications and instructions by the Engineer.

The Contractor shall supply all material, plant and labour and perform all activities required for the complete installation 11 KV pipe ducts including excavation, dewatering if required, bed preparation, backfilling with approved material and concrete encasement of ducts by concrete class K140 at road crossings. All works shall be carried out in accordance with the Contract's drawings and ME (E & W)'s Typical Drawings and Specifications.

The Contractor shall be responsible for verifying site conditions and carry out necessary investigations in order acquaint himself with the nature and type of soil to be excavated. The contractor shall remove and cart away debris and unsuitable material found in the excavated trenches at no additional cost to the Employer or extension of time.

The Contractor shall allow for maintaining the excavated trenches free of underground water and implementing an approved dewatering system when necessary.

The foundation of the pipes bedding shall be firm over the full length of the excavated trench and shall be prepared in accordance with the Specifications and Engineer's instructions.

Unapproved over-excavation shall be reinstated to the specified foundation level and to the satisfaction of the Engineer using compacted suitable material or Class K-140 concrete at no additional cost to the employer or extension of time.

Pipe laying and bedding shall only commence after the inspection and approval of the foundation by the Engineer.

All backfilling operations shall be in accordance with the Contract's specifications and shall not be carried until pipe laying is approved by the Engineer.

The Contractor shall comply with all ME (E & W) requirements and specifications allow in his program for the cabling works by others and coordinate the interfacing between the installation of ducts, and the cabling works by others.

G.4.1.2 Laying of 132 KV and 300 KV Electrical Ducts

The Contractor shall manually or mechanically excavate trench bed, supply and lay 200 mm UPVC pipe ducts of various duct configurations and backfill trench and in accordance with the Specifications and instructions by the Engineer.

The Contractor shall supply all material, plant and labour and perform all activities required for the complete installation 132 KV and 300 KV pipe ducts including excavation, dewatering if required, bed preparation, backfilling with approved material and concrete encasement of ducts by concrete class K140 at road crossings. All works shall be carried out in accordance with the Contract's drawings and ME (E & W)'s Typical Drawings and Specifications.

The Contractor shall be responsible for verifying site conditions and carry out necessary investigations in order acquaint himself with the nature and type of soil to be excavated.

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The contractor shall remove and cart away debris and unsuitable material found in the excavated trenches at no additional cost to the Employer or extension of time.

The Contractor shall allow for maintaining the excavated trenches free of underground water and implementing an approved dewatering system when necessary.

The foundation of the pipes bedding shall be firm over the full length of the excavated trench and shall be prepared in accordance with the Specifications and Engineer's instructions.

Unapproved over-excavation shall be reinstated to the specified foundation level and to the satisfaction of the Engineer using compacted suitable material or Class K-140 concrete at no additional cost to the employer or extension of time.

Pipe laying and bedding shall only commence after the inspection and approval of the foundation by the Engineer.

All backfilling operations shall be in accordance with the Contract's specifications and shall not be carried until pipe laying is approved by the Engineer.

The Contractor shall comply with all ME (E & W) requirements and specifications allow in his program for the cabling works by others and coordinate the interfacing between the installation of ducts, and the cabling works by others.

G.4 1.3 K140 Concrete surround for Duct Laying under proposed road crossings

The Contractor shall supply all material, plant and labour required for complete construction of class K140 concrete encaissement whrere required under road crossings for all types of electrical ducts and various configurations as shown on the Contract's Drawings, ME (E & W) & MPW standard drawings and as instructed by the Engineer.

G.4.1.4 Removal of Unsuitable Material

The Contractor shall excavate and remove unsuitable material below trench foundation of all excavations and cart away and replace with suitable material and compact to the original foundation level. Unsuitable material shall satisfy the requirements of the relevant clauses in Earthworks section of the Contract's General Specifications and as directed by the Engineer.

G.4.2 Design Requirements

The Drawings outline the general layout of all 11 KV , 132 KV and 300 KV ducts and indicate the location details and number of ducts to be laid.

The Contractor shall review all the information presented in the Contract Documents and modify the design as needed to suit site conditions and successfully install 11KV,132 KV and 300 KV utilities in accordance with the Contract requirements.

The contractor shall comply with ME (E & W) standards and requirements and address the following issues as a minimum:

G.4.2.1 Dewatering

The requirements for dewatering outlined in Sections B of this document shall apply.

G.4.2.2 Temporary Support Structures

The requirements for temporary support structures outlined in Sections B of this document shall apply.

G.4.2.3 Groundwater

The requirements for groundwater outlined in Section B of this document shall apply

G.4.2.4 Concrete Protection against Aggressive Environment

3

The requirements for concrete protection against aggressive environment outlined in Section B shall apply.

G.4.2.5 Works By Others

The 11KV,132 KV and 300 KV cabling work, if required under ME (E & W) instructions and decisions, will be carried out by another contractor appointed by ME (E & W); this work includes the supply of cables, extending the cables through the ducts and connection to existing cables. The Contractor shall include in his work program adequate time to allow for the above work. The Contractor shall obtain in writing from the ME (E & W) the time it requires for their contractor to do the work and the advance notice time required. Failure to obtain such agreement of time schedule in advance of work may mean that the Contractor will not qualify for claims resulting from delay on part of ME (E & W) contractors.

The Contractor shall coordinate with, and provide site access to, ME (E & W) staff and their consultants and contractors, in order to allow the cabling works to be carried out in a timely manner, with minimum disruption to the Contract Works. The Contractor shall regularly notify MOE/ME (E & W) of the work progress status and provide all information that will assist ME (E & W) in the planning and execution of the cabling works.

G.4.2.6 Utilities Coordination

The Contractor shall coordinate the design of the proposed ducts with other existing and proposed utilities and ensure that there will be no conflict between the utilities. The Contractor shall comply with the requirements and conditions of other respective utility authorities.

G.4.3 Construction, Material and Quality Assurance Requirements

Construction, Material and Quality Assurance requirements shall be in accordance with the relevant sections of the General Specifications as modified in Division II of this Document. The Contractor shall also comply with the requirements of ME (E & W) and utilize ME (E & W) particular specifications for work related to ME (E & W).

G.4.4 Submittal Requirements

In addition to submittal requirements listed in other parts of the Contract, the following is required:

G.4.4.1 Pre-Construction

■ Shop Drawings: The Contractor shall submit shop drawings for approval in accordance with the General Specification as modified in Division II of this document.

■ Approvals: The Contractor shall obtain all approvals and permits, necessary to complete the Contract Works, in accordance with Contract Conditions and Specification.

■ Coordination with ME (E & W): The Contractor shall provide copies of correspondence with ME (E & W) to demonstrate compliance with the requirements to coordinate with ME (E & W) in relation to the cabling works.

■ Method Statement:

The Contractor shall submit a detailed method statement showing his proposed construction methods for meeting the contract requirements and specification, including as a minimum:

- Excavation method including rock excavation and temporary support structures

- Protection of existing utilities

- Dewatering, if required

- Procedure for the installation of new ducts, including connection to the existing

4

network

- Required interface between different elements of works

- Time schedule

■ Materials: The Contractor shall submit for approval a list of all materials to be used with details about their source and properties in accordance with the General Specification as modified in Division II of this document.

G.4.4.2 Post-Construction

■ The Contractor shall submit As-Built drawings in accordance with the General Specification as modified in Division II of this document

■ All testing and inspection results, as required.

G.4.5 Measurement and Payment

G.4.5.1 Installation of 11 KV Electrical Road Crossing Ducts

The quantity of excavation for and installation of ducts to be paid for will be the length of the installed duct group in meter run as shown in the Bill of Quantities. The depth and width of excavation shall be as specified. The length of duct group for payment will be calculated as the length of actual duct run between under the carriageway limit plus 90 cm on both sides.

Excavation and bedding will not be measured separately and will be included in the rate provided in the Bill of Quantities. Any over excavation outside the specified depth and length of the trench will not be paid for.

G.4.5.2 Installation of 132 KV and 300 KV Electrical Road Crossing Ducts

The quantity of excavation for and installation of ducts to be paid for will be the length of the installed duct group in meter run as shown in the Bill of Quantities. The depth and width of excavation shall be as specified. The length of duct group for payment will be calculated as the length of actual duct run between under the carriageway limit plus a length as instructed by the Engineer on both sides.

Excavation and bedding will not be measured separately and will be included in the rate provided in the Bill of Quantities. Any over excavation outside the specified depth and length of the trench will not be paid for.

G.4.5.3 K140 Concrete surround for Duct Laying under proposed road crossings

The quantity of concrete surround for various ducts configurations to be paid for will be the length of the concrete surround for duct group laid under road crossings in meter run as shown in the Bill of Quantities. The length of concrete encasement duct group for payment will be calculated as the length of duct run between the manholes or handholds.

Payment will be made for each meter run of the length of K140 concrete encasement at the rate provided in the Bill of Quantities.

G.4.5.4 Removal of Unsuitable Material

Unsuitable material for payment encountered at or below the foundation level and required to be removed, carted away and replaced with suitable material as instructed by the Engineer, shall be the volume excavated and measured in meter cubes. The rate provided in the Bill of Quantities will allow for the cost of all necessary operations including replacement with a suitable material, compaction, sheeting, bracing and dewatering if required.

5

General specifications for MEW in state of KUWAIT must be obtained for all items listed below

• General specifications for high tensions cables ( 300 KV & 132 KV) over head and under ground.

• General specifications for Medium tensions cables ( 66 KV & 33 KV) over head and under ground.

• General specifications for 11 KV transmission lines cables

6

GOVERNMENT OF KUWAIT

MINISTRY OF ELECTRICITY & WATER

SUPPLY & INSTALLATION OF 132 KV XLPE

POWER CABLES, OPTICAL FIBER CABLES AND ACCESSORIES GENERAL SPECIFICATIONS 3.1 Extent of Contract The contract shall be for the manufacturing, testing in the factory, packing, shipment and delivery CIF to Ministry of Electricity & Water, customs and import duties, handling charges, transport to site, excavations, laying and installations, pulling through ducts, backfilling, reinstating of the ground, jointing and terminating, testing at site and putting to work the circuits, outlined in Detailed Scope of Work. 3.1.1 Supply The lengths of the various circuits as indicated in Detailed Scope of Work are approximate and will have to be worked out after the layout of the various equipment are finalized. The payments for the supply shall be based on measured lengths of the circuits installed. N.B.: This contract covers the supply of all jointing materials, compounds and

metals necessary for the installation and jointing of all these cables to their respective terminations.

The contract covers the installations and jointing of the circuits outlined in Detailed Scope of Work. The lengths of the various circuits as indicated in Detailed Scope of Work are approximate and will have to be worked out after the layout of the various equipment are finalized. The payments for the installations shall be based on measured lengths of the circuits installed. To facilitate easy determination of installation charges, uniform flat rates shall be quoted for cable installation whether buried (including excavations in ground or soil of any nature, tiling, install of protection nets and warning tapes and backfilling) or pulled through ducts, or laid in concrete trenches or on trays or supported by cleats. The quoted rates for installations shall be firm and shall not be subject to any variation throughout the contract period.

7

The arrangement of circuits in Detailed Scope of Work does not depict the chronological sequences of installation operations. The actual sequence of operations will be fixed at the time of installation of the circuits with respect to the prevailing load conditions. The installation work shall be carried out during the normal working hours of the Ministry of Electricity & Water. If the contractor wishes to carry out the installation works after the normal working hours for his own convenience or to meet the contract completion dates, he should get the approval of the purchaser. 3.1.3 Surplus Cables Expense of surplus cables will not be paid by the purchaser. Accordingly, the contractor shall make an accurate survey to meet the actual lengths of the cables required to complete the items detailed in the scope of works. Disposal of excess or scrap materials is the contractor's responsibility. 3.2 Details of Existing System The 132kV and 33kV systems have the following characteristics: 132kV System 33kV System a) Voltage 132000V+10% 33000V+10% b) No. of Phases Three Three c) Frequency 50 Hz 50 Hz d) Fault Level 10000 MVA at 1000 MVA 145 KV e) Maximum fault duration 1.25 seconds 1.5 seconds f) System neutral earthing directly earthed Through 39 ohms resistor. 3.3 Site Conditions Climatic conditions in Kuwait are rigorous and during summer, the ambient shade temperature rises to 55 C and the sun temperature to 85 C as measured with a black bulb thermometer. Periods of high humidity are common and a relative humidity of 100% at 30 C has been recorded. Violent sand and dust storms occur, even on comparatively still days, fine dust is carried in suspension in the atmosphere.

8

The cables will be laid partly in ducts or concrete trenches and partly buried in the ground at a depth of 1.4 meters for 33 KV cables and 1.5 meters for 132kV cables where the soil varies from sandy to rock-like gatch compared to dry hard clay with a corresponding ground thermal resistivity "g" of 120 C cm/watt and a ground temperature varying from 35 C in summer to 15 C in winter. The cables called for in this specification shall, therefore give trouble free service under the worst conditions encountered in Kuwait and shall carry rated currents continuously under the worst temperature conditions which prevail in summer and shall also withstand maximum fault current without damage or deterioration. The cables will be exposed to direct rays of the sun at the terminations of the outdoor sealing ends and at the transformers. They should be capable of withstanding such exposure continuously in service without any deleterious effect on the insulation, sheathing or covering, by using sun shielding for cables and sealing-ends. They should also be suitable for storage in the open for a period of at least two years with patterns. The soil in Kuwait is very corrosive. Sulphate reducing bacteria is common to all soils in the Kuwait Area and as the soil is generally rich in sulphate, the anaerobic conditions which may arise in contact with buried pipes and cables, favors the development of these anaerobic organisms which generate hydrogen sulphide and consequently render these areas more corrosive. In view of the above and the high temperatures encountered in Kuwait, it should be stressed that PVC plasticizers should be of the long chain; high molecular weight type to reduce the loss of plasticizers in the hot and corrosion conditions. The prevents shrinkage of the PVC with subsequent cracking of the film. Typical analysis of a soil sample is as follows: - Appearance : Wet coarse sand with some clay - Ph value of water in contact with the sand. : 10.0 - Calcium sulphate as Ca SO4 : 25.00% dry basis - Calcium Carbonate as Ca CO3 : 40.00% dry basis Silica as Si O4 : 22.00 % dry basis - Magnesium Sulphate as Mg SO4 : 6.00 % dry basis

9

- Sodium Chloride as NaCl : 5.00 % dry basis - Iron as Fe2O3 : 2.00 % dry basis - Sulphate reducing bacteria : Present - Moisture : 15.00 % N.B.: The sand is not corrosive under dry aerated conditions, but under anaerobic

conditions, the sulphate reducing bacteria in the sand will result in serious corrosion of metals in contact with the sand. The cables coverings over the lead sheath as stated in these specifications are designed to combat this. Where PVC or HDPE (as sheath serving or overall covering) is used, the PVC or HDPE should be suitable for the above soil conditions.

3.4 Details and General Requirements Applicable to Power Cables & Fiber Optic

Cables, Coaxial Cables and Accessories 3.4.A XLPE Cables The cables called for in this specification shall have insulation levels to withstand to voltage surges that may occur due to switching operations, sudden load variations and faults ...etc. The cable shall satisfy the requirement of: IEC 60502 for 33 KV cables and IEC 60840 for 132 KV Cables as a minimum: a) Conductors

The strands used in the making -up of different sizes of conductors shall be plain, smooth, annealed high conductivity copper wires laid up and shaped into circular cores complying with IEC 60228 and BSS 6480 recommendations.

Oval or sector shaped cores will not be accepted sizes and numbers of wires shall be stated in the schedules. Also aluminum conductors will not be accepted.

b) Insulation

Insulation for the cables shall be of the best quality dry cured XLPE type. The insulation for 132kV cables shall be designed for an impulse voltage level of 650kV peak and the 33 KV cables shall be designed for impulse voltage level of 195kV peak the insulation should be designed for a life time of 50 years.

c) Sheath

To ensure the highest degree of protection against the ingress of moisture, the cable shall have a metallic sheath consists of lead alloy type "E" (PK021S) or ½ C (PK012S) or tellurium lead alloy sheath ( Kb-pb Te 0.04 ) as per the

10

requirements of BS EN 12548 & BS EN 50307. The sheath for all types of cables should be manufactured using continuous lead machines; sheathing with discontinuous machines will not be accepted.

d) Armour Wires All armour wires shall be of the galvanized steel to B.S. 1442 Galvanizing shall be carried out in accordance with BBS 443. Sizes and numbers of wires shall be stated in the schedules of this specification.

e) Compound

The compound used shall not melt or run when exposed to the temperature conditions prevailing during transit or at site in Kuwait or during operation.

e) Serving

The soil in Kuwait is naturally very corrosive and it is essential, therefore, that the serving of the cables be designed to prevent corrosion. Reference should be made to “Site Conditions “Clause 3.3.

3.4.A.1 XLPE 1000 sq.mm. 1/core 132 KV Cables The XLPE cables for 132kV should comply generally with the requirements of latest IEC 840-88 1) Conductor

The conductor shall consist of stranded, plain annealed electrolytic copper wires either circular and compacted or compacted segmentally Milliken type having a cross sectional area of 1000 sq.mm complying with IEC 60228 and BS. 6360.

2) Conductor Water Sealing

The conductor shall be water sealed by adding a swelling material between the conductor strands.

3) Conductor Screen

This screen consists of an extruded layer firmly bonded to the XLPE insulation. The material is a semi-conductive compound. The interface between the screen and the insulation must be smooth as much as possible. The conductor screen, the insulation and the insulation screen are to be extruded in one single process “the triple extrusion process, the conductor screen shall have suitable thermal and mechanical properties.

11

A non-hydro scopic semi conducting tape is to be applied between the conductor and the extruded semi conducting material.

4) Insulation

The insulation shall consist of one layer of extruded chemically cross-linked polyethylene (XLPE) which shall be dry cured. The insulation shall be firmly and continuously bonded to the extruded conductor screen a very clean grade of insulation is to be employed which is conveyed from sealed boxed to sealed extruded hopper without being exposed to atmospheric contamination.

The insulation thickness shall be designed to have a life time of more than 50 years based on working voltage of 132 KV r.m.s., and BIL (Basic Impulse level of 650 KV. peak). However, the nominal insulation thickness should not be less than 20 mm. The insulation thickness should be measured in accordance with IEC 60811-11 clause 8, the average of the measured valves rounded to 0.1 mm shall not be less than the specified nominal thickness. The lowest measured value shall not fall below the specified nominal thickness by more than 10% of the specified nominal thickness:

tm > tn - 0.1 tn mm

5) Insulation Screen (core screen)

The insulation screen shall consist of an extruded layer of semi conducting compound. This core screen should be fully bonded to the insulation so that intimate contact with the insulation is ensured. Conductor screen, insulation, and core screen are to be extruded in one single process (the triple extrusion process). Two layers of conductive swelling tapes shall be applied over the extruded semi conductive compound.

6) Metallic Screen

The metallic screen shall consist of a combination of plain annealed copper wires applied concentrically and copper tapes applied helically semi conducting layer to be applied over the copper tape (as bedding) The metallic screen shall be capable to carry the return earth fault currents specified.

7) Metallic Sheath

To ensure the highest degree of protection against the ingress of moisture, the cable shall have a metallic sheath consists of lead alloy type "E" (PK021S) or ½ C (PK012S) or tellurium lead alloy sheath ( Kb-pb Te 0.04 ) as per the

12

requirements of BS EN 12548 & BS EN 50307. The nominal thickness of lead sheath shall not be less than 3.3mm. - Short circuit current is 40 KA for 1.25 seconds

N.B: The calculation of short circuit current shall consider the flow of the current in the metallic layers on parallel basis. 8) Armour

The cable shall be armoured over the lead alloy sheath, using stainless steel tapes or Tine Bronze or copper tape A suitable bedding of extruded PVC under the armour shall be used. 9) Anti-Corrosion Covering

The following layers shall be applied over the metallic sheath:

1. Anti-corrosion protection consists of a thin layer of bitumen compound (Coating of waterproof insulation compound) and suitable bedding.

2. The outer sheath shall be extruded layer of HDPE type ST7 capable

to withstand the temperature and soil condition as mentioned in clause 3.3

3. The portion of cable laying in building/basements and similar areas shall be provided with fire retardant coating. The minimum average thickness of this sheath shall be not less than 4.0 mm.

4. A thin layer of resin bonded graphite coating is to be applied to the anti-corrosion covering to permit electrical tests.

10) Graphite Coating

A thin layer of resin bonded graphite coating is to be applied to the anti-corrosion

3.4.A.2 XLPE 630 sq.mm. 1/core 132 KV Cables The XLPE cables for 132kV should comply generally with the requirements of latest IEC 840-88

13

1) Conductor

The conductor shall consist of stranded, plain annealed electrolytic copper wires either circular and compacted or compacted segmentally Milliken type having a cross sectional area of 630 sq.mm complying with IEC 60228 and BS. 6360.



3) Conductor Screen

This screen consists of an extruded layer firmly bonded to the XLPE insulation. The material is a semi-conductive compound. The interface between the screen and the insulation must be smooth as much as possible. The conductor screen, the insulation and the insulation screen are to be extruded in one single process “the triple extrusion process, the conductor screen shall have suitable thermal and mechanical properties. A non-hygroscopic semi conducting tape is to be applied between the conductor and the extruded semi conducting material.

4) Insulation

The insulation shall consist of one layer of extruded chemically cross-linked polyethylene (XLPE) which shall be dry cured. The insulation shall be firmly and continuously bonded to the extruded conductor screen a very clean grade of insulation is to be employed which is conveyed from sealed boxed to sealed extruded copper without being exposed to atmospheric contamination.

The insulation thickness shall be designed to have a life time of more than 50 years based on working voltage of 132 KV r.m.s., and BIL (Basic Impulse level of 650 KV. peak). However, the nominal insulation thickness should not be less than 20 mm. The insulation thickness should be measured in accordance with IEC 811-11 clause 8, the average of the measured valves rounded to 0.1 mm shall not be less than the specified nominal thickness. The lowest measured value shall not fall below the specified nominal thickness by more than 10% of the specified nominal thickness:

tm > tn - 0.1 tn mm

14

5) Insulation Screen (core screen)

The insulation screen shall consist of an extruded layer of semi conducting compound. This core screen should be fully bonded to the insulation so that intimate contact with the insulation is ensured. Conductor screen, insulation, and core screen are to be extruded in one single process (the triple extrusion process). Two layers of conductive swelling tapes shall be applied over the extruded semi conductive compound.

6) Metallic Screen

The metallic screen shall consist of a combination of plain annealed copper wires applied concentrically and copper tapes applied helically semi conducting layer to be applied over the copper tape (as bedding) The metallic screen shall be capable to carry the return earth fault currents specified.

7) Metallic Sheath

To ensure the highest degree of protection against the ingress of moisture, the cable shall have a metallic sheath consists of lead alloy type "E" (PK021S) or ½ C (PK012S) or tellurium lead alloy sheath ( Kb-pb Te 0.04 ) as per the requirements of BS EN 12548 & BS EN 50307. The nominal thickness of lead sheath shall not be less than 3 mm. - Short circuit current is 40 KA for 1.25 seconds 8) Armour

The cable shall be armoured over the lead alloy sheath, using stainless steel tapes or Tine Bronze or copper tape A suitable bedding of extruded PVC under the armour shall be used.

9) Anti- Corrosion Covering

The following layers shall be applied over the metallic sheath:

1. Anti-corrosion protection consists of a thin layer of bitumen compound (Coating of waterproof insulation compound) and suitable bedding.

2. The outer sheath shall be extruded layer of HDPE type ST7 capable

to withstand the temperature and soil condition as mentioned in clause 3.3

15

3. The portion of cable laying in building/basements and similar areas shall be provided with fire retardant coating. The minimum average thickness of this sheath shall be not less than 3.6 mm.

4. A thin layer of resin bonded graphite coating is to be applied to the anti-corrosion covering to permit electrical tests.

10) Graphite Coating

A thin layer of resin bonded graphite coating is to be applied to the anti-corrosion covering to permit electrical tests.

3.4.A.3 XLPE 300 sq.mm 1/C 33kV Cable This cable should comply generally with the requirements of latest IEC 60502-83. 1) Conductor Same as 3.4.1.1 above, except that the cross sectional area of conductor is 300 sq.mm. 2) Conductor Water Sealing Same as 3.4.1.2 above 3) Conductor Screen Same as 3.4.1.3 above. 4) Insulation Same as 3.4.1.4 above except for the following: a) The working voltage is 33kV r.m.s. b) Basic impulse level is 195kV c) The nominal thickness of insulation should not be less than 8 mm. 5) Insulation Screen Same as 3.4.1.5 above 6) Metallic Screen Same as 3.4.1.6 above.

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7) Metallic Sheath

Same as 3.4.1.7 above except that, the nominal thickness of lead sheath should not be less than 2.5 mm. 8) Armour Same as 3.4.1.8 above 9) Anti-Corrosion Covering Same as 3.4.1.9 above except that the PVC outer covering shall be 3 mm. 10) Graphite coating Same as 3.4.1.10 above. 3.4.A.4 XLPE 300 sq.mm 3/C 33kV Cable The XLPE cables should comply generally with the requirements of latest IEC 502 - 83. 1) Conductors

Each of the three conductors shall consist of stranded, plain annealed electrolytic copper wires circular and compacted having a cross sectional area of 300 sq.mm complying with IEC 228 and BS. 6360.



3) Conductor Screen

Each of the three conductors of the cable shall be separately screened. This screen consists of an extruded layer firmly bonded to the XLPE insulation. The material is a semi-conductive compound compatible with the insulation of the conductor. The interface between the screen and the insulation must be smooth as much as possible. The conductor screen, the insulation and the insulation screen are to be extruded in one single process “the triple extrusion process “, the conductor screen shall have suitable thermal and mechanical properties. (Allowable operating temperature equal or higher than the insulation).

17

A non-hygroscopic semi conducting tape is to be applied between the conductor and the extruded semi conducting material.

The extruded layer shall be easily removable from the conductor. 4) Insulation

The insulation shall consist of one layer of extruded chemically cross-linked polyethylene (XLPE) which shall be dry cured. The insulation shall be firmly and continuously bonded to the extruded conductor screen a very clean grade of insulation is to be employed which is conveyed from sealed boxed to sealed extruded hopper without being exposed to atmospheric contamination. The insulation thickness shall be designed to have a life time of more than 50 years based on working voltage of 33 KV r.m.s., and BIL (Basic Impulse level of 195kV. peak). However, the nominal insulation thickness should not be less than 8 mm. The insulation thickness should be measured in accordance with IEC 60811-1-1 clause 8, the average of the measured valves rounded to 0.1 mm shall not be less than the specified nominal thickness. The lowest measured value shall not fall below the specified nominal thickness by more than 10% of the specified nominal thickness:

tm > tn - 0.1 tn mm

5) Insulation screen (core screen)

The insulation screen shall consist of an extruded layer of semi conducting compound. This core screen should be fully bonded to the insulation so that intimate contact with the insulation is ensured. Conductor screen, insulation, and core screen are to be extruded in one single process (the triple extrusion process). Two layers of conductive swelling tapes shall be applied over the extruded semi conductive compound. The extruded insulation semi conducting screen shall be removable without damaging the insulation, leaving no conducting material that cannot readily be removed. An insulation screen that requires heat for removal shall not be supplied. 6) Metallic Screen

Each core shall have separate metallic screen. The metallic screen shall consist of a combination of plain annealed copper wires applied concentrically and copper tapes applied helically semi conducting layer to be applied over the copper tape (as bedding) The metallic screen shall be capable to carry the return earth fault currents specified. However, the total cross-section of copper screen, covering the three cores shall not be less than 35 mm2.

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7) Inner Covering and Assembly of Cores An extruded inner covering shall be provided over the cores assembly. The metallic screens of the cores shall be in contact with each other.

7.1) Inner Covering and Fillers Requirements

The inner coverings and fillers shall be of materials suitable for the operating temperature of the cable and compatible with the insulation. Fillers shall be non- hygroscopic.

Inner covering material shall be PVC type 9 of table of BSS 67 46 - 84.

8) Metallic Sheath

To ensure the highest degree of protection against the ingress of moisture, the cable shall have a metallic sheath consists of lead alloy type "E" (PK021S) or ½ C (PK012S) or tellurium lead alloy sheath ( Kb-pb Te 0.04 ) as per the requirements of BS EN 12548 & BS EN 50307. The nominal thickness of lead alloy sheath shall not be less than 2.5 mm. - Short circuit current is 25 KA for 1.5 seconds

9) Armour

The cable shall be armoured over the lead alloy sheath, using stainless steel tapes or Tine Bronze or copper tape A suitable bedding of extruded PVC under the armour shall be used.

10) Anti-Corrosion Covering

The cable shall have an outer covering of PVC jacket, the PVC shall conform to type 9 of table 1 of BSS 6746 the nominal thickness of the PVC outer covering shall be 3.6mm. 11) Graphite Coating

A thin layer of resin bonded graphite coating is to be applied to the anti-corrosion covering to permit electrical tests.

3.4.B Accessories for XLPE Cables 3.4.B .1 General The accessories shall be designed for operation on the system specified and to comply with the requirements laid down by this specification, and in accordance with the Purchaser's system design.

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They shall be suitable for satisfactory operation under the atmospheric and climatic conditions prevailing at the site and under such sudden variations of load and voltage as may occur under working conditions on the network. 3.4.B.2 Joints Joints shall be designed such that their electrical, mechanical and thermal characteristics shall be suitable for use on the cable system and in site conditions under clause 3.3 above. 3.4.B.3 Straight Joints

a) Straight Joints shall be supplied complete and be suitable for either direct burial or installation in joint pits.

b) Copper conductors shall be joined by compression. The method of

conductor jointing shall be subject to MEW approval. c) The insulation of the joint shall be performed using tapes, performed

mouldings, site mouldings, site extrusion or a combination thereof subject to the Purchaser's approval.

d) Straight joints shall be continuous sheath types. e) Bonding connections shall be provided at continuous sheath joints.

f) The complete joint shall be enclosed in a protective casing in accordance with ESI-12 - 18 which shall provide adequate clearance for all bonding connections. The joint shall be adequately supported within the box.

g) The casing shall be filled with suitable waterproof compound to

protect the outer metallic screen of the joint from corrosion and to withstand sheath standing voltages and surge voltages. The joint shall be watertight.

h) The completed assembly shall be capable of withstanding the

required commissioning tests and the annual maintenance test of the cable sheath anti-corrosion serving.

i) The design of the straight joint, together with the jointing instructions

and relevant drawings shall be subject to the approval of the Purchaser.

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3.4.B.4 Transition Joints

a) A type test shall be done according to IEC standards and the price for such test shall be included in the tender price.

b) All conditions for this test shall be as specified in clause 3.16 c) A type test procedure and report shall be handed over to the MEW.

3.4.B.5 Terminations The terminations shall be designed such that their electrical, mechanical and thermal characteristics shall be suitable for use on the cable system and in the environment whose parameters are as detailed in “site conditions “clause. 3.3 above. 3.4.B.5-1 Air Insulated Termination’s (132kV Out-door Cable Sealing End Boxes)

a) 132kV Outdoor Cable Sealing end boxes shall be supplied complete with porcelain, bass plate and support insulators suitable for mounting on steel supporting structures, also the sealing end shall be suitable for 1000 sq.mm copper conductor 1/Core XLPE insulated, lead sheath and served 132kV Cable.

b) Copper conductors shall be terminated by compression. The method

of conductor terminating shall be subject to the approval of the Purchaser.

c) The insulation of the termination shall be performed using tapes and /

or performed mouldings of an approved material.

d) The termination base plate shall be isolated from the support structure by the use of support insulators of porcelain or other approved material.

e) The gland of the termination shall have provision for bonding and

earthling connections.

f) The outer porcelain insulator shall be free from defects and shall have a creepage length of not less than 4818 mm. It shall be suitable for use in the atmospheric conditions as described in site conditions.

g) The completed assembly of the gland, porcelain insulator and

conductor termination assembly shall be such as to prevent either the ingress of dust, sand, etc or the leakage of any filling compound where installed.

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The connecting stalk shall be in accordance with the Purchasers design requirements.

h) The completed assembly shall be capable of withstanding the

required commissioning tests and the annual maintenance test of the cable anti-corrosion serving.

i) The tenders shall attach to their offers, drawings showing in detail the proposed method of terminating the cables.

The termination of the cables in the sealing end boxes shall also include the supply and installation of the necessary galvanized steel structures for supporting the sealing ends of the cables near the switchgear or the overhead line take off gantry, and shall also include making of the necessary R.C. foundations for the structure. These structures must be designed as to make possible easy jumpering between the sealing ends and the switchgear bushings or the slack span conductors at the take-off gantry. The height of the steel supporting structures above ground level shall be such that the minimum clearance between the live parts and the ground shall not be less than 4600 mm and the spacing between phases not less than 2600 mm. Exposed cables shall be protected against sun rays by means of an approved sun shields. The maximum distance between the sealing ends and the take-off gantries or terminal towers can be taken as two meters.

j) The Design of the termination with the joint instructions and relative

drawings arrangement of sealing ends, their supporting structures, foundations works shall be subject to the approval of the purchaser.

3.4.B.5-2 Gas Insulated Termination (SF6 sealing Ends) The XLPE cable will be terminated to SF6 sealing ends. Thus the scope of work of cable contractor for this tender shall include the supply of all necessary materials to terminate the XLPE cable to the SF6 switchgear this include all necessary modifications to the sealing ends or even the supply of new SF6 sealing ends to suit XLPE cables if found necessary. The contractor shall arrange with switchgear manufacturer to get his written confirmation that all the materials which the cable contractor will supply under this contract related to the SF6 sealing ends are suitable for the switchgear. Also the cable contractor will be responsible for co-ordination of interface design and shall clearly show on assembly drawings those materials which will be supplied by him and he will be responsible to obtain mutual agreement on the above mention assembly drawing, and this drawing will be subject to MEW approval. The following points have also to be considered: -

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i) Copper conductors shall be terminated by compression. The method

of conductor terminating shall be subject to the approval of the Purchaser.

ii) The insulation of the termination shall be performed using tapes,

and/or preformed moulding of an approved material.

iii) The cable sheath or screen shall be isolated from earth by means of an isolator contained in the gland of the termination.

iv) The gland of the termination shall have provision for bonding and

earthing connection(s).

v) The insulating bushing shall be free from defects and shall be suitable for installation in an SF6 gas environment.

vi) The completed assembly shall prevent the leakage of either filling

compound, where supplied, into the gas chamber or the leakage of gas into the termination.

vii) The connecting stalk shall be in accordance with the switchgear

manufacturer design requirements.

viii) The completed assembly shall be capable of withstanding the required commissioning tests and the annual maintenance test of the cable anti-corrosion serving.

ix) The design of the termination, together with the jointing instructions

and relevant drawings shall be subject to the approval of the purchaser.

3.4.B.6 Bonding and Earthing Materials All materials, equipment and items of plant forming part of the bonding and earthing system shall be designed and manufactured such that, their electrical and mechanical characteristics shall be suitable for use on the cable system and in the environment whose parameters are as detailed (site condition clause 3,3 and shall be subject to the Purchaser’s approval.) Two types of general bonding arrangements may be used:

- Solid bonding where the cable sheaths of the three phases are solidly earthed at both ends of the cable (this is applicable for complete circuits).

- Single point bonding where the cable sheaths of the three phases are bonded

together and earthed at only one location along the cable. This location may

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be at one end of the cable and the other end will be earthed through sheath voltage limiters (This is applicable for cable tail circuits to O/H lines.)

3.4. B.6-1 Sheath Voltage Limiters Sheath voltage limiters (SVLs) shall be supplied, where required, to protect the anti-corrosion serving on the cable sheath from damage due to induced sheath surge. They shall be suitable for used on the system and shall normally be installed at unearthed positions or at terminations as required. They should be adequate for both normal and fault conditions. 3.4.B.6-2 Bonding Lead Bonding lead shall be either single core or concentric core copper conductor with a PVC serving. The sheaths, including the inner sheath of the concentric lead, shall be capable of withstanding the commissioning and annual maintenance test relevant to the system on which it is to be installed. The exterior surface of all bonding leads shall be coated with graphite to facilitate site voltage testing. 3.4.B.6-3 Link Boxes All links and SVLs, other than those directly connected across sectionalizing insulation at metal clad equipment terminations, shall be enclosed in link boxes which shall be earthed by connection to an adjacent earth system. SVLs and associated links shall be accommodated in a common box. The boxes shall be provided with a means of preventing incorrect link positioning, and shall also be provided with a label showing the normal link arrangement. The terminal posts, links, and SVL connections shall be designed so that the contact resistance as tested after installation shall not exceed 20 mircrohms. The terminal posts and links shall also be suitable for the short circuit requirements specified. The internal insulation of the link boxes shall be capable of withstanding impulse type tests of 35 KV between links and 17.5kV from link to earth. Link boxes shall be installed below ground in pits, above ground outdoor or indoor according to MEW approval. Link boxes for installation below ground, in shallow pits, shall be of the horizontal type with diving bell lids or bolted on lids.

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Link boxes for installation above ground outdoor shall be of weatherproof outdoor type with degree of protection IP54 suitable for vertical mounting, eg. on sealing end supporting structures. Boxes for indoor installation shall be to MEW requirements. There shall be a label inside the box which details the circuit identification and bears the legend: - THIS/THESE LINK/S MUST BE CLOSED WHEN THE CABLE IS IN SERVICE A phase identification label shall be provided adjacent to each terminal. Provision shall be made for padlocking the lid. 3.4.B.6-4 Earth Rods Copper-clad steel earth rods shall be supplied (if applicable) and shall be in accordance with the Purchaser's design requirements. They shall be supplied complete with a screw on steel driving cap and a connecting lug for earth wire. The length of the rod shall be in accordance with MEW requirements. 3.4.C Oil Filled Cables The cables called for in this specification shall have insulation levels to withstand the voltage surges that may occur due to switching operations, sudden load variations and faults...etc.

The cables shall satisfy the requirements of the IEC Publication 141.1 and ESI 09-04 a) Conductors

The strands used in the making-up of different sizes of conductors shall be plain, smooth, annealed high conductivity copper wires laid up and shaped into circular cores complying with IEC 228 recommendations.

Oval or sector shaped cores will not be accepted sizes and numbers of wires shall be stated in the schedules. Also aluminum conductors will not be accepted.

b) Insulation

Insulation for the cables shall be of the best quality wood pulp kraft paper. The insulation for 132 KV cables shall be designed for an impulse voltage level of 650 KV peak.

c) Sheath

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The sheath shall be either of lead alloy 1/2 C conforming to BSS.801 or tellurium alloyed lead (Kb-Pb Te 0.04) conforming to DIN 17640 for oil filled cables. The sheath for all types of cable should be manufactured using continuous lead machines; sheathing with discontinuous machines will not be accepted.

d) Compound

The compound used shall not melt or run when exposed to the temperature conditions prevailing during transit or at site in Kuwait or during operation.

e) Serving

The soil in Kuwait is naturally very corrosive and it is essential, therefore, that the serving of the cables be disigned to prevent corrosion. Reference should be made to "Site Conditions” Clause 3.3.

3.4.C-1 Oil Filled 630 sq.mm 1/Core 132 KV Cables i) Conductors

The conductors shall be of stranded plain annealed high conductivity copper shaped into circular cores and shall have a cross-sectional area of 630 sq.mm and formed with central oil duet of 12 mm diameter.

ii) Insulation

The thickness shall not be less than the value corresponding to peak impulse voltage level of 650 KV and system's highest voltage of 145 KV, but the minimum thickness shall not be less than 8.5 mm.

iii) Screening

Two layers of semi-conducting carbon paper tape having a total nominal thickness of 0.2 mm shall be applied for each conductor and a metallized paper or non-ferrous metal tape screen shall be applied over the paper insulation and reinforced by a copper woven fabric tape.

iv) Sheathing

The cable shall then be drawn into lead alloy 1/2 C conforming to BSS.801 or tellorium alloyed lead (Kb-Pb-Te 0.04) conforming to DIN 17640 and lightly reinforced by means of helically aplied metal tapes as detailed below. The minimum average thickness of sheath shall

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not be less than 2.5 mm and the minimum thickness at any point shall not be less than 2.3 mm. The sheath should be applied on the insulated cable using continuous lead sheath machines (see clause 3.4 above).

v) Serving & Bedding The following layers shall be applied over lead alloy sheath:

1. For all cables except cables mentioned in schedule E - Spare Parts – if applicable

a) Coating of water - proof insulating compound.

b) Suitable bedding and metal tape reinforcements which shall consist of

2 layers of non-magnetic material, tin bronze, stainless steel or hard copper tapes and further served as follows: -

c) Outer covering of extruded Black PVC jacket of minimum average

thickness and minimum thickness at any point not less than the values given in table below. The PVC shall conform to BSS. 6746 and shall fulfill the test requirements for PVC type 9 of table 3 of BSS 6746 as minimum and shall be suitable for site conditions stated under clause 3.3

The PVC sheath shall be embossed with voltage designation (132kV) and the manufacturer's name with same manner described in BSS 6480 and ESI standard 09-4. Tenderers shall submit with their offers a guarantee for the suitability of the PVC with the site conditions mentioned in the specifications.

2. For cables mentioned under schedule E - Spare Parts - (if applicable)

Same as above however an additional 2 mm nominal thickness extruded (PE) sheath to be applied above the a/m PVC outer covering. However, a polyethylene rephtalat (PET) foil will be applied as a separator between the two extruded PVC & PE sheaths mentioned above to facilitate the removal of the (PE) sheath if required.

Tenderers shall submit with their offers a guarantee for the suitability of

the PVC with the site conditions mentioned in the specification.

N.B.: The lime wash should be such as to prevent adhesion between turns and layers of cables and between cables and drums at temperatures likely to be met with during transit or storage into the open areas.

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The thickness of PVC sheath for serving to be used for the various cables mentioned above shall comply with the following table:

Calculated Diameter Under PVC Overhead sheath

Minimum Average thickness

Minimum thickness at any point

Above (mm)

Upto & Including (mm)

(mm)

(mm)

25 30 2 1.6 30 35 2.2 1.77 35 40 2.4 1.94 40 45 2.5 2.11 45 50 2.8 2.28 50 62.5 3.0 2.45 62.5 77.5 3.3 2.71 77.5 -- -- -- 3.4.C-2 Oil Filled 300 sq.mm 1/Core 132 KV Cables i) Conductors

The conductors shall be of stranded plain annealed, high conductivity copper wires shaped into circular cores of a cross-sectional area 300 sq.mm. And formed with central oil ducts of 12 mm diameter.

ii) Insulation

The thickness shall not be less than the value corresponding to an impulse voltage level of 650 KV peak and system’s highest voltage of 145 KV but not less than 9.3 mm.

iii) Screening As 3.4.C-1 (iii) above. iv) Sheathing

The cable shall then be drawn into lead alloy 1/2 C alloy sheath of adequate thickness. The minimum average sheath thickness shall not be less than 2.3 mm. and the minimum at any point shall not be less than 2.08 mm. The sheath shall be applied on the insulated cable using continuous lead sheath machine (see clause 3.4 above).

v) Serving and Bedding As 3.4 C-1 (v) above.

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3.4.D Oil Filled Cable Accessories 3.4.D-1 General Same as 3.4.B.1 above 3.4.D-2 Joints Same as 3.4.B-2 above 3.4.D-3 Straight Joints

Same as 3.4.B-3 above 3.4.D-4 Terminations

Same as 3.4.B-4 except that the Sealing End shall be suitable for Oil Filled Cables.

3.4.D-4-1 Air Insulated Termination

Same as 3.4.B-4-1 except that the sealing end shall be suitable for 630 sq.mm oil filled cable.

3.4.D-4-2 Gas Insulated termination ( SF6 Sealing End )

Same as 3.4.B-4-2 except that the Sealing End shall be suitable for Oil Filled Cables.

3.4.D-5 Bonding and earthing Materials Same as 3.4.B-5 3.4.D-5-1 Sheath voltage limiters Same as 3.4.B-5-1 3.4.D-5-2 Bonding lead Same as 3.4.B-5-2 3.4.D-5-3 Link Boxes Same as 3.4.B-5-3

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3.4.D-5-3 Earth Rods Same as 3.4.B-5-4 3.4.D-6 Hydraulic Requirements

1. In each oil section under no load minimum temperature condition, there should exist a quantity of oil, known as "surplus oil", which should be available to maintain pressure with an oil leak present until remedial action can be taken. As an absolute theoretical minimum, the quantity of surplus oil has been suggested as 10 liters but in assessing practical designs. The purchaser will expect to find proposals that lead to quantities of surplus oil greater than this figure.

2. Preliminary hydraulic design details based on the foregoing principles

and taking into consideration the cooling and heating transients will be settled with the Purchaser after the approved route has been issued (see schedule A-II - vii)

3. Pressure gauges with alarm contacts shall be equipped with 2 stage

contacts so as to detect a changed situation and bring out outomatically in a sequence the following actions:

a) Firstly, an alarm signal to indicate that a pressure value has been dropped which is just below the minimum operating pressure.

b) Secondly, an intimation signal at emergency minimum pressure to

cause the circuit to be tripped out.

The contractor shall wire up these contacts to marshalling kiosks provided by others in end substations. Pressure gauges shall normally be arranged from - 1 bar to 6 bars and will be fitted at the Substation end.

4. All hydraulic piping works, tanks, etc. must be prevented from

carrying power system fault current e.g. by using insulating coupling connectors and all metallic parts of tanks , pipes, etc, should be earthed.

5. gauges contacts shall be suitable for 240 volts AC/DC and each gauge

terminals shall be connected to terminal blocks which shall be housed in water proof casing gauge contacts should be of magnetic snap action.

6. Valves:

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The oil control system shall be designed such that leak location and testing may be carried out without the disconnection of any permanent pipe work.

Valves additional to those specified below shall be installed only with the approval of the Engineer:

a) Three valves per tank " one to feed the system, one to fill or boost

the tank and one for the gauge, the latter being of a three way, two position type to facilitate testing of the gauge.

b) One per manifold where two or more tanks are installed in an in

accessible position and the tanks are feeding to a single position. c) One for each individual oil feed. 7. Provision shall be made for the hydraulic testing of gauges i.e it

should be possible to test LOP alarms by reducing the pressure in the gauge. If it is not possible to employ test blocks then the contractor should ensure that any gauge bleed pipes shall be sealed off with a blank nut and nipple so that unintentional operation of valves will not results in loss of oil.

8. Oil pipes should be either PVC insulated copper or PVC oversheathed, steel armoured lead depending on circumstances of use - copper for inside substations and in open pits, but armoured lead for all buried applications. Buried pipes should be protected by cover tiles, protection net and warning tape.

9. Oil tanks and other hydraulic equipment should be provided with

purpose made earthing lugs or bosses.

Bonding cables for hydraulic equipment shall be of suitable size copper, PVC insulated, single core.

3.4.D-7 Bonding and Earthing Requirements for 132 KV Cables for Feeder

Tails

1. Single point bonding of the power cable lead sheaths is required to eliminate sheath circulating currents.

2. Cables and terminations shall be designed , manufactured and

installed so as to result in a fully insulated sheath and to permit the routine application of PVC oversheath test 10kV D.C for 1 minute prior to commissioning and subsequently 5kV D.C for 1 minute.

3. The maximum permitted sheath standing voltage to earth under full

load conditions shall be 65 volts.

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4. A stranded 300 sq.mm copper earth continuity conductor insulated with PVC (minimum average thickness 3.3 mm) complying with BS 6346 so far as it applies shall be provided along the whole length of each single point bonded circuit and in close proximity to the power cables, with cables laid in flat formation, the earthing cable shall be installed between two of power cables and transposed mid-way. The earthing cable shall be connected at both ends to the main substation earthing system and at suitable position to the main sheath bonds.

5. Sheath voltage limiter units (SVL’s) shall be connected to the

unearthed end(s) of the tails. The star point of the SVL's shall be connected to the earthing cable specified in (4) above.

6. All sheath bonding connections shall be made via. disconnecting link boxes so as to facilitate routine oversheath integrity testing. All bonding leads shall be PVC insulated, of conductor size 300 sq.mm copper and be made as short as possible.

7. Link boxes shall be galvanized steel with lockable lids bearing

externally the legend" DANGER - ELECTRICITY” and internally the legend “THESE LINKS MUST BE CLOSED WHEN THE CABLE IS IN SERVICE ". The insulation shall be such as to withstand an impulse test of 17.5kV from link to earth and 37.5kV between links. Link contact resistance shall not exceed 20 micro-ohms. Links and contact faces shall be tinned copper and shall be held firmly together by bolts.

The legends should be written in both Arabic and English words.

8. Inside Substations the bonding cable from the "Earthed" end of the link box shall be connected to the inner earth ring bar. The specified 300 sq.mm bonding cable shall be used to connect to the earthing system. The connection to the substation earth bar shall be by brazing a flag connector to the bar and bolting the bonding cable lug on the flag.

9. Hydraulic pipe work shall be prevented from carrying any power

system fault current by means of the installation of pipe line insulators at appropriate positions, e.g adjacent to termination. Hydraulic equipment (tanks, gauges, pipes, etc.) shall be bonded using suitable size of PVC insulated single core cable and connected to earth. The arrangement of bonding of the hydraulic system shall be submitted by the contractor for approval by the purchaser for each particular installation. Hydraulic equipment shall have purpose made flags or bosses or studs to enable proper bonding connections to be made.

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10. On termination glands there need to be earthing connection flags or bosses of sufficient size to accommodate the connection to the specified size of bonding cable.

11. On flanged joint sleeves there should be two such flags, one each side

of the flange so that the bonding cable can be connected to both sides of the sleeve without having to relay on the electrical continuity of the flange bolts.

12. The foregoing paragraphs represent summary of significant

requirements but it is expected that in case any queries arise on this topic reference would be made to internationally recognized source documents which should include the following :-

a. Electra paper No. 28, May 1973 by study Committee No. 21.

The design of specially bonded cable system (also follow up paper No. 47)

b. British Electricity Boards document C.55/2 insulated sheath

power cable systems.

c. For 33 KV Solid cable tails the sheath will be solidly bonded from both sides.

3.4.D-8 Oil Pressure Tank Pits

Oil pressure tanks shall be housed in suitable pits which shall be designed and built in accordance with the following requirements. All pits shall be provided with galvanized steel access ladders and shall be such as to prevent the ingress of rain or ground water. The size of all pits shall be such as to allow comfortable working space. These pits shall be provided with manhole cover (with locking and lifting device) of adequate size to allow the removal of any equipment that may be required. This cover to be of circular type with clear opening of minimum diameter of 60 cm. Padlocks shall be provided to manhole covers. The manhole covers shall be of ready-made cast iron. Tenderers shall submit design drawings and calculations which will be subject to the approval of the purchaser. Not more than one set of tanks shall be located in each pit (set per circuit).

3.4.D-9 Pits within Substation Boundaries

Pits for tanks shall be consisting of cast in-situ concrete floor slab minimum 15 cms thick and reinforced with suitable steel mesh, 15 cms thick in situ or precast reinforced concrete walls with fair face finish internally. Top slabs

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shall be made of precast reinforced concrete, removable strips with a maximum width of 70 cms and each to be provided with galvanized steel handles for lifting and shall be adequate to sustain super-imposed load of 250 kg/sq.M. and to be designed in a manner to stop rain water. The level of the top cover shall be 30 cms above yard level. Suitable concrete or steel bollards shall be provided around the pits, 75 cms high and spaced at one metre centres.

1. In situ concrete mix to be 1: 2: 4 with crushing strength of (Minimum)

240 kg/sq.cm. Crushing strength for precast reinforced concrete to be 320 kg/sq.cm.

2. Stability shall be required for the pit as one unit under several working conditions.

3. Pits for feeding joints ( if applicable ) shall be of similar designs to

above, except that the covers to be designed to sustain a wheel load of 10 tonnes to withstand the effect of a vehicle mounting adjacent to the pit. Top edge of walls to be at level of 10 cms above the ground level.

N.B.: For the materials suppliers, see clauses 3.7.2, P.C. Concrete supplier

and 3.7.3. Ready mix concrete supplier. 3.4.E 34 Core Pilot and Telephone Cables

These cables are required for the conveyance of alarm, control, protection, telephone and telemetry signals throughout the existing and future networks. These cables shall be of copper conductors, polythene insulated and polythene inner sheathed armoured with galvanized steel wire armour and overall sheathed with PVC. The cables shall be insulated to withstand induced voltage level up to 15 KV and should generally comply with Electricity supply industry (ESI - 09-6) standard as a minimum:

A) Make-up of Pilot Cables

i) 2 - core ( one pair ) each core shall consist of copper conductor of cross -sectional area 2.5 sq.mm polythene insulated, and the two cores twisted together and the pair shall be screened for used with Solkor protection system.

ii) 4 - core (two pairs) each core shall consist of copper conductor of

cross-sectional area 2.5 sq.mm polythene insulated, and each pair twisted and screened with copper screen for use with inter-tripping system.

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iii) Twenty eight cores (14 pairs) each core shall consist of copper

conductor of cross sectional area 0.635 sq.mm unscreened and polythene insulated. Each pair shall be separately twisted for use with telephony and telemetry system.

B) Conductor

The conductors shall comply with B.S. 6360 in so far as applicable for plain annealed copper wires.

C) Insulation

The cores shall be insulated with polythene of type ( 03 ) compound in accordance with B.S. 6234 / 69. The thickness of insulation shall not be less than 0.8 mm.

D) Inner Sheath (Bedding) The inner sheath around the liad up 17 pairs shall consist of an

extruded covering of black polythene which shall be type (03C) compound in accordance with B.S. 6234. / 1969. The thickness of inner sheath shall not be less than 1. 8 mm.

E) The Overall Screen

A suitable overall screen made of copper around 17 pairs shall be applied over the above mentioned inner sheath.

F) Bedding

A suitable PE bedding of minimum thickness of 0.5 mm shall be applied above the overall screen.

G) Armour

The armour shall consist of one layer of galvanized steel wire complying with the requirements of B.S. 1442 (metric units) and of diameter not less than 1.6 mm.

N.B.: These cables shall be designed to withstand induced voltage level up

to 15kV. However, the above insulation and inner sheath thickness, overall screen and armour, wire diameter are minimum and may have to be increased to suit the above induced voltage level and to meet the maximum attenuation requirements specified later.

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H) Overall sheath

The overall sheath shall consist of an extruded PVC jacket. It shall be black in color and withstand without deterioration during storage and site conditions outlined above. The PVC shall comply with B.S No. 6746 / 1969 (type 9 of table 1). The thickness of PVC overall sheath shall not be less than 1.9 mm.

I) Attenuation

The maximum attenuation of the audio pairs at 1 KHz and at 10oC shall not exceed 0.77 db/1000 meters.

The nominal attenuation of the audio pairs at above conditions shall be 0.7 db / 1000 meters. The measured attenuation shall be corrected by multiplying the value obtained by (1 + .002) (T + .10) where T is temperature of the cable in oC.

J) Cross - talk Cross-talk between all pairs shall not be worse than 74 db at 1300 Hz. K) Impedance Nominal impedance at 1 KHz shall be 490 ohms. L) Method of twining and laying-up

The lengths of lay of conductors forming pairs shall differ for adjacent pairs and shall not exceed 150 mm. The lengths of the lay of the pairs shall be chosen that cross-talk is as small as possible.

The direction of lay of successive layers is at the discretion of the manufacturer.

M) Identification of cores The cores shall be clearly identified by colours. The following scheme of identification shall be used: Blue / White : For Solkor Yellow / White : Inter-tripping and inter locking Green / White : Brown / White : Slate / White : Blue / White / White : ` Blue / Yellow / White : Blue / Green / White :

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Blue / Brown / White : Blue / Slate / White : Telephony & telemetry Yellow / White / White : Yellow / Brown / White : Yellow / Slate / White : Green/ White / white : Green / Brown / White : Green / Slate / White : Alternatively, the following scheme of identifications can be offered: For Solkor : Blue / white For Inter-Tripping : Red / Yellow, Green / Brown For Telemetry and telephony : Black/Violet, Red/Yellow Green / Brown - Alternative Concluding Blue / White. 3.4.F Fiber Optic Cables General

Fiber optic cable shall be manufactured and supplied from one of the following approved suppliers:

1) Prysmian 2) Viscas 3) Corning

4) Taihan Electric Wire 3.4.F.1 48 Fiber Cores

1. Performance requirements Fiber optic cable shall be designed to withstand all prevailing environmental conditions (operating temperature up to 85 °C) including the effects of high electric and magnetic fields produced by the proximity of live power conductors. A service life of at least 30 years is required, and test evidence to support Manufacturer’s claim in this respect shall be submitted with the Tender. In addition, the Tenderer shall provide full details of the method of support and installation procedures, including the jointing and splicing techniques emphasized. Fiber optic cable shall be designed to use non-zero dispersion-shifted single-mode optical fiber complying with ITU-T G.655 recommendation. The optical cable shall contain 48 fiber cores.

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Fiber Attributes

Attribute Detail Value Mode Field Core diameter Wavelength 1550 nm

Range of nominal values 9.2 – 9.6 µm Tolerance + 0.5µm

Cladding diameter Nominal 125 µm Tolerance + 1µm

Core Concentricity error Maximum 0.8 µm Cladding non-circularity Maximum 2% Cable Cut off Wavelength Maximum 1450 nm Macrobend loss Radius 30mm

Number of turns 100 Maximum at 1625 nm 0.05

Proof Stress Minimum 0.69 GPa Chromatic dispersion coefficient (ps/nm.km)

Minimum and maximum wavelength

According to G655

Dmin Dmax Sign Dmax - Dmin

Cable Attributes:

Attribute Detail Value

Attenuation coefficient Maximum at 1550 nm 0.22 dB/Km Maximum at 1625 nm 0.25 dB/Km

PMD coefficient M According to G655 Q Maximum PMDQ

Fiber Attenuation Variation of fibber attenuation at different temperature profiles shall be provided.

2. Ends of the Optical Fibers Cable After factory acceptance tests, the inner ends of the cable shall be fitted with a suitable cap to ensure water tightness, the outer end shall be fitted with a watertight head compatible with cable pulling. Caps (material and implementation) shall comply with the applicable standards.

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3. Junction Boxes and Splices

Junction boxes shall be provided to protect splices from all construction and working stresses likely to deteriorate their characteristics. They shall be installed on a suitable metallic structure at hand and conform to the relevant standards applicable. During mounting and installation as well as throughout the full life of the communication link, the junction box shall be subjected to various climatic and mechanical stresses, namely: - Stresses related to mounting and installation: - Tensile stress applied to the box by the optical cable coming from the top

of the tower. - Mechanical shocks - Stress occurring during operation: - Mechanical stresses due to elongation (or contractions) of optical central

support during temperature and mechanical load variations to which the OPGW, UGOP is subjected.

- Wind provoked vibrations. - Temperature effects and variations on box. - Variation of relative humidity and effects of industrial and slat pollution. - Mechanical shocks.

a) The Junction box shall be designed for: - Ensuring continuity of optical core sheath water tightness at junction box. - Ensuring attachment in the box of all the components (core, tube, etc.)

except the optical fibers. - Guaranteeing that the mechanical and climatic stresses likely to be induced

on the fibers and fiber splices within the box during mounting, installation and working life do not lead to a high risk of breaking during the minimum expected working life of the communication link.

- Guaranteeing that the properties of all the materials making up the

junction box shall not change during the life time (in particular no problem

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of incompatibility) likely to result in an appreciable risk of failure during the expected working life of the communication link.

Junction box technology shall enable.

- Cables entering only through the bottom thereof. - Rapid disassembly of box cover giving access to fiber splices. - Repair of fiber splicing at least (5) times during transmission line working

life.

b) Splices The same standard way of splicing shall be implemented on the whole network. The Tenderer shall submit a description of the tools and instruments needed to make the splices as well as the method to be used. Type test certificates shall be submitted to show evidence that the following procedures of quality control have been applied.

4. Cable Construction The optical fiber cable shall be of a loose tube construction suitable for installation in underground ducts. The cable must be armoured, robust and have extremely good strain relief characteristics. The fiber is to be helically wound and overfed into polymer tubes in such a way as to allow maximum flexibility in bending and stretching the cable. To avoid problems with induced voltages, the cable shall have a non-metallic strength member. The Tenderer shall provide details of the materials offered.

The interstices of the cable shall be filled with a suitable water blocking compound and the Tenderer shall provide details of the armoring and filling material. In addition, it is desirable that the cable be provided with a non-metallic laminate to prevent the ingress of moisture. The cable shall be armored and outer sheath shall be black PE. The cable shall withstand induced voltages up to 15kV.

5. Optical Fibers The fibers shall be entirely suitable for jointing by means of automatic fusion splicing technique. Fibers shall be able to withstand high temperature rise due to maximum fault current of the power circuits.

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Fiber Material The fiber shall be manufactured from high grade silica and doped as necessary to provide the required transmission performance. The chemical composition of the fiber shall be specifically designed to minimize the effect of hydrogen on the transmission properties. Fiber Coating The primary coating shall consist of an inert material which can be readily removed for jointing purposes without damage to the fibber and without necessitating the use of hazardous chemicals. A secondary coating may be applied directly over the primary coating or alternatively a loose jacket may be provided. Where a tight fitting secondary coating is provided it shall consist of an inert material. The secondary coating of loose tube shall be colour coded throughout the length of the cable. If not part of the material of the secondary coating the colour coding shall be fast and capable of withstanding normal handling during termination. The fiber coating shall be translucent such that fiber splicing techniques, using optical alignment of cores by means of injection and detection of light through the cladding, shall be supported. In addition, the fiber coating shall be optically matched to the cladding to promote cladding more stripping. The composition of the cable shall be specifically designed to reduce the production of hydrogen gas and to prevent the migration of hydrogen and water into the fiber.

6. Fiber Insulation Colors Color coding system shall be used to mark the fibers. The thickness and chemical properties and color coding of the fibber insulation shall be provided.

7. Mechanical Properties The design of the cable shall be such that it performance will not be unduly degraded when operating under normal environmental conditions over a period of time. The Tenderer shall state the expected lifetime of the cable and indicate the degree of degradation expected as a result of ageing. The Tenderer shall indicate the maximum cable drum length. It is expected that the cable will be installed in lengths of up to 2,000m. Exact lengths will be provided following completion of detailed route survey. Tenderers

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should provide size and weight of drums for 2,000m lengths. Standards and guidelines for pulling the cable offered should be provided as part of the Tender. The following information shall be provided: Crush strength, maximum pulling force during installation, minimum bending radius in pulling, final installation and method of paying out the optical underground cable.

8. External Identification The PE oversheath shall be embossed in English along two lines equally spaced around the circumference of the cable with the name of the manufacturer, year of manufacture, cable type, FOC every meter. The PE oversheath shall also be embossed on the circumference of the cable indication cumulative marking length of the cable wound on the drum. The marking starting with “0000” on the inner end of the cable shall indicate in integer actual length of the cable on the drum.

9. Joints All fiber joints shall be of the fusion type, except where demountable connectors are specified. Fusion splicing shall be carried out by trained personnel using automatic fusion splicing equipment designed for the fiber type. Fiber ends shall be prepared for splicing using methods and tools recommended by the fibber and splicing equipment manufacturers. The cleanliness and accurate cleaving of fiber ends shall be ensured prior to splicing. Splices shall be mechanically strengthened and protected from the environment by means of purpose designed splice sleeves or enclosures. The finished splice shall be supported within the buried splice box by means of suitable clips or restraints. It shall be possible to remove and replace the splice in the support device without risk of damage to the splice or fiber. The cable splice box shall be buried and contain in water and heat-proof enclosures. Each fusion splice shall have a spare length of fiber on either side of approximately 1 meter associated with it. This excess fiber shall be coiled neatly and clipped (or otherwise retained) within the splice box. Tenderers shall provide full details of the joint box including design and construction details, indicating how the unit is sealed and how the fiber splices and fibber slack are arranged. The cables used to interconnect modules, equipment shelves and distribution frames shall be fitted with specialized connectors at each end of the cable.

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10. Fiber Optic Installation:

The fiber optic associated with power cable will be installed in UPVC ducts of adequate size along the route; the cost of supply of these UPVC ducts is to be included in the cost of installation of the fiber optic cables.

A) Site Test

Site tests shall be carried out on the complete fiber optic cable to show that the guaranteed performance figures are achieved and the UGOP comply with the requirements of this Specification and guarantee stated in the appendices. Transmission characteristics of the optical fiber shall be measured. The main tests shall be: - End to end optical power loss. - The characteristics of every optical fiber through an optical time domain

reflectometer (OTDR) in the best window (1550nm & 1625nm) monitoring of the evolution of splices and connectors.

B) Type Test

Type test certificates for the UGOP cable must be produced by the tenderer in order to prove the performances of the cable in the following aspects:

- Optical characteristics including fiber attenuation, chromatic dispersion, mode field diameter ( according to IEC 60793-1) – spot size of the fundamental mode and Cut-off wavelength ( according to IEC 60793-1) – wavelength above which the fiber allows single mode propagation

- Cable tests (IEC 60794, IEEE 1138) - Fiber Excess length (FEL) ( ratio between fiber length and cable length) - Crush test. - Impact test. - Tensile strain and stress - DC resistance - Weight - Admissible fault current (kA2s)(short circuit test). - Temperature and temperature cycling. - Water ingress - Aeolian vibration - Galloping - Sheave.

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C) Factory Test

The cable shall undergo factory testing in a systematic manner and by sampling depending upon the nature of the tests. The contractor shall submit its test procedure for the cables for the employer’s approval. These tests shall include (but are not limited to) the following:

- Optical Characteristics including fiber attenuation for each cable drum and

chromatic dispersion for each drum - Cable diameter and geometry - Tensile strength and elongation break - DC conductivity - Torsion

3.4.G Cable Cover Tiles

1. All the materials used for making the cable cover tiles shall be to the latest relevant Kuwait Standards or BSS and samples of each kind of materials has to be submitted to the engineer for testing and approval prior to starting of casting. All rejected material has to be removed from the site of work. The sizes of cable cover tiles will be as per attached drawing No. MD/1/560.

2. Cracked, chipped and/or damaged tiles, markers shall not be accepted

and the tenderer shall include in his tender price an allowance for wastage and damages of tiles, etc. Rejected materials must be replaced at the contractor's cost and the damaged tiles etc. shall be transported to dump and disposed off by the contractor.

3.4.H Warning Tapes and Cable Protection Net

Warning tape and protection net shall be supplied from one of the approved manufacturers. Any new proposed Manufacturers shall provide all information about their product for MEW study and qualification. MEW has the right to approve or reject such approval requests. Warning tapes and protection net are available via the approved companies.

1. Warning tapes

The warning tapes shall be of yellow colored, for 132kV cable and orange color for 33kV cables, Made from Polypropylene UV Stabilized Woven fabric with Printed BOPP Tape laminated - made by Extrusion lamination.

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The tape should not be less than 15 cms width and 0.5 mm thickness. This warning tape should be labeled in capital letters “Danger High Voltage 132kV Cable” in both English and Arabic languages. The size of the letters should not be less than 4 cms in length and the letters should be printed in black color. A sample of this tape should be submitted with the offer and will be subject to MEW approval.

2. Cable Protection Net The Cable protection net shall be of high density polyethylene suitable for site conditions mentioned under clause 3.3 of this specification. (Yellow color for 132kV & orange color for 33kV).

The Protection net shall be of 70 cms width for 400 kV, 60 cms width, for 132kV and 40 cms width for 33kV cable for single circuit and for double circuits two protection nets shall be used. The thickness of this protection net should not be less than 3mms.

3.5 Design and Standardization

The contract works shall be designed to give continuous trouble free and satisfactory service under the rigorous conditions encountered in Kuwait. The continuity of supply is the prime consideration and the design shall ensure satisfactory operation. All corresponding parts of apparatus under this contact shall be made to gauge and shall be wherever possible, interchangeable in order to reduce the stocks of spares to minimum.

Where a specification or publication has been issued by the British Standard Institute or the International Electro-Technical Commission (IEC) dealing with any apparatus, equipment or material forming any part of this contract, such apparatus equipment and material shall be in accordance with the latest relevant specifications of publication unless otherwise herein agreed in writing by the purchaser (see clause 3:17 standard specification).

3.6 Progress, Inspection and Tests

The contractor shall within one month of the award of the contract submit a programmed chart and shall subsequently submit monthly progress reports on the manufacturer, shipping and installation of the contract works.

All material and equipments shall be subject to inspection by an inspector

appointed by the Purchaser during manufacture at the maker's works. The contractor shall provide all materials and equipment and shall carry out all tests in accordance with clauses 3.16 Tests of this specification.

The contractor shall carry out tests that the inspector may deem necessary to

ascertain that the materials or equipment complies with the requirements of this specification. The cost of the inspector only shall be to the Purchaser’s

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account. All other costs of materials, equipment and testing shall be to the contractor's account.

Fourteen days notice of readiness for tests at the factory shall be given by the contractor to the inspector. All tests shall be carried out to the satisfaction of the inspector and at such times as he may reasonably require.

No inspection or passing by the Purchaser and/or his inspector of works, plant or material, whether carried out or supplied by the contractor, shall relieve the contractor from his liability to complete the contract or exonerate him from any of his guarantees.

3.7 Sub-contracting 3. 7. 1 Sub-contractor

Sub-contracting will only be permitted for secondary items of the contract. The contractor shall indicate in the schedules, the names of the sub-contractors and the items to be subcontracted.

The contractor will be responsible for the materials and equipment supplied by the sub-contractors and shall ensure that orders are placed and deliveries obtained in good time so as not to delay the contract works due to all the deliveries by the sub-contractors.

The sub-contractor shall be responsible to the main contractor and this shall be bound by all conditions and terms of this contract.

3.7.2 P.C. Concrete Supplier

Precast reinforced concrete elements shall be manufactured and supplied by one of the following companies approved by the Ministry of Commerce and Industry.

1. M/S. Kuwait Precast Building Co. 2. M/S. Real Estate Industrial Co. 3. M/s. United Building Co. 4. M/S. Kuwait Precast System Co. 5. M/S. Al Rabiah International contracting Co. 6. M/S. Real Estate Construction & Fabrication Co. 7. M/S. National Industries Factory.

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3.7.3 Ready Mix Concrete Suppliers

When ready mix concrete is used, this shall be supplied by supplier licensed by the Ministry of Finance. Therefore, the successful tenderer is required to submit the name of his approved supplier of the ready mix concrete to MEW for approval. 1. National Industries Company for Building Materials (K.S.C) 2. Kuwait British Ready Mix WLL 3. The Kuwait Company for Process Plant Construction & Contracting K.S.C

(KUPC) 4. Future Company 5. National Construction Real Estate 6. Al-Ahmadiah Contracting & Trading Company 7. AlMahaliya Ready Mix Concrete Co. 8. Kuwait United Pre Cast System Company (KUPS) 9. Al enma`a Real Estate Company 10. Gulf Ready Mix Concrete 11. Al ESSA Ready Mix Concrete Company 12. Al Muthahedoon Ready Mix Est 13. Al Mubarakia Ready Mix Company 14. Kuwait Austria General Trading Cont. Co. 15. Bubiyan Ready Mix Co. W.L.L.

3.8 Packing Delivery of Cables and Accessories

Tenderers are warned that the equipment is liable to very rough handling enrooted from the factory to the site in Kuwait. It is essential that the packing is efficient and strong with extra reinforcement where necessary to ensure the safe delivery to site. All packages shall have the Purchaser's name, shipping marks and manufacturer's identification marks clearly indicated. Factory measured oil pressure shall be recorded on the drum together with temperature at which measurements were made. The cable on the drums shall be provided with the necessary pressure tanks and gauges to keep the oil pressure inside the cables.

3.8.1. Cables

The finished cables shall be wound on strong cable steel drums. And provided with central core through which an axle can pass. The drums shall be provided with wooded battens to protect the cable from damage. The drums shall be adequately labeled to indicate particulars of cable i.e.

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voltage, length, conductor size, number of cores, gross and net weights, etc. The direction for rolling shall be indicated by an arrow. For oil filled cables the factory measured oil pressure shall be recorded on the drum together with temperatures at which measurements were made, the cable on the drum shall be provided with the necessary pressure tanks and gauges to keep the oil pressure inside the cables. The drum lengths of each type of cable shall be proportioned to ensure that minimum number of joints is needed and that wastage is reduced to a minimum. The contractor shall arrange for disposal of all the empty drums and packing materials. The drum length of co-axial cables shall not be less than 1 KM unless otherwise stated in detailed scope of work.

3.8.2 Accessories

All necessary materials including consumable material for each joint or termination shall be packed as complete units and marked accordingly. Each such package to include within it an itemized packing list detailing part number, description and quantity enclosed. A copy of the relevant jointing / terminating instruction and all necessary drawings shall also be included in each package.

Any shortage of material, as notified to the contractor, shall be immediately made good at the Contractor's expense including any necessary air freight charges where required.

3.8.3 Staff, Installation Requirements, Jointing and Termination 3.8.3 a) Staff for the main Contractor

The cables joints and terminations shall be supplied from one of the approved cable manufacturing list or from the accessories manufacturer qualified with the cable contractor qualification. Furthermore, the main contractor shall hold full responsibility for the guarantee of the joints and terminations supplied and installed by him in the contract. The manufacturer shall employ on this contract fully qualified and experienced personnel who have been in his employment continuously for the last five years and who have had previous experience on comparable installation and this shall cover the supervision, erection and test engineer and sufficient number of jointers as a minimum. These staff should be allocated for this project only and shall not leave Kuwait without prior written approval of MEW. The installation of the cables and accessories shall be the responsibility of the main contractor as part of his contract. No member of main contractor's staff employed on the installation works shall be changed without prior written approval of the Purchaser. In addition to the above staff, the contractor shall employ as a minimum, one civil engineer and one supervisor.

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3.8.3. b) Subcontractor for Cable Civil Works

The Tenderer should fill schedule “C” giving at least four (4) names for his sub-contractors from MEW approved subcontractors list and this will be subject to MEW approval and MEW has the right to study any one of those names nominated by the contractor later for MEW approval without any objection from the side of the contractor (then the contractor has to nominate another name for study/approval in case of disapproval). However, the scope of sub-contractor work is limited to the following:

1. Excavation of trenches along the cable route.

2. Installation of cable cover tiles, warning tapes protection net.

3. Construction of road crossing ducts.

4. Backfilling the trenches and final reinstatement of ground.

5. Construction of joint and tank pits. (these to be constructed by a civil

subcontractor whose name will be subject to MEW approval) It is to be noted that all works related to cable laying jointing and terminations are not part of the sub-contractor works and this will be done only by the staff f of the main contractor.

The main contractor is responsible for all works executed by his Sub-contractor. Moreover, the tenderer should guarantee that these sub-contractors are capable of executing the works (1- 5) mentioned above. The Successful Contractor should submit the name of his Cable Civil Sub-Contractors not before six months from signing the contract and not later than three months before commencement of actual works at site.

3.8.3. c) General Installation Requirements

The cables shall be laid along the routes and in the locations indicated on the attached drawings. The Engineer shall have the right to alter the cable routes and locations where it is considered necessary to avoid obstructions or to suit finalized routes, locations or proposed circuits and existing cables and other services, all at no extra cost.

The purchaser will supply at the commencement of the contract, site works, sets of drawings showing the finalized routes, locations of proposed circuits and existing cables and other services. Before starting on site, the contractor shall be responsible for obtaining from the purchaser, the exact approved routes and locations and the permit to open the ground.

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The contractor shall take all necessary precautions to prevent damage to existing services and electric cables. The contractor shall be liable to meet any costs for repairing any damaged caused by the executions of the contract works.

The arrangement of cables, method of laying and installation shall be approved by the purchaser. Cables shall be laid in trefoil formations and sheaths will be single point bonding for O/H line cable tails, and solidly bonded for cable circuits.

Installation radii should be as large as possible and the minimum shall be 30 D along the routes and 15 D adjacent to terminations with former and 20 D without former ( D is the overall diameter of the cable ) and provided that cable can be bent safety for these radii.

Suitable pulling eyes shall be fitted to the cables leaving the factory to be used when drawing cables in ducts.

The contractor shall supply and install all labels for the cables, properly numbered and located and subject to the approval of the engineer. All power, pilot and coaxial cables shall be identified at approved positions by means of bands, which shall be engraved with the name of the circuit, size of cable or cores and also phase colour of power cables, number of feeder circuits. The bands shall be made of materials resistant to corrosion.

3.8.3. d) Excavation

Where power cables are laid direct in the ground, they shall be generally at a depth of 1.5 meters below the kerbstone level. The width of the trench for 132kV cables, single circuit shall be 60 cms and that for a double circuit either in one trench of 120 cms or two trenches each of 60 cms width as instructed by the Engineer. Also the 33kV cables are laid direct in the ground. The 33kV cable trenches shall be excavated to 1.5 meters depth measured from kerbstone level and the cables shall be laid generally at a depth of 1.4 meters measured from the kerbstone level to the lowest point of 33kV power cable surfaces. The width of the trench for a single circuit shall be 60 cm and that for a double circuit either one trench of 120 cms or two trenches of each 60 cms width as instructed later by the Engineer and the trenches shall be excavated, exactly in accordance with the relevant drawings and cross sections. Where triple circuit is called for, the cables can be laid in separate trenches or in trench of at least 1.8 meters wide.

The coaxial cable shall be laid in separate trench at a depth of 1 metre and cable cover tiles, protective grid of 40 cm width, and warning tapes to be laid as shown on drawing No. MDA /1/498 sheet 2. However, inside the substation area, each circuit may have to be laid in a separate trench to suit

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the substation layout. Where the trenches run parallel to existing services, the contractor shall maintain a distance of atleast 45 cms between the existing services and the edges of the new trenches. The contractor shall cross existing services with utmost care and shall ensure that the cables are adequately protected, in this respect he may consult the engineer and obtain his written approval concerning the method of crossing the existing services.

Excavation for road crossings shall be carried out only on one half of the carriage way at any one time. When asphalt surfaces are broken, the contractors shall be responsible for topping and maintenance of the temporary surfaces, the actual reinstatement of the final surfaces. However will be carried out by the Ministry of Public Works at the Purchaser’s expense.

The quoted prices and rates shall cover excavations in ground or soil of any nature and no claims for any abnormalities will be considered.

Excavation in paved sidewalks shall be carried out with special care. When taking off paving slabs, the contractor shall take necessary precautions to avoid breakage and to stack them and store then in such a way as to avoid their breakage and discoloration by other uses.

3.8.3. e) Backfilling

After the cables are laid, the contractor shall backfill the trenches in stages (according to the steps mentioned under clause 3.9.2 below) with selected soil, ram it well using a power ram, consolidate the backfilling and carefully reinstated all to the satisfaction of the Engineer.

The contractor shall be responsible for public safety and hence shall provide picket fences or ropes along the route of open trenches and danger notices, barrier and red warning lights at road crossing. During the hours of darkness, an adequate number of danger lights shall be provided where required and a watch man shall be provided for every 500 meters of open trench. Furthermore the attached “special conditions for works of Public Services” (in Arabic Text) forms part of this specification. The contractor and/or his subcontractor shall adhere to these conditions and regulations. Details of safety rules will be submitted by the contractor before starting the work and this will be subject to MEW approval.

3.9. Installation, Jointing and Terminations General

The cables joints and terminations shall be supplied from one of the approved cable manufacturing list or from the accessories manufacturer

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qualified with the cable contractor qualification. Furthermore, the main contractor shall hold full responsibility for the guarantee of the joints and terminations supplied and installed by him in the contract. The manufacturer shall employ on this contract fully qualified and experienced personnel who have been in his employment continuously for the last five years and who have had previous experience on comparable installation and this shall cover the supervision, oil and test engineer and sufficient number of jointers as a minimum. These staff should be allocated for this project only and shall not leave Kuwait without prior written approval of MEW. The installation of the cables and accessories shall be the responsibility of the main contractor as part of his contract. No member of main contractor's staff employed on the installation works shall be changed without prior written approval of the Purchaser. In addition to the above staff, the contractor shall employ as a minimum, one civil engineer and one supervisor.

However, the scope of subcontractor's works is only excavation, backfilling of trenches, reinstate of ground and construction of joints pits and other civil works. The tenderer should fill schedule "C" giving at least four names for his sub-contractors and this will be subject to MEW approval. Moreover, the tenderer should guarantee that these sub-contractors are capable of executing the works called in this specification (Man-power and equipment)

The cables shall be laid along the routes and in the locations indicated on the attached drawings. The Engineer shall have the right to alter the cable routes and locations where it is considered necessary to avoid obstructions or to suit finalized routes, locations or proposed circuits and existing cables and other services, all at no extra cost.

The purchaser will supply at the commencement of the contract, site works, sets of drawings showing the finalized routes, locations of proposed circuits and existing cables and other services.

Before starting on site, the contractor shall be responsible for obtaining from the purchaser, the exact approved routes and locations and the permit to open the ground.

The contractor shall take all necessary precautions to prevent damage to existing services and electric cables. The contractor shall be liable to meet any costs for repairing any damaged caused by the executions of the contract works.

The arrangement of cables, method of laying and installation shall be approved by the purchaser. Cables shall be laid in tre-foil formations and sheaths will be single point bonding for O/H line cable tails, and solidly bonded for cable circuits.

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Installation radii should be as large as possible and the minimum shall be 30 D along the routes and 15 D adjacent to terminations with former and 20 D without former (D is the overall diameter of the cable) and provided that cable can be bent safety for these radii.

Suitable pulling eyes shall be fitted to the cables leaving the factory to be used when drawing cables in ducts.

The contractor shall supply and install all labels for the cables, properly numbered and locate and subject to the approval of the engineer. All power, pilot and coaxial cables shall be identified at approved positions by means of bands, which shall be engraved with the name of the circuit, size of cable or cores and also phase color of power cables, number of feeder circuits. The bands shall be made of materials resistant to corrosion.

3.9.1. Excavation and Backfilling

Where power cables are laid direct in the ground, they shall be generally at a depth of 1.5 meters below the kerbstone level. The width of the trench for 132kV cables, single circuit shall be 60 cms and that for a double circuit either in one trench of 120 cms or two trenches each of 60 cms width as instructed by the Engineer.

Also the 33kV cables are laid direct in the ground. The 33kV cable trenches shall be excavated to 1.5 meters depth measured from kerbstone level and the cables shall be laid generally at a depth of 1.4 meters measured from the kerbstone level to the lowest point of 33kV power cable surfaces. The width of the trench for a single circuit shall be 60 cm and that for a double circuit either one trench of 120 cms or two trenches of each 60cms width as instructed later by the Engineer and the trenches shall be excavated, exactly in accordance with the relevant drawings and cross sections. Where triple circuit is called for, the cables can be laid in separate trenches or in trench of at least 1.8 meters wide. The fiber optic cable shall be laid in UPVC duct along the route and where fiber optic cable laid separately this will be trench shall be laid in separate trench at a depth of 1 meter and cable cover tiles, protective grid of 40 cm width, and warning tapes to be laid as shown on drawing No. MDA /1/498 sheet 2.

However, inside the substation area, each circuit may have to be laid in a separate trench to suit the substation layout. Where the trenches run parallel to existing services, the contractor shall maintain a distance of at least 45 cms between the existing services and the edges of the new trenches. The contractor shall cross existing services with utmost care and shall ensure that the cables are adequately protected, in this respect he may consult the engineer and obtain his written approval concerning the method of crossing the existing services.

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Excavation for road crossings shall be carried out only on one half of the carriage way at any one time. When asphalt surfaces are broken, the contractors shall be responsible for topping and maintenance of the temporary surfaces, The actual reinstatement of the final surfaces. However will be carried out by the Ministry of Public Works at the Purchaser's expense. The quoted prices and rates shall cover excavations in ground or soil of any nature and no claims for any abnormalities will be considered.

Excavation in paved sidewalks shall be carried out with special care. When taking off paving slabs, the contractor shall take necessary precautions to avoid breakage and to stack them and store then in such a way as to avoid their breakage and discoloration by other uses.

After the cables are laid, the contractor shall backfill the trenches in stages (according to the steps mentioned under clause 3.9.2 below) with selected soil, ram it well using a power ram, consolidate the backfilling and carefully reinstated all to the satisfaction of the Engineer.

The contractor shall be responsible for public safety and hence shall provide picket fences or ropes along the route of open trenches and danger notices, barrier and red warning lights at road crossing, During the hours of darkness, an adequate number of danger lights shall be provided where required and a watch man shall be provided for every 500 meters of open trench. Furthermore, the attached "special conditions for the works of Public Services" (in Arabic text ) forms part of this specification. The contractor and/ or his sub-contractor shall adhere to these conditions and regulations. Details of safety rules will be submitted by the contractor before starting the work and this will be subject to MEW approval.

3.9.2 Cable laying and Installation

The cables will be partly buried directly in the ground and partly pulled through ducts. Cables shall be laid direct from the drums into the trenches and special rollers shall be employed for this purpose. 132kV cables shall be laid in trefoil formation. where burying directly in the ground , the contractor shall excavate trenches of 1.5 meters depths from kerbstones or final ground level provide a bedding of 10 cms of fine sieved sand at the bottom of the trench, laying of power cables and pilot and provide covering of sieved sand to a height of 15 cms over the cable. Cable cover tiles shall then be laid over the line of cable covering the power cable and pilot cable.. Each circuit shall be separately tiled.

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Backfill the trench further 30 cms of excavated material, laying of cable protection grid, further backfilling 20 cms laying of warning tapes, completion of the backfilling to the normal ground level ( see attached drawing ).No. MD/1/498. In built up areas, the Contractor shall before placing the "Warning Tapes" in the cable trench, water and well ram the backfilled trench. Also, after placing the warning tapes and final backfilling of the trench, the contractor shall water and well ram the backfilled trench and compaction should be done to 90%. For road crossing, and where spare ducts are not available, the contractor shall arrange to install the ducts in the required position. The ducts shall be laid in level concrete foundations previously prepared consolidated with concrete. The end of ducts shall protrude to a distance of 90 cms. Beyond the kerbstone. Before pulling the cables through ducts, these shall be cleared from any foreign objects and materials. Where cables are laid in concrete trenches or substation basements, they shall be neatly arranged and single cores cables shall be arranged in trefoil formation. Where cables are laid on trays or supported by cleats, they shall be neatly and symmetrically arranged. Cross-over shall be avoided; otherwise the contractor should use galvanized steel bridges for cable crossings.

3.9.3 Jointing and Terminating

The contractor shall supply all materials necessary for jointing and terminating of cables including compound , insulating tapes, paper , plumbing metal, solder, etc. of approved type and shall carry out all work necessary for proper termination of all cables installed, except the termination of coaxial cables, which will be done by others. Where ever the cables shall be terminated to SF6 switchgear, the contractor shall arrange with the switchgear manufacturer to get his written confirmation that the jointing materials to be used are suitable for the switchgear ( see clause 3.4, 6.4-2 ) Also the contractor shall arrange with the switchgear manufacturer to supervise the terminating work and to do the necessary preparation work on the switchgear, for terminating and testing the cables, the cost of all these arrangements are included in tender price. Before jointing Contractor shall be responsible for the provision, erection, installation, maintenance and removal of all equipment, plant, etc. required for the provision of a suitable environmentally controlled jointing enclosure. This shall include all frameworks, covers, environment conditioning plant, generators, etc. Where required by the Engineer this provision shall also apply to terminating works inside uncompleted stations.

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The contractor shall specify limits for climatic conditions in the jointing area such that neither the accessory assembly nor the workmanship of the jointing personnel shall be impaired. These shall include humidity levels and the precautions to be taken against the ingress of sand or dust into the jointing / terminating area. These limits and the means by which they are to be achieved will be subject to the approval of the Engineer. Power cables joints shall be water tight, free from joints or ridges and thoroughly cleaned internally. Provision shall be made for expansion of the filling medium and arrangements are to be made to prevent the formation of air packets when filling. The filling medium used in all boxes shall not have deleterious effect on the XLPE insulation used in the associated cable. Tenders shall be accommodated by detailed descriptions of method or fault detection and repair of the cables offered. A complete and detailed list of tools and equipment required for jointing, terminating and putting the cables to work shall be submitted with the offer.

3.9.4 Bonding and Earthing Requirements for 132/33kV Cables

3.9.4.1 For 132 & 33kV Cable Tail Circuits to O/H Lines A) For 132 KV Cable Tail Circuits

1. Single point bonding of the power cable lead sheaths is required to eliminate sheath circulating currents.

2. Cables and terminations shall be designed, manufactured and

installed so as to result in a fully insulated sheath and to permit the routine application of PVC over sheath test 10kV D.C. for 1 minute prior to commissioning and during the first two years of service, the anti- corrosion covering to be tested at six monthly intervals at 5kV DC for one minute.

3. The maximum permitted sheath standing voltage to earth under full

load conditions shall be 65 volts.

4. For 132kV Cables a stranded 300 sq.mm copper earth continuity conductor

insulated with PVC (minimum average thickness 3.3 mm ) complying with BS 6346 so far as it applies , shall be provided along the whole length of each single point bonded circuit and in close proximity to the power cables, with cables laid in flat formation, the earthing cable shall be installed between two of power cables and transposed mid way. The earthing cable shall be connected at both ends to the main substation earthing system and at suitable position to the main

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sheath bonds for 33kV cables the cross section of Earth continuity conductor shall be 120 sq.mm

5. Sheath voltage limiter units (SVL’s) shall be connected to the

unearthed end(s) of the tails. The star point of the SVL’s shall be connected to the earthing cable specified in (4) above.

6. All sheath bonding connections shall be made via disconnecting link

boxes so as to facilitate routine over sheath integrity testing. All bonding leads shall be PVC insulated, of conductor size 300 sq.mm. copper and be made as short as possible.

7. Link boxes shall be galvanized steel with lockable lids bearing

externally the legend 'DANGER - ELECTRICITY" and internally the legend 'THESE LINK MUST BE CLOSED WHEN THE CABLE IS IN SERVICE ". The insulation shall be such as to withstand an impulse test of 17.5kVp form link to earth and 37.5kV between links. Link contact resistance shall not exceed 20 micro-ohms. Links and contacts faces shall be tinned copper and shall be held firmly together by bolts.

The legends should be written in both Arabic and English words.

8. Inside substations the bonding cable from the "Earthy" end of the link box shall be connected to the inner earth ring bar. The specified 300 sq.mm bonding cable shall be used to connect to the substation earthing system. The connection to the substation earth bar shall be made by brazing a flag connector to the bar and bolting the bonding cable lug on to the flag.

9. On termination glands there need to be earthing connection flags or

bosses of sufficient size to accommodate the connection to the specified size of boding cable.

10. On flanged joint sleeves there should be two such flags , one on

each side of the flange s that the bonding cable can be connected to both sides of the sleeve without having to rely on the electrical continuity of the flange bolts.

11. The foregoing paragraphs represent summary of significant

requirements but it is expected that in case any queries arise on this topic reference would be made to internationally recognized source documents which would include the following:

1- Electra paper No. 28, May 1973 by Study Committee NO. 21.

The design of specially bonded cable system (also follow up paper No.47).

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2- British Electricity Boards document C 55/2 Insulated sheath power cable systems.

B) For 33kV Cable tails to O/H Lines

The sheath will be solidly bonded from both sides (at switchgear and at Out-door sealing ends).

3.9.4.2 Earthing Requirements for 132 & 33kV Complete feeder Circuits 1. Solid bonding of the power cable lead sheaths is required. The overall design

shall be such as to permit the routine application of PVC over sheath tests (10kV) DC for 1 minute prior to commissioning and during the first two years of service, (5kV) DC of 1 minute .

2. At terminations and trifurcating joints the lead sheaths of the three single

core cables forming one circuit shall be connected to earth using insulated bonding cables ( see 3, below ) and via 3 - phase link boxes ( Sec 5, below )

3. Bonding cables for power cable sheaths shall in all cases be of single core,

300 mm2 stranded copper, PVC insulated construction. This size of cable shall be used regardless as to the anticipated magnitude of fault current at any particular point in the network. The insulation thickness shall be 3.3 mm. minimum averages. The cable shall be embossed with the wording “ELECTRIC CABLE” - BONDING LEAD “and the outer surface of the PVC shall be graphite coated. The construction of the cable shall be in accordance with B.S. 6346 in so far as it applies. The insulation shall be spark tested at 25kV D.C. for 1 minute.

4. Link boxes shall be galvanized steel with lockable lids bearing externally the

legend “DANGER - ELECTRICITY” and internally the legend “THESE LINKS MUST BE CLOSED WHEN THE CABLE IS IN SERVICE". The insulation shall be such as to withstand an impulse test of 17.5kVP from link to earth and 37.5kVp between links. Link contact resistance shall not exceed 20 micro-ohms. Links and contact faces shall be tinned copper and shall be held firmly together by bolts.

The legends should be written in both Arabic and English words. 5. Inside sub-stations the bonding cable from the “Earthed" end of the link box

shall be connected to the inner earth ring bar. At joint bays the bonding cable shall be connected to 4 earth rods each 1.25 M. long driven in at the corners of the bay. In all cases the specified 300 sq.mm. bonding cable shall be used to connect to the earthing system. The connection to the sub-station earth bar shall be by brazing a flag connector to the bar and bolting the bonding cable lug on to the flag.

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6. Where a Contractor is required to install 132kV feeder tails out of a sub-station (for future connection to the network) then the relevant parts of the foregoing specification shall apply in the same manner as though the cables were about to be energized as a completed feeder. Regarding the cap ends on tails whilst they may be left unbounded they shall, nevertheless, be insulated so as to permit the application for PVC over sheath tests.

7. On joint sleeves and termination glands there need to be earthing connection

flags or bosses of sufficient size to accommodate the connection to the specified size of bonding cable.

8. On flanged joint sleeves there should be two such flags, one on each side of

the flange so that the bonding cable can be connected to both sides of the sleeve without having to relay on the electrical continuity of the flange bolts.

3.9.5 132 & 33 KV Joint Pits

Pits for straight joints or trifurcating joints shall consist of pre-fabricated elements or steel mesh reinforced concrete base slabs minimum 15 cm. thick, concrete block walls and 30 cms. deep top R.C. beams the size of all pits shall be such as to allow comfortable working space for jointers. The joint shall be protected using fiber glass sleeve and the space between the outer joint sleeve and the fiber glass sleeve shall be filled with bitumen. The joint shall be supported over its entire length and also the cable from where it leaves the trench to enter into joint box. The complete joints shall be surrounded by sieve sand carefully compacted by hand to a depth of 10 cms. above the top of the fiber glass sleeve. Precast paving slabs shall be placed on top of the pit and backfilled with selected sand up to ground level. Suitable markers post (minimum 2) shall be positioned 20 cms above the surface. The whole arrangement shall be subjected to MEW approval. Where sheath bonding link boxes are required, they shall be installed in a shallow pit adjacent to the straight joint pit and accessible from the surface.

Tenderers shall submit design drawings and calculations which will be subject to MEW approval. Not more than one set of joints shall be located in each pit (set per circuit). Also it will not be permitted to pass more than the cables of one circuit inside the pit, and thus if two circuits were specified, the cables of the second circuit will pass under the pit in concrete encased asbestos ducts to be constructed under the pit. The cost of this duct is included in the pit price. The cover of the manhole shall consist of locking and lifting device.

3.10 Cables Schedule and Records

The contractor shall supply three sets of standard 35 mm silver halide micro film aperture cards made from as fitting or as built original drawings. The front face of these aperture cards should be left blank for MEW drawing

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office use on the reverse face of the card, following details should be shown by the contractor :-

Specimen Microfil Aperture Card ______________________________________________

Contractor Contract No.

Title of ProjectTitle of DrawingsDrawing No.Reduction Ra tioDa te :

______________________________________________ The contractor has to specify the year of the contract against the contract No. date when the microfilms were made is also to be shown against the word date on the aperture card. A sample of processed microfilm aperture card to be submitted to the Ministry for approval. The records shall be carefully taken on site during the installation of the works. The final presentation of the records and schedules shall be approved by the purchaser. The records shall show the routes, the exact locations of each cable, the date of the jointing , the name of jointer, the serial number of the cable drums, the direction of the lay of the cable, i.e A and Z ends , soil conditions, positions and ducts and sectional inserts of the cable trench giving the relative positions of the cables, tiles , depths and spacings. All as-built drawing shall be submitted on 6 CD’s and 6 flash memories having the maximum capacity as directed by MEW engineers. Price of the same shall be considered as included in the tender prices. The as build record and coordination shall be suitable to be implemented in the GIS system. Any other services that cross the route of the cable shall be recorded. Measured values of resistance and capacitance shall be recorded for each length of cable between terminations. 3.11 Installation and Maintenance Equipment 1 - The contractor shall supply all tools, haulage and lifting equipment and

transport required for the installation of the various circuits. The contractor shall supply all testing and commissioning equipment for the contract works. An itemized list of equipment supplied shall be entered in schedule H.

3.12. Storage, Site Work and Labour The contractor will provide the necessary suitable space provided with arrangement for storage of the cable drums and accessories and he shall be strictly responsible for

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the cables and accessories and shall arrange for a watchman where he thinks is necessary. The contractor shall make his own arrangement for the storage of jointing materials and accessories. The contractor shall be responsible for arranging the work on site with such limited materials and tools as may be necessary to enable him to execute the contract works. He shall also be responsible for keeping the site reasonable clean and for removing all waste materials as it accumulated and as directed by the Engineer. The contract price shall cover the cost of all labour i.e foreign skilled, local skilled and unskilled. All personnel to be employed in this contract shall be subject to the approval of the purchaser. The contractor shall arrange, at his own expenses for accommodation, messing, transport, etc. for the personnel employed on this contract. The contractor shall abide by all local regulations that may be in force with regard to conditions of employment of Kuwait. The contractor should provide carriage facilities four nos. for the Ministry representative engs. from the ministry office to the site works starting within one month from the date of signing the contract up to the date of issuing the taking over certificate of the last time. Casting shall not be carried out if the contractor fails to provide such requirements. gas, periodic service and full insurance shall be contractor’s responsibility. Communication services are also contractor responsibility to be provided to the contract engineers. Details shall be discussed after signing the contract The tenderer shall quote the estimated time required to complete the installation of the works, giving details of the number and grades of personnel to be employed. Full details shall be given in Schedule "G of the number and costs per month of personnel. These costs shall include accommodation, messing, salaries, allowances, local transport, etc. Return travelling expenses to and from Kuwait of personnel recruited abroad shall be shown separately. The contractor shall submit a list showing the number and grades of labour to be employed on this contract, and shall maintain a labour force of such size to adequately complete the contract works within the specified completion, testing and handing over periods. 3.13. Drawings, Maintenance Instructions and Information All tenderers shall be accompanied by such drawings and descriptive literature as are necessary and details of terminations and technical data of the components used in each termination to fully describe the equipment offered and to assist the purchaser

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to assess the merits of the offer. Details of drawings to be submitted with offer are given in schedule "A". The contractor shall supply four hard copy sets of drawings as finally approved for all the equipment supplied and four complete and detailed sets of maintenance instructions manuals to facilitate maintenance and operation of the contract works. In addition to that two sets of the same should be submitted on computer CD discs. These sets of instructions manuals shall include details of termination instructions, drawings, manuals, etc. all of which shall be in English language. Furthermore, 3 sets of standard 35 mm microfilm aperture cards, photographed from the approved cable record drawings must be also supplied. See clause 3.10 above. 3.14. Dates of completion and Progress Reports a) Each tenderer shall fill in the schedule giving the number of weeks or

calendar months needed after the date of signing the contract for delivery F.O.B. commencement of installation and completion of testing and ready for commissioning of each item of the contract.

b) The contractor shall submit monthly progress reports during both

manufacture and installation of the work covered by this contract with reasons for delay, if any affecting the set program.

If at any time during installations, it appears to the purchaser that the contractor will be unable to complete any part of the contract works in the time stipulated, then the contractor shall, if asked by the purchaser, carry on working outside normal working hours and shall not make any claims for any extra expenses incurred thereby. 3.15. Delays Caused by the Purchaser In case of delay in the substation building or electrical equipment erection, the contractor will be notified to extend his schedules with corresponding extension of completion dates. Therefore, the contractor shall not ship the main cables of any item before obtaining the written approval of the Purchaser. If, for reasons for which the contractor is not responsible, it was not possible to energize the cables of any circuit of any item after completion and successful testing of his contract works, then the guarantee period of one year shall begin form the date of concerned cable circuit was energized and for a maximum period of fifteen (15) calendar months from the date of completion and testing. For the period between testing and energizing the purchaser will pay only for the commissioning and service engineer's waiting time or his return air fare ( as may be decided by the Purchaser ) at the rates given in schedule "G" In this case, the contractor will not be entitled to any other additional costs.

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3.16 Tests Factory and Site Tests for 132kV and 33kV Power cables, Pilot cables, Coaxial Cables and accessories. 3.16.1 General

All tests shall be carried out by the contractor at his own expenses. The contractor shall supply specimens, testing apparatus and labor required for carrying out the prescribed tests. For the pressure tests of high voltage cables at site, the contractor shall make available a suitable D.C. cable testing set.

The tests shall be carried out in the presence of the inspector at the

manufacturer's factory and of the Engineer at site.

The tender price shall include the cost of all tests specified. The purchaser may however, relieve the contractor from carrying out certain type tests provided the contractor produces type test certificates from a recognized testing authority acceptable to the purchaser.

In such cases, the contract price will be reduced by an amount equal to the costs of type tests waived by the purchaser. For this purpose, the tenderers should quote separately the costs of the type tests specified.

All samples used for testing shall be at the contractor’s expense and shall not affect the lengths of cable to be supplied under this contract. This also applies to joint boxes and other accessories.

Six copies of the records of all site tests shall be furnished to the Engineer. The contract works will not be accepted by the Engineer until they have passed the prescribed site tests and which shall be approved in writing by the Engineer. The contractor shall not be entitled to any payment whatsoever or any extension of time of completion because of tests, or failure of any tests or the rejection of any part of material or plant as a result of any tests or inspection.

3.16.2 Calibration

All instruments used for testing purposes shall, if required by the Engineer, be calibrated by an approved authority.

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3.16.3 Test of Power Cables (132 & 33kV) 3.16.3.1 XLPE Cables

The tests shall be carried out generally in accordance with IEC 840 for 132kV cables and IEC 60502 for 33kV cables unless otherwise specified hereunder. :

A) Routine Tests

The following tests shall be carried out on each manufactured length of cable, to check that the whole of each length complies with the requirements.

1. Conductor resistance measurements:

The complete Cable length shall be in the test room, which shall be maintained at a reasonable constant temperature for at least 12 hours before the test. If it is doubtful whether the conductor temperature is the same as the room temperature the resistance shall be measured after the cable has been in the test room for 24 hours. Alternatively, the resistance shall be measured on a sample of conductor, conditioned for at least 1 hour in a temperature controlled bath.

The D.C resistance of the conductor shall be corrected to a temperature of 20 0C and 1 Km length in accordance with IEC Publication 60228.

The D.C resistance of the conductor at 20oC shall not exceed the appropriate maximum value specified in IEC Publication 60228 if applicable.

2. Measurement of capacitance:

The capacitance shall be measured between conductor and metallic screen. The measured value shall not exceed the nominal value specified by the manufacturer by more than 8%.

3. Partial discharge test:

The partial discharge test shall be carried out in accordance with IEC Publication 60885 - 2, except that the sensitivity as defined in IEC Publication 60885 - 2 shall be 10 pC or less.

The test voltage shall be raised to and held at 1.75 Uo for 10 s and then slowly reduced to 1.5 Uo.

The magnitude of the discharge at 1.5 Uo shall not exceed 10 pC.

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4. Voltage Test:

The Voltage test shall be made at ambient temperature using an alternating test voltage at power frequency.

The test voltage shall be raised gradually to the specified value which shall then be held for 30 min between the conductor and metallic screen.

The test voltage shall be 2.5 Uo.

No breakdown of the insulation shall occur. 5. Electrical test on non- metallic sheath:

The non - metallic sheath shall be subjected to the routine electrical test specified in IEC Publication 60229.

B) Sample Tests General

The following tests shall be made on samples of manufactured cables, the No of samples chosen shall be limited to not more than 10% of the number of lengths

1. Conductor examination.

2. Measurement of thickness of insulation and non-metallic sheaths.

3. Measurement of the thickness of metallic sheaths. 4. Hot set test for XLPE insulation.

The above tests shall be carried out in accordance with the requirements of IEC 60840 for 132kV cables and IEC 60502 for 33kV cable and shall fulfill the values given there in.

C) Type Tests General

The appropriate type tests specified hereunder shall be made before the manufacturer supplies, on a general commercial basis, a type of cable covered by this standard, in order to demonstrate satisfactory performance requirements.

The type tests shall comprise the electrical tests on the complete cable and the appropriate tests on cable components.

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D) Electrical Tests on complete cable

The following sequence of tests shall be performed on samples of complete cable at least 10 m in length excluding the test accessories

1. Bending test followed by partial discharge test. 2. Tan Delta measurement

3. Heating cycle voltage test, followed by partial discharge measurement.

4. Impulse withstand test followed by a power frequency voltage

test. The above tests except (2 above) shall be applied successively on the same samples.

Details of Tests:

1) Bending test followed by partial discharge test

a) The sample shall be bent around a test cylinder (e.g. the hub of a drum) at room temperature for at least one complete turn. It shall then be unwound and the process repeated except that the bending of the sample shall be in the reverse direction.

This cycle of operation shall be carried out three times in total. b) The diameter of the test cylinder shall not be greater than: 25 (d + D) + 5 % for cables with lead and corrugated aluminum sheath or with overlapped longitudinally applied metal foil 20 (d + D) + 5 % for others

Where : D = measured external diameter of the cable in millimeters.

`d = measured diameter of the conductor in millimeters

c) On completion of this test, the cable shall be subjected to the partial discharge test as described in IEC Publication 885 - 2, the sensitivity being 5 pC or less. The magnitude of the discharge at 1.5 Uo shall not exceed 5 pC.

2) Tan Delta Measurement a) The sample shall be heated by a suitable method and the

temperature of the conductor determined either by measuring its

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resistance or by thermocouples on the surface of the screen, or by thermocouples on the conductor of another sample of the same cable heated by the same means.

The sample shall be heated until the conductor reaches a temperature equal to the maximum rated temperature of the insulation in normal operation within + 50C.

b) Tan Delta shall be measured at a power frequency voltage of Uo at

the temperature specified above. c) The measured value shall not exceed the value specified in table II of IEC 60840. 3) Heating cycle voltage test a) The sample shall be in a U bend having a diameter specimen b) The sample shall be heated by a suitable method, until the conductor

reaches a temperature which shall be not less than 10 oC and not greater than 15 oC above the maximum rated temperature of the insulation in normal operation.

c) The heating shall be applied for at least 8 hours and shall be followed

by at least 16 hours of natural cooling. The conductor temperature shall be maintained within the stated temperature limits for the last 2 hours of each current loading period.

d) The cycle of heating and cooling shall be carried out 20 times.

e) During the whole of the test period a voltage of 2 Uo shall be applied to the sample.

f) After the final cycle the sample at ambient temperature shall be

subjected to and comply with the requirements of the partial discharge test in accordance with Sub-clause 1 - C above.

4) Impulse voltage Test (followed by a. c voltage test)

a) The impulse test shall be performed on the sample at a conductor temperature which shall be not less than 5 oC and not greater than 10- oC above the maximum rated temperature of the insulation for normal operation.

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The impulse voltage shall be applied according to the procedures given in IEC Publication 60230.

b) The cable shall withstand without failure 10 positive and 10

negative voltage impulses of the appropriate value specified in Table 1. of IEC 60840.

c) After the impulse test, the cable sample shall be subjected to ambient

temperature to a power frequency voltage test at 2.5 Uo for 15 min. No breakdown of the insulation shall occur.

5) Type tests on Cable Components:

The non-electrical type tests and type tests to check that the materials used for the cable components have satisfactory properties shall be carried out as detailed in IEC 840.

The method of tests and test results should satisfy the requirement of IEC 840:-

6) Electrical Tests after Installation (Site Tests) 1. Insulation:

Tests on new installations are made when the installation of the cable and its accessories has been completed.

1.1 A. C Testing:

An a.c voltage test at power frequency, in accordance with Item a) or b) below, can be used:

a) Test for 5 min with the phase to phase voltage (U)

applied between the conductor and the metallic screen.

b) Test for 24 hours with the normal phase to earth

voltage of the system (U o).

1.2 As an alternative to the above test, an a.c. test with a series resonant set will be conducted the values of the test voltage will be subject to MEW approval.

2. Non-metallic Sheaths

The non-metallic sheath shall be subjected to the site tests specified in IEC Publication 229.

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3. Partial Discharge Test: Partial discharge test shall be conducted on cable after the installation according to the IEC standard. Any needed equipment shall be provided by the contractor

3.16.3.2 Oil Filled Cables The Tests shall be carried out generally in accordance with IEC 141-1. A) Routine Tests All lengths of cable shall be tested before dispatch according to the following: 1. Power Cables

i) Conductor Resistance Tests

The copper resistance of the conductors shall be measured by direct current at room temperature in accordance with IEC publication 141-1. The values thus obtained shall not be greater than the guaranteed values as per IEC Publication 141-1.

ii) Capacitance Tests

The electrostatic capacitance of each drum length of completed cable shall be measured at length of completed cable shall be measured at power frequency and shall not be greater than the guaranteed values stated in Schedule "F".

iii) High Voltage Tests

The voltage tests shall be carried out with alternative current in accordance with IEC publications 141-1 for oil filled cables.

iv) Di-electric Power Factor/Voltage Tests

Each drum length of completed cable shall be tested for power factor at normal frequency and at ambient temperature and at 100 and 200 percent of normal voltage for 132kV cables. The power factor of the charging KVA, after correction to a temperature of 20oC shall not exceed the guaranteed values stated in the schedules of guarantees. These guaranteed values shall be in accordance with IEC publication 141-1.

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v) Voltage Tests on Anti-Corrosion Coverings :

This shall be carried out in accordance with IEC-141 and engineering recommendation C55 for 132kV cables.

2. Accessories

i) Visual dimensional checks on selected samples of each batch of joint boxes (not less than one joint box of each 50 boxes).

ii) Tests to check inner lead sleeve composition.

iii) Tests analysis of plumbing and solder to check compliance with B.S

219. Tests should be carried out on samples selected from each batch ( but not less than one sample of each 200 sticks )

B) Type Tests

1. Power Cables & Accessories

The following tests shall be made on samples taken from cables manufactured for the contract.

i) Measurements of thickness of Insulation sheathing and serving & Weights A sample shall be selected from each 400 meters of each type of completed cables and shall be at least 60 cms long. Then the minimum and average thickness of insulation shall be determined and the paper checked for wrinkles or tears. The minimum and average thickness of lead sheath, armouring and the various coverings of bedding and serving shall be determined, and these shall agree with the guaranteed values. Also the weights of copper, lead and steel per meter of cable shall be determined. ii) Mechanical Tests and Hot Impulse Voltage Tests The bending tests shall be made on a sample of the completed cable (with all coverings) having a length of not less than hundred times the diameter of the cable over the lead sheath. The bending tests shall be conducted in accordance with IEC Publication 141-1 for oil filled cables. This sample shall than be incorporated in a miniature installation comprising of a straight joint, sealing end boxes and other accessories, representative of the actual circuits called for in this tender. This miniature installation shall then be subject to an impulse voltage test and a power frequency high voltage test in accordance with IEC publication 141-1 for oil filled cables.

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During this test, no break-down in any part of the test assembly of flashover of the sealing ends shall occur. A specimen taken from the sample that has been tested shall then be dismantled and examined. The condition of the paper insulation, lead sheath, protective covering and armour shall comply with the requirements of IEC specification. iii) Loading Cycle - Power Factor Tests This test shall be carried out on a sample of cable selected from the contract works. The sample shall be completed with joint, sealing end boxes and other accessories and shall not be less than 30 meters in length, with adjacent accessories not less than 4 meters apart, and shall be laid out on the floor of the test bay. The sample shall be heated up to the maximum conductor temperature stated in Schedule "F" by passing current through the conductors. During the twenty days of test, the cable shall be alive at 1.5 x the service voltage. This heating current shall be maintained for six hours with conductor temperature at 5 deg. C above normal temperature or at least three hours, and switched off for 18 hours and the cycle repeated twenty times. The power factor of the charging KVA shall be measured at 100% and 200 % of normal voltage as follows:

a) Before the commencement of the test.

b) When the cable has reached the maximum temperature during each cycle.

c) When cable has cooled to minimum temperature

during each cycle. The power factor shall, in addition, be measured at normal voltage at temperature of about 60 oC and 40 oC during cooling in each cycle. The power factor at the stipulated voltage shall not vary substantially from cycle to cycle and for oil filled cables, it shall be within the limits stipulated in IEC Publication 141-1. iv) Dielectric Thermal Resistance Tests A sample of the cable, selected by the inspector shall be tested for thermal resistance of the dielectric at the maximum temperature at which the cable is specified to operate and under stipulated conditions. v) Mechanical Tests on Pressure - Retaining Sheath A sample of the cable at least 5 meters long is to be maintained for seven days at an internal pressure equal to twice the maximum design pressure, during which period no leakage shall occur.

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vi) Dielectric Security Tests A sample of the cable at least 10 meters long (excluding terminations) shall be subject to a power frequency test voltage applied between conductor and screen. The value of the lest voltage shall be 190kV for 132kV cables and it shall be applied for 24 hours without occurrence of breakdown of the insulation or flash over of the sealing ends. vii) Tests on Accessories Pressure tests on joints sleeves and sealing end bushings, pressure tanks, pressure gauges and alarm gauges shall be carried out in accordance with clause 21 of IEC Publication 141-1. c) Site Tests

1. Power Cables

After the complete installation of the various circuits and before commissioning, each circuit shall be subject to the following tests.

i) Resistance Measurements The copper resistance of each core of the completed circuits shall be measured and the value corrected to an ambient temperature of 20 oC. ii) Capacitance Measurements The capacitance between phases and between each phase and the lead sheath shall be measured and the ambient temperature recorded. iii) High voltage Tests After the circuit has been brought up to its design oil pressure, a D.C voltage of 305kV shall be applied to 132kV cables between each core and screen for a duration of 15 minutes, the other two phases being earthed. iv) Oil Circuit Tests The oil filled cables shall be subject to the following tests:

a) Oil Flow Test

This test shall be carried out on the connections between pressure tanks and cable to make sure that the loss of head allowed for in the design is not exceeded. It shall also be carried out on the installed cable to ensure that

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there are no abnormal restrictions in the cable ducts, etc. This is done by measuring the pressure drop in the section under measured oil follow.

The theoretical pressure drop (bar) which should be obtained is given by: P = Q b1

Where P = Total pressure difference on the section (allowing for route profile)

Q = Rate of flow in liters / sec. l = Length of cable section in meters. b = Coefficient of friction of oil in the cable ducts. b = 25.5 n (for circular ducts or pipes) r4

n = Dynamic viscosity of oil (Centipedes) at the test temperature.

r = Internal radius ( mm ) of the pipes or ducts measured inside the spiral .

For three core cables with ducts in the interstices, coefficient (b) is one third of that resulting from the above mentioned formula. The theoretical oil flow for a given pressure in a single core cable is thus given by : Q = P r4 litres / seconds 25.5 nL In comparing the flows obtained on finished cable installation, it should be remembered that joints are included and the theoretical figures serves as a guide.

b) Impregnation Tests This test shall be carried out in the installed cable to determine the efficiency of the impregnation. This test shall be conducted in the following manner. A measured quantity of oil shall be drawn from the cable system (with feed tanks shut - off) and the consequent drop in pressure noted. The impregnation coefficient K as given below shall not be greater than 4.5 x 10 -4.

K = dv x 1 v dp

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Where dv : volume of oil withdrawn ( liters )

dp : drop in pressure ( bar ) v : volume of oil (liters) in installation (excluding insulated feed tanks )

The volume of K obtained on complete installation show considerable variations depending on type of cables, number of accessories, average pressure in the section, etc. Notes: 1. The contractor should submit the name, graduation certificate and

experience of the testing Engineer. 2. The contractor should submit a complete testing programme before commencing the actual testing. 3. After the completion of all commissioning, testing specified, a request

for taking over should be made in writing enclosing four copies of all tests results duly signed by the Testing Engineer. No work will be deemed as completed and no payment due will be released without the receipt of such test certificate and their approval.

3.16.4 Tests of Pilot Cables and Their Accessories The tests shall be carried out generally in accordance with ESI 09 - 6. A) Routine Tests i) Measurement of conductor resistance

The resistance of the conductors shall be measured as specified in B.S. 6360/1969 and shall meet the requirements of this standard.

ii) Voltage Routine Tests

The voltage test shall be made with alternating current of approximately sign form and at any frequency from 40 - 62 Hz. inclusive. The voltage shall be increased gradually and maintained continuously for one minute at 10kV (rms) between all unscreened conductors whilst excluding the screened pairs by connecting its cover and screens to the centre tap of a 10kV test transformer secondary for the duration of the test.

For screened pairs a separate 10kV D.C. tests shall be conducted with the screens connected to the zero potential connection and 15kV (rms) between conductors and armour which shall be earthed.

Alternatively, the following D.C. test procedure may be followed:

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* Core - Core 20kV D.C. with the screen maintained at the intermediate leve

of 10kV D.C.

* Core - Armour: 30kV D.C. with the screen connected to the cores. iii) Mutual capacitance Test

The mutual capacitance of the cable shall be measured between the two conductors of each pair with the other conductors and the armour earthed. The measurements shall be made using alternating current and a suitable bridge and the main value obtained shall be recorded.

iv) Capacitance Unbalance Tests

Pair to pair capacitance unbalance measurements shall be made at audio frequency. All conductors other than those under test being connected to the armour and earth. The measured values shall be divided by:

1/2 (L / 500 + L / 500) Where L is the length in meters.

Lengths less than 100 meters being considered as 100 meters. No corrected unbalance measurements shall exceed 500 pf. The corrected unbalance between carried pairs shall not exceed 50 pf. In order to limit the amount of testing, measurements will normally be made between adjacent pairs except that all combinations between carrier pairs shall be measured. The measured values of capacitance unbalance shall be recorded for use in the preparation of jointing schedules to obtain the necessary balance to meet the cross - talk requirements.

v) Mutual Inductance

Mutual inductance measurements shall be made at 5 KHz on carrier pairs. The measured values shall be divided by:

1/2 (L / 500 + L/500)

Where L is the length in meters of the cable under test. Lengths less than 100 meters being considered as 100 meters. The corrected mutual inductance shall not exceed 0.50 mH.

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vi) Galvanized Routine Tests

Samples selected by the purchaser's representative of all galvanized materials shall be subject to the galvanized tests set out in BSS 443, testing of zinc coating on galvanized wires.

vii) Insulation Resistance Tests

The insulation resistance shall be measured between each conductor and the other conductors connected to armour by applying 500 volts D.C. for one minute. The insulation resistance shall not be less than 12500 mega-ohm/Km at 20oC

viii) Extruded P.V.C. Over sheath Tests

Extruded P.V.C. over sheath shall be sparked tested in the manner described in clause 16.2 of B.S. 6346/1969.

ix) Voltage tests on anti-corrosion coverings in accordance with BSS.

6480. B) Type Tests

i) Measurements of Thickness of Insulation, Sheathing, Armoring , Serving and Bedding

Ten representative samples of the manufactured cables shall be examined and average thickness of insulation sheathing, armouring, bedding and serving shall be determined. These samples shall be at least 60 cms. long and shall be cut not less than 30 cms from the end of the drum length. Also the weights of copper and steel per metre of cable shall be determined.

ii) Voltage Tests

A sample of the manufactured cable together with a joint box shall be tested and shall not break down when a voltage of 5kV is applied for 5 minutes between pilot cores and between core and the lead connected to armour. Subsequently, the sample shall be tested and shall not break-down when a voltage of 2.5kV is applied for five minutes between screened cores and between each screened core and the armour. Screens and armours shall be earthed during this test.

C) Site Tests a) After Laying and before Jointing: The following tests shall be carried out on each length of cable:

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i) Continuity The continuity of all conductors shall be confirmed. ii) Insulation Resistance

The insulation resistance of individual lengths shall be measured between each conductor and other conductors connected to the armour by applying 500 V.D.C. for one minute.

b) After Laying and Jointing: The following tests shall be carried out in each laid and jointed cable: i) Voltage Withstand Tests

Each laid and jointed cable shall be subjected to the following high voltage tests

1) Each of unscreened pairs shall be tested with 15kV D.C. applied

between the two conductors of the pairs. 2) For screened pairs, the following tests shall be carried out

a) 10kV D.C. between the conductors of the screened pair, with the screen floating .

b) 5kV D.C. between the conductors of the screened pair and the screen which shall be earthed.

3. 25kV D.C. between all conductors and screen jointed together with the armour. The armour being earthed during the tests.

ii) Conductor Resistance The conductor resistance shall be measured and recorded. iii) Insulation Resistance

The insulation resistance shall be measured between each conductor and the other conductors connected to the armour by applying 500 volts D.C. for one minute. iv) Attenuation, cross-talk and impedance tests in accordance with ESI

(og - 6 standard).

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3.16.5 Tests on Fiber Optic Cables

A) Routine Test

Routine test shall be carried out on the complete fiber optic cable to show that the guaranteed performance figures are achieved and the UGOP comply with the requirements of this Specification and Guarantees stated in the appendices. Transmission characteristics of the optical fiber shall be measured. The main tests shall be:

- End to end optical power loss. - The characteristics of every optical path through an optical time

domain reflectometer (OTDR) in the best window (1310 & 1550 nm) monitoring the evolution of splices and connectors.

B) Site Test

Type test certificates for the UGOP cable must be produced by the tenderer in order to prove the performances of the cable in the following aspects:

- Mode Field diameter (according to IEC 60793-1) – spot size of the fundamental mode.

- Cut-off wavelength (according to IEC 60793-1) – wavelength above which the fiber allows Single Mode propagation.

- Cable tests (IEC 60794, IEEE 1138). - Fiber Excess Length (FEL) (ratio between fiber length and cable

length) - Crush test. - Impact test. - Tensile strain and stress. - DC resistance. - Weight. - Admissible fault current (kA2s) (Short Circuit test). - Temperature and Temperature cycling. - Water ingress. - Aeolian vibration. - Galloping. - Sheave test.

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C) Sample Test

The cable shall undergo factory testing in a systematic manner and by sampling depending upon the nature of the tests. The contractor shall submit its test procedures for the cables for the employer's approval. These tests shall include (but are not limited to) the following:

- Fiber attenuation for each cable drum - Chromatic dispersion for each drum - Cable diameter and geometry - Tensile strength and elongation break - DC conductivity - Torsion

3.16.6 Tests on Power Cables Accessories A) Routine Tests

Routine tests shall be carried out on porcelain insulator, and bonding leads as follows:

1. Porcelain Insulators i) Visual dimensional checks ii) Power frequency wall test iii) Hydraulic Pressure tests. The above tests shall confirm with ES 109 - 10. 2. Bonding Leads a) Spark test for the insulation of single core leads. b) Spark test on inner and outer insulation of concentric leads. B) Sample Tests

Sample test shall be carried out on porcelain insulators in accordance with the following:

i) Porosity test on one sample in accordance with ESI 09-10.

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ii) Temperature cycle test on one sample in accordance with ESI 09-10 followed by:

a) Power Frequency wall test. b) Hydraulic pressure. Also sample test for joint boxes is carried out as follows:

i) Visual dimensional checks on selected samples of each batch of joint boxes (not less than one joint box of each 50 Boxes)

ii) Tests to check inner lead sleeve composition.

iii) Tests analysis of plumbing and solder to check compliance with B.S. 219. Tests should be carried out on samples selected from each batch (but not less than one sample of each 200 sticks).

C) Type Tests

Type tests on accessories shall be performed on a cable and accessory installation where the cable lengths used shall have been previously subjected to the partial discharge and bending tests. There shall be at least 5 m of cable between accessories, with a minimum total cable length of 10 m; type test shall be carried out on the following accessories:

1) Straight joints, terminations. 2) Link boxes. 3) Porcelain insulators of outdoor sealing ends. The details of tests are as follows: (1) Straight joints and terminations The following tests will be carried out on cables and accessories:

a) Partial discharge test According to IEC 60540 sensitivity to be 5 P.C. or less, initial voltage 133 KV (1.75 Uo) for 132kV cables. Partial discharge at 114kV (1.5 Uo) shall not be more than 10 PC for 33kv cables the initial value of 33.3kV and partial discharge at 28.5kV (1.5 Uo) shall not be more than 20 PC.

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b) Load cycle test followed by partial discharge : Load cycle test according to IEC 60840 for 132 KV cable and IEC 502 for 33 KV cable followed by partial discharge test., the partial discharge at 1. 5 Uo should not be more than 10 PC.

c) Impulse test followed by voltage test : Impulse test of 650kV for 132kV cables and 170kV for 33kV cables according to IEC 60230 , 10 _+, 10- impulse at condition temperature 95 oC followed by 190kV AC for 15 min for 132kV cables and 47.6kV AC for 15 min for 33kV cables no breakdown should occur.

d) High Voltage Test for Four Hours : 228kV A/C for 4 hours for 132kV cables and 57kV A/C for 4 hours for 33kV cables. no breakdown should occur.

e) D.C. Voltage Test 305kV A/C. for 15 min at room temperature for 132kV cables. 81kV D/C for 15 min at room temperature for 33kV cables, No breakdown should occur.

(2) Link Boxes Impulse voltage:

a) Between links according to IEC 230 10 +, 10 - impulse of 33kV for 132kV. b) Links to earth according to IEC 60230 , +10, -10kV impulses for 17.5kV

for 132 KV cables. for 33kV cables according to the values given in IEC 502, No breakdown shall occur.

(3) Porcelain insulator for outdoor sealing ends Artificial pollution test according to IEC 60507 General Note on Tests

1. The contractor should submit the name, graduation certificate and experience of the testing engineer.

2. The contractor should submit a complete testing program before

commencing the actual testing.

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3. After the completion of all commissioning, testing specified, a request for taking over should be made in writing enclosing four copies of all tests duly signed by the testing engineer. No work will be deemed as completed and no payment due will be released without the receipt of such test certificate and their approval.

3.17 Standard Specification Attention of all tenderers is hereby drawn to the following: a) All materials and equipment shall comply as a minimum: i) With the latest relevant recommendations of the International Electro-technical Commission (IEC) if available. ii) If (i) above is not available, with the latest relevant British Standard Specifications.

b) Tenderers who wish to base their offers on standards other than those mentioned under (a) above can do so provided that they confirm in their offers that such standards meet the requirements under (a) as a minimum and in due time the successful tenderers will be asked to prove this and if needed, be verified by the Inspectors appointed by the Purchaser.

c) What is mentioned under (a) and (b) above applies to wherever B.S.S.

is mentioned in the different clauses of this tender specification. 3.18 Tender Schedule & Contract Documents

All tenderers shall note that all pages of all the technical schedules and price schedules must be completely filled signed and stamped by both the local agent and the principals. The principal, who must be the 132kV and 33kV cables manufacturer, shall sign the contract documents as main contractor.

3.19 Road Crossings (If specified)

All cables shall pass through approved ducts under roads and elsewhere as directed by the Engineer. The quantity of ducts required to be constructed (if any) will be specified in schedule of Prices for the relevant item under (B) Installation.

3.19.1 U.P.V.C. Pipes Under Asphalted Roads ( If specified )

1. Ducts shall be of 4 “, 6", 8”, 12”, 16” diameter UPVC pipes, purchased from the National Industries Co.

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2. Pipes shall be of standard quality with minimum crushing strength of 450 kgm/sq.cms.laid in one single length place under the road or each carriage way where possibly both ends of pipe cut perfectly perpendicular to the axis of the pipe. The ducts shall extend by 90 cm. beyond the road kerbstone at each end as per Clause 3.9.2.

3. If more than one single length is to be used, both ends of pipes shall

be butt-jointed, held firmly together in position wrapped with building paper or other approved material before casting or surrounding concrete.

4. All U.P.V.C. ducts shall be laid in mass concrete mix 1 : 3 : 6

extending 10 cms. below the bottom and 15 cms. above the top duct with 5 cms. separation between ducts.

5. Cement to be used for encasing of concrete shall be ordinary Portland

and sand and coarse aggregate. 6. Small lengths or cut-pieces of pipes with multiple jointing to make one

single length under any road crossing shall not be permitted. 7. Pieces of pipes shorter than 3.00 meters long shall not be used unless

under unavoidable circumstances. 8. All depths at which the ducts are to be laid under road crossings

should be agreed by the Engineer. 9. Both ends of all spare ducts under road crossings shall be plugged

with suitable soft wood plugs of tapered type approved by the Engineer before backfilling.

3.19.2 Prices of Road Crossings The prices of installation of road crossing should include the cost of making these road crossings and the supply of all necessary materials. The route length of crossing and number of pipes required are to be estimated by the tenderer. All necessary works for making of ducts using thrust boring and/or open cut methods for HDPE ducts shall be carried out under the scope of work of this tender. 3.20 Training in Kuwait: The training will be done at one period after six months of signing the contract. The contractor shall provide actual training (complete workshop) for the purchaser's staff on power cables and fiber optic cables jointing and the tests to be done after installing a repair joint. The training shall be done at a suitable air conditioned place where the purchaser's staff will joint two pieces of cables under the supervision and guidance of the main contractor. The main contractor is responsible to provide the best training tools and staff to ensure the best quality of training session. The

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trainees will be responsible to prepare and install the joints at site for maintenance purposes. Certificates will be given to these trainees to verify that they are qualified to do all repair, maintenance and testing works related to XLPE cables, Fiber optics cables and their accessories. The materials and tools used in training and training expenses are included in tender price and will be handed to the maintenance department. Training place and schedule will be reviewed by MEW for approval. 3.21 Training in Factory: The contractor shall provide training course for MEW Engineers (6 No.) at the contractor’s factories for at least 2 weeks. The subjects to be covered shall include:

1- The manufacture process for the UG cables. 2- Joints and any accessories used at the contract. 3- Maintenance for the UG cables. 4- Installation of the UG cables and accessories. 5- Tests on UG cables.

The contractor shall submit a schedule showing details of covered subjects and duration and shall be subject to MEW approval. Tickets (business), Visa, Transportation, Accommodation, three meals shall be covered by the contractor and included in the tender price. - Detailed Training schedule shall be submitted for MEW-DEN for approval. - Departure date shall be 2 days before the training program start date and the arrival date shall be 1 day after the end of the training program.

3.22 Existing Services:

The contractor is responsible to check the site condition for any obstacles or existing services. Services owned by citizens such as car shades agriculture…etc shall be arranged with the owners and to be returned back if possible. Services owned by government sector such as PAAF shall be returned back to its original state and costs of such works to be included in the contract price.

Contract RA/266



C - TELEPHONE WORKS (PTT)

MOC TND Specification No. 4

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STATE OF KUWAIT

MINISTRY OF COMMUNICATIONS

TELEPHONE NETWORK DEPARTMENT

SPECIFICATION NO. 4

PART - III

PARTICULAR SPECIFICATION FOR INSTALLATION OF CIVIL PLANT FOR TELEPHONES BY GOVERNMENT AND

SEMI GOVERNMENT AGENCIES.

***************************************************************************************

:BAS:/D.22-94/FTPGMPW:

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MOC TND SPECIFICATION NO. 4

PARTICULAR SPECIFICATION FOR

INSTALLATION OF CIVIL PLANT FOR TELEPHONES BY

GOVERNMENT AND SEMI GOVERNMENT AGENCIES.

I N D E X

D e s c r i p t i o n P a r a n o.’ s General 1 – 1 to 1 – 3 Price Quotations 1 – 4 Materials supplied by the Ministry. 2 – 1 Materials required to be supplied by Contractor. 2 -- 2 Civil Work Installation Materials. 3 – 1.1 to 3 – 1.22 Excavation. 3 -- 2 Depth of Trenches. 3 -- 3 Duct Laying. 3 -- 4 Expansion of existing ducts. 3 – 4.1.2 Replacement of existing ducts. 3 – 4.1.3 Repair of ducts and blocked ducts. 3 – 4.1.4 & 3 – 4.1.5 Jointing of ducts. 3 – 4.2 Protection of ducts. 3 – 4.3 Termination of ducts 3 – 4.4 Rearrangement ducts 3 – 4.5 Test after laying ducts. 3 – 4.6 Leakage of ground water. 3 – 4.7 Backfilling. 3 -- 5 Drawings references and construction Of Manholes and Handholes 3 -- 6 Lead – in Ducts 3 -- 7 Clearance to underground services and facilities 3 -- 8 Installation of Distribution Cabinates. 3 -- 9 Completion Reports and Drawings. 3 -- 11 Inspection & Acceptance Tests. 3 -- 12

ATTACHEMENTS:

MOC Standard G20:10:001:22.. MOC Standard G20:10:001:23.. MOC Standard G20:10:001:32.. MOC Standard G20:10:001:33.. MOC Standard G20:10:001:34.. APPENDIX: 1,2,3&4

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INSTALLATION OF CIVIL PLANT FOR TELEPHONES BY GOVERNMENT AND SEMI GOVERNMENT AGENCIES.

GENERAL 1-1 This Technical Specification and MOC Standards for Materials, covers supply of materials and

installation of the various items of work required in connection with the construction of civil works for the Telephone Network Department of the Ministry of Communications (hereinafter called MOC). These works include lying of ducts/pipes and construction of Manholes and Hand holes and associated works.

The following MOC Standards and Appendix also form part of this specification

(a) G20:l0:00l:22 Hardware for use in MH & HH. (b) G20:l0:00l:23 Manhole and Handhole Covers. (c) G20:l0:00l:32 PVC Ducts, Bends, Couplings, Duct Bonding Materials and Spacers. (d) G20:l0:00l:33 Materials for Civil Work. (e) G20:l0:00l:34 Galvanized Ducts and Troughs. (f) Appendix-1 MoC Important Notes (g) Appendix-2 BOQ Format (h) Appendix-3 MoC Monogram (i) Appendix-4 MoC Standard Legend 1-2 The Contractor shall be required to carry out necessary field surveys, viz, accurate field measurements

(including level measurements), acquaintance of the route, verification of existing services by digging Pilot holes, and make drawings present accurately all details by correcting incongruities with the drawings and/or making necessary supplement, as well as the other necessary drawings, prepare details and submit them for Ministry’s approval. After obtaining the Ministry’s approval, the Contractor will proceed with execution.

The Contractor has to submit B.O.Q and estimated amount in Design , shop & as built drawings for MOC Approval.

In case necessity arises for making on-the-spot corrections and changes in drawings during certain phases of the construction work, the Ministry will not issue revised drawings to the Contractor. When changes are made, dated and initialed by the Ministry’s Engineer in one of the Contractor’s drawings, it shall be Contractor’s responsibility to incorporate the corrections in all other relevant drawings in his possession.

All documents, including drawings to be submitted by the Contractor, must be prepared in quadruplicate. 1-3 Contents of the Tender Specification Ministry of Public works /Public authority for Housing Welfare/ consultant/contractor

must take MOC’s signature on the Hard copy booklet of approved specification along with B. O. Q. and on A_1 size Final design polyester drawings before quoting the

rates for tendering.

This tender specification consists of installation specifications, materials specifications, drawings, etc. The appendices and MOC Standards as revised from time to time are also considered to form part of this specification. Ministry of Communications reserves the right to make amendments to the specifications and working practices during the Contract period. No claim shall be made for minor amendments which shall be complied by the Contractor.

The Tenderers are expected to provide for all necessary associated materials, even if they are not stipulated in the specification. The unit rate quoted for each item should include all accessories & allied

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works and no separate claim shall be acceptable for such items required during execution of work.

1-4 Price Quotations

The rates shall include for the following:

(a) Supplying & Laying of unp1asticised PVC Ducts:

Supply of ducts, fittings, bends, cleanser, jointing adhesive and spacers, protection, laying, jointing and testing. The work shall include excavation, backfilling, encasing with concrete when required, carting away surplus excavations and cleaning of site. All work to be as per drawings and specifications and to the satisfaction of the MOC Engineer.

(b) Supplying & Laying of Leading-in ducts and supplying & fixing of G.I. Boxes:

Supply of UPVC Ducts, Bends, Galvanized Iron Ducts, Bends,draw boxes and Accessories, protection, laying buried or fixing on walls or poles and jointing, applying one coat of approved bitumen compound. The work shall include excavation, backfilling, carting away surplus excavation, cleaning of site. All work to be as per drawings and specifications and to the satisfaction of the MOC Engineer.

(c) Construction of Manholes and Handholes:

Construction of Manholes and Handholes as per contract drawing including excavation, backfilling, carting away surplus excavation, concrete building base, walls and top slab, neck for M/H and concrete surrounding for H/H, supply and fix complete ironwork and ductile iron /Glass reinforced plastic cover, frame, ladders and number plate as per drawings and specifications and to the satisfaction of the MOC Engineer.

(d) Rates for above items of works shall include cost of field survey, all associated works, safety precautions

and protection of all existing services, submission of completion drawings, as built drawings and documentations, and all types of testing.

1-5 In carrying out the work, if it proves necessary to move a cable or other existing MOC installation, the

Contractor may do so with the approval of MOC Engineer at his own expense provided that it does not interrupt the normal telephone service and the moved cables/installations are returned to their original place or suitable place designated by MOC Engineer after the completion of the work. In case the depth of the existing ducts is reduced due to subsequent change in levels, the ducts should be encased with concrete.

2-1 Materials to be supplied by MOC No materials will be supplied by the Ministry of Communications. 2-2 Materials to be supplied by the Contractor: 2-2.1 The Contractor shall provide all the required materials as per MOC’s specification and standard.

Materials manufactured in Kuwait such as UPVC duct,, G.I. Pipe, Steel Pipe, MH Cover, HH Cover, Spacers for ducts, ready mixed concrete etc. shall be used. The Contractor is responsible for the quality of the materials supplied, and their continuous and timely delivery.

2-2.2 The contractor has to submit samples of materials with technical literature/ specification and test reports for MOC’s approval before supply/ Installation

2-2-3 This approval shall be valid only for the particular project for the period of two years. . 2-2.4 The materials for civil work such as sand, cement, aggregate cement blocks, iron bars, water etc. shall be

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considered as part of the installation cost. 3. CIVIL WORKS INSTALLATION 3-1.1 Cement:

Cement to be used shall be sulphate resisting type 5.

The cement shall meet the requirements shown in MOC Standard G20:l0:00l:33 and satisfy the tests contained in ASTM C-150.

Cement with appearances of setting even to a limited extent shall not be used.

The cement to be used for construction work must be brought in sealed branded bags and stored in a proper manner.

3—1.2 Sand

Sand should be clean, sharp, gritty and free from loam, organic matter or adherent coatings and should conform to BS 410, 812, 882 and MOC Standard G20:l0:00l:33. Sand, which on being shaken with water in a graduated glass and allowed to settle, shows a layer of silt greater than 5% is unsuitable and will be rejected. Sand for concrete should be well grained, the grains varying in size upto 0.5 (half) centimeter, maximum.

3-1.3 Aggregate

The aggregate for concrete should be clean screened ballast, gravel or stone conforming to BS 410, 812 and 882. The material should be in the form of cubes or spheres (not flakes), and should be uniformly graded from 0.5 (half) centimeters upwards to the maximum size of 4 cms. It should be free from dirt, floury stone dust, loam and earth or other like materials. Clinker, brick, sandstone or other porous stones should not be used.

3-1.4 Water

Only water from the potable supply system of Kuwait may be used. For curing or washing aggregate, the water used shall not contain vegetable matter, acids, excessive phosphates or other salts in such quantities as to cause efflorescence on the face of the concrete or adversely affect the setting time.

3-1.5 Concrete Mixes

3-1.5.1 The grades of concrete to be used in construction shall be as follows R E Q U I R E M E N T S CLASSOFOONCRETE K—140 K—300

Minimum crushing strength Kgf/Cm2 Preliminary Test Cubes at 7 days. 140 300

Minimum crushing strength Kgf/Cm2 Work Test Cubes at 7 days. 100 220


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Slump Maximum in Cm. 8 5

Water Cement ratio (Maximum). 65% 50%

Nominal Mix. 1:2.5:5 1:2:4 Minimum cement content required is 220 Kg/M3 for K-140 and 380 Kg/M3 for K-300. 3-1.5.2 Use of different classes of Concrete

Unless, otherwise specifically mentioned:

Concrete Class K-140 shall be used for all non-structural concrete works.

Concrete Class K—300 shall be used for all structural concrete works.

3-1.5.3 The minimum Crushing Strength of work test cubes at 7 days and 28 days must be strictly adhered to.

The test results shall be recorded properly and submitted to the Ministry, at the time of Final Inspection.

Work Test Cubes should be as specified in BS 1881 for each new grade of concrete, or as directed by the Ministry/MOC Engineer. Six (6) Test Cubes (6 in.) should be taken at each time and should be marked with Date, Section of Work from which it was taken and other information required and despatched to the approved Laboratory for testing for compressive strength. Three (3) cubes shall be tested after 7 (seven) days. A further three (3) cubes shall be tested after 28 days. Their average strength must not fall below the minimum strength specified for each type of concrete and the lowest test result shall not be more than 20 percent below the average for the 3 cubes. If the result of 28 days test is unsatisfactory, all concreting shall be stopped at the Contractor’s expense, and the Contractor shall then in accordance with the instructions of MOC Engineer conduct tests of the concrete in the suspected parts of the structure. The concrete may be test loaded in situ or cylindrical test cores may be drilled out and tested. Should the tests prove that the concrete is unsatisfactory or the Engineer judge that any sections of the concrete works are defective, then the condemned concrete shall be cut out, removed and replaced by the Contractor at his own expense. All the above shall be at the expense and responsibility of Contractor.

3-1.5.4 The ingredients shall be measured in gauging boxes or by other approved means and mixing shall be

done by machine. The mixing must be thorough. 3-1.5.5 Concrete shall be mixed in a batch mixer of type ‘approved by the Ministry Engineer and in good

condition having a drum rotating about a horizontal or inclined axis. Continuous mixer shall not be used. Each mixer is to be fitted with a water measuring device having an accuracy within one per cent (1%) of the quantity of water required for the batch. The water measuring device shall be such that its accuracy is not affected by variations in the water supply pressure.

3-1.5.6 The batch shall be so charged into the mixer that some water (about 10%) enters the drum in advance of

the cement and aggregates. Water shall then be added gradually while the drum is in motion such that all required water shall be in the drum by the end of the first quarter of the mixing time.

3-1.5.7 The concrete shall be mixed until a mixture of uniform colour and consistency is obtained. Where

double—drum high performance mixers of a type approved by the Ministry Engineer are used, a minimum mixing time of 70 seconds may be allowed.

The amount of concrete’ ‘mixed in any one batch is not to exceed the rated capacity of the mixer. The

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whole of the batch is to be removed before materials for a fresh batch enter the drum. 3-1.5.8 On cessation of work, including all stoppages exceeding 20 minutes, the mixer and all handling plant

shall be washed with clean water. If old concrete deposits remain in the mixer drum, it shall be rotated with clean aggregate and water prior to production of new concrete.

Concrete mixed as above is not be modified by the addition of water or in any other manner to facilitate handling or for any other reason.

3-1.5.9 In very cold weather (+50C or below) rapid hardening cement shall be used by the Contractor for

concreting, if required by the Ministry. 3-1.5.10 Water-proofing material shall not be added to cement without the consent of the Ministry Engineer. 3-1.6 READY-MIXED CONCRETE 3-1.6.1 In selecting the concrete plant, consideration shall be paid as to the required transportation time to a

work—site, the production capacity, the numbers of transporting vehicles, the production facilities in the plant and quality control procedures applied in the plant.

For ordering concrete, designation of standard design, strength, the slump as well as the maximum measurement of the coarse aggregate shall be made. Also proper instruction as to the class of cement, kinds of aggregate, water—cement ratio, the limit of cement unit amount as well as the air volume shall be given from time to time.

The Contractor shall hold meeting with concrete producer as to the delivery date, class of concrete, qualities, unloading place and timing of delivery, prior to concrete placing, to ensure smooth concrete placing work. Also, the Contractor shall be in continuous contact with the concrete Manufacturer in the course of concrete placing work, so that no disruption of concrete placing work occurs.

3-1.7 TRANSPORTATION AND POURING OF CONCRETE 3-1.7.1 Concrete shall be delivered without any delay in order to minimize materials separation time and be

readily placed and be thoroughly compacted. 3-1.7.2 Cleaning of transportation equipment and placing machine as well as mould prior to concrete placing

work, is required to prevent mixing of dirts in the concrete. Precaution must be taken to moisten portion of surfaces, before concreting, which are likely to absorb moisture from the concreting.

3-1.7.3 Concrete once mixed shall be used within a maximum time of one hour and any un-used material left

after expiry of one hour from the time of mixing shall be discarded. Cleanliness shall be observed in all operations and in regard to all materials.

3-1.7.4 The concrete shall be deposited (not thrown) into its position, as quickly as possible after being mixed

and shall be lightly vibrated using a mechanical poker 40 mm diameter to fill all cavities and to produce a dense and uniform mass. Floors and foundations shall be leveled carefully.

3-1.7.5 On pouring concrete, care shall be taken so that arrangement of reinforced bars may be firmly

maintained. Also, care shall be taken to minimize moving of concrete once it is placed inside the mould. 3-1.7.6 The coarse aggregate which is separated, shall be buried in the concrete with high mortar mix. In case of

observing noticeable material separation in the course of placing work, the concrete shall be remixed to have even mixture.

3-1.7.7 It shall be the practice to carryout concrete placing horizontally in one block of placing area. Height of

one layer for the concrete placing shall be less than 40 cm.

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MOC TND Specification No. 4 3-1.7.8 In case of concrete placing of more than two layers, upper layer shall be placed prior to hardening of the

concrete in lower layer. 3-1.7.9 The use of internal vibrator shall be adopted for compacting concrete. Care shall be taken to allow the

concrete reach around the circumference of reinforced bar and into every nook and corner of mould. Care should be taken not to touch the reinforced bars with the vibrating poker. Poker size shall not be greater than 40 mm dia.

3-1.8 Curing 3-1.8.1 Concrete shall be prevented from drying too rapidly by shielding it from sun and wind. The concrete

shall be kept moist for 7 days by covering it with saturated sack cloth and sprinkling frequently with water.

3-1.8.2 Where necessary, placed concrete shall be covered to protect it against excavation material falling on it.

Any foreign matter falling, in spite of precautions, shall be carefully removed. 3-1.9 Mortar 3-1.9.1 Mortar for cement blocks shall be of 1:3 mix of cement and sand. 3-1.9.2 The materials, after being gauged, shall be thoroughly mixed in a dry state on a non-absorbent base and

then worked up with sufficient sweet water, applied through a hose or sprinkler to form a stiff paste. Mortar once mixed shall be promptly used before the initial setting takes place, i.e. it must be used within one hour of mixing. Where mortar is not used within this time, the materials should be discarded. The addition of fresh material to restore stiffness to sloppy mortar or the addition of water after setting has commenced is not permissible.

3-1.9.3 The walls shall be kept continuously damp for at least 2 days. 3-1.10 Cement Blocks

The cement blocks shall be used only in case of repair of existing Block type Manholes or Handholes and all new MHs and HHs constructed shall be reinforced type.

Cement Blocks shall be solid and of first quality to the specifications of Kuwait Government, Ministry of Public Works, made in vibrating pressure machines and thoroughly cured. All blocks shall be for bearing walls and when tested according to B.S. Standard or Kuwait Standards have minimum compressive strength of 50 Kg/Cm2 and average value of compressive strength for 12 blocks shall not be less than 60 Kg/Cm2 after 28 days of casting. The blocks shall be hard, sound and clean with sharp well defined edges and of dimensions required for the work. The blocks shall be presoaked for a minimum of 4 hours immediately prior to use.

The Ministry’s/MOC’s Supervising Officer may at his discretion, send samples of blocks proposed to be used for inspection and test by the Kuwait Government Testing Station. Work shall not normally be delayed for the result of the tests to be ascertained but should blocks prove unsatisfactory under test, the unused portion of the consignment will be rejected. The MOC will have the right to either reject any work on which the particular blocks of unsatisfactory quality have been used or require from the Contractor an indemnity against any loss which may be incurred from imperfection of the work which may show up subsequently.

3-1.11 Reinforcing Bars 3-1.11.1 All reinforcing bars used shall comply with the requirements given in MOC Standard G20:10:001:33.

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The cost of the steel reinforcement shall be included in the concrete rates and shall not be measured separately.

3-1.11.2 The quantity of reinforcing bars shall be as shown in the approved drawings. 3-1.11.3 The reinforcing bars shall be free from Mill Scales, Cracks, rust or other deformities. 3-1.11.4 The reinforcing bars shall not suffer any impairment on bending. 3-1.11.5 The reinforcement bars shall be made in accordance with the shape and measurement given in the design

drawing, by the method without spoiling the quality of materials being used. 3-1.11.6 The reinforcing bars shall be cleared and cleaned prior to assembly from rust, mud, oil and paint, etc., on

the surface. 3-1.11.7 Reinforcement bars shall be properly arranged at designated positions and be firmly tied with mild steel

wire. Approved spacer blocks of cement mortar shall be provided to maintain spacing between formwork and bars, so that they may not be shifted at the time of concrete placing.

3-1.11.8 The tensile reinforcement joints shall, when they are lap joints, be composed of lapping of a length more

than 40 times of the bar diameter, clamped in several places with more than 0.9 mm annealed iron wire, or by any other method equally or more effective than the one just mentioned.

No separate payment shall be made for steel reinforcement, its fabrication, placement in RCC works, which will be deemed to be included in the RCC MH or relevant item in the bill of quantities.

3-1.12 Iron works and fittings in Manholes and Handholes etc. 3-1.12.1 All iron works used in Manhole, Handhole etc. shall conform to MOC Standard G20:l0:00l:22. Mild steel

anchor irons, cable racks and support, ladder and other iron required for manhole, handhole, etc. shall conform to B.S. 4360 or equivalent and be in accordance with the MOC Drawing TX368/1, TX—483.

The contractor has to submit samples of materials with technical literature/specification and test reports as per MOC’s specification for approval before supply./Installation 3-1.12.2 Manhole and Handhole Covers: MOC is looking for the proposal to upgrade existing metallic manhole and handhole cover as per

present new developed technology with latest best suitable available materials Hence, MPW/NHA/consultant /contractor contact MOC and obtained latest approved specification of

manhole and hand hole covers before quoting the rate for tendering or supplying manhole and hand hole covers.

The contractor has to submit samples of materials with technical literature/specification and test reports as per MOC’s specification for approval before supply./Installation This approval is valid only for the particular project for the period of two years.

Manhole Covers are of medium duty ductile iron and Handhole must be double hinge type with medium duty ductile iron. Each complete manhole cover shall consist of the cover and its frame. Each complete handhole cover shall consist of two pieces called the upper cover and lower cover and its frame. The and Handhole Covers shall conform with MOC Standard G20:l0:00l:23 and MOC drawings shown below

Manhole Covers & Frames (Ductile). ... TX:481A Handhole Covers & Frames.(Ductile) … TX: 482A

In the case of Key hole the following dimensions are permissible : —

9

MOC TND Specification No. 4 Specified Acceptable to MOC.

15 mm. 14 to 16 mm.

30 mm. 29.5 to 33 mm. 3-1.13 Formwork for Concrete

The Contractor shall be responsible for the supply, design, erection, stability, striking and removal of any formwork and centering required so as to preserve the concrete from damage or distortion during setting. The form work shall be of such quality and strength as will ensure complete rigidity during placing, ramming, setting and curing of concrete. Removal of forms shall not begin until the concrete has either obtained the percentage of the 28 day design strength or until after the period shown below unless otherwise authorized by the Ministry Engineer:

False work supporting. Period. Percentacie DesicTn Strencith.

Slabs or beams. 7 days. 80% Walls. 1 day. 70%

The Ministry Engineer shall be informed in advance when the Contractor intends to strike any form work.

All new-placed concrete shall be cured and curing shall begin immediately after removal of form work and shall be continued throughout any finishing processes and for at least seven days.

Any work that causes loading of manhole and passage of traffic can start after concrete has required design strength.

No separate payment shall be made for erecting and removing form work, curing etc.

3-1.13.1 Concrete Finishes

On completion of RCC manhole/handhole, the floor shall be rendered with cement mortar in accordance with relevant drawings. The walls of concrete manhole shall have a smooth finish, any slight cavities disposed when the shuttering is removed shall be made good with cement mortar and any projections removed. Under no circumstances shall the walls be coated with a cement or cement/sand wash or mortar rendering/plastering.

Finally inside the neck, soffit roof slab and top side of the wall shall be cleaned using a suitable water soluble detergent followed by a clean water rinse to remove shuttering oil.

3-1.14 Bitumen

Bitumen used should conform to B.S. 3416 Type — 1 or equivalent. 3-1.15 Unplasticised P.V.C. Ducts 3-1.15.1 Unplasticised PVC Ducts and Spacers shall conform with MOC Standard G20:l0:00132.

When PVC Ducts are procured, the installation Contractor shall make a thorough examination to ensure that the ducts are undamaged. Damaged ducts shall be rejected and promptly removed from site of works.

When bends are used at curved positions, the materials of the PVC bends proposed shall be in conformity

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with MOC Specifications for ducts and prior approval from MOC shall be obtained for sample of bends. 3-1.15.2 PVC Ducts for MH and HH Route

The PVC ducts shall be supplied in 6 meter lengths. The ducts laid in Manhole/Handhole routes shall have minimum 100 mm internal diameter and minimum 4.5 mm wall thickness. The PVC ducts shall have one end plain and the other end a 100 mm expanded socket for spigot coupling. The expanded end shall have a wall thickness not less than that specified for the duct, and the tolerance on the fit of the spigot and socket shall be compatible with the requirements for jointing specified herein. Suitable couplers shall be used for jointing PVC ducts with steel ducts when required and the sample of these couplers shall be got approved by MOC.

The spigot end of each duct shall be indelibly marked with a continuous circumferential black line 100 mm from the end of the duct. This line shall be used as a measure of the penetration of the spigot into the socket of the adjoining duct. Joints which show, in the opinion of the MOC Engineer, inadequate penetration may be rejected. Manufacturer’s name and year of manufacture shall be clearly marked on the duct.

Pre-made slow bends of 100 mm dia., PVC Pipe shall be in full conformity with the material specification and dimensional details shown in Figure I (G20:10:001:32). A 90 mm dia. x 300 mm long mandrel shall pass through this bend. Sample shall require due approval from MOC.

3-1.15.3 PVC Ducts for Leading-in

The ducts shall be supplied in 4 meters lengths. The ducts shall have a minimum 3 mm wall thickness and external diameter of 50 mm.

The ducts shall be jointed using the method of spigot and socket couplings and cement solvent. The coupling for jointing with G.I. duct shall be made of PVC and have one end threaded, and the other end shall be sealed with solvent cement. Suitable reducing couplers shall be used for jointing 50 mm PVC ducts with subscriber’s duct of different sizes. The manufacturer’s name and year of manufacture shall be marked on each duct.

Pre-made 90 degree long bends of 50 mm PVC Pipe shall be in full conformity with the material specification and its dimensional details shown on Figure 2 (G20:10:00l:32). Sample shall require due approval from MOC.

3-1.16 Storage of PVC Ducts

Unless otherwise approved by the Ministry’s Engineer, PVC ducts shall be stacked in accordance with the Manufacturer’s instructions and in inside storage. Where outside storage is approved the ducts shall be supported at least 300 mm above ground on suitable bases spaced to avoid bending of the ducts. The ducts shall not be stacked to more than 10 layers height and be covered with impermeable sheets and secured with ropes to avoid movement. The ducts shall be stored in~ the shade at all times.

3-1.17 Cement Solvent

All joints for PVC Ducts are to be made with cement solvent conforming to MOC Standard G20:l0:001:32.

The number of joints that can be made with one kg of solvent and one kg of cleanser shall be indicated. Shelf life and any special precaution to be taken during use, must be clearly stated. Solvent cement and cleanser shall be packed in airtight tins of 1 kg. and 0.5 kg. respectively. The Contractor shall submit the test result of shear strength and long term hydrostatic pressure for approval.

3-1.18 Asbestos Cement Duct

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MOC TND Specification No. 4 MOC do not use A .C. pipes . This detail is just for reference .

Cement Asbestos Ducts of 100 mm internal diameter shall be in accordance with the Canadian Government Specifications Boards No. 34-GP-8 and subject to the Crushing Test and Bending Test requirements specified in the I.S.O. Recommendation R-160.

The ducts shall be in lengths of 4 meters for laying along the straight routes and 1 meter length for laying along the curves.

The cement asbestos joints shall be pressed home and shall be made water tight with bitumen or approved sealing compound.

4 Meters long ducts shall be bi-conical and must allow the jointing collars to enter from either side for a distance of 25 + 2.5 mm, when snugly fit to form a dust tight joint.

1 Meter long ducts shall have Magnani Jointing Collars and Rubber Rings.

The ducts shall be stored, handled and laid in strict conformance with the recommendations of the Manufacturer.

3-1.19 Steel Ducts

The steel ducts shall conform with MOC Standard G20:10:001:34. Steel Ducts for MH and HH route shall be of 100 mm internal diameter.

The ducts shall be supplied in 6 metre lengths.

The wall thickness of the 100 mm G.I. Duct shall be 5.4 mm.

Threaded coupling shall be used for jointing two lengths and the joints shall be made water tight by applying white lead pigment. The ducts shall be given two coats of an approved first quality anticorrosive paint.

3-1.20 For Service Ducts used for leading-in from Handhole/Manhole to building/compound wall

Steel ducts, accessories and couplings used for service ducts (leading-in) or for coupling with P.V.C. leading-in ducts for use in exposed portions shall be medium duty, seamless, galvanized steel ducts of 40/50 mm nominal bores and 3.25/3.65 mm wall thickness conforming to MOC Standard G20:l0:001:34 and the International Standards referred therein.

3-1.21 Draw Box

The size of the Draw Box to be fixed at the end of leading-in duct will be 300 x 300 x 75 mm.

Draw Box is referred to in Drawing No. TX-483 or latest updated if any.. Draw Box and accessories shall be of best quality, galvanized steel, conforming to BS 21, 427, and 1387. The colour of box should be light yellow powder coating .

The cover shall be with steel hinged to the body and shall be locked with a triangular head key and/or as approved by MOC. There should be MOC monogram and supplier/ Manufacturer name on th box.

Sample of draw box has to be submitted to MOC for approval before use.

Cable clamps shall be provided inside the box to keep the cable in position. 3-1.22 Spacers for PVC Ducts

The Spacers shall conform with MOC Standard G20:10:001:32 Clause 4-10. Samples of spacers are to be submitted to MOC for approval before use.

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MOC TND Specification No. 4 3-2 EXCAVATION 3-2.1 Excavation by hand or mechanical aids shall be carried out down to the required level by the Contractor

in all types of surfaces, soils and rocks in any part of Kuwait. 3-2.2 The Contractor shall normally carry out the excavation in Telephone Plant reservation in carriageways

and sidewalks indicated in the contract drawings and where no such reservations exist, in the position indicated by the Ministry Engineer. These reservations will be given to the Contractor.

3-2.3 The Contractor shall support the sides of the trench with timber or other materials, where the depths of

the trench, nature of soil or proximity of other services make this necessary. The Contractor cannot claim charges for any extra quantity of excavations that is necessitated by his failure to provide adequate timbering or due to the need for laying ducts or constructing manholes with additional depth. No separate charges will be paid for sheeting, bracing etc.

3-2.4 The Contractor shall dig pilot holes at his cost to confirm the location of existing services before he

commences his works in an area where existing services of MOC and third party might exist. 3-2.5 Great care shall be taken by the Contractor to avoid undermining or otherwise disturbing the ducts,

cables and installation. If despite precautions, such soil is disturbed, the plant concerned shall be temporarily supported and the void filled with a concrete mixture of K-140.

3-2.6 The Contractor shall protect and/or transfer, if necessary, all MOC and other existing services in a

manner approved by the concerned Ministry and in accordance with the instructions of the Ministry Engineer, at Contractor’s expense.

3-2.7 The Contractor shall keep all excavations clear of water during laying of ducts or cables, installation of

manholes and handholes and joints. He shall install well point system if required. No separate charges are payable for water removal.

3-2.8 The line of trench shall be kept as straight as possible. Where a change in direction is indicated between

manholes or handholes, the trench shall be excavated so as to provide as large radius as possible, unless otherwise noted in the drawing.

3-2.9 In no case, shall, the width of trench excavation be greater than is necessary for the satisfactory execution

of work. The width of the trench beneath the surface shall never exceed the width at the surface. 3-2.10 The Contractor shall be solely responsible for settling of all claims, damages and other suits arising out of

his work and the MOC shall neither be involved nor held responsible for settling such claims. 3-3 Depth of Trenches 3-3.1 In case of installing Nos. of ducts of less than maximum capacity for the type of MH, the lowest duct

shall be laid at 40 cm from the base of manhole, so that standard depth may be ensured for future expansion.

3-3.2 (a) Standard Depth of Trench for Manhole Route

The depth below the surface to the top of the uppermost ducts shall be 0.80 Meter or more.

(b) Standard Depth of Trench for Handhole Route The depth below the surface to the top of uppermost ducts shall be 0.6 Meter or more.

(c) In case of direct buried cables the depth below the surface to the top of the cable shall be 1 Meter or

more.

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(d) Leading-in Duct

The depth below the surface to the top of the leading duct shall be 0.4 Meter or more.

(e) In case that these routes cross the carriageway, the depth below the surface shall be 0.2 Meter extra.

(f) In case the depth of laying of ducts is likely to be different from standard depth due to the presence of

buried facilities or other reasons, the Contractor should submit the longitudinal profile drawings of the proposed duct route showing the location, elevation and size etc. of all other buried facilities including MOC ducts and manholes to the Ministry for approval.

(g) Meaning of “SURFACE” in the above context :

The “Surface” appearing in the context of the foregoing sub— paragraphs means the level of horizontal extension of the kerb top in case of footways and the centre of the asphalted road in case of carriageways.

Where a MH — HH has to be connected with a carriageway crossing, all depths are to be related to the depths of its carriageway crossing, not less than the standard construction dimension.

3-3.3 Where the surface of the ground is uneven; the trench shall be dug to a greater depth so that the ducts or

cables shall not undulate like the surface. Any grading of level, such as, is necessary at road crossings or in passing from sidewalk to carriageway and vice versa or where ducts have to enter manholes, handholes or in any other circumstances, shall be gradual as the Ministry Engineer may direct. The Ministry Engineer may also require the Contractor to lay ducts in depths other than the Standard Depths given above.

3-4 LAYING OF DUCTS 3-4.1.1 In general, UPVC ducts shall be used for all duct laying works with exception of situation, in the case of

steel ducts. AC ducts are to be used, only when it is required to repair or to be jointed with existing AC ducts. Jointing between AC and UPVC ducts shall be allowed in exceptional cases, after the approval of MOC Engineer.

The Contractor shall lay steel ducts in a portion where sufficient depth below the surface is not practicable, after obtaining the Ministry’s approval.

The Contractor shall use PVC Ducts in accordance with the design drawings and instruction of the MOC Engineer.

The duct configuration must be based on the standards given in Drawing No. TX: 347/4/D-l & TX: 347/4/D-lA.

The Contractor shall propose to the MOC, the expansion method after performing detailed field survey.

When proposing the expansion method, studies on the number of ducts in expansion and existing ducts, depth and arrangements of existing ducts, laying status of existing cable, road reservation and construction method as well shall be duly taken into consideration.

Consideration shall also be made as to the shift of existing ducts and re-arrangement of duct position.

Where required by Ministry, the Contractor has to lay new ducts instead of existing ducts which are to be abandoned. The Contractor shall make all necessary termination arrangements and seal abandoned ducts by approved methods. No separate payment will be made for such works and the whole work will be measured as laying of new ducts.

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In principle, expansion toward upper direction or horizontal direction shall be made for spans between manholes.

In installing duct at manhole position, a minimum depth below the surface and the minimum distance from duct axis to side wall / roof / base slab shall be ensured and effective duct arrangement shall be taken into consideration so that cable can be easily accommodated in manhole.

The work for feeder route where overlapped with distribution route shall be carried out with utmost care so as not to cause any damage to existing ducts of distribution route and not to interfere with cable work.

The Contractor should provide the spacers at intervals of 2 M. to hold the ducts in proper alignment. Spacers should also be provided at 1 M on either side of the joint point. Hence, for each AC duct, 2 spacers are to be provided whereas, 3 spacers for PVC ducts.

Two types of spacers viz. (1) top and bottom spacers, (2) intermediate spacers are to be used for the purpose. The top and bottom spacers are single sided and the intermediate spacers are double sided.

The spacers provided at one point should be in the same vertical plane and it may be fastened tightly with vinyl rope of less than 5 mm dia over the spacers to secure the duct nest with a minimum of two bindings. Alternatively, any other method for jointing of spacers may be used with prior approval of the MOC. In case of expansion of ducts, only the new ducts are to be connected together.

If ducts are not occupied fully in a pair of spacer, small length of 30 cm. of duct should be provided in order to have a compact strength.

Spacers should be divided into two categories such as, one for AC ducts and the other for PVC ducts. Spacers supplied shall be suitable for various configurations shown in Civil Drawing No. TX: 347/4/D-lA.

The Contractor may also use separate spacers with the interconnecting facilities. These spacers can be jointed for increasing the number of ducts and the minimum tensile strength of the connecting portion shall be 50 kg/sq. cm., or more. Spacers should be capable of withstanding a minimum compressive load of 500 Kg.

Spacers should be made of synthetic resin material and should be hard. Sample of spacer shall require approval from MOC before use.

The Tenderer should submit the specification, drawings, and sample spacers while submitting the offer. The cost of providing spacers shall be included in the cost of duct laying and no separate charges shall be claimed by the Contractor.

The installation cost of laying ducts should include, asphalt, RCC / Concrete cutting, removal of tiles, pilot holes, excavation of all types of soil and rock, shuttering, dewatering, protection and transfer or rearrangement of existing cables, protection of existing MOC ducts and other services, removal of any existing ducts, laying and jointing of ducts, providing of spacers, termination of ducts in MH and HH wall, sealing of ducts in cable vaults or tunnels, sealing of all ducts in the first manhole from cable vault, sealing / plugging of all ducts in other MHs and HHs, concrete encasement, backfilling and compaction, reinstatement and retiling to match with the original surface, mandrel test, pressure test, cleaning of work site and other necessary works.

As a matter of general instructions, utmost care shall be taken at the time of installation, not to damage any cable or joints provide perfect protection as per MOC standard and with consultation.

The bottom of the trench shall be cleaned of all water, dirt, sand, rubbish etc. , and shall be carefully leveled, watered and rammed. Where the ground is rocky, the duct shall be laid on well rammed 8 cms

15


thick layer of earth, free from stone, arranged by the Contractor. The Contractor must examine each duct before it is laid. If any defective or broken duct is laid, the Contractor should replace it at his expense. The Contractor cannot claim any additional charges for this from the Ministry. In case the ducts are required to be laid through the manholes of other services viz, water etc., the Contractor shall secure permission from the concerned Ministry, make suitable holes in the walls of the manholes with utmost care and seal them properly with cement mortar of 1:2 mix of cement and sand after laying the ducts etc. No additional charges shall be paid to the Contractor for such works.

The ducts shall not be constructed in an ‘S’ curve either in the latitudinal or longitudinal section except the portion near manhole in case of duct expansion as shown in Drawing Nos. 347/4/D-1 & D-lA.

A maximum of two grades shall be used in ducts between manholes or handholes. Duct run shall be straight for a distance of not less than 3 M. from the face of any manhole or handhole.

Level of any part of a duct between manholes shall not be lower than the duct terminating level at the manholes to prevent stagnation of water.

3-4.1.2 Expansion of existing Ducts — Where new ducts are shown on the drawings or are directed by the

Ministry Engineer to be installed to increase the size of an existing duct run, the new ducts shall be laid so as to maintain a standard duct configuration as far as is possible.

Wherever practical, and subject to the approval of the Engineer and the Ministry of Communications, the new ducts shall be laid on top of the existing duct. The practicality of such a procedure shall be determined by the minimum cover available and the requirements for duct termination arrangements at the adjacent manholes being acceptable to the Ministry of Communications.

Where the installation of new ducts on top of an existing duct is impractical or is not approved, the Contractor shall install the new ducts in accordance with the details shown on the drawings for “Duct Expansion” TX: 347/4/Dl & D-lA.

The method of excavation, laying of the new ducts and backfilling shall be agreed with the Ministry Engineer before work is commenced.

The existing duct run shall be adequately supported at all times to the satisfaction of the Ministry Engineer.

In all cases the new ducts shall be of UPVC.

In the case of expansion or increase of ducts the Contractor shall make necessary re—arrangement at the terminating position if proper clearances are not obtained.

3-4.1.3 Replacement of existing Ducts — Where a new duct route conflicts with an existing route which is to be

removed after re-cabling, the existing ducts containing cables shall be carefully broken out to provide slack in the cables to allow clear passage for the new work. Subject to the approval of the Engineer and the Ministry of Communications additional. slack may be obtained by releasing cables from clamps in adjacent manholes. The releasing of cables shall only be permitted under the supervision of the Ministry of Communications. The exposed cables shall be supported and protected to the entire satisfaction of the Engineer and the Ministry of Communications.

3-4.1.4 Repair of Ducts - The Contractor shall repair ducts in the following cases

(1) When directed by the MOC Engineer. (2) Whenever existing ducts which are to be retained are damaged, and the Ministry’s approval to

carry out repair work has been obtained.

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Ducts shall be repaired so that the original level and alignment of the ducts are maintained and so that cable can be laid or removed smoothly without obstruction.

The Contractor shall carry out all necessary excavation, backfilling and testing in accordance with the requirements of these specifications.

The Mandrel Test shall be carried out on all repaired ducts which do not contain cables.

3-4.1.5 Blocked Ducts in Manhole and Handhole Routes

If, after mandrel test, an existing duct is found to be blocked at one place in a span, it is to be repaired.

If blockages are found at more than one place in a span, the duct can be abandoned or removed, as instructed by the Ministry’s Engineer. New ducts be installed in lieu of abandoned ducts and it will be considered for payment purposes at the rate of laying of new ducts. Removal of abandoned ducts shall not be measured or paid separately but will be considered as incidental to the rates for installing the ducts.

3-4.2 Jointing of Ducts

(a) A.C. Duct joints shall be pressed home and shall be securely sealed with the bitumen or rubber rings, so

that the resultant joint is watertight. In no circumstances shall dirt or grit be allowed to enter the joints or foreign matter allowed to enter the ducts.

(b) Jointing of UPVC ducts using cement solvent.

The unplasticised PVC ducts shall be jointed with an approved cement solvent resulting in permanent gas tight and watertight joints.

After cleaning the duct ends for minimum 10 cms for dirt, dust, grease, oil etc., a thin coat of solvent cement shall be applied on both sides at the joint points and pushed until snugly fit. Shear strength and long term hydrostatic pressure of cement solvent when tested shall be in accordance with BS 4346. Joints should not be disturbed for at least 15 minutes. At very low temperature a longer time shall be allowed.

The Contractor shall provide documentary evidence that the cement solvent proposed for use is compatible with the UPVC ducts to be used and that it has been used in similar conditions to produce watertight and gas tight joints which would satisfy the requirements of this specifications. It shall conform to MOC Standard G20:l0:00l:32 Clause 4.9 and International Specifications (B.S. 4346, DIN 16970 or equivalent) referred therein. Before the procurement of solvent cement in larger quantities the Contractor shall supply 2 samples of joints made with the UPVC ducts and the cement solvent proposed for use along with test certificate from an independent laboratory for its strength and ability to withstand high pressure.

The Contractor shall also submit in detail, method of jointing employed to make the sample joints.

After getting approval from MOC Engineer for the sample joints the Contractor shall submit a detailed proposal regarding method of field jointing which shall include manufacturer’s recommended jointing procedure with any deviations there from. The Contractor shall demonstrate the suitability of his proposed jointing method by making 4 test joints under field conditions in the presence of the MOC Engineer and get his approval.

After getting approval for the test joints the Contractor shall strictly adhere to the method of jointing and

17


any deviation from the above method shall be made only with the prior written approval of the MOC Engineer.

The cement solvent shall be supplied in sealed containers with the Manufacturer’s name and date of manufacture and date of expiry of the solvent clearly marked on them. The cement solvent shall be uniform in quality and shall contain no precipitation or floating agent.

If the cement solvent is to be used with a primer the Contractor should also supply the primer along with the cement solvent. The solvent shall be stored with the containers tightly closed in a dark and cool place away from fire

(c) Cutting of ducts

Where it is necessary to cut ducts all burrs are to be removed and the cut end of the duct is to be

chamfered.

3-4.3 Protection of Ducts - If the depth below the ground surface to the top of duct is less than 80 Cm in the

case of manhole route and less than 60 Cm in the case of handhole route the ducts should be protected by concrete K-140. Ducts laid at all road crossings shall be encased in concrete K—140 irrespective of their buried depth.

A concrete encasement shall be constructed around the duct as shown in Drawing No. TX: 347/4/Dl & D-lA.

Concrete : K-140. Length : As required. Thickness : Ref. Drawing No. TX: 347/4/Dl & D-lA. Width : Ref. Drawing No. TX: 347/4/Dl & D-lA.

The actual method of installing the encasement shall be agreed with the MOC Engineer before commencement of work.

3-4.3.1 The duct arrangement and concrete protection wherever provided shall be based on the standard given in

Drawing Nos. TX: 347/4/D—l & D—lA.

Spacers shall be used to hold ducts in proper alignment and to keep the stipulated space between each duct. The Contractor shall submit Technical Specification, Test Report, drawings and two samples of the proposed spacers and obtain the MOC Engineer’s approval for the materials of spacers to be used before ordering any spacers for the work.

3-4.4 Termination of Ducts

To install ducts in new or existing manhole, handhole or exchange vault, K-300 concrete shall be used to perform the water—proofing work. For manholes specified in Drawing Nos. TX: 347/4/D1 & D-lA, place the water-proof concrete in 20 cms. thickness from the outside of the wall and similar terminations can be made in the case of handhole also. In the case of Exchange vault, place 100 cms. thickness water-proof concrete.

In case of R.C.C. Manholes and Handholes waterproofing membrane, rubber rings and protection to waterproofing shall be provided to make the termination of ducts completely watertight. The Contractor should submit the proposal and get it approved by the Ministry Engineer before execution of work.

All ducts installed in Exchange cable vault or tunnel, and first manhole from cable vault should be sealed by spigot of synthetic rubber or compound irrespective of whether the ducts are occupied or unoccupied, in order to prevent entry of water and insect into the exchange before execution. Sealing/plugging shall be done for all new ducts in MH/HH.

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In such cases, the end of ducts shall be stopped 3 cms inside the wall from the inner wall surface of manhole, handhole or exchange cable vault.

And thereafter, taking duct axis, as a centre point, finishing shall be made in a trumpet shape with mortar of 1:2 mix, so that there are no projections on the surface which may cause damage to the cable. (Refer to Drawing Nos. TX: 347/4/Dl & D-lA).

In the case of PVC ducts the duct socket (Bellmouth) may be used at the end of duct in the manholes/handholes instead of duct termination method mentioned in the previous two sub-paragraphs.

In case, duct bellmouths are to be used, the Contractor shall submit the sample, drawings and technical data for approval of the MOC before commencement of the work.

The material for the duct bellmouth should be the same as that of the PVC ducts. Regarding the size and shape of the duct socket, the Contractor may refer to the Drawings that will be supplied by the Ministry so as to facilitate proper cable accommodation and to have necessary strength for the joint of the Bellmouth with the PVC duct.

The whole work of sealing, termination of ducts into the wall, providing waterproof membrane, rubber rings, protection to water proofing, breaking of walls in existing manholes, handholes and exchange cable vault or tunnels, refacing or plastering the complete wall and dressing ducts ends shall be considered as part of the laying of ducts for the purpose of payment.

3-4.4.1 At road crossings, if the ends of ducts are not terminated in manholes or handholes, the duct openings

shall be effectively sealed with an approved sealing material or end cap to prevent possible blockage of the ducts by entry of soil or water.

The duct at road crossing shall extend beyond the Kerb or asphalt line upto the centre line of the telephone reservation. Where the number of ducts to be installed is less than the maximum capacity of the manhole type designated, the ducts shall be laid to form the lowest rows of the standard configuration duct layout unless other wise shown on the drawings.

3-4.5 Re-arrangement of ducts termination for manhole wall

The Contractor shall make necessary arrangement for duct terminating position whenever cable laying work inside manhole is difficult or if any instruction given by the Engineer, due to improperly existing duct terminating position in the manhole.

In such case, the Contractor shall make necessary excavation for duct-moving and re-construction of a part of manhole, if necessary.

Cost of any such rearrangement shall be included in the cost of duct laying / manhole construction.

3-4.6 Testing of Ducts

Testing of ducts shall be carried out after laying and backfilling, but with any dewatering system still in operation, in accordance with the following requirements

All tests shall be carried out in the presence of the Engineer or his representative and of a representative of Ministry of Communications.

(a) Mandrel Test

All ducts in every duct run shall be checked for alignment and freedom from foreign matter by passing two brushes attached to the ends of an approved iron or hard wood or plastic mandrel through in both directions. Where necessary or where directed by the Ministry Engineer the

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Contractor shall clean ducts with a stiff brush.

The mandrel shall be 90 mm in diameter and not less than 300 mm in length. The ends of the mandrel shall not have more than a 10 mm radius bevel. The diameter of the brushes shall be at least 60 mm greater than the nominal diameter of the ducts and at least 80 mm in length.

All labour and materials required for the testing shall be provided by the Contractor. The testing shall be successful if the mandrel passes freely through the duct in both directions.

In the event of any length of any duct failing to pass the test the entire length of duct will be rejected.

Test results obtained by the Mandrel Test shall be properly recorded and shall be immediately made available to the Ministry Engineer upon request. All results shall be presented to the MOC Engineer prior to the Final Acceptance Testing.

A Vinyl rope of 5 mm shall be provided after successful mandrel test of all ducts newly laid and after successfully rodding in existing ducts where required by the Ministry and all tested ducts shall be suitably colour marked as approved by the Ministry. The Vinyl draw rope shall be left in the duct and securely tied to the hardware at each end for future cabling.

(b) Pressure Test

After successful completion of the Mandrel Test the Contractor shall test a minimum of 10% of the UPVC Duct runs in every MH/HH span (subject to minimum of one duct run) with air at a pressure equivalent to a head of 10 M. of water using equipment and a method of test approved by the MOC Engineer.

Each duct run shall be stoppered and the pressure applied for a minimum period of 10 minutes to allow stabilization of conditions within the duct. The pressuring unit shall then be shut off and the pressure must remain without measurable loss for a period of 10 minutes.

The pressure shall be measured by an approved pressure gauge accurate to 2% at the required test pressure or an equivalent water head.

In the event of any duct run failing to pass this test all duct runs in the duct shall be tested, and the MOC Engineer shall decide upon the acceptability of the duct based on the results of all the tests. Should the MOC Engineer decide that the duct is unacceptable the Contractor shall carry out such remedial, repair or replacement works as approved by the MOC Engineer and the duct shall be retested.

3-4.6.1 Retesting

Should the MOC Engineer have cause to believe that damage or disturbance has occurred to any duct at any time after completion of the pressure test, he shall have the right to order retesting of the duct by the mandrel and/or pressure test.

3-4.6.2 Acceptance of Ducts for Payment Purposes

Notwithstanding any approvals given by the Engineer in accordance with the requirements of this clause, the installed ducts shall not be considered as accepted for payment until they have passed all the tests specified in this clause and written approval has been obtained from the Ministry of Communications.

3-4.7 Leakage of Ground Water

Any leakage of ground water into any duct run of any duct shall be cause for the MOC Engineer to reject the whole of that duct between adjacent manholes or handholes.

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MOC TND Specification No. 4 3-5 BACKFILLING 3-5.1 No backfilling shall be commenced before obtaining the approval of the Ministry Engineer for the works

covered by the backfilling. 3-5.2 The space outside the walls of manholes, handholes, and around ducts shall be carefully filled in with

earth free from stones and rammed, care being taken to avoid any damage. 3-5.3 Backfilling and compaction around ducts shall be carried out as each layer of duct is installed using fine

sand (Filler material). If more than one layer of ducts are to be installed the spacers required for supporting the second layer of ducts must be pushed on before the filler material is bedded around the first duct layer. When laying all further layers proceed in a similar manner.

The filler material introduced into the trench should be watered and compacted between the ducts with wooden rammers. The filler material is levelled with each laid out PVC duct layer in succession, whereby the thickness of filler material above the upper most duct layer must be 10 cm.

The upper layer above ducts shall be filled only after approval of pressure test and compaction between ducts by Ministry’s representative.

3-5.4 All excavated materials shall be screened to get soil free from rubbish, stone, deleterious materials etc.

and soil shall be approved before backfilling. This soil shall be replaced in layers not exceeding 20 Cm thick after compaction, the compaction field density to a degree of 95% in paved areas and 90% in unpaved areas of the maximum possible density of the same type of soil as tested after being compacted in the laboratory or to the requirements as per the General Specifications for Roads and Drainage. Compaction in the laboratory will be achieved by modified proctor method. Power rammers shall be used whenever practicable and where such use is impracticable, hand ramming may be employed.

3-5.5 Degree of compaction of backfilled material shall be tested in accordance of ASTM or BS or Kuwait

Standard Test Procedure. Test should be carried out at the rate of at least one specimen per span per layer or as directed by the Ministry Engineer. In case the specimen does not confirm to the required density and thickness, additional test may be taken to ascertain the limit of failing duct span, after which the Contractor shall re-excavate, breakup, fill, water, compact and level the layer again, if necessary, replace the material or add new earth at his own expense. The Contractor shall allow in his daily schedule of work enough time to permit the performance and checking of test before proceeding to any subsequent operation. Any faulty compaction shall be rectified by the Contractor to the satisfaction of the MOC’s Supervisor. The test for Compaction shall be performed by the Contractor at Government laboratory at his own expense.

Test result obtained through proctor test method shall be properly recorded and be included as document for Final Inspection and Acceptance Tests.

3-5.6 The Contractor shall remove all surplus material such as waste earth, broken ducts, and all debris from

site and leave all affected areas and surfaces in a clean and proper condition to the satisfaction of the Municipality Inspector and Road Section of the Ministry of Public Works. The Contractor shall furnish a certificate that all surplus materials have been cleared after the completion of the work; this certificate shall. accompany the Contractor’s bill.

3-5.7 The Contractor shall daily maintain the level of all road crossings by providing fill as necessary until re-

surfacing 3-5.8 The surface of all footway trenches shall also be regularly maintained by the Contractor until such time

as he shall undertake permanent reinstatement.

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MOC TND Specification No. 4 3-5.9 Poor compaction of fill, failure to leave the site of work clean and tidy or non-observance of any

requirements laid down above or of directions given from time to time will be regarded as a serious breach of contract which if repeated, be sufficient to justify the Ministry taking action against the Contractor.

3-5.10 The Contractor shall reinstate trenches in paved or unpaved footways to match the original surface.

Reinstatements of concrete in site or concrete flags and tile pavings shall be carefully executed and matched to the original surface. Any new flags or tiles used in replacement of broken / chipped ones shall match the original in colour, size, design and shall be mortar bedded and jointed. All necessary materials shall be provided by the Contractor at his cost.

3-5-11 Installation of subducts The contractor has to install 4(four ) numbers of 32 mm dia HDPE sub duct of different colours

having pulling rope ( GREEN , YELLOW, ORANGE , BLACK ) to lay relocate new /existing optical fibre cables .Two numbers of 100mm dia pipes to be subducted along all new or relocated routes irrespective of number of duct ways.

The contractor has to obtain material approval from MOC. All sub ducts must be installed in top layer of pipe configuration in consultation with MOC . The material of HDPE sub ducts must be as per MOC’S specification no . G20: 10: 001:40

3-6 MANHOLES AND HANDHOLES 3-6.1 Drawing References.

The Contractor shall construct Manholes and Handholes etc. according to the following latest standard amended Construction Drawings of the Ministry of Communications

22


NOTE

1. All Manholes shall be constructed with neck as shown in Drawing TX:368/l.

2. Manhole Covers recess to be filled with K—300 concrete.

K-300 concrete shall be used for construction of manholes and ‘handholes. A leveling course with 10 Cm

No. Description No. of Ducts Drawing No. No. of Sheets

1 Handhole (Precast or insitu) Upto 2 TX:371/5A 1 2 S1 Type Manhole (reinforced) 4 TX:347/9-1R 1 3 S2 Type Manhole (reinforced) 5 – 9 TX:347/9A-1R 1 4 S3 Type Manhole (reinforced) 10 – 20 TX:347/9B-1R 1 5 S4 Type Manhole (reinforced) 21 – 28 TX:347/9C-1R 1 6 S5 Type Manhole (reinforced) 29 – 40 TX:347/9D-1R 2 7 S6 Type Manhole (reinforced) 41 – 48 TX:347/9E-1R 2 8 L1 Type Manhole (reinforced) 4 TX:347/9-2R 2 9 L2 Type Manhole (reinforced) 5 – 9 TX:347/9A-2R 2 10 L3 Type Manhole (reinforced) 10 – 20 TX:347/9B-2R 2 11 L4 Type Manhole (reinforced) 21 – 28 TX:347/9C-2R 2 12 L5 Type Manhole (reinforced) 29 – 40 TX:347/9D-2R 3 13 L6 Type Manhole (reinforced) 41 – 48 TX:347/9E-2R 3 14 T1 Type Manhole (reinforced) 4 TX:347/9-3R 2 15 T2 Type Manhole (reinforced) 5 – 9 TX:347/9A-3R 2 16 T3 Type Manhole (reinforced) 10 – 20 TX:347/9B-3R 2 17 T4 Type Manhole (reinforced) 21 – 28 TX:347/9C-3R 2 18 T5 Type Manhole (reinforced) 29 – 40 TX:347/9D-3R 2 19 MT2 Type Manhole (reinforced) 9 TX:347/9A-4R 2 20 MT3 Type Manhole (reinforced) 10 – 20 TX:347/9B-4R 2 21 MT4 Type Manhole (reinforced) 21 – 28 TX:347/9C-4R 2 22 MT5 Type Manhole (reinforced) 29 – 40 TX:347/9D-4R 2 23 Exchange Manhole (reinforced) TX:347/5R 2 24 Pre- Cast Manhole TX:347/15 & 15-1 2 25 Standard Duct Arrangement,

Encasement for existing and proposed ducts, termination of ducts.

TX:347/4D-1 & D-1A

1

26 Base of Cabinet. TX:347/6B/D 1 27 Iron work and construction of

Necks for Manhole. TX:348/1 1

28 Laying & Coupling of leading in duct

TX:347/4D 1

29 Standard Draw Box and Sump hole Cover for Manhole.

TX:483 1

30 Typical Services Distribution in sidewalks.

TX:320/G 1

31 Manhole Cover and Frame(Ductile)

TX:481A 1

32 Handhole Cover and Frame(Ductile)

TX:482A 1

33 Guard Post for Cabinet TX:449/1 1 34 Symbol for Telephone Network TX:347/8D 1 35 Handhole (Precast in two part) TX:371/5B 1

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thick K—140 concrete shall be provided below the bottom slab of all R.C.C. Manholes/Handholes. The offset for the leveling course shall be of 10 Cm on all sides.

The Contractor should inform the MOC Engineer to check the measurement of reinforced bars according to the diagrams prior to the placing of concrete in the mould in case of R.C.C. Manho1es/Handholes.

R.C.C. Manholes situated wholly or partially below the ground water level shall be protected by applying self adhering waterproofing membrane to the external surface. Manholes situated wholly above the ground water level shall be protected by painting two coats with rubberised bitumen. The Contractor shall submit to the MOC Engineer for approval the samples and procedure of work before execution.

Pre-cast Manholes shall be provided with 100 mm UPVC bell mouths on all faces according to the full capacity of the Manhole. Pre-cast handholes shall be terminated with 2 Nos. 100 mm PVC bell mouths on each terminated face and two Nos. 50 mm UPVC bell mouths on each terminating face for leading in pipe termination. Cast insitu handholes shall be terminated 100 mm PVC ducts instead of bell mouths. Two Nos. 50 mm PVC leading-in duct termination of 1 M. length sha11 be provided on each side of cast insitu handholes instead of bell mouths. Duct ends, bell mouths and lead-in ducts which are not extended shall be sealed in an approved manner at both ends.

In all R.C.C. manholes / handholes (cast insitu) in which number of ducts terminated is less than the full capacity, additional number of ducts required to make up full capacity shall be installed for a length of 1 M. on each termination face and their ends shall be sealed in an approved manner. Wherever there is existing cables, MOC proposes to construct insitu Manhole & Hand hole. Or handhole in two part as per moc’s approved drawing no. TX-371/5B in consultation and approval from MOC.

All the above work including materials shall be considered as part of the work of manhole / handhole construction for purpose of payment.

Bell mouths for Manhole / Handhole shall be approved by the MOC Engineer before execution.

3-6.2 Iron works for manhole and handholes shall conform to MOC’ specifications and standard . The contractor has to submit samples of materials with technical literature/ specification and test

reports for MOC’s approval before supply . Anchor iron should not be placed by breaking a part of manhole but should be placed before placing of

concrete. For RCC Manholes, anchor iron should be set in shuttering and concrete cast.

Position of step installation shall be between neck and slab in case the neck is provided and at a middle point of slab in ease neck is not provided.

3-6.3 The cement blocks approved by the Ministry for repair of existing Manhole/Handhole etc. shall be

properly bedded in mortar with all joints full, courses level and faces vertical. Cement blocks shall be pre-soaked for a minimum of 4 hours immediately prior to use.

Exposed faces and internal faces of manholes or handholes shall be finished smoothly as there is no ruggedness of cement and bond and plaster as shown in the drawings.

The block work for the outer face of MH/HH should be well pointed.

3-6.4 In paved areas (Carriageway, Footways etc.) MH & HH covers shall be set to the same level and to the

same falls as the surrounding paved areas. In unpaved areas MH neck shall be set 200 mm above finished surface level unless otherwise shown on the drawings or directed by the Ministry Engineer. In all cases

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the Contractor should collect information about future plan of road and should decide the level in consultation with the MOC Engineer.

3-6.5 The Contractor may also be required to build manholes and handholes of dimensions different from the

standard type of manholes and handholes. In this case, the Contractor shall prepare new drawings and submit them to the Ministry for due approval and shall submit the strength calculations of the structure also. The above mentioned work such as designing, drawing and strength calculation etc. of special type of manholes and handholes are duly a part of the work of the Contractor and hence the Contractor cannot claim any additional payment for this from Ministry.

If the variation in the total quantity of reinforcement concrete + cement concrete + cement blocks due to the modification, alteration etc. is less than 15% of the total quantity of the above items of each standard manhole, handhole, no extra charges are payable. For calculation of the excess mentioned above, the neck shall not be taken into consideration.

The rate of charge for the special type of manholes and handholes shall be calculated on pro—rata basis of the manhole / handhole volume as against that of similar types of standard manholes / handholes.

3-6.6 Duct termination in manholes and handholes shall be in position so as to facilitate accommodation of

cables. When new ducts are installed or expanded in the manhole they shall be terminated at the centre portion of the manhole in the horizontal plane as far as possible. Minimum distance between the top duct axis and the roof slab or the bottom duct axis and the base slab shall be 40 Cms. Corresponding ducts shall be terminated on the same level as far as possible. However in L & T type and Exchange Manholes, level difference between ducts fixed in the straight direction and branching off direction should be not less than 34 Cm to avoid interference in cable laying and jointing. The angle of ducts termination with manhole and handhole shall be at right angle. If this is not possible the Contractor should submit the longitudinal profile drawings of the proposed duct route showing the Location, size and elevation etc. of all other services including MOC ducts, handhole and manhole to the MOC for approval. If the number of ducts terminated is less than the maximum capacity of the Manhole / Handhole spare ducts of length 1.0 M. shall be provided to obtain the maximum capacity of the Manhole / Handhole. The ends of these ducts shall be sealed in accordance with these specifications. No additional payment will be given for these spare ducts.

NOTE :

Cable racks fitting position for S-1 and L-1 type manholes shall be only one side (Building side) and so position of duct termination shall be at the cable racks fitting side from the centre line of the manhole.

3-6.7 In the case of manholes in water-logged areas, water-proofing, shall be done by the Contractor at his own

expense. 3-6.8 The manholes and handholes shall be thoroughly cleaned after construction is over and shall be free from

water, dirt, sand, rubbish etc.

All manholes and handholes shall be watertight and constructed at locations as shown in the approved drawings.

3-6.9 The Contractor shall provide housing base on the roof of new manhole designated for, installation of

distribution cabinet in accordance with MOC Drawing No. TX 347/6B/D or as approved by MOC according to the type of cabinet used.

In case of fixing of cabinet, on an existing manhole, the Contractor shall construct cabinet base on the new slab after demolishing the roof in full and in accordance with detailed drawings, approved by the MOC.

25


Removal of cabinet from existing manhole shall be made by removing bolts fixed to the housing base and then the base may be removed. The gap shall be filled with K-300 concrete after chiselling a portion about 20 Cms. in width and 5 Cms. in depth. Cabinets shall be returned to the MOC Store.

3-6.10 The Contractor shall provide necks for all newly installed manholes (Refer to Drawing No. TX 368/1).

The construction of neck shall be of R.C.C.

Height of the neck shall be of 20 Cms. Necks of height above 20 Cms. upto 60 Cms. is allowed if the site conditions do not permit to have 20 Cms. height. Whenever the height is less than 20 Cms or more than 60 Cms, the Contractor shall submit the necessary document for MOC’s approval. A neck higher than 60 Cms. may be directed by MOC in special cases. If neck high is more than 40cm,steps shall be provided at every 25cms.

Contractor shall fix the number plates for each new and existing Manholes and Handholes respectively.

The number plate shall be of size 100 mm x 60 mm and shall be made of stainless steel plate 1 mm thick. The plate shall be provided with four (4) holes 4 mm diameter for fixing on wall with screws and dowels. Letters shall be of size 7 mm, embossed or engraved and painted in black with white background painting in the plate.

Number plate for manhole shall clearly mention name of Exchange area, manhole number, type and size of manhole and year of installation. Number plate for handhole shall mention name of exchange area, handhole number and year of installation. Sample of number plate and method and position of fixing should be got approved by MOC, before commencement of work.

Number plate shall be fixed with screws and dowels on the neck of manhole or the shorter side wall of handhole at 10 Cms below the frame.

In the case of existing manhole without neck, number plate shall be fixed at roof slab near the frame of manhole cover.

3-6.11 The Contractor may have to construct neck on existing manholes to a height upto 20 Cms. or above 20

Cms. upto 60 Cms. depending on the ground level conditions. A neck higher than 60 Cms. may be directed by MOC in special cases.

.The existing manhole cover and frame shall have to be recovered in the first stage, taking due care for the existing cables, joints, fixtures etc., inside the manhole. The existing roof shall be chiselled to a depth of 5 Cms. and width of 25 Cms around.

Construction of the neck is the same as in the case of new manhole construction (Refer Drawing No. TX: 368/1).

The surface of roof around the neck shall be given a smooth finish and the manhole cover placed after curing.

3-6.12 In case that neck of existing manhole is just out of the road surface, banking around the neck should be

done to avoid danger to pedestrians and vehicles etc. The correct banking material should be piled up to the same level as the neck with easy slope and should be compacted sufficiently so that it is not blown away by wind etc.

Contractor should investigate about the places where the banking is to be done at the time of field survey and should get approval from MOC.

3-6.13 In case the existing manhole or handhole is to be demolished and re-constructed or a manhole or

handhole is to be newly established in the middle of the existing duct route, the cable in the duct concerned and other facilities shall be supported and protected with a completely safe method as approved by the MOC.

26


Manholes or Handholes and the portions of the duct termination shall be such that on completion, all existing cables will be fully supported on the cable racks.

Existing ducts falling within the newly constructed manhole shall be cut without damaging cables, if required by Ministry. Such cutting and removal of ducts shall be treated as part of manhole construction.

3-6.14 The Contractor shall install a manhole cover to the existing manhole where cover is missing or damaged.

Manhole covers voids shall be filled with K-300 concrete. 3-6.15 The existing Manhole roofs which have slid or are damaged, shall be replaced. In demolishing the roof

for replacement, care must be taken not to cause any damage to cables and other facilities in the manhole. 3-6.16 In case of having duct projected inside the existing manhole, the Contractor shall shave the inner wall

face of the manhole in the area of 3 Cm of duct circumference and 3 Cm in depth to cut the duct off.

The treatment as mentioned in para.3-4.4 shall be applied. Duct face shall be finished by plastering. In this case, care shall be taken not to cause damage to the existing cable.

3-6.17 In case of removing the existing manhole and handhole, the Contractor shall perform the removal work

with utmost care, so that the jointing points and other places are not damaged. In case new manhole construction is required at the same place, where the existing manhole has been removed, costs for excavation, backfilling and restoration shall not be duplicated in the price schedule.

3-6.18 In case, cable racks are not sufficient in quantity or corroded in the existing manhole, the Contractor shall

provide cable racks at the specified position, in accordance with the specified drawing and the specified position for supporting cables. For installing the cable rack, it is necessary to make a cavity at the position of fixing the hook-bolt and to fill the same with mortar (mixing ratio -Cement, Sand 1:2) and insert the hook-bolt in to the cavity. Surface shall be finished with plastering.

3-6.19 The Contractor shall provide iron ladder for the existing manhole, if the ladder is not provided with the

Manhole No. duly embossed or engraved on it.

Necessary step shall be installed. Position of step installation shall be between neck and slab in case the neck is provided and at a middle point of slab in case the neck is not provided. If the neck height is more than 40 Cms, steps shall be provided at every 25 Cms.

3-6.20 Pre-cast handhole may be constructed for the new handhole route where there is no existing

cables (Refer to Drawing No. TX: 371-5A). Approval to be taken from MOC before execution. 3-6.21 Pre-cast manholes can also be proposed by the Contractor where there is no existing cables and

approval obtained from the MOC before execution. Design details and calculations must be submitted by the Contractor. Rates shall not exceed rate for similar RCC Manholes and shall be subject to approval of the Ministry.

3-6.22 The newly constructed manholes shall be equipped with the following

Hinged type Manhole Cover and Ring according to Drawing No. TX: 481A.

Steel Ladder.

Cable Racks.

* Cable Supports.

Steps.

Anchor Iron and Sump hole Cover. 27


Number Plate.

* Each Cable Rack shall be equipped with Cable Supports in all positions (Full capacity).

3-6.23 The newly constructed handhole shall be equipped with hinged type handhole cover and its frame

(Drawing No. TX - 482 A), cable rack for handhole and number plate. 3-7 LEAD-IN DUCT 3-7.1 The Contractor shall lay lead-in duct (for laying the lead-in cable to the subscriber’s premises or building

from manhole, handhole or pole) to the subscriber’s intake duct or draw box fixed on the boundary wall and shall joint the lead-in duct with the intake duct or draw box.

The lead-in ducts shall be of UPVC from the manhole, handhole or pole to the draw box, except the exposed portions. The exposed portions near the draw box or pole• shall be of galvanized iron in accordance with material specifications. Suitable adaption according to the size of the ducts must be provided by the Contractor to connect the G.I. and PVC ducts with the approval of the MOC Engineer.

If there is no draw box on a boundary wall in the subscriber’s premises, as most of the subscribers have lead-in duct ready upto the outside of their premises, the Contractor shall carry out the field survey at the site, locating the existing duct by excavation, if necessary, and shall arrange to have the new PVC ducts effectively coupled to the existing duct, adopting a coupling and have the proposed method of coupling approved, by the MOC., securely tied to its hardware A draw rope of thermoplastic material of minimum 5 mm dia shall be provided throughout the full length of duct from handhole to Draw Box, in order to lay cable at a later stage at each end.

3-7.2 In case, no lead-in duct exists in the subscriber’s premises, the Contractor shall obtain the subscriber’s

consent on the position of Draw Box to be fixed on a boundary wall, and with the approval of the MOC Engineer, the Contractor shall lay lead-in duct from manhole, handhole or pole to level wherever possible, along the boundary wall. the boundary wall of the subscriber and shall fix Draw Box to the end of the lead-in duct raised to 160 Cms from the ground Alternatively, if so required by the Engineer, the Contractor shall inform the subscriber, in writing, to install the lead-in duct. In case there is no boundary wall, leading in duct shall be terminated in a draw box 300 x 300 x 75 mm at a place approved by the Ministry.

3-7.2A Incase of rehabilitation of area along with other services, the Contractor has to install a new leading in pipe along with draw box to each house.

3-7.3 The route of the lead-in ducts shall be shortest. In footpaths, care is to be taken of other services and

standard reservations as shown in Drawing No. TX: 320/G. 3-7.4 The lead-in duct shall bend smoothly at radius more than 6 times the outer diameter. The depth from

ground surface to the top of the duct should be 40 Cms. The ducts shall be so coupled throughout the whole length that there will be no difficulty in laying of the lead-in cable.

Joints of leading in PVC ducts shall be made with PVC couplings and sealed with solvent cement (BS 4346).

Coupling for jointing PVC duct to 50 mm G.I. duct should be made of PVC and have one end threaded and the other end shall be suitable for sealing with solvent cement.

In case of existing subscriber duct having different diameter, a reducing coupling shall be used.

The Contractor shall in these cases, submit sample for approval of MOC.

Premade bends should have a minimum radius of 6 times the outer diameter of the duct (See MOC

28


Standard G20:10:001:32) 3-7.5 All galvanised steel ducts to be buried, should be given a protective coating of bitumen. 3-7.6 The Contractor shall write the D.P. Number on the D.P. Box cover, installed on the pole or boundary

wall as well as draw box, as instructed by the Ministry of Communications. 3-7.7 Any damage to subscriber’s property during the work shall be made good by the Contractor at his own

expense. 3-7.8 After laying the ducts, both ends shall be carefully sealed with removable sealing compound to prevent

insects and reptiles getting entry into the building. 3-7.9 The Contractor shall reinstate all trenches for laying lead-in duct in paved or unpaved footpath and all

other places to match the original surface. 3-7.10 In case that lead-in duct is newly laid or replaced in manhole or handhole, regardless of existing

conditions, in general principle, the duct should be fitted on the same side as main duct.

However, in case it is not possible to fix the duct on the same side, Contractor should take approval from the MOC Engineer.

3-7.11 The cost of leading intake shall include all accessories, Draw Box / DP Box, Duct Termination in

Box and Handhole Coupling to existing subscriber’s ducts, numbering etc. 3-8. CLEARANCE TO UNDERGROUND SERVICES AND FACILITIES 3-8.1 Storm water and Sanitary Sewers, Water and Gas Mains and other Services Duct lines - Subject to the

requirements of other service Ministries, Authorities and Companies, a minimum clearance of 150 mm shall be provided between telephone installations (ducts, ducts and cables) and storm water and sanitary sewers, water and gas mains and other services duct lines.

3-8.2 Electricity Supply Poles and Pylons, Road Lighting Poles and Masts, Traffic Sign and Signal Poles,

Gantries and Overhead Supports - A minimum of 150 mm shall be provided from the above facilities and their foundations to any telephone installations.

3-8.3 Electric Cables — The minimum clearance between telephone cables and electrical cables shall be as

follows

(i) High Voltage Single Core Cables of Voltage greater than or equal to 650 V, but not more than 132 KV. ... 450 mm.

(ii) High Voltage Multicore ‘Cables of Voltage greater than or equal to 650 V, but not more than l32 KV. (with resistance earthing of neutral for 132 KV). ... 300 mm.

(iii) Low Voltage cables of Voltage less than 650 V. ... 150 mm.

Exceptionally, with the permission of the MEW Engineer and the MOC Engineer, the clearances given in (i) and (ii) above may be reduced at crossings of electric cables to a minimum of 150 mm. In such cases, a 75 mm. thick layer of K-140 concrete shall be placed between the electric cables and the telephone cables. The concrete layer shall be sufficiently wide to overlap the electricity cables by 75 mm on either side and be not shorter than the width of the telephone plant.

29


The minimum clearance between telephone installations and electric cables of voltage of 132 KV with direct earthing of neutral and all cables carrying voltages greater than 132 KV shall be determined as a special case for each location.

No reduction of the clearance shown on the drawings will be permitted without prior approval of the MEW Engineer and the MOC Engineer.

The Contractor shall be responsible for obtaining details of the type of electric cables to be crossed by or to run adjacent to the telephone plant to be installed under the contract.

3-9 INSTALLATION OF DISTRIBUTION CABINETS

In case distribution cabinets are required to be supplied and installed by other Ministry’s Contractor, the following specifications shall be applicable.

3-9.1 Distribution Cabinets of size 2400 pairs shall be supplied and installed by the Contractor. The locations

of these Cabinets will be shown in the Drawings of T.P. F.D. enclosed. The Cabinet shall be of such a size that it can be installed on any type of manholes.

3-9.2 It shall be installed on a reinforced concrete base in accordance with Drawing 347/6B/D, or as approved

by MOC according to the type of Cabinet used, to be cast along with the roof of the Manhole (while the manholes being newly constructed) or the base may have to be cast over an existing manhole.

3-9.3 The foundation bolts suitable for the make of the Cabinets shall be fixed while casting the concrete.

Special care shall be taken to ensure that the articles shall be securely fixed/embedded with correct position and the Contractor shall, at his own expense, provide all necessary templates, temporary supports and other plant and labor required.

Items to be embedded in the concrete shall be clean and free from oil or foreign matter that would weaken the bond of concrete to these items.

The Contractor shall make the distribution cabinet watertight, by sealing all apertures in the cabinet base.

3-9.4 The distribution cabinet shall normally be installed at the down side corner of the Manhole, on the

building line side, so that it is parallel to the road and facing the building side. In case of cabinets with doors on both sides, the side facing building will be front side (Face A) and side facing road will be back side (Face B). The position and type of the Cabinet shall be got approved from MOC before execution.

3-9.5 The Contractor shall write the cabinet number at front and back on each cabinet as instructed by the

MOC. The lettering shall be 100 mm block lettering. 3-9.6 The Contractor shall install guard posts around manhole cabinets newly installed and existing cabinets as

shown in Drawing No. TX: 449/1 to protect the cabinet from vehicles etc.

The Contractor should investigate about manholes for which guard posts are to be installed at the time of field survey, and should get approval from MOC.

3-9.7 The cabinets shall be earthed as specified in MOC Standard G20:10:001:24. The earth wire entry duct

installed in the Cabinet base shall be sealed properly after installation of earth wire, to prevent entry of water. The Contractor should include in his field survey report the details of existing cabinets which are to be earthed.

3-10 CONTRACTOR’S RESPONSIBILITY FOR PROTECTION OF THE INSTALLED PLANT

30


The Contractor shall be solely responsible for maintenance and protection of plant installed by him until such plants are provisionally handed over to the Ministry. In case any damage is caused to MOC Plant before provisional handing over, due to work by other Contractor / Agencies, it is the responsibility of the Contractor himself to get the plant repaired without delay and any cost incurred due to such damages should be settled with such Agencies / Contractors and any of the above responsibilities shall not be transferable to MOC in any manner.

3-11 COMPLETION REPORTS AND DRAWINGS 3—11.1 On completion of work, the Contractor shall prepare a written report of the final acceptance testing

including the tabulated results of all mandrel, pressure and compaction tests carried out, to the MOC Engineer which shall be accompanied by

(a) Set of completion drawings 3 copies with newly installed plant marked in red and As-built

Drawings to scale 1:2000 and conforming to A-l size showing actual status of As-built facilities. As-built drawings shall include three sets of prints and one set of Auto CAD polyester film of 75 Microns (0.003”), from which prints can be taken out along with CD with latest version of Auto Cad. Write on CD Project no. and Detail of Areas/ Road name .

(b) All As-built drawings must be Geographic Information Compatible pro-forma

with Coordinates as per WGS 84 GPS Projection system in decimal degree.

(c) Key map to a suitable scale showing clearly the location of Area / Street / Road.

(d) The as built drawing should include the following information

(i) Name or number of main road, street name / number.

(ii) Width of road / footpath. (iii) Distance of central line of plant from Kerbstone or centre of road.

Road Name Road No. Width of road Foot Path

Width

MOC’s centre line from kerb

stone

31


Where, A - Width of Footpath. B - MOC centre line from Kerb Stone. T.L - Telephone Line. K.S - Kerb Stone. B.L - Building Line.

(iv) Manhole No., Handhole No and drawing numbers. (v) Type of MH S1, S2 etc. and if ordinary or R.C.C. (vi) MH Span, HH Span (from Centre to Centre of HH or MH).

240.00 (9) UPVC

(vii) Cabinet No., Draw Box No., DP No. (viii) Nos. and types of ducts.

(ix) Depth of top level of ducts if it exceeds 1 M. (or complete profile drawings).

(x) Details of protection of ducts (concrete surroundings).

(xi) Size of drawing.

59.4cm MOC’s monogram

as per standard 2cm 84.0 cm

(xii) Direction of north may be marked on location plan & detail plan.

(xiii) When depth of top level of ducts if it exceeds 1M, complete profile drawings

should be submitted.

(xiv) Details of protection of ducts ( Concrete Encasement ) to be marked.

(xv) As built quantities:

MOC’S

STANDARD SIZE DRAWING

32


Legend Quantities

Existing Hand hole

Existing Manhole Type S-1

Existing Manhole Type L-1

Legend Quantities

Pipe laying 1 way

Pipe laying 2 way

( 2 ) Pipe laying 4 way

( 4 )

When the Engineer is satisfied that the work is complete, that all testing as specified have been carried out, and all documents have been submitted, he will inform the Ministry of Communications, who will carry out a final acceptance inspection for the provisional acceptance of the plant.

(d) In case of partial inspection also the above drawings and details must be submitted by the

Contractor to MOC.

3-12 INSPECTION AND ACCEPTANCE TESTS 3-12.1 The Inspection and Acceptance Tests specified herein shall be made after the physical completion of the external

plant facilities and shall not replace the normal supervision, inspections and tests to be made by the Contractor and the Engineer during the progress of the construction work. All Inspection and Acceptance Tests specified herein shall be performed by the Contractor at his cost under the supervision of MOC Engineer. Any reinstatement after the inspection is to be done by the Contractor at his cost.

3- 12.2 The main items of Inspection and Acceptance Tests by Ministry of Communications are given below: Inspection Acceptance Tests (1) Structure. (1) Mandrel Test. (2) Sump Hole. (2) Pressure Test for (3) Accessory Material. PVC Ducts. (4) Pulling Bolt (Anchors) (3) Proctor Compaction (5) Step. Test. (6) Ladder. (7) Cover Greasing.

33

MOC TND Specification No. 4 (8) Cleaning (9) Duct Laying and Termination. (10) Manhole No. Plate. (11) Cabinet. (12) Draw Box. (13) Lead – in Duct (14) Handhole No. Plate. (15) Wayer tightness of MHs/HHs. (16) Break Inspection (To Ascertain the depth of duct, concrete encasement, pointing, providing of spacers) and any other required information. 3- 12.3 “The physical completion of External Plant facilities” means:

(A) Manholes and Ducts for Feeder Cables.

After all works concerning Manholes and Ducts for the Feeder Cables to the farthest point from the Exchange in each Subscriber direction are completed.

(B) Handholes and Ducts for the Distribution Cables. After all works concerning Handholes and ducts from a Cabinets to its dead-end for the Distribution Cables are completed , including leading- in duct.

3- 12.4 Necessary equipment, laborers and costs for the Acceptance Tests and for any other tests required under this specification shall be provided by the contractor. Written reports including the tabulated results of the tests made by the contractor shall be prepared, signed by the contractor and the Engineer and submitted to MOC upon completion of the work.

3- 12.5 The Contractor shall perform Mandrel Test by using hard wooden mandrel of 90 mm in diameter and 300 mm in

length. The Contractor shall also perform Pressure Test as per Para 3-4.6(b) of this specification. Ducts to be tested shall be designated by the Ministry of Communications.

In case the test mandrel cannot be pulled through the duct or failure of pressure test during the acceptance tests

the ducts shall be rejected. 3- 12.6 The Contractor should repair all defects in the plant and re-offer for second inspection within 21 days from the

date of first inspection. If the work is again rejected in the second inspection or if the contractor fails to repair the defects within 21 days , MOC reserves the right to accept the work with due compensation from the contractor to the ministry for repairing the defects. If third inspection is required MOC may charge the contractor an inspection fee which will be decided by MOC. These compensation and other charges are with prejudice to any provision contained in the contract or penalty for delay etc.

34

Technical Standard No. G 20:10:001:22

M I N I S T R Y O F C O M M U N I C A T I O N S

T E L E C O M M U N I C A T I O N S S E C T O R

T E C H N I C A L S T A N D A R D

F O R

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H A R D W A R E F O R U S E

I N

M A N H O L E S A N D H A N D H O L E S

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I N D E X

1. SCOPE OF SPECIFICATION ................................................................................................................................................... 3 2. ASSOCIATED DOCUMENTS .................................................................................................................................................. 3 3. DESCRIPTION AND APPLICATION OF ITEMS ....................................................................................................................... 3 4. MATERIAL REQUIREMENTS ................................................................................................................................................ 3 5. MECHANICAL STRENGTH REQUIREMENTS.......................................................................................................................... 4 6. TESTS AND INSPECTIONS .................................................................................................................................................... 4 7. PACKING AND MARKING .................................................................................................................................................... 4

Drawing References Item MOC Drawing Reference

Cable Support (2 Cables) TX 368/1 Cable Support (4 Cables) TX 368/1

Cable Rack Manhole TX 368/1 Cable Rack Hand hole TX 368/1

Ladder Manhole TX 368/1 Step Manhole TX 368/1

Anchor Cable Pulling (Anchor Iron) TX 368/1 Sump hole Cover:

Hook Bolt Rack Bolt

TX 368/1

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1. SCOPE OF SPECIFICATION This specification covers the steel hardware used in the mnaholes and handholes of the local distribution network in Kuwait i.e.:

i. Cable Supports ii. Cable Racks in Manholes and Hand holes iii. Ladders in Manholes iv. Manhole Steps v. Anchor Irons vi. Sump-hole cover, Hook Bolt, Rack Bolt.

2. ASSOCIATED DOCUMENTS Standards of the International Organistion for Standardisatic (ISO) have been used when available. Where International standards are not available Standards in accordance with the British Standards Institute (BS) have been specified. A Tenderer proposing any other standards shall include the standards in his proposal for approval. The following standards have been referred to in this specification.

MOC G 30:10:03 Test and Inspection Manufacture MOC G 40:10:03 Tests and Inspections - Local ISO R 1459 Metallic Coatings: Protection against corrosion. Guiding principles ISO R 1460 Metallic Coatings: Hot dip BS 729 Part (I) Galvanised Coatings of Ferrous Metals ISO R 1461 Metallic Coatings: Hot dip galvanised Coatings on Fabricated Ferrous products ES 4360 Mild Steel; Composition MOC Drawing No.368/1 Iron Works and Construction of neck for Hand holes and Manholes

3. DESCRIPTION AND APPLICATION OF ITEMS

No. Description Of Item MOC Detail Drawing No. Application

1 Cable Support- 2 Cables TX-368/1 Used Together With Cable Racks In Manholes For Cable Support


3 Cable Rack Manhole TX-368/1 Used Together With Cable Racks In Manholes For Cable Support

4 Cable Rack Hand hole TX-368/1 Cable Support In Hand Holes

5 Ladder - Manhole TX-368/1 Provided In Manhole To Aid Descent And Ascent

6 Step - Manhole TX-368/1 Provided Inside The Neck Or Slab To Hook The Ladder

7 Anchor - Cable Pulling (Anchor Iron) TX-368/1 For Anchoring Guide Block Chain When

Pulling Cable 8 Sump Hole Cover And Bolts TX-368/1

Table 1

4. MATERIAL REQUIREMENTS 4.1. The material used for hardware shall be mild steel conforming to BS 4360 or equivalent. 4.2. The surfaces of the hardware shall be given a uniform galvanised coating of 610 g/m2 for steel items having a

thickness of 5 mm or more, 460 g/m2 for items aving thickness less than 5mm and 305 g/m2 for threaded items of 10 mm diameter and over. The galvanising shall be applied by dipping the products into molten zinc in accordance with ISO Standards R-1459, R-1460, R-1461, BS 729 Part I and LSO Standards or equivalent.

4.3. Anchors cable pulling must be secured to a plate, which is cemented into the concrete in non-re-enforced manholes and shall be secured to reinforcement bars in re-inforced manholes. They should be installed in such a way that they shall withstand a pulling force of 3O KN.

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5. MECHANICAL STRENGTH REQUIREMENTS 5.1. Cable supports and racks shall be able to support a dead weight of 120 Kg applied to their outer extremity

(non-wall side of manhole or hand hole) when tested in situ. 5.2. Ladders shall be able to support a vertical weight of 200 kg applied on any of the rungs without any cracking,

buckling, or bending of the whole ladder assembly or individual rungs.

6. TESTS AND INSPECTIONS All items must conform to the Tests and Inspection requirements detailed in MOC Standards G 30:10:03 and G 40:10:03.

7. PACKING AND MARKING Where supplied externally to Kuwait all items shall be suitably packed for overseas transportation. Where manufactured within Kuwait the method of packing and delivery shall be agreed with MOC. All packing shall be clearly labelled as follows:

i. Ministry of Communications, Kuwait plus Order number ii. Name of Supplier and Country of Origin iii. Description of items iv. Quantity of Items v. Gross Weight

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M A N H O L E A N D H A N D H O L E C O V E R S

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1. SCOPE ................................................................................................................................................................................. 3 2. ASSOCIATED DOCUMENTS .................................................................................................................................................. 3 3. QUALITY OF MATERIALS .................................................................................................................................................... 3 4. MANUFACTURE AND WORKMANSHIP ................................................................................................................................. 3 5. DIMENSIONS ....................................................................................................................................................................... 3 6. INSPECTION AND TESTING .................................................................................................................................................. 4 7. PACKING AND MARKING .................................................................................................................................................... 4

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1. SCOPE

1.1. This technical specification describes Medium Duty ductile Iron Manhole and Handhole Covers. 1.2. Each complete manhole cover shall consist of the cover and its frame. 1.3. Each complete handhole cover consists of two pieces called the “Upper Cover” and “Lower Cover” and the

receptacle called the “Frame”. 1.4. The Handhole cover must be double hinged type as per approved MOC’s drawing . The gasket has to be

provided in frame to stop entry of water . 1.5. MOC is studying the proposal to upgrade existing metallic manhole and hand hole covers to Glass reinforced

plastic (GRP) as soon as it is finalized. Hence, MPW/NHA/consultant /contractor should confirm MOC’s approval of GRP covers before quoting or supplying manhole and hand hole covers

2. ASSOCIATED DOCUMENTS Kuwait Standards (KS) , American standard and British Standards (BS) have been used where applicable and are

detailed below: G 30:10:03 MOC Tests and Inspection - Manufacture G 40:10:03 MOO Tests and Inspection - Local KS 22 1971 Kuwait Standard relating to Manhole and Handhole covers

BS – 2789 Grade 500/7 standard relating to Manhole and Handhole covers

En 124 Method for the Loading verification of testing machines MOC Drawing No. TX: 481A Manhole Covers and Frames MOC Drawing No. TX: 482A Handhole Covers and Frames

3. QUALITY OF MATERIALS The covers and frames shall conform to Kuwait Standards Specification No. KS22-1971 and BS-2789 Grade 500/7 and ASTM A 536 and MOC Requirements detailed in the following Paras. The metal used for these items shall be suitable for the method of manufacture, and shall be of a quality no less suitable than those specified in BS 2789 Grade 500/7 and ASTM A 536 (Ductile Iron).

3.1. The tensile strength shall not be less than 19 Kg/mm3 i.e. 12 tons/in2 in case of 30.5 mm diameter of Test Bar as cast (US 1452).

3.2. The weight shall be corresponding to the dimensions as specified in KS 22-1971and tolerance of + 5 % is permissible.

3.3. All covers and Frames shall be coated with black bitumen paint and greased after treatment by heat for anti~rust protection. The paint coating shall be smooth and tenacious and shall not flow or chip when exposed to temperatures of between –10 °C and 85 °C.

4. MANUFACTURE AND WORKMANSHIP All covers and frames shall be cleanly cast and shall be free from air holes, sand holes, cold shuts and chill. They shall be neatly dressed and carefully fettled. All castings shall be free from voids whether due to shrinkage, gas inclusion, or other causes. The covers shall fit the frames properly and tightly and shall not leave any crack. Any crack or defect is not acceptable.

5. DIMENSIONS The dimensions shall be according to KS 22-1971 and up dated as per ductile iron material and approved drawing and are detailed in the following drawings: Manhole Cover Frame Drawing No. TX: 481A Manhole Cover Drawing No. TX: 481A Handhole Cover Frame Drawing No. TX: 482A Handhole Upper Cover Drawing No. TX: 482A Handhole Lower Cover Drawing No. TX: 482A

5.1. Tolerance of + 2.5 % for all dimensions except the gap between the cover and the ring which must not exceed 5 mm in the case of manhole cover and 2 mm in the case of handhole covers, tolerance between 0.8 mm and 1.5 mm in the upper edge of the inside of the frame and respective tapering position of the cover and + 0.5 mm in the case of keyholes, are permissible.

5.2. On the top of each cover shall appear the letter Telephone Net work in Arabic and English and on the backside the manufacturer's name and year of manufacture.

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5.3. The handhole covers shall indicate the difference between upper and lower covers , “UP” and ‘DN’ may be written on respective cover .

5.4. The manufacture/ Supplier has to obtain Manhole and Handhole cover drawing approval for ductile iron from MOC before manufacturing .

6. INSPECTION AND TESTING

6.1. Inspection and Testing shall be carried out in accordance with MOC Standards G 30:10.03 Test and Inspections Manufacture and G 40:10:03 Test and Inspection - Local. These tests shall include the load test detailed in Para 6.2 below.

6.1.1. The covers shall be available for inspection and testing at any time during manufacture or after finish, by the MOC appointed Inspector. The manufacturer shall provide necessary equipment and testing facilities.

6.1.2. One cover and frame in every 50 of each type manufactured, shall be tested by the method and to the requirement specified in Para 6.2 for test loading. In the event of any one of the Articles in the batch of 50 failing to meet the requirement of the standard, the articles in the batch shall be rejected, unless all the particular articles are individually tested.

6.2. Loading Test 6.2.1. The covers shall be required to satisfy the necessary load test and shall be considered satisfactory if they

sustain a 20 tonne force for a manhole cover and 15 tonne force for a handhole cover for period of 30 sec without fracture. The diameter of the bearing block used shall be 300 mm.

6.2.2. The procedure for loading test shall be as follows: 6.2.2.1. The apparatus required for the loading test shall consists of: 6.2.2.2. A supporting frame which shall be a standard frame or a specially made support, used solely for

testing purposes which shall provide the same conditions of support as a standard frame. 6.2.2.3. A bearing block, of 300 mm diameter. It shall be made of hardwood faced with hard rubber, or other

resilient material, and sufficiently rigid to ensure that the load on the cover is evenly distributed over the full area of the block.

6.2.2.4. A device preferably a hydraulic testing machine for applying the load. The device shall be capable of applying a load at least 25 % greater than the appropriate load specified in Para 6.2.1. If a testing machine is used, it shall comply as regards accuracy with Grade B of BS 1610 (Method for the Loading verification of testing machines). If any other load-measuring device is used, it shall be accurate to within two per cent of the indicated load.

6.2.3. The load test shall be carried out as follows: The cover or grating shall be supported in the frame and the bearing block shall be placed centrally over the cover. The appropriate load specified in Para 6.2.1 shall be applied without shock and shall be sustained for a minimum period of 30 sec.

7. PACKING AND MARKING Frames and covers shall be securely packed for overseas transportation when ordered from outside Kuwait. When ordered locally the method of packing and delivery will be agreed between MOC and the Supplier. All packages must be securely labelled with the following information:

i. Ministry of Communications, Kuwait plus Order Number ii. Description of Item iii. Quantity or Length of Item iv. Gross Weight of Item v. Manufacturer's Name and-Country of Origin

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U P V C D U C T S , B E N D S , C O U P L I N G A N D B O N D I N G

M A T E R I A L S A N D S P A C E R S

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1. SCOPE ................................................................................................................................................................................. 3 2. ASSOCIATED DOCUMENTS .................................................................................................................................................. 3 3. TEMPERATURE AND ENVIRONMENT ................................................................................................................................... 3 4. MATERIALS ........................................................................................................................................................................ 3 5. MECHANICAL, THERMAL AND ELECTRICAL PROPERTIES ................................................................................................... 5 6. TESTS AND INSPECTION...................................................................................................................................................... 6 7. STORAGE ............................................................................................................................................................................ 6 8. PACKING AND MARKING .................................................................................................................................................... 6

Item Description Of Item Use 1 UPVC Duct 100 mm 0 × 6 m 2 UPVC Duct 50 mm 0 × 4 m 3 Couplings for 50 mm Ducts 4 Cement Solvent Compound 5 Spacers for UPVC Ducts 6 Bends

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1. SCOPE This specification covers the manufacture, testing, and supply of UPVC ducts and accessories for use in the cable ducting network in Kuwait. 1.1. The ducts fall into two categories i.e.

i. 100 mm diameter duct for manhole and hand hole linkage. ii. 50 mm ducts for lead-in facilities to subscribers premises when small size cables are used.

2. ASSOCIATED DOCUMENTS 2.1. Standards of the International Organisation for Standards (ISO), British Standards (BSI) and the American

Society for testing and materials (ASTM) are applicable in this specification the latest issues shall apply and deemed to be an integral part of this specification. Where equivalent international or other standards are used details shall be submitted with any tender.

2.2. The following standards have been referred to in this specification. BS 2782 BS 3505 Un-plasticised UPVC Duct/Spacer BS 3506 BS 102c Softening Point BS 4346 Cement Solvent ASTM D 2564 - 73A Solvent ASTM 792 Density ASTM D 1708 Modulus Elasticity ASTM D 2240 Hardness ISO R 174-E Modulus of Viscosity

3. TEMPERATURE AND ENVIRONMENT 3.1. The ducts are for installation in excavated trench works throughout Kuwait. They shall be capable of meeting

the following temperature requirements. Installed: -10 °C to +55 °C Ambient Temperature During Storage & Transportation

i. –100 °C to +550 °C Ambient Temperature ii. +89 °C maximum sun Radiation Temperature for period of days

3.2. The ducts shall be resistant to any corrosive elements found naturally in the ground in Kuwait. They shall be unaffected by water, oil, oxidising Agents, salinity, aggressive soil, sand, fungi growth and bacterial or electrolytic actions.

4. MATERIALS 4.1. The duct compound shall be rigid UPVC without plasticiser, lubricants, and stabilisers. Anti-oxidants and

pigments may be added. 4.2. No constituent material shall be used which will adversely affect the long-term mechanical strength of the

UPVC. All constituents shall be uniformly and fully dispersed. 4.3. The tenderer shall state in his proposal the name of the manufacturer of the UPVC compound and also its name

or code number. 4.4. The colour of the material shall be light grey. Pigments shall be titanium oxide and carbon black. The

maximum pigment and filler content shall be 5 %. 4.5. Ducts shall be homogeneous throughout. All surfaces shall be clean smooth, and without any visible cracks,

grooves, blisters, wrinkles, dents, beat marks or foreign inclusions. Ends shall be square and free from sharp edges.

4.6. UPVC Ducts For MH And HH Route The UPVC ducts shall be supplied in 6 m lengths. The ducts shall have minimum 100 mm internal diameter and minimum 4.5 mm thickness. The UPVC ducts shall have one end plain and the other end a 100 mm expanded socket for spigot coupling. The expanded end shall have a wall thickness not less than that specified for the duct, and the tolerance on the fit of the spigot and socket shall be compatible with the requirements for jointing specified herein. Bends shall mainly conform to Figure 3-a. The spigot end of each duct shall be indelibly marked with a continuous circumferential black line 100 mm from the end of the duct. This line shall be used as a measure of the penetration of the spigot into the socket of the adjoining duct, so that joints, which show in the opinion of the Ministry Engineer, inadequate penetration may be rejected. The manufacturer’s name and year of manufacture shall be clearly marked on each duct.

4.7. UPVC Ducts For Leading-In The ducts shall be supplied in 4 m lengths. The ducts shall have a minimum 3 mm wall thickness and external diameter of 50 mm. Bends shall mainly conform to Figure 3-b.

4.8. 50 mm ducts shall be jointed with couplings and cement solvent. The coupling pieces shall be made of identical UPVC material to the ducts and shall be 98 mm in length.

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4.9. Cement Solvent 4.9.1. All joints for UPVC ducts are to be made with cement solvent. 4.9.2. The cement solvent shall be in accordance with BS 4346 or equivalent. The cement solvent shall be

supplied in sealed containers with the manufacturer’s name, date of manufacture and date of expiry of the solvent clearly marked on them. The cement solvent shall be uniform in quality and shall contain no precipitation or floating agent.

4.9.3. If the cement solvent is to be used with a primer, the contractor should also supply the primer along with the cement solvent. The solvent shall be stored with the containers tightly closed in a dark and cool place away from fire.

4.9.4. The joint made with the cement solvent shall have a min. shear strength of 6 Kg/cm² after one hour and 20 Kg/cm² after 24 hours and 50 Kg/cm² after 336 hours. The joint shall not leak when tested for long-term pressure of 47 bars for 25 hours and 40 bars for 1000 hours at 20 °C in laboratory conditions.

4.9.5. 50 mm UPVC ducts for leading in shall be jointed with a coupling and cement solvent. The coupling shall be made of UPVC and 98 mm long. The coupling for jointing with GI duct shall be made of UPVC and have one end threaded, and the other end shall be sealed with solvent cement. Suitable reducing couplers shall be used for jointing 50 mm UPVC ducts with subscriber’s duct of different sizes.

4.9.6. The number of joints that can be made with 1 Kg of solvent and one kg of cleanser shall be indicated. Shelf life and any special precaution to be taken during use must be clearly stated. Solvent cement and cleanser shall be packed in airtight tins of 1 Kg and 0.5 Kg respectively. The contractor shall submit the test result of shear strength and long-term hydrostatic pressure for approval.

4.10. Spacers For UPVC Ducts Materials for spacers for UPVC pipes/ducts should be made of synthetic Resin or UUPVC conforming to clause 5 below and should be hard. Spacers supplied shall be suitable to hold the pipe nest together without any deformation or damage in the various duct configuration (max. 8 rows × 6 pipes) shown in MOC Civil Drawing No. TX: 47/4D-1. Two types of spacers shall be supplied:

1. Intermediate Spacers (Figure 1). 2. Top and bottom Spacers (Figure 2).

The width of the rim supporting the duct shall be 28 + or - 0.2 mm all around. The inner diameter of the rim shall be minimum 111 mm with a maximum tolerance of + 0.5 mm / -0.0 mm. The spacers supplied for UPVC Ducts shall conform with the MOC Drawings shown above and shall be grey in colour. The spacers shall be provided with interlocking facilities such that it can be used with any duct configuration. The spacers should be capable of withstanding a minimum compressive load of 500 Kg and shall take a minimum tension load of 150 Kg without break. The minimum tensile strength of interlocking portion shall be 50 Kg/cm². Certified test data from KISR or any International Testing Organisation shall be submitted and the Spacers shall require MOC approval before use in MOC Plant.

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5. MECHANICAL, THERMAL AND ELECTRICAL PROPERTIES 5.1. MOC Requirements for the UPVC material and the finished products are as detailed in Table 1.

Item Description of Quality MOC Requirements Test Method

1 Density (without filler) 1.4 – 1.5 gm/cm³ ASTM D 792 2 Co-efficient of viscosity (without filler) 57 – 70 ISO R174-1961E 3 Modulus of Elasticity 27-32 KP/cm² ASTM D 1708 4 Hardness Shore D 80 - 85 ASTM D 2240 5 Tensile Strength Min. 500 KgF/cm2 BS 3505/6 6 Softening Point Min. 85°C BS 102/C 7 Flexural Strength 950 KgF/cm2 +/- 10% BS 3505/6 8 Compressive Strength 560 KgF/cm2 (Min) BS 3505/6 9 Impact Strength 4.5 Joules/M BS 3505/6

10 Co-efficient of Linear Expansion 5X 10-5 °C BS 3505/6 11 Insulation Resistance at 60 degrees C 600 MΩ MOC Requirement 12 Dielectric Strength at 270C 1000 V/mil(min) MOC Requirement 13 Specific Heat 0.25 Cal./°C/gm BS 3505/6

Table 1

5.2. The ducts, couplings and spacers shall not ignite or support their own combustion.

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6. TESTS AND INSPECTION 6.1. Manufacturers will be expected to supply certified test data in respect the required qualities detailed in Table 1.

If MOC inspection is required they will also be required to demonstrate the required tests at the MOC appointed Inspector’s discretion.

6.2. In the event of samples failing the required tests MOC reserve the right to reject all of the consignment involved unless duct lengths are tested individually.

6.3. Test and Inspections will be as defined in MOC Standards G 30:10:08 and G 40:10:08. 6.4. Where ducts are delivered directly to a contractor it is his responsibility to advise MOC so that inspection may

be carried out and a materials acceptance certificate issued. No materials may be utilised by a contractor prior to the issue of this certificate.

7. STORAGE Ducts shall not be stored in direct sunlight for long periods and shall be stored in such a manner that sagging and bending is prevented.

8. PACKING AND MARKING The method of packing and delivery of ducts shall be agreed between MOC and the Manufacturer / Supplier in case of ducts manufactured in Kuwait. When the ducts are supplied from outside Kuwait, a label indicating the following information shall be fixed on each packing.

i. Ministry of Communications Kuwait and Order Number ii. Size of ducts iii. Quantity of Ducts iv. Manufacturer’s name

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F O R

M A T E R I A L S

N O . G 2 0 : 1 0 : 0 0 1 : 3 3

M A T E R I A L S

F O R

C I V I L W O R K S

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I N D E X

1. SCOPE ................................................................................................................................................................................. 3 2. ASSOCIATED DOCUMENTS .................................................................................................................................................. 3 3. CEMENT.............................................................................................................................................................................. 3 4. SAND .................................................................................................................................................................................. 3 5. WATER ............................................................................................................................................................................... 3 6. AGGREGATE ....................................................................................................................................................................... 3 7. STEEL RE-ENFORCING BARS .............................................................................................................................................. 3 8. TESTS AND INSPECTION ..................................................................................................................................................... 4 9. PACKING AND MARKING .................................................................................................................................................... 4

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1. SCOPE This specification defines the required standard for materials used in the civil works involved in the installation of outside plant. Materials covered are as follows:

i. Cement ii. Sand iii. Aggregate iv. Water v. Steel Re-enforcing bars.

2. ASSOCIATED DOCUMENTS MOC G 30:10:09 - Tests and Inspections - Manufacture MOC G 40:10:09 - Tests and Inspections - Local AST C 150 BS 410 BS 812 BS 882 BS 4449 BS 4482

3. CEMENT 3.1. Cement shall be sulphate resistant type 5. 3.2. The cement shall meet the requirements and satisfy the tests contained in ASTM C-150. 3.3. The cement shall consist of a uniform fine powder with no evidence of bonding of the powder articles. Any

cement showing traces of particle bonding shall be rejected.

4. SAND 4.1. Sand shall be clean, sharp, gritty and free from loam, organic matter or adherent coatings. It shall not be shore

sand taken from a seashore. 4.2. The sand shall conform to BS 410, 812, and B82. 4.3. The sand shall be well grained. Grains shall be of varying size upto a maximum limit of 2.36 mm, and the

percentage by mass passing through a 2.36 mm sieve shall be betwwen 60 % and 100 %.

5. WATER Water from the potable (drinkable) supply system of Kuwait shall be used. No other source is permissible without specific agreement from MOC in writing after an analysis of the proposed supply has been carried out at the cost of the proposer.

6. AGGREGATE The aggregate for concrete should be clean-screened ballast, gravel or stone conforming to BB 410, 812, and 882. The material should be in the form of cubes or spheres (not flakes) and should be uniformly graded from 2 cm upwards to the maximum size of 4 cm. It should be free from dirt, floury stone dust, loam and earth or other like materials. Clinker, brick, sandstone or other porous stones shall not be used.

7. STEEL RE-ENFORCING BARS All reinforcing steel bars shall comply with the requirements of AASH TO M 31 (ASTM - 615) and shall be grade 60 deformed steel bars and shall be minimum requirements as detailed below

Property Grade

Tensile Strength (minimum) 6327 Kg/cm² Yield (minimum) 4218 Kg/cm²

Elongation In 200 mm Length Bar size up to 20 mm 9 mm

21 to 24 mm 8 mm 25 to 30 mm 7 mm

Table 1

7.1. The reinforcing bars shall be free from mill scales, cracks, heavy rusting or other deformities. Only light rusting is acceptable.

7.2. The reinforcing bars shall not suffer any impairment when bent. 7.3. The reinforcing bars shall be made in accordance with the shape and measurement given in the design

drawing, by a method, which is not detrimental to the quality of materials being used.

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7.4. Re-enforcing bars shall be free of all heavy rust, mud, oil, paint ore prior to use. Only light rusting is acceptable.

8. TESTS AND INSPECTION Test and Inspection shall be carried out in accordance with MOC Standards G 30:10:09 and G 40:10:09.

9. PACKING AND MARKING 9.1. Cement shall be delivered in sealed branded bags. The bags shall be of adequate strength to withstand handling

during transportation and storage. Bags shall be marked with the Manufacturer’s name and the grade of cement.

9.2. Sand and Aggregate may be delivered in loads in open vehicles. A certificate of quantity shall be supplied at the time of delivery.

9.3. Steel reinforcing bars shall be delivered in such a manner that they are not subject to excessive bending or crushing during transportation.

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G A L V A N I S E D P I P E S A N D T R O U G H S

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Description Of Items

Item Description Of Item

1 Steel Pipes 50 & 100 mm 2 Coupling Pieces for Steel Pipe 50 & l00 mm 3 Right Angle Bends for Steel Pipe 50 mm 4 Steel Troughs 30 mm2, Length: 300 cm 5 Steel Troughs 55 mm2, Length: 300 cm 6 Steel Troughs 105 mm2, Length: 300 cm 7 Right Angle Couplings for Steel Trough 30 mm2 8 1 Right Angle Couplings for Steel Trough 65 mm2 9 Right Angle Coupling for Steel Trough 105 mm2

I N D E X

1. SCOPE ................................................................................................................................................................................. 3 2. ASSOCIATED DOCUMENTS .................................................................................................................................................. 3 3. MATERIAL AND MANUFACTURE ........................................................................................................................................ 3 4. DIMENSIONS ....................................................................................................................................................................... 3 5. COMPLIANCE ...................................................................................................................................................................... 4 6. INSPECTION ........................................................................................................................................................................ 4 7. PACKING AND MARKING .................................................................................................................................................... 4

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1. SCOPE This specification covers the requirements of galvanized steel pipes and steel troughs.

2. ASSOCIATED DOCUMENTS 2.1. The latest issues of standards shall apply and deemed to be integral parts of this specification. A Tenderer

applying any other Standard, which is equivalent or better, shall submit the standard for approval with their proposal. The following standards are referred to in this specification: MOC G 30:10:11 - Tests and Inspections - Manufacture MOC G 40:10:11 - Tests and Inspections - Local ISO R 630 - Steel Quality ISO R 228 - Threads ISO R 1459 - Hot Dip Galvanizing ISO R 1460 - Hot Dip Galvanizing ISO R 1461 - Hot Dip Galvanizing

3. MATERIAL AND MANUFACTURE 3.1. Steel Pipes

3.1.1. The steel quality for the steel pipes shall be in accordance with ISO R 630, FE 37A, BS 21, 427, 1387. 3.1.2. The pipes shall be Medium Duty seamless, free from dents and internal roughness. The ends of the tubes

shall be reamed to prevent abrasion against the cable. 3.1.3. The outside ends of the pipes shall be threaded with a pipe thread to ISO Recommendation (International

Standardisation Organization) R 228. 3.1.4. The pipes shall be joined together by means of a coupling of the same material as the pipes. 3.1.5. After completion of forming operations the pipes and couplings shall be hot dip galvanized to meet the

requirements of the ISO Recommendations R 1459, R 1460 and R 1461. The zinc coat shall have a minimum thickness equivalent to 305 g/m².

3.2. Steel Troughs 3.2.1. The troughs shall be made of hot-rolled steel. 3.2.2. After completion of the forming operation the troughs shall be hot dip galvanized to meet the

requirements of the ISO Recommendations R 1459, R 1460, R 1461, and BS 729 Part (I). The zinc coating shall have a minimum thickness equivalent to 610 g/m².

4. DIMENSIONS 4.1. Steel Pipes

4.1.1. The pipes shall have the dimensions as stated in Table 1.

Nominal Inside Diameter (mm)

Nominal Wall Thickness (mm)

40/50 3.25/3.65 100 5.40

Table 1 4.1.2. Straight pipes shall be supplied in lengths of 2 – 6 m as specified. 4.1.3. Bends shall be provided for 900 angle. The bending radius shall be approximately 500 mm.

4.2. Steel Troughs 4.2.1. The troughs shall have dimensions as stated in Table 2.

Incise Wall

Thickness (mm)

Width (mm)

Height (mm)

30 30 1 55 55 1

105 105 1

Table 2 4.2.2. The troughs shall be supplied in lengths of 300 cm. 4.2.3. 900 bends of steel to fit the troughs shall be provided.

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5. COMPLIANCE The Tenderers shall state their compliance with the specification. Any deviations suggested by the Manufacturer, shall be fully documented and presented in the form of an alternative offer.

6. INSPECTION Inspection shall be performed as described in MOC Standards G 30:10:11 and G 40:10:11.

7. PACKING AND MARKING Pipes and troughs shall be delivered in such a manner that no damage is incurred during transportation. Banding of pipes into bundles will be allowed but not for troughing. Consignments shall be clearly labelled with the following details:

i. Ministry of Communications Kuwait plus Order Number ii. Description of Items iii. Quantity of Items

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H D P E S U B D U C T S A N D A C C E S S O R I E S

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I N D E X

1. SCOPE.................................................................................................................................................................3

2. ASSOCIATED DOCUMENTS ...................................................................................................................................3

3. TEMPERATURE AND ENVIRONMENT ....................................................................................................................3

4. MATERIALS...........................................................................................................................................................3

5. HDPE SUB DUCTING ACCESSORIES......................................................................................................................4

6. TESTS AND INSPECTION........................................................................................................................................4

7. STORAGE...............................................................................................................................................................4

8. PACKING AND MARKING...............................................................................................................................4

Item Description of Item Use 1 HDPE Subducts 32(OD)/28(ID)mm 2 HDPE Subducts 25(OD)/21(ID)mm 3 HDPE Subducting accessories

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1. SCOPE This specification covers the manufacture, testing, and supply of HDPE Subducts and accessories for use in cable ducting network in Kuwait. 1.1. The ducts fall into two categories i.e.

i. 32mm OD Subduct for feeder and junction routes. ii. 25mm OD Subducts for feeder and distribution route.


Society for testing and materials (ASTM) are applicable in this specification the latest issues shall apply and deemed to be an integral part of this specification.

Where equivalent international or other standards are used details shall be submitted with any tender. 2.2. The following standards have been referred to in this specification.

ASTM 1238 DIN 8074 & 8075

3. TEMPERATURE AND ENVIRONMENT 3.1. The subducts are for installation inside 100mm (ID) PVC ducts throughout Kuwait. They shall be capable of

meeting the following temperature requirements. Installed: -10 °C to +55 ° C Ambient Temperature During Storage & Transportation.

i. -10 °C to +55°C Ambient Temperature ii. +89°C maximum sun Radiation Temperature for period of days

3.2. The Subducts shall be unaffected by water, oil, oxidising Agents, salinity, aggressive soil, sand, fungi growth and bacterial or electrolytic actions.

4. MATERIALS 4.1. The duct compound shall be HDPE. Anti-oxidants and pigments may be added. 4.2. No constituent material shall be used which will adversely affect the long-term mechanical strength of the

HDPE. All constituents shall be uniformly and fully dispersed. 4.3. The tenderer shall state in his proposal the name of the manufacturer of the HDPE compound and also its

name or code number. Test certificate for HDPE compound shall be submitted from Kuwait Institute of Scientific Research (KISR) for MOC’s approval.

4.4. Subducts shall be homogeneous throughout. All surfaces shall be clean smooth, and without any visible cracks, grooves, blisters, wrinkles, dents, beat marks or foreign inclusions. Ends shall be square and free from sharp edges.

4.5. The subduct 32mm OD and 25mm OD shall be supplied in coils of specified lengths. The colour shall be as per the requirement on the basis of configuration in Para 4.6

4.6. Subduct size, manufacturer’s name and length shall also be indelibly marked on the outer surface.HDPE single subducts are supplied in coil along with Nylon draw wire (1mm Φ) with length up to the requirements of MOC contractor.

Feeder/main route 4 way Sub ducting 1ST 32mm OD - Black 2nd 32mm OD - Green

3rd 32mm OD - Yellow 4th 32 mm OD – Orange

Distribution route 5 way Sub ducting 1st 25mm OD - Black

2nd 25mm OD - Grey 3rd 25mm OD – Green 4th 25 mm OD – Orange 5th 25mm OD – Yellow

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4.7. Requirements of Tests for the HDPE material and the finished products are in Table 1 7 2 below.

Table 1: Properties of HDPE material Properties Test Method Requirement

Density DIN 53479 0.95 g/cm3 Melt Flow Index ASTM D 1238 0.5 g/10 min

Coefficient of linear expansion DIN 8075 1.5X10-4 m/m (k)

Crush Resistance

ASTM D 2412

Recovery shall be more than 95% within

2.5 minutes Tensile strength at Yield ASTM F 2160 >20 N\mm2

Elongation at break ASTM F 2160 >500% Impact Strength ASTM D 2444 No crack/Split

Di-Electric Strength at 27°C - >500 Volt/mil Insulation Resistance at 60°C - >600 Mohm

Vicat softening Point ASTM D 1525 110-128°C Brittle Temperature - -86°C

Hardness ASTM D 2240 60-80 ShoreD

Table 2: Dimensions of Subducts Outer dia (mm) Inner dia (mm) Wall Thickness (mm)

25 21 2.0 32 28 2.0

5. HDPE SUB DUCTING ACCESSORIES The Contractor shall supply suitable rubber plugs for plugging 100mm ID PVC pipes subducted with different configuration stated in Para 4.6 The plugs shall withstand the climatic conditions and soil/water contents. The plugs for subducts (empty and occupied) shall also be supplied by the contractor. The plug used for empty subduct shall be suitable for tying the vinyl pulling rope specified in Para 4.6

6. TESTS AND INSPECTION 6.1. Manufacturers will be expected to supply certified test data as per the requirements detailed in table 1 & 2.



6.3. Where Subducts are delivered directly to a contractor, it is his responsibility to advise MOC so that inspection may be carried out and a materials acceptance certificate issued. No materials may be utilised by a contractor prior to the issue of this certificate.

7. STORAGE Subduct shall not be stored in direct sunlight for long periods.

8. PACKING AND MARKING The method of packing and delivery of subducts shall be agreed between MOC and the Manufacturer/Supplier in case of ducts manufactured in Kuwait. i. Ministry of Communications, Kuwait and Order number ii. Size of subducts iii. Quantity of subducts iv. Manufacturer’s name The Contractor shall submit samples of HDPE subducts 32mm OD and 25mm OD, different subducting configuration using sealing plugs 100mm ID PVC pipe and end plugs for HDPE subducts of 32mm OD & 25mm OD. The manufacturers test certificate for raw material as well as finished products shall be submitted with the samples.

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Contract RA/266



C - TELEPHONE WORKS (PTT)


*****************************************************************************************

STATE OF KUWAIT

MINISTRY OF COMMUNICATIONS

TELEPHONE NETWORK DEPARTMENT

SPECIFICATION NO. 4

PART - III

PARTICULAR SPECIFICATION FOR INSTALLATION OF CIVIL PLANT FOR TELEPHONES BY GOVERNMENT AND

SEMI GOVERNMENT AGENCIES.

***************************************************************************************

:BAS:/D.22-94/FTPGMPW:

1


MOC TND SPECIFICATION NO. 4


INSTALLATION OF CIVIL PLANT FOR TELEPHONES BY

GOVERNMENT AND SEMI GOVERNMENT AGENCIES.

I N D E X

D e s c r i p t i o n P a r a n o.’ s General 1 – 1 to 1 – 3 Price Quotations 1 – 4 Materials supplied by the Ministry. 2 – 1 Materials required to be supplied by Contractor. 2 -- 2 Civil Work Installation Materials. 3 – 1.1 to 3 – 1.22 Excavation. 3 -- 2 Depth of Trenches. 3 -- 3 Duct Laying. 3 -- 4 Expansion of existing ducts. 3 – 4.1.2 Replacement of existing ducts. 3 – 4.1.3 Repair of ducts and blocked ducts. 3 – 4.1.4 & 3 – 4.1.5 Jointing of ducts. 3 – 4.2 Protection of ducts. 3 – 4.3 Termination of ducts 3 – 4.4 Rearrangement ducts 3 – 4.5 Test after laying ducts. 3 – 4.6 Leakage of ground water. 3 – 4.7 Backfilling. 3 -- 5 Drawings references and construction Of Manholes and Handholes 3 -- 6 Lead – in Ducts 3 -- 7 Clearance to underground services and facilities 3 -- 8 Installation of Distribution Cabinates. 3 -- 9 Completion Reports and Drawings. 3 -- 11 Inspection & Acceptance Tests. 3 -- 12

ATTACHEMENTS:

MOC Standard G20:10:001:22.. MOC Standard G20:10:001:23.. MOC Standard G20:10:001:32.. MOC Standard G20:10:001:33.. MOC Standard G20:10:001:34.. APPENDIX: 1,2,3&4

2



INSTALLATION OF CIVIL PLANT FOR TELEPHONES BY GOVERNMENT AND SEMI GOVERNMENT AGENCIES.

GENERAL 1-1 This Technical Specification and MOC Standards for Materials, covers supply of materials and

installation of the various items of work required in connection with the construction of civil works for the Telephone Network Department of the Ministry of Communications (hereinafter called MOC). These works include lying of ducts/pipes and construction of Manholes and Hand holes and associated works.

The following MOC Standards and Appendix also form part of this specification

(a) G20:l0:00l:22 Hardware for use in MH & HH. (b) G20:l0:00l:23 Manhole and Handhole Covers. (c) G20:l0:00l:32 PVC Ducts, Bends, Couplings, Duct Bonding Materials and Spacers. (d) G20:l0:00l:33 Materials for Civil Work. (e) G20:l0:00l:34 Galvanized Ducts and Troughs. (f) Appendix-1 MoC Important Notes (g) Appendix-2 BOQ Format (h) Appendix-3 MoC Monogram (i) Appendix-4 MoC Standard Legend 1-2 The Contractor shall be required to carry out necessary field surveys, viz, accurate field measurements

(including level measurements), acquaintance of the route, verification of existing services by digging Pilot holes, and make drawings present accurately all details by correcting incongruities with the drawings and/or making necessary supplement, as well as the other necessary drawings, prepare details and submit them for Ministry’s approval. After obtaining the Ministry’s approval, the Contractor will proceed with execution.

The Contractor has to submit B.O.Q and estimated amount in Design , shop & as built drawings for MOC Approval.

In case necessity arises for making on-the-spot corrections and changes in drawings during certain phases of the construction work, the Ministry will not issue revised drawings to the Contractor. When changes are made, dated and initialed by the Ministry’s Engineer in one of the Contractor’s drawings, it shall be Contractor’s responsibility to incorporate the corrections in all other relevant drawings in his possession.

All documents, including drawings to be submitted by the Contractor, must be prepared in quadruplicate. 1-3 Contents of the Tender Specification Ministry of Public works /Public authority for Housing Welfare/ consultant/contractor

must take MOC’s signature on the Hard copy booklet of approved specification along with B. O. Q. and on A_1 size Final design polyester drawings before quoting the

rates for tendering.

This tender specification consists of installation specifications, materials specifications, drawings, etc. The appendices and MOC Standards as revised from time to time are also considered to form part of this specification. Ministry of Communications reserves the right to make amendments to the specifications and working practices during the Contract period. No claim shall be made for minor amendments which shall be complied by the Contractor.

The Tenderers are expected to provide for all necessary associated materials, even if they are not stipulated in the specification. The unit rate quoted for each item should include all accessories & allied

3


works and no separate claim shall be acceptable for such items required during execution of work.

1-4 Price Quotations

The rates shall include for the following:

(a) Supplying & Laying of unp1asticised PVC Ducts:

Supply of ducts, fittings, bends, cleanser, jointing adhesive and spacers, protection, laying, jointing and testing. The work shall include excavation, backfilling, encasing with concrete when required, carting away surplus excavations and cleaning of site. All work to be as per drawings and specifications and to the satisfaction of the MOC Engineer.

(b) Supplying & Laying of Leading-in ducts and supplying & fixing of G.I. Boxes:

Supply of UPVC Ducts, Bends, Galvanized Iron Ducts, Bends,draw boxes and Accessories, protection, laying buried or fixing on walls or poles and jointing, applying one coat of approved bitumen compound. The work shall include excavation, backfilling, carting away surplus excavation, cleaning of site. All work to be as per drawings and specifications and to the satisfaction of the MOC Engineer.

(c) Construction of Manholes and Handholes:

Construction of Manholes and Handholes as per contract drawing including excavation, backfilling, carting away surplus excavation, concrete building base, walls and top slab, neck for M/H and concrete surrounding for H/H, supply and fix complete ironwork and ductile iron /Glass reinforced plastic cover, frame, ladders and number plate as per drawings and specifications and to the satisfaction of the MOC Engineer.

(d) Rates for above items of works shall include cost of field survey, all associated works, safety precautions

and protection of all existing services, submission of completion drawings, as built drawings and documentations, and all types of testing.

1-5 In carrying out the work, if it proves necessary to move a cable or other existing MOC installation, the

Contractor may do so with the approval of MOC Engineer at his own expense provided that it does not interrupt the normal telephone service and the moved cables/installations are returned to their original place or suitable place designated by MOC Engineer after the completion of the work. In case the depth of the existing ducts is reduced due to subsequent change in levels, the ducts should be encased with concrete.

2-1 Materials to be supplied by MOC No materials will be supplied by the Ministry of Communications. 2-2 Materials to be supplied by the Contractor: 2-2.1 The Contractor shall provide all the required materials as per MOC’s specification and standard.

Materials manufactured in Kuwait such as UPVC duct,, G.I. Pipe, Steel Pipe, MH Cover, HH Cover, Spacers for ducts, ready mixed concrete etc. shall be used. The Contractor is responsible for the quality of the materials supplied, and their continuous and timely delivery.

2-2.2 The contractor has to submit samples of materials with technical literature/ specification and test reports for MOC’s approval before supply/ Installation

2-2-3 This approval shall be valid only for the particular project for the period of two years. . 2-2.4 The materials for civil work such as sand, cement, aggregate cement blocks, iron bars, water etc. shall be

4


considered as part of the installation cost. 3. CIVIL WORKS INSTALLATION 3-1.1 Cement:

Cement to be used shall be sulphate resisting type 5.

The cement shall meet the requirements shown in MOC Standard G20:l0:00l:33 and satisfy the tests contained in ASTM C-150.

Cement with appearances of setting even to a limited extent shall not be used.

The cement to be used for construction work must be brought in sealed branded bags and stored in a proper manner.

3—1.2 Sand

Sand should be clean, sharp, gritty and free from loam, organic matter or adherent coatings and should conform to BS 410, 812, 882 and MOC Standard G20:l0:00l:33. Sand, which on being shaken with water in a graduated glass and allowed to settle, shows a layer of silt greater than 5% is unsuitable and will be rejected. Sand for concrete should be well grained, the grains varying in size upto 0.5 (half) centimeter, maximum.

3-1.3 Aggregate

The aggregate for concrete should be clean screened ballast, gravel or stone conforming to BS 410, 812 and 882. The material should be in the form of cubes or spheres (not flakes), and should be uniformly graded from 0.5 (half) centimeters upwards to the maximum size of 4 cms. It should be free from dirt, floury stone dust, loam and earth or other like materials. Clinker, brick, sandstone or other porous stones should not be used.

3-1.4 Water

Only water from the potable supply system of Kuwait may be used. For curing or washing aggregate, the water used shall not contain vegetable matter, acids, excessive phosphates or other salts in such quantities as to cause efflorescence on the face of the concrete or adversely affect the setting time.

3-1.5 Concrete Mixes

3-1.5.1 The grades of concrete to be used in construction shall be as follows R E Q U I R E M E N T S CLASSOFOONCRETE K—140 K—300




5



Slump Maximum in Cm. 8 5

Water Cement ratio (Maximum). 65% 50%

Nominal Mix. 1:2.5:5 1:2:4 Minimum cement content required is 220 Kg/M3 for K-140 and 380 Kg/M3 for K-300. 3-1.5.2 Use of different classes of Concrete

Unless, otherwise specifically mentioned:

Concrete Class K-140 shall be used for all non-structural concrete works.

Concrete Class K—300 shall be used for all structural concrete works.

3-1.5.3 The minimum Crushing Strength of work test cubes at 7 days and 28 days must be strictly adhered to.

The test results shall be recorded properly and submitted to the Ministry, at the time of Final Inspection.

Work Test Cubes should be as specified in BS 1881 for each new grade of concrete, or as directed by the Ministry/MOC Engineer. Six (6) Test Cubes (6 in.) should be taken at each time and should be marked with Date, Section of Work from which it was taken and other information required and despatched to the approved Laboratory for testing for compressive strength. Three (3) cubes shall be tested after 7 (seven) days. A further three (3) cubes shall be tested after 28 days. Their average strength must not fall below the minimum strength specified for each type of concrete and the lowest test result shall not be more than 20 percent below the average for the 3 cubes. If the result of 28 days test is unsatisfactory, all concreting shall be stopped at the Contractor’s expense, and the Contractor shall then in accordance with the instructions of MOC Engineer conduct tests of the concrete in the suspected parts of the structure. The concrete may be test loaded in situ or cylindrical test cores may be drilled out and tested. Should the tests prove that the concrete is unsatisfactory or the Engineer judge that any sections of the concrete works are defective, then the condemned concrete shall be cut out, removed and replaced by the Contractor at his own expense. All the above shall be at the expense and responsibility of Contractor.

3-1.5.4 The ingredients shall be measured in gauging boxes or by other approved means and mixing shall be

done by machine. The mixing must be thorough. 3-1.5.5 Concrete shall be mixed in a batch mixer of type ‘approved by the Ministry Engineer and in good

condition having a drum rotating about a horizontal or inclined axis. Continuous mixer shall not be used. Each mixer is to be fitted with a water measuring device having an accuracy within one per cent (1%) of the quantity of water required for the batch. The water measuring device shall be such that its accuracy is not affected by variations in the water supply pressure.

3-1.5.6 The batch shall be so charged into the mixer that some water (about 10%) enters the drum in advance of

the cement and aggregates. Water shall then be added gradually while the drum is in motion such that all required water shall be in the drum by the end of the first quarter of the mixing time.

3-1.5.7 The concrete shall be mixed until a mixture of uniform colour and consistency is obtained. Where

double—drum high performance mixers of a type approved by the Ministry Engineer are used, a minimum mixing time of 70 seconds may be allowed.

The amount of concrete’ ‘mixed in any one batch is not to exceed the rated capacity of the mixer. The

6


whole of the batch is to be removed before materials for a fresh batch enter the drum. 3-1.5.8 On cessation of work, including all stoppages exceeding 20 minutes, the mixer and all handling plant

shall be washed with clean water. If old concrete deposits remain in the mixer drum, it shall be rotated with clean aggregate and water prior to production of new concrete.

Concrete mixed as above is not be modified by the addition of water or in any other manner to facilitate handling or for any other reason.

3-1.5.9 In very cold weather (+50C or below) rapid hardening cement shall be used by the Contractor for

concreting, if required by the Ministry. 3-1.5.10 Water-proofing material shall not be added to cement without the consent of the Ministry Engineer. 3-1.6 READY-MIXED CONCRETE 3-1.6.1 In selecting the concrete plant, consideration shall be paid as to the required transportation time to a

work—site, the production capacity, the numbers of transporting vehicles, the production facilities in the plant and quality control procedures applied in the plant.

For ordering concrete, designation of standard design, strength, the slump as well as the maximum measurement of the coarse aggregate shall be made. Also proper instruction as to the class of cement, kinds of aggregate, water—cement ratio, the limit of cement unit amount as well as the air volume shall be given from time to time.

The Contractor shall hold meeting with concrete producer as to the delivery date, class of concrete, qualities, unloading place and timing of delivery, prior to concrete placing, to ensure smooth concrete placing work. Also, the Contractor shall be in continuous contact with the concrete Manufacturer in the course of concrete placing work, so that no disruption of concrete placing work occurs.

3-1.7 TRANSPORTATION AND POURING OF CONCRETE 3-1.7.1 Concrete shall be delivered without any delay in order to minimize materials separation time and be

readily placed and be thoroughly compacted. 3-1.7.2 Cleaning of transportation equipment and placing machine as well as mould prior to concrete placing

work, is required to prevent mixing of dirts in the concrete. Precaution must be taken to moisten portion of surfaces, before concreting, which are likely to absorb moisture from the concreting.

3-1.7.3 Concrete once mixed shall be used within a maximum time of one hour and any un-used material left

after expiry of one hour from the time of mixing shall be discarded. Cleanliness shall be observed in all operations and in regard to all materials.

3-1.7.4 The concrete shall be deposited (not thrown) into its position, as quickly as possible after being mixed

and shall be lightly vibrated using a mechanical poker 40 mm diameter to fill all cavities and to produce a dense and uniform mass. Floors and foundations shall be leveled carefully.

3-1.7.5 On pouring concrete, care shall be taken so that arrangement of reinforced bars may be firmly

maintained. Also, care shall be taken to minimize moving of concrete once it is placed inside the mould. 3-1.7.6 The coarse aggregate which is separated, shall be buried in the concrete with high mortar mix. In case of

observing noticeable material separation in the course of placing work, the concrete shall be remixed to have even mixture.

3-1.7.7 It shall be the practice to carryout concrete placing horizontally in one block of placing area. Height of

one layer for the concrete placing shall be less than 40 cm.

7

MOC TND Specification No. 4 3-1.7.8 In case of concrete placing of more than two layers, upper layer shall be placed prior to hardening of the

concrete in lower layer. 3-1.7.9 The use of internal vibrator shall be adopted for compacting concrete. Care shall be taken to allow the

concrete reach around the circumference of reinforced bar and into every nook and corner of mould. Care should be taken not to touch the reinforced bars with the vibrating poker. Poker size shall not be greater than 40 mm dia.

3-1.8 Curing 3-1.8.1 Concrete shall be prevented from drying too rapidly by shielding it from sun and wind. The concrete

shall be kept moist for 7 days by covering it with saturated sack cloth and sprinkling frequently with water.

3-1.8.2 Where necessary, placed concrete shall be covered to protect it against excavation material falling on it.

Any foreign matter falling, in spite of precautions, shall be carefully removed. 3-1.9 Mortar 3-1.9.1 Mortar for cement blocks shall be of 1:3 mix of cement and sand. 3-1.9.2 The materials, after being gauged, shall be thoroughly mixed in a dry state on a non-absorbent base and

then worked up with sufficient sweet water, applied through a hose or sprinkler to form a stiff paste. Mortar once mixed shall be promptly used before the initial setting takes place, i.e. it must be used within one hour of mixing. Where mortar is not used within this time, the materials should be discarded. The addition of fresh material to restore stiffness to sloppy mortar or the addition of water after setting has commenced is not permissible.

3-1.9.3 The walls shall be kept continuously damp for at least 2 days. 3-1.10 Cement Blocks

The cement blocks shall be used only in case of repair of existing Block type Manholes or Handholes and all new MHs and HHs constructed shall be reinforced type.

Cement Blocks shall be solid and of first quality to the specifications of Kuwait Government, Ministry of Public Works, made in vibrating pressure machines and thoroughly cured. All blocks shall be for bearing walls and when tested according to B.S. Standard or Kuwait Standards have minimum compressive strength of 50 Kg/Cm2 and average value of compressive strength for 12 blocks shall not be less than 60 Kg/Cm2 after 28 days of casting. The blocks shall be hard, sound and clean with sharp well defined edges and of dimensions required for the work. The blocks shall be presoaked for a minimum of 4 hours immediately prior to use.

The Ministry’s/MOC’s Supervising Officer may at his discretion, send samples of blocks proposed to be used for inspection and test by the Kuwait Government Testing Station. Work shall not normally be delayed for the result of the tests to be ascertained but should blocks prove unsatisfactory under test, the unused portion of the consignment will be rejected. The MOC will have the right to either reject any work on which the particular blocks of unsatisfactory quality have been used or require from the Contractor an indemnity against any loss which may be incurred from imperfection of the work which may show up subsequently.

3-1.11 Reinforcing Bars 3-1.11.1 All reinforcing bars used shall comply with the requirements given in MOC Standard G20:10:001:33.

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The cost of the steel reinforcement shall be included in the concrete rates and shall not be measured separately.

3-1.11.2 The quantity of reinforcing bars shall be as shown in the approved drawings. 3-1.11.3 The reinforcing bars shall be free from Mill Scales, Cracks, rust or other deformities. 3-1.11.4 The reinforcing bars shall not suffer any impairment on bending. 3-1.11.5 The reinforcement bars shall be made in accordance with the shape and measurement given in the design

drawing, by the method without spoiling the quality of materials being used. 3-1.11.6 The reinforcing bars shall be cleared and cleaned prior to assembly from rust, mud, oil and paint, etc., on

the surface. 3-1.11.7 Reinforcement bars shall be properly arranged at designated positions and be firmly tied with mild steel

wire. Approved spacer blocks of cement mortar shall be provided to maintain spacing between formwork and bars, so that they may not be shifted at the time of concrete placing.

3-1.11.8 The tensile reinforcement joints shall, when they are lap joints, be composed of lapping of a length more

than 40 times of the bar diameter, clamped in several places with more than 0.9 mm annealed iron wire, or by any other method equally or more effective than the one just mentioned.

No separate payment shall be made for steel reinforcement, its fabrication, placement in RCC works, which will be deemed to be included in the RCC MH or relevant item in the bill of quantities.

3-1.12 Iron works and fittings in Manholes and Handholes etc. 3-1.12.1 All iron works used in Manhole, Handhole etc. shall conform to MOC Standard G20:l0:00l:22. Mild steel

anchor irons, cable racks and support, ladder and other iron required for manhole, handhole, etc. shall conform to B.S. 4360 or equivalent and be in accordance with the MOC Drawing TX368/1, TX—483.

The contractor has to submit samples of materials with technical literature/specification and test reports as per MOC’s specification for approval before supply./Installation 3-1.12.2 Manhole and Handhole Covers: MOC is looking for the proposal to upgrade existing metallic manhole and handhole cover as per

present new developed technology with latest best suitable available materials Hence, MPW/NHA/consultant /contractor contact MOC and obtained latest approved specification of

manhole and hand hole covers before quoting the rate for tendering or supplying manhole and hand hole covers.

The contractor has to submit samples of materials with technical literature/specification and test reports as per MOC’s specification for approval before supply./Installation This approval is valid only for the particular project for the period of two years.

Manhole Covers are of medium duty ductile iron and Handhole must be double hinge type with medium duty ductile iron. Each complete manhole cover shall consist of the cover and its frame. Each complete handhole cover shall consist of two pieces called the upper cover and lower cover and its frame. The and Handhole Covers shall conform with MOC Standard G20:l0:00l:23 and MOC drawings shown below

Manhole Covers & Frames (Ductile). ... TX:481A Handhole Covers & Frames.(Ductile) … TX: 482A

In the case of Key hole the following dimensions are permissible : —

9

MOC TND Specification No. 4 Specified Acceptable to MOC.

15 mm. 14 to 16 mm.

30 mm. 29.5 to 33 mm. 3-1.13 Formwork for Concrete

The Contractor shall be responsible for the supply, design, erection, stability, striking and removal of any formwork and centering required so as to preserve the concrete from damage or distortion during setting. The form work shall be of such quality and strength as will ensure complete rigidity during placing, ramming, setting and curing of concrete. Removal of forms shall not begin until the concrete has either obtained the percentage of the 28 day design strength or until after the period shown below unless otherwise authorized by the Ministry Engineer:

False work supporting. Period. Percentacie DesicTn Strencith.

Slabs or beams. 7 days. 80% Walls. 1 day. 70%

The Ministry Engineer shall be informed in advance when the Contractor intends to strike any form work.

All new-placed concrete shall be cured and curing shall begin immediately after removal of form work and shall be continued throughout any finishing processes and for at least seven days.

Any work that causes loading of manhole and passage of traffic can start after concrete has required design strength.

No separate payment shall be made for erecting and removing form work, curing etc.

3-1.13.1 Concrete Finishes

On completion of RCC manhole/handhole, the floor shall be rendered with cement mortar in accordance with relevant drawings. The walls of concrete manhole shall have a smooth finish, any slight cavities disposed when the shuttering is removed shall be made good with cement mortar and any projections removed. Under no circumstances shall the walls be coated with a cement or cement/sand wash or mortar rendering/plastering.

Finally inside the neck, soffit roof slab and top side of the wall shall be cleaned using a suitable water soluble detergent followed by a clean water rinse to remove shuttering oil.

3-1.14 Bitumen

Bitumen used should conform to B.S. 3416 Type — 1 or equivalent. 3-1.15 Unplasticised P.V.C. Ducts 3-1.15.1 Unplasticised PVC Ducts and Spacers shall conform with MOC Standard G20:l0:00132.

When PVC Ducts are procured, the installation Contractor shall make a thorough examination to ensure that the ducts are undamaged. Damaged ducts shall be rejected and promptly removed from site of works.

When bends are used at curved positions, the materials of the PVC bends proposed shall be in conformity

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with MOC Specifications for ducts and prior approval from MOC shall be obtained for sample of bends. 3-1.15.2 PVC Ducts for MH and HH Route

The PVC ducts shall be supplied in 6 meter lengths. The ducts laid in Manhole/Handhole routes shall have minimum 100 mm internal diameter and minimum 4.5 mm wall thickness. The PVC ducts shall have one end plain and the other end a 100 mm expanded socket for spigot coupling. The expanded end shall have a wall thickness not less than that specified for the duct, and the tolerance on the fit of the spigot and socket shall be compatible with the requirements for jointing specified herein. Suitable couplers shall be used for jointing PVC ducts with steel ducts when required and the sample of these couplers shall be got approved by MOC.

The spigot end of each duct shall be indelibly marked with a continuous circumferential black line 100 mm from the end of the duct. This line shall be used as a measure of the penetration of the spigot into the socket of the adjoining duct. Joints which show, in the opinion of the MOC Engineer, inadequate penetration may be rejected. Manufacturer’s name and year of manufacture shall be clearly marked on the duct.

Pre-made slow bends of 100 mm dia., PVC Pipe shall be in full conformity with the material specification and dimensional details shown in Figure I (G20:10:001:32). A 90 mm dia. x 300 mm long mandrel shall pass through this bend. Sample shall require due approval from MOC.

3-1.15.3 PVC Ducts for Leading-in

The ducts shall be supplied in 4 meters lengths. The ducts shall have a minimum 3 mm wall thickness and external diameter of 50 mm.

The ducts shall be jointed using the method of spigot and socket couplings and cement solvent. The coupling for jointing with G.I. duct shall be made of PVC and have one end threaded, and the other end shall be sealed with solvent cement. Suitable reducing couplers shall be used for jointing 50 mm PVC ducts with subscriber’s duct of different sizes. The manufacturer’s name and year of manufacture shall be marked on each duct.

Pre-made 90 degree long bends of 50 mm PVC Pipe shall be in full conformity with the material specification and its dimensional details shown on Figure 2 (G20:10:00l:32). Sample shall require due approval from MOC.

3-1.16 Storage of PVC Ducts

Unless otherwise approved by the Ministry’s Engineer, PVC ducts shall be stacked in accordance with the Manufacturer’s instructions and in inside storage. Where outside storage is approved the ducts shall be supported at least 300 mm above ground on suitable bases spaced to avoid bending of the ducts. The ducts shall not be stacked to more than 10 layers height and be covered with impermeable sheets and secured with ropes to avoid movement. The ducts shall be stored in~ the shade at all times.

3-1.17 Cement Solvent

All joints for PVC Ducts are to be made with cement solvent conforming to MOC Standard G20:l0:001:32.

The number of joints that can be made with one kg of solvent and one kg of cleanser shall be indicated. Shelf life and any special precaution to be taken during use, must be clearly stated. Solvent cement and cleanser shall be packed in airtight tins of 1 kg. and 0.5 kg. respectively. The Contractor shall submit the test result of shear strength and long term hydrostatic pressure for approval.

3-1.18 Asbestos Cement Duct

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MOC TND Specification No. 4 MOC do not use A .C. pipes . This detail is just for reference .

Cement Asbestos Ducts of 100 mm internal diameter shall be in accordance with the Canadian Government Specifications Boards No. 34-GP-8 and subject to the Crushing Test and Bending Test requirements specified in the I.S.O. Recommendation R-160.

The ducts shall be in lengths of 4 meters for laying along the straight routes and 1 meter length for laying along the curves.

The cement asbestos joints shall be pressed home and shall be made water tight with bitumen or approved sealing compound.

4 Meters long ducts shall be bi-conical and must allow the jointing collars to enter from either side for a distance of 25 + 2.5 mm, when snugly fit to form a dust tight joint.

1 Meter long ducts shall have Magnani Jointing Collars and Rubber Rings.

The ducts shall be stored, handled and laid in strict conformance with the recommendations of the Manufacturer.

3-1.19 Steel Ducts

The steel ducts shall conform with MOC Standard G20:10:001:34. Steel Ducts for MH and HH route shall be of 100 mm internal diameter.

The ducts shall be supplied in 6 metre lengths.

The wall thickness of the 100 mm G.I. Duct shall be 5.4 mm.

Threaded coupling shall be used for jointing two lengths and the joints shall be made water tight by applying white lead pigment. The ducts shall be given two coats of an approved first quality anticorrosive paint.

3-1.20 For Service Ducts used for leading-in from Handhole/Manhole to building/compound wall

Steel ducts, accessories and couplings used for service ducts (leading-in) or for coupling with P.V.C. leading-in ducts for use in exposed portions shall be medium duty, seamless, galvanized steel ducts of 40/50 mm nominal bores and 3.25/3.65 mm wall thickness conforming to MOC Standard G20:l0:001:34 and the International Standards referred therein.

3-1.21 Draw Box

The size of the Draw Box to be fixed at the end of leading-in duct will be 300 x 300 x 75 mm.

Draw Box is referred to in Drawing No. TX-483 or latest updated if any.. Draw Box and accessories shall be of best quality, galvanized steel, conforming to BS 21, 427, and 1387. The colour of box should be light yellow powder coating .

The cover shall be with steel hinged to the body and shall be locked with a triangular head key and/or as approved by MOC. There should be MOC monogram and supplier/ Manufacturer name on th box.

Sample of draw box has to be submitted to MOC for approval before use.

Cable clamps shall be provided inside the box to keep the cable in position. 3-1.22 Spacers for PVC Ducts

The Spacers shall conform with MOC Standard G20:10:001:32 Clause 4-10. Samples of spacers are to be submitted to MOC for approval before use.

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MOC TND Specification No. 4 3-2 EXCAVATION 3-2.1 Excavation by hand or mechanical aids shall be carried out down to the required level by the Contractor

in all types of surfaces, soils and rocks in any part of Kuwait. 3-2.2 The Contractor shall normally carry out the excavation in Telephone Plant reservation in carriageways

and sidewalks indicated in the contract drawings and where no such reservations exist, in the position indicated by the Ministry Engineer. These reservations will be given to the Contractor.

3-2.3 The Contractor shall support the sides of the trench with timber or other materials, where the depths of

the trench, nature of soil or proximity of other services make this necessary. The Contractor cannot claim charges for any extra quantity of excavations that is necessitated by his failure to provide adequate timbering or due to the need for laying ducts or constructing manholes with additional depth. No separate charges will be paid for sheeting, bracing etc.

3-2.4 The Contractor shall dig pilot holes at his cost to confirm the location of existing services before he

commences his works in an area where existing services of MOC and third party might exist. 3-2.5 Great care shall be taken by the Contractor to avoid undermining or otherwise disturbing the ducts,

cables and installation. If despite precautions, such soil is disturbed, the plant concerned shall be temporarily supported and the void filled with a concrete mixture of K-140.

3-2.6 The Contractor shall protect and/or transfer, if necessary, all MOC and other existing services in a

manner approved by the concerned Ministry and in accordance with the instructions of the Ministry Engineer, at Contractor’s expense.

3-2.7 The Contractor shall keep all excavations clear of water during laying of ducts or cables, installation of

manholes and handholes and joints. He shall install well point system if required. No separate charges are payable for water removal.

3-2.8 The line of trench shall be kept as straight as possible. Where a change in direction is indicated between

manholes or handholes, the trench shall be excavated so as to provide as large radius as possible, unless otherwise noted in the drawing.

3-2.9 In no case, shall, the width of trench excavation be greater than is necessary for the satisfactory execution

of work. The width of the trench beneath the surface shall never exceed the width at the surface. 3-2.10 The Contractor shall be solely responsible for settling of all claims, damages and other suits arising out of

his work and the MOC shall neither be involved nor held responsible for settling such claims. 3-3 Depth of Trenches 3-3.1 In case of installing Nos. of ducts of less than maximum capacity for the type of MH, the lowest duct

shall be laid at 40 cm from the base of manhole, so that standard depth may be ensured for future expansion.

3-3.2 (a) Standard Depth of Trench for Manhole Route

The depth below the surface to the top of the uppermost ducts shall be 0.80 Meter or more.

(b) Standard Depth of Trench for Handhole Route The depth below the surface to the top of uppermost ducts shall be 0.6 Meter or more.

(c) In case of direct buried cables the depth below the surface to the top of the cable shall be 1 Meter or

more.

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(d) Leading-in Duct

The depth below the surface to the top of the leading duct shall be 0.4 Meter or more.

(e) In case that these routes cross the carriageway, the depth below the surface shall be 0.2 Meter extra.

(f) In case the depth of laying of ducts is likely to be different from standard depth due to the presence of

buried facilities or other reasons, the Contractor should submit the longitudinal profile drawings of the proposed duct route showing the location, elevation and size etc. of all other buried facilities including MOC ducts and manholes to the Ministry for approval.

(g) Meaning of “SURFACE” in the above context :

The “Surface” appearing in the context of the foregoing sub— paragraphs means the level of horizontal extension of the kerb top in case of footways and the centre of the asphalted road in case of carriageways.

Where a MH — HH has to be connected with a carriageway crossing, all depths are to be related to the depths of its carriageway crossing, not less than the standard construction dimension.

3-3.3 Where the surface of the ground is uneven; the trench shall be dug to a greater depth so that the ducts or

cables shall not undulate like the surface. Any grading of level, such as, is necessary at road crossings or in passing from sidewalk to carriageway and vice versa or where ducts have to enter manholes, handholes or in any other circumstances, shall be gradual as the Ministry Engineer may direct. The Ministry Engineer may also require the Contractor to lay ducts in depths other than the Standard Depths given above.

3-4 LAYING OF DUCTS 3-4.1.1 In general, UPVC ducts shall be used for all duct laying works with exception of situation, in the case of

steel ducts. AC ducts are to be used, only when it is required to repair or to be jointed with existing AC ducts. Jointing between AC and UPVC ducts shall be allowed in exceptional cases, after the approval of MOC Engineer.

The Contractor shall lay steel ducts in a portion where sufficient depth below the surface is not practicable, after obtaining the Ministry’s approval.

The Contractor shall use PVC Ducts in accordance with the design drawings and instruction of the MOC Engineer.

The duct configuration must be based on the standards given in Drawing No. TX: 347/4/D-l & TX: 347/4/D-lA.

The Contractor shall propose to the MOC, the expansion method after performing detailed field survey.

When proposing the expansion method, studies on the number of ducts in expansion and existing ducts, depth and arrangements of existing ducts, laying status of existing cable, road reservation and construction method as well shall be duly taken into consideration.

Consideration shall also be made as to the shift of existing ducts and re-arrangement of duct position.

Where required by Ministry, the Contractor has to lay new ducts instead of existing ducts which are to be abandoned. The Contractor shall make all necessary termination arrangements and seal abandoned ducts by approved methods. No separate payment will be made for such works and the whole work will be measured as laying of new ducts.

14


In principle, expansion toward upper direction or horizontal direction shall be made for spans between manholes.

In installing duct at manhole position, a minimum depth below the surface and the minimum distance from duct axis to side wall / roof / base slab shall be ensured and effective duct arrangement shall be taken into consideration so that cable can be easily accommodated in manhole.

The work for feeder route where overlapped with distribution route shall be carried out with utmost care so as not to cause any damage to existing ducts of distribution route and not to interfere with cable work.

The Contractor should provide the spacers at intervals of 2 M. to hold the ducts in proper alignment. Spacers should also be provided at 1 M on either side of the joint point. Hence, for each AC duct, 2 spacers are to be provided whereas, 3 spacers for PVC ducts.

Two types of spacers viz. (1) top and bottom spacers, (2) intermediate spacers are to be used for the purpose. The top and bottom spacers are single sided and the intermediate spacers are double sided.

The spacers provided at one point should be in the same vertical plane and it may be fastened tightly with vinyl rope of less than 5 mm dia over the spacers to secure the duct nest with a minimum of two bindings. Alternatively, any other method for jointing of spacers may be used with prior approval of the MOC. In case of expansion of ducts, only the new ducts are to be connected together.

If ducts are not occupied fully in a pair of spacer, small length of 30 cm. of duct should be provided in order to have a compact strength.

Spacers should be divided into two categories such as, one for AC ducts and the other for PVC ducts. Spacers supplied shall be suitable for various configurations shown in Civil Drawing No. TX: 347/4/D-lA.

The Contractor may also use separate spacers with the interconnecting facilities. These spacers can be jointed for increasing the number of ducts and the minimum tensile strength of the connecting portion shall be 50 kg/sq. cm., or more. Spacers should be capable of withstanding a minimum compressive load of 500 Kg.

Spacers should be made of synthetic resin material and should be hard. Sample of spacer shall require approval from MOC before use.

The Tenderer should submit the specification, drawings, and sample spacers while submitting the offer. The cost of providing spacers shall be included in the cost of duct laying and no separate charges shall be claimed by the Contractor.

The installation cost of laying ducts should include, asphalt, RCC / Concrete cutting, removal of tiles, pilot holes, excavation of all types of soil and rock, shuttering, dewatering, protection and transfer or rearrangement of existing cables, protection of existing MOC ducts and other services, removal of any existing ducts, laying and jointing of ducts, providing of spacers, termination of ducts in MH and HH wall, sealing of ducts in cable vaults or tunnels, sealing of all ducts in the first manhole from cable vault, sealing / plugging of all ducts in other MHs and HHs, concrete encasement, backfilling and compaction, reinstatement and retiling to match with the original surface, mandrel test, pressure test, cleaning of work site and other necessary works.

As a matter of general instructions, utmost care shall be taken at the time of installation, not to damage any cable or joints provide perfect protection as per MOC standard and with consultation.

The bottom of the trench shall be cleaned of all water, dirt, sand, rubbish etc. , and shall be carefully leveled, watered and rammed. Where the ground is rocky, the duct shall be laid on well rammed 8 cms

15


thick layer of earth, free from stone, arranged by the Contractor. The Contractor must examine each duct before it is laid. If any defective or broken duct is laid, the Contractor should replace it at his expense. The Contractor cannot claim any additional charges for this from the Ministry. In case the ducts are required to be laid through the manholes of other services viz, water etc., the Contractor shall secure permission from the concerned Ministry, make suitable holes in the walls of the manholes with utmost care and seal them properly with cement mortar of 1:2 mix of cement and sand after laying the ducts etc. No additional charges shall be paid to the Contractor for such works.

The ducts shall not be constructed in an ‘S’ curve either in the latitudinal or longitudinal section except the portion near manhole in case of duct expansion as shown in Drawing Nos. 347/4/D-1 & D-lA.

A maximum of two grades shall be used in ducts between manholes or handholes. Duct run shall be straight for a distance of not less than 3 M. from the face of any manhole or handhole.

Level of any part of a duct between manholes shall not be lower than the duct terminating level at the manholes to prevent stagnation of water.

3-4.1.2 Expansion of existing Ducts — Where new ducts are shown on the drawings or are directed by the

Ministry Engineer to be installed to increase the size of an existing duct run, the new ducts shall be laid so as to maintain a standard duct configuration as far as is possible.

Wherever practical, and subject to the approval of the Engineer and the Ministry of Communications, the new ducts shall be laid on top of the existing duct. The practicality of such a procedure shall be determined by the minimum cover available and the requirements for duct termination arrangements at the adjacent manholes being acceptable to the Ministry of Communications.

Where the installation of new ducts on top of an existing duct is impractical or is not approved, the Contractor shall install the new ducts in accordance with the details shown on the drawings for “Duct Expansion” TX: 347/4/Dl & D-lA.

The method of excavation, laying of the new ducts and backfilling shall be agreed with the Ministry Engineer before work is commenced.

The existing duct run shall be adequately supported at all times to the satisfaction of the Ministry Engineer.

In all cases the new ducts shall be of UPVC.

In the case of expansion or increase of ducts the Contractor shall make necessary re—arrangement at the terminating position if proper clearances are not obtained.

3-4.1.3 Replacement of existing Ducts — Where a new duct route conflicts with an existing route which is to be

removed after re-cabling, the existing ducts containing cables shall be carefully broken out to provide slack in the cables to allow clear passage for the new work. Subject to the approval of the Engineer and the Ministry of Communications additional. slack may be obtained by releasing cables from clamps in adjacent manholes. The releasing of cables shall only be permitted under the supervision of the Ministry of Communications. The exposed cables shall be supported and protected to the entire satisfaction of the Engineer and the Ministry of Communications.

3-4.1.4 Repair of Ducts - The Contractor shall repair ducts in the following cases

(1) When directed by the MOC Engineer. (2) Whenever existing ducts which are to be retained are damaged, and the Ministry’s approval to

carry out repair work has been obtained.

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Ducts shall be repaired so that the original level and alignment of the ducts are maintained and so that cable can be laid or removed smoothly without obstruction.

The Contractor shall carry out all necessary excavation, backfilling and testing in accordance with the requirements of these specifications.

The Mandrel Test shall be carried out on all repaired ducts which do not contain cables.

3-4.1.5 Blocked Ducts in Manhole and Handhole Routes

If, after mandrel test, an existing duct is found to be blocked at one place in a span, it is to be repaired.

If blockages are found at more than one place in a span, the duct can be abandoned or removed, as instructed by the Ministry’s Engineer. New ducts be installed in lieu of abandoned ducts and it will be considered for payment purposes at the rate of laying of new ducts. Removal of abandoned ducts shall not be measured or paid separately but will be considered as incidental to the rates for installing the ducts.

3-4.2 Jointing of Ducts

(a) A.C. Duct joints shall be pressed home and shall be securely sealed with the bitumen or rubber rings, so

that the resultant joint is watertight. In no circumstances shall dirt or grit be allowed to enter the joints or foreign matter allowed to enter the ducts.

(b) Jointing of UPVC ducts using cement solvent.

The unplasticised PVC ducts shall be jointed with an approved cement solvent resulting in permanent gas tight and watertight joints.

After cleaning the duct ends for minimum 10 cms for dirt, dust, grease, oil etc., a thin coat of solvent cement shall be applied on both sides at the joint points and pushed until snugly fit. Shear strength and long term hydrostatic pressure of cement solvent when tested shall be in accordance with BS 4346. Joints should not be disturbed for at least 15 minutes. At very low temperature a longer time shall be allowed.

The Contractor shall provide documentary evidence that the cement solvent proposed for use is compatible with the UPVC ducts to be used and that it has been used in similar conditions to produce watertight and gas tight joints which would satisfy the requirements of this specifications. It shall conform to MOC Standard G20:l0:00l:32 Clause 4.9 and International Specifications (B.S. 4346, DIN 16970 or equivalent) referred therein. Before the procurement of solvent cement in larger quantities the Contractor shall supply 2 samples of joints made with the UPVC ducts and the cement solvent proposed for use along with test certificate from an independent laboratory for its strength and ability to withstand high pressure.

The Contractor shall also submit in detail, method of jointing employed to make the sample joints.

After getting approval from MOC Engineer for the sample joints the Contractor shall submit a detailed proposal regarding method of field jointing which shall include manufacturer’s recommended jointing procedure with any deviations there from. The Contractor shall demonstrate the suitability of his proposed jointing method by making 4 test joints under field conditions in the presence of the MOC Engineer and get his approval.

After getting approval for the test joints the Contractor shall strictly adhere to the method of jointing and

17


any deviation from the above method shall be made only with the prior written approval of the MOC Engineer.

The cement solvent shall be supplied in sealed containers with the Manufacturer’s name and date of manufacture and date of expiry of the solvent clearly marked on them. The cement solvent shall be uniform in quality and shall contain no precipitation or floating agent.

If the cement solvent is to be used with a primer the Contractor should also supply the primer along with the cement solvent. The solvent shall be stored with the containers tightly closed in a dark and cool place away from fire

(c) Cutting of ducts

Where it is necessary to cut ducts all burrs are to be removed and the cut end of the duct is to be

chamfered.

3-4.3 Protection of Ducts - If the depth below the ground surface to the top of duct is less than 80 Cm in the

case of manhole route and less than 60 Cm in the case of handhole route the ducts should be protected by concrete K-140. Ducts laid at all road crossings shall be encased in concrete K—140 irrespective of their buried depth.

A concrete encasement shall be constructed around the duct as shown in Drawing No. TX: 347/4/Dl & D-lA.

Concrete : K-140. Length : As required. Thickness : Ref. Drawing No. TX: 347/4/Dl & D-lA. Width : Ref. Drawing No. TX: 347/4/Dl & D-lA.

The actual method of installing the encasement shall be agreed with the MOC Engineer before commencement of work.

3-4.3.1 The duct arrangement and concrete protection wherever provided shall be based on the standard given in

Drawing Nos. TX: 347/4/D—l & D—lA.

Spacers shall be used to hold ducts in proper alignment and to keep the stipulated space between each duct. The Contractor shall submit Technical Specification, Test Report, drawings and two samples of the proposed spacers and obtain the MOC Engineer’s approval for the materials of spacers to be used before ordering any spacers for the work.

3-4.4 Termination of Ducts

To install ducts in new or existing manhole, handhole or exchange vault, K-300 concrete shall be used to perform the water—proofing work. For manholes specified in Drawing Nos. TX: 347/4/D1 & D-lA, place the water-proof concrete in 20 cms. thickness from the outside of the wall and similar terminations can be made in the case of handhole also. In the case of Exchange vault, place 100 cms. thickness water-proof concrete.

In case of R.C.C. Manholes and Handholes waterproofing membrane, rubber rings and protection to waterproofing shall be provided to make the termination of ducts completely watertight. The Contractor should submit the proposal and get it approved by the Ministry Engineer before execution of work.

All ducts installed in Exchange cable vault or tunnel, and first manhole from cable vault should be sealed by spigot of synthetic rubber or compound irrespective of whether the ducts are occupied or unoccupied, in order to prevent entry of water and insect into the exchange before execution. Sealing/plugging shall be done for all new ducts in MH/HH.

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In such cases, the end of ducts shall be stopped 3 cms inside the wall from the inner wall surface of manhole, handhole or exchange cable vault.

And thereafter, taking duct axis, as a centre point, finishing shall be made in a trumpet shape with mortar of 1:2 mix, so that there are no projections on the surface which may cause damage to the cable. (Refer to Drawing Nos. TX: 347/4/Dl & D-lA).

In the case of PVC ducts the duct socket (Bellmouth) may be used at the end of duct in the manholes/handholes instead of duct termination method mentioned in the previous two sub-paragraphs.

In case, duct bellmouths are to be used, the Contractor shall submit the sample, drawings and technical data for approval of the MOC before commencement of the work.

The material for the duct bellmouth should be the same as that of the PVC ducts. Regarding the size and shape of the duct socket, the Contractor may refer to the Drawings that will be supplied by the Ministry so as to facilitate proper cable accommodation and to have necessary strength for the joint of the Bellmouth with the PVC duct.

The whole work of sealing, termination of ducts into the wall, providing waterproof membrane, rubber rings, protection to water proofing, breaking of walls in existing manholes, handholes and exchange cable vault or tunnels, refacing or plastering the complete wall and dressing ducts ends shall be considered as part of the laying of ducts for the purpose of payment.

3-4.4.1 At road crossings, if the ends of ducts are not terminated in manholes or handholes, the duct openings

shall be effectively sealed with an approved sealing material or end cap to prevent possible blockage of the ducts by entry of soil or water.

The duct at road crossing shall extend beyond the Kerb or asphalt line upto the centre line of the telephone reservation. Where the number of ducts to be installed is less than the maximum capacity of the manhole type designated, the ducts shall be laid to form the lowest rows of the standard configuration duct layout unless other wise shown on the drawings.

3-4.5 Re-arrangement of ducts termination for manhole wall

The Contractor shall make necessary arrangement for duct terminating position whenever cable laying work inside manhole is difficult or if any instruction given by the Engineer, due to improperly existing duct terminating position in the manhole.

In such case, the Contractor shall make necessary excavation for duct-moving and re-construction of a part of manhole, if necessary.

Cost of any such rearrangement shall be included in the cost of duct laying / manhole construction.

3-4.6 Testing of Ducts

Testing of ducts shall be carried out after laying and backfilling, but with any dewatering system still in operation, in accordance with the following requirements

All tests shall be carried out in the presence of the Engineer or his representative and of a representative of Ministry of Communications.

(a) Mandrel Test

All ducts in every duct run shall be checked for alignment and freedom from foreign matter by passing two brushes attached to the ends of an approved iron or hard wood or plastic mandrel through in both directions. Where necessary or where directed by the Ministry Engineer the

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Contractor shall clean ducts with a stiff brush.

The mandrel shall be 90 mm in diameter and not less than 300 mm in length. The ends of the mandrel shall not have more than a 10 mm radius bevel. The diameter of the brushes shall be at least 60 mm greater than the nominal diameter of the ducts and at least 80 mm in length.

All labour and materials required for the testing shall be provided by the Contractor. The testing shall be successful if the mandrel passes freely through the duct in both directions.

In the event of any length of any duct failing to pass the test the entire length of duct will be rejected.

Test results obtained by the Mandrel Test shall be properly recorded and shall be immediately made available to the Ministry Engineer upon request. All results shall be presented to the MOC Engineer prior to the Final Acceptance Testing.

A Vinyl rope of 5 mm shall be provided after successful mandrel test of all ducts newly laid and after successfully rodding in existing ducts where required by the Ministry and all tested ducts shall be suitably colour marked as approved by the Ministry. The Vinyl draw rope shall be left in the duct and securely tied to the hardware at each end for future cabling.

(b) Pressure Test

After successful completion of the Mandrel Test the Contractor shall test a minimum of 10% of the UPVC Duct runs in every MH/HH span (subject to minimum of one duct run) with air at a pressure equivalent to a head of 10 M. of water using equipment and a method of test approved by the MOC Engineer.

Each duct run shall be stoppered and the pressure applied for a minimum period of 10 minutes to allow stabilization of conditions within the duct. The pressuring unit shall then be shut off and the pressure must remain without measurable loss for a period of 10 minutes.

The pressure shall be measured by an approved pressure gauge accurate to 2% at the required test pressure or an equivalent water head.

In the event of any duct run failing to pass this test all duct runs in the duct shall be tested, and the MOC Engineer shall decide upon the acceptability of the duct based on the results of all the tests. Should the MOC Engineer decide that the duct is unacceptable the Contractor shall carry out such remedial, repair or replacement works as approved by the MOC Engineer and the duct shall be retested.

3-4.6.1 Retesting

Should the MOC Engineer have cause to believe that damage or disturbance has occurred to any duct at any time after completion of the pressure test, he shall have the right to order retesting of the duct by the mandrel and/or pressure test.

3-4.6.2 Acceptance of Ducts for Payment Purposes

Notwithstanding any approvals given by the Engineer in accordance with the requirements of this clause, the installed ducts shall not be considered as accepted for payment until they have passed all the tests specified in this clause and written approval has been obtained from the Ministry of Communications.

3-4.7 Leakage of Ground Water

Any leakage of ground water into any duct run of any duct shall be cause for the MOC Engineer to reject the whole of that duct between adjacent manholes or handholes.

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MOC TND Specification No. 4 3-5 BACKFILLING 3-5.1 No backfilling shall be commenced before obtaining the approval of the Ministry Engineer for the works

covered by the backfilling. 3-5.2 The space outside the walls of manholes, handholes, and around ducts shall be carefully filled in with

earth free from stones and rammed, care being taken to avoid any damage. 3-5.3 Backfilling and compaction around ducts shall be carried out as each layer of duct is installed using fine

sand (Filler material). If more than one layer of ducts are to be installed the spacers required for supporting the second layer of ducts must be pushed on before the filler material is bedded around the first duct layer. When laying all further layers proceed in a similar manner.

The filler material introduced into the trench should be watered and compacted between the ducts with wooden rammers. The filler material is levelled with each laid out PVC duct layer in succession, whereby the thickness of filler material above the upper most duct layer must be 10 cm.

The upper layer above ducts shall be filled only after approval of pressure test and compaction between ducts by Ministry’s representative.

3-5.4 All excavated materials shall be screened to get soil free from rubbish, stone, deleterious materials etc.

and soil shall be approved before backfilling. This soil shall be replaced in layers not exceeding 20 Cm thick after compaction, the compaction field density to a degree of 95% in paved areas and 90% in unpaved areas of the maximum possible density of the same type of soil as tested after being compacted in the laboratory or to the requirements as per the General Specifications for Roads and Drainage. Compaction in the laboratory will be achieved by modified proctor method. Power rammers shall be used whenever practicable and where such use is impracticable, hand ramming may be employed.

3-5.5 Degree of compaction of backfilled material shall be tested in accordance of ASTM or BS or Kuwait

Standard Test Procedure. Test should be carried out at the rate of at least one specimen per span per layer or as directed by the Ministry Engineer. In case the specimen does not confirm to the required density and thickness, additional test may be taken to ascertain the limit of failing duct span, after which the Contractor shall re-excavate, breakup, fill, water, compact and level the layer again, if necessary, replace the material or add new earth at his own expense. The Contractor shall allow in his daily schedule of work enough time to permit the performance and checking of test before proceeding to any subsequent operation. Any faulty compaction shall be rectified by the Contractor to the satisfaction of the MOC’s Supervisor. The test for Compaction shall be performed by the Contractor at Government laboratory at his own expense.

Test result obtained through proctor test method shall be properly recorded and be included as document for Final Inspection and Acceptance Tests.

3-5.6 The Contractor shall remove all surplus material such as waste earth, broken ducts, and all debris from

site and leave all affected areas and surfaces in a clean and proper condition to the satisfaction of the Municipality Inspector and Road Section of the Ministry of Public Works. The Contractor shall furnish a certificate that all surplus materials have been cleared after the completion of the work; this certificate shall. accompany the Contractor’s bill.

3-5.7 The Contractor shall daily maintain the level of all road crossings by providing fill as necessary until re-

surfacing 3-5.8 The surface of all footway trenches shall also be regularly maintained by the Contractor until such time

as he shall undertake permanent reinstatement.

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MOC TND Specification No. 4 3-5.9 Poor compaction of fill, failure to leave the site of work clean and tidy or non-observance of any

requirements laid down above or of directions given from time to time will be regarded as a serious breach of contract which if repeated, be sufficient to justify the Ministry taking action against the Contractor.

3-5.10 The Contractor shall reinstate trenches in paved or unpaved footways to match the original surface.

Reinstatements of concrete in site or concrete flags and tile pavings shall be carefully executed and matched to the original surface. Any new flags or tiles used in replacement of broken / chipped ones shall match the original in colour, size, design and shall be mortar bedded and jointed. All necessary materials shall be provided by the Contractor at his cost.

3-5-11 Installation of subducts The contractor has to install 4(four ) numbers of 32 mm dia HDPE sub duct of different colours

having pulling rope ( GREEN , YELLOW, ORANGE , BLACK ) to lay relocate new /existing optical fibre cables .Two numbers of 100mm dia pipes to be subducted along all new or relocated routes irrespective of number of duct ways.

The contractor has to obtain material approval from MOC. All sub ducts must be installed in top layer of pipe configuration in consultation with MOC . The material of HDPE sub ducts must be as per MOC’S specification no . G20: 10: 001:40

3-6 MANHOLES AND HANDHOLES 3-6.1 Drawing References.

The Contractor shall construct Manholes and Handholes etc. according to the following latest standard amended Construction Drawings of the Ministry of Communications

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NOTE

1. All Manholes shall be constructed with neck as shown in Drawing TX:368/l.

2. Manhole Covers recess to be filled with K—300 concrete.

K-300 concrete shall be used for construction of manholes and ‘handholes. A leveling course with 10 Cm

No. Description No. of Ducts Drawing No. No. of Sheets

1 Handhole (Precast or insitu) Upto 2 TX:371/5A 1 2 S1 Type Manhole (reinforced) 4 TX:347/9-1R 1 3 S2 Type Manhole (reinforced) 5 – 9 TX:347/9A-1R 1 4 S3 Type Manhole (reinforced) 10 – 20 TX:347/9B-1R 1 5 S4 Type Manhole (reinforced) 21 – 28 TX:347/9C-1R 1 6 S5 Type Manhole (reinforced) 29 – 40 TX:347/9D-1R 2 7 S6 Type Manhole (reinforced) 41 – 48 TX:347/9E-1R 2 8 L1 Type Manhole (reinforced) 4 TX:347/9-2R 2 9 L2 Type Manhole (reinforced) 5 – 9 TX:347/9A-2R 2 10 L3 Type Manhole (reinforced) 10 – 20 TX:347/9B-2R 2 11 L4 Type Manhole (reinforced) 21 – 28 TX:347/9C-2R 2 12 L5 Type Manhole (reinforced) 29 – 40 TX:347/9D-2R 3 13 L6 Type Manhole (reinforced) 41 – 48 TX:347/9E-2R 3 14 T1 Type Manhole (reinforced) 4 TX:347/9-3R 2 15 T2 Type Manhole (reinforced) 5 – 9 TX:347/9A-3R 2 16 T3 Type Manhole (reinforced) 10 – 20 TX:347/9B-3R 2 17 T4 Type Manhole (reinforced) 21 – 28 TX:347/9C-3R 2 18 T5 Type Manhole (reinforced) 29 – 40 TX:347/9D-3R 2 19 MT2 Type Manhole (reinforced) 9 TX:347/9A-4R 2 20 MT3 Type Manhole (reinforced) 10 – 20 TX:347/9B-4R 2 21 MT4 Type Manhole (reinforced) 21 – 28 TX:347/9C-4R 2 22 MT5 Type Manhole (reinforced) 29 – 40 TX:347/9D-4R 2 23 Exchange Manhole (reinforced) TX:347/5R 2 24 Pre- Cast Manhole TX:347/15 & 15-1 2 25 Standard Duct Arrangement,

Encasement for existing and proposed ducts, termination of ducts.

TX:347/4D-1 & D-1A

1

26 Base of Cabinet. TX:347/6B/D 1 27 Iron work and construction of

Necks for Manhole. TX:348/1 1

28 Laying & Coupling of leading in duct

TX:347/4D 1

29 Standard Draw Box and Sump hole Cover for Manhole.

TX:483 1

30 Typical Services Distribution in sidewalks.

TX:320/G 1

31 Manhole Cover and Frame(Ductile)

TX:481A 1

32 Handhole Cover and Frame(Ductile)

TX:482A 1

33 Guard Post for Cabinet TX:449/1 1 34 Symbol for Telephone Network TX:347/8D 1 35 Handhole (Precast in two part) TX:371/5B 1

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thick K—140 concrete shall be provided below the bottom slab of all R.C.C. Manholes/Handholes. The offset for the leveling course shall be of 10 Cm on all sides.

The Contractor should inform the MOC Engineer to check the measurement of reinforced bars according to the diagrams prior to the placing of concrete in the mould in case of R.C.C. Manho1es/Handholes.

R.C.C. Manholes situated wholly or partially below the ground water level shall be protected by applying self adhering waterproofing membrane to the external surface. Manholes situated wholly above the ground water level shall be protected by painting two coats with rubberised bitumen. The Contractor shall submit to the MOC Engineer for approval the samples and procedure of work before execution.

Pre-cast Manholes shall be provided with 100 mm UPVC bell mouths on all faces according to the full capacity of the Manhole. Pre-cast handholes shall be terminated with 2 Nos. 100 mm PVC bell mouths on each terminated face and two Nos. 50 mm UPVC bell mouths on each terminating face for leading in pipe termination. Cast insitu handholes shall be terminated 100 mm PVC ducts instead of bell mouths. Two Nos. 50 mm PVC leading-in duct termination of 1 M. length sha11 be provided on each side of cast insitu handholes instead of bell mouths. Duct ends, bell mouths and lead-in ducts which are not extended shall be sealed in an approved manner at both ends.

In all R.C.C. manholes / handholes (cast insitu) in which number of ducts terminated is less than the full capacity, additional number of ducts required to make up full capacity shall be installed for a length of 1 M. on each termination face and their ends shall be sealed in an approved manner. Wherever there is existing cables, MOC proposes to construct insitu Manhole & Hand hole. Or handhole in two part as per moc’s approved drawing no. TX-371/5B in consultation and approval from MOC.

All the above work including materials shall be considered as part of the work of manhole / handhole construction for purpose of payment.

Bell mouths for Manhole / Handhole shall be approved by the MOC Engineer before execution.

3-6.2 Iron works for manhole and handholes shall conform to MOC’ specifications and standard . The contractor has to submit samples of materials with technical literature/ specification and test

reports for MOC’s approval before supply . Anchor iron should not be placed by breaking a part of manhole but should be placed before placing of

concrete. For RCC Manholes, anchor iron should be set in shuttering and concrete cast.

Position of step installation shall be between neck and slab in case the neck is provided and at a middle point of slab in ease neck is not provided.

3-6.3 The cement blocks approved by the Ministry for repair of existing Manhole/Handhole etc. shall be

properly bedded in mortar with all joints full, courses level and faces vertical. Cement blocks shall be pre-soaked for a minimum of 4 hours immediately prior to use.

Exposed faces and internal faces of manholes or handholes shall be finished smoothly as there is no ruggedness of cement and bond and plaster as shown in the drawings.

The block work for the outer face of MH/HH should be well pointed.

3-6.4 In paved areas (Carriageway, Footways etc.) MH & HH covers shall be set to the same level and to the

same falls as the surrounding paved areas. In unpaved areas MH neck shall be set 200 mm above finished surface level unless otherwise shown on the drawings or directed by the Ministry Engineer. In all cases

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the Contractor should collect information about future plan of road and should decide the level in consultation with the MOC Engineer.

3-6.5 The Contractor may also be required to build manholes and handholes of dimensions different from the

standard type of manholes and handholes. In this case, the Contractor shall prepare new drawings and submit them to the Ministry for due approval and shall submit the strength calculations of the structure also. The above mentioned work such as designing, drawing and strength calculation etc. of special type of manholes and handholes are duly a part of the work of the Contractor and hence the Contractor cannot claim any additional payment for this from Ministry.

If the variation in the total quantity of reinforcement concrete + cement concrete + cement blocks due to the modification, alteration etc. is less than 15% of the total quantity of the above items of each standard manhole, handhole, no extra charges are payable. For calculation of the excess mentioned above, the neck shall not be taken into consideration.

The rate of charge for the special type of manholes and handholes shall be calculated on pro—rata basis of the manhole / handhole volume as against that of similar types of standard manholes / handholes.

3-6.6 Duct termination in manholes and handholes shall be in position so as to facilitate accommodation of

cables. When new ducts are installed or expanded in the manhole they shall be terminated at the centre portion of the manhole in the horizontal plane as far as possible. Minimum distance between the top duct axis and the roof slab or the bottom duct axis and the base slab shall be 40 Cms. Corresponding ducts shall be terminated on the same level as far as possible. However in L & T type and Exchange Manholes, level difference between ducts fixed in the straight direction and branching off direction should be not less than 34 Cm to avoid interference in cable laying and jointing. The angle of ducts termination with manhole and handhole shall be at right angle. If this is not possible the Contractor should submit the longitudinal profile drawings of the proposed duct route showing the Location, size and elevation etc. of all other services including MOC ducts, handhole and manhole to the MOC for approval. If the number of ducts terminated is less than the maximum capacity of the Manhole / Handhole spare ducts of length 1.0 M. shall be provided to obtain the maximum capacity of the Manhole / Handhole. The ends of these ducts shall be sealed in accordance with these specifications. No additional payment will be given for these spare ducts.

NOTE :

Cable racks fitting position for S-1 and L-1 type manholes shall be only one side (Building side) and so position of duct termination shall be at the cable racks fitting side from the centre line of the manhole.

3-6.7 In the case of manholes in water-logged areas, water-proofing, shall be done by the Contractor at his own

expense. 3-6.8 The manholes and handholes shall be thoroughly cleaned after construction is over and shall be free from

water, dirt, sand, rubbish etc.

All manholes and handholes shall be watertight and constructed at locations as shown in the approved drawings.

3-6.9 The Contractor shall provide housing base on the roof of new manhole designated for, installation of

distribution cabinet in accordance with MOC Drawing No. TX 347/6B/D or as approved by MOC according to the type of cabinet used.

In case of fixing of cabinet, on an existing manhole, the Contractor shall construct cabinet base on the new slab after demolishing the roof in full and in accordance with detailed drawings, approved by the MOC.

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Removal of cabinet from existing manhole shall be made by removing bolts fixed to the housing base and then the base may be removed. The gap shall be filled with K-300 concrete after chiselling a portion about 20 Cms. in width and 5 Cms. in depth. Cabinets shall be returned to the MOC Store.

3-6.10 The Contractor shall provide necks for all newly installed manholes (Refer to Drawing No. TX 368/1).

The construction of neck shall be of R.C.C.

Height of the neck shall be of 20 Cms. Necks of height above 20 Cms. upto 60 Cms. is allowed if the site conditions do not permit to have 20 Cms. height. Whenever the height is less than 20 Cms or more than 60 Cms, the Contractor shall submit the necessary document for MOC’s approval. A neck higher than 60 Cms. may be directed by MOC in special cases. If neck high is more than 40cm,steps shall be provided at every 25cms.

Contractor shall fix the number plates for each new and existing Manholes and Handholes respectively.

The number plate shall be of size 100 mm x 60 mm and shall be made of stainless steel plate 1 mm thick. The plate shall be provided with four (4) holes 4 mm diameter for fixing on wall with screws and dowels. Letters shall be of size 7 mm, embossed or engraved and painted in black with white background painting in the plate.

Number plate for manhole shall clearly mention name of Exchange area, manhole number, type and size of manhole and year of installation. Number plate for handhole shall mention name of exchange area, handhole number and year of installation. Sample of number plate and method and position of fixing should be got approved by MOC, before commencement of work.

Number plate shall be fixed with screws and dowels on the neck of manhole or the shorter side wall of handhole at 10 Cms below the frame.

In the case of existing manhole without neck, number plate shall be fixed at roof slab near the frame of manhole cover.

3-6.11 The Contractor may have to construct neck on existing manholes to a height upto 20 Cms. or above 20

Cms. upto 60 Cms. depending on the ground level conditions. A neck higher than 60 Cms. may be directed by MOC in special cases.

.The existing manhole cover and frame shall have to be recovered in the first stage, taking due care for the existing cables, joints, fixtures etc., inside the manhole. The existing roof shall be chiselled to a depth of 5 Cms. and width of 25 Cms around.

Construction of the neck is the same as in the case of new manhole construction (Refer Drawing No. TX: 368/1).

The surface of roof around the neck shall be given a smooth finish and the manhole cover placed after curing.

3-6.12 In case that neck of existing manhole is just out of the road surface, banking around the neck should be

done to avoid danger to pedestrians and vehicles etc. The correct banking material should be piled up to the same level as the neck with easy slope and should be compacted sufficiently so that it is not blown away by wind etc.

Contractor should investigate about the places where the banking is to be done at the time of field survey and should get approval from MOC.

3-6.13 In case the existing manhole or handhole is to be demolished and re-constructed or a manhole or

handhole is to be newly established in the middle of the existing duct route, the cable in the duct concerned and other facilities shall be supported and protected with a completely safe method as approved by the MOC.

26


Manholes or Handholes and the portions of the duct termination shall be such that on completion, all existing cables will be fully supported on the cable racks.

Existing ducts falling within the newly constructed manhole shall be cut without damaging cables, if required by Ministry. Such cutting and removal of ducts shall be treated as part of manhole construction.

3-6.14 The Contractor shall install a manhole cover to the existing manhole where cover is missing or damaged.

Manhole covers voids shall be filled with K-300 concrete. 3-6.15 The existing Manhole roofs which have slid or are damaged, shall be replaced. In demolishing the roof

for replacement, care must be taken not to cause any damage to cables and other facilities in the manhole. 3-6.16 In case of having duct projected inside the existing manhole, the Contractor shall shave the inner wall

face of the manhole in the area of 3 Cm of duct circumference and 3 Cm in depth to cut the duct off.

The treatment as mentioned in para.3-4.4 shall be applied. Duct face shall be finished by plastering. In this case, care shall be taken not to cause damage to the existing cable.

3-6.17 In case of removing the existing manhole and handhole, the Contractor shall perform the removal work

with utmost care, so that the jointing points and other places are not damaged. In case new manhole construction is required at the same place, where the existing manhole has been removed, costs for excavation, backfilling and restoration shall not be duplicated in the price schedule.

3-6.18 In case, cable racks are not sufficient in quantity or corroded in the existing manhole, the Contractor shall

provide cable racks at the specified position, in accordance with the specified drawing and the specified position for supporting cables. For installing the cable rack, it is necessary to make a cavity at the position of fixing the hook-bolt and to fill the same with mortar (mixing ratio -Cement, Sand 1:2) and insert the hook-bolt in to the cavity. Surface shall be finished with plastering.

3-6.19 The Contractor shall provide iron ladder for the existing manhole, if the ladder is not provided with the

Manhole No. duly embossed or engraved on it.

Necessary step shall be installed. Position of step installation shall be between neck and slab in case the neck is provided and at a middle point of slab in case the neck is not provided. If the neck height is more than 40 Cms, steps shall be provided at every 25 Cms.

3-6.20 Pre-cast handhole may be constructed for the new handhole route where there is no existing

cables (Refer to Drawing No. TX: 371-5A). Approval to be taken from MOC before execution. 3-6.21 Pre-cast manholes can also be proposed by the Contractor where there is no existing cables and

approval obtained from the MOC before execution. Design details and calculations must be submitted by the Contractor. Rates shall not exceed rate for similar RCC Manholes and shall be subject to approval of the Ministry.

3-6.22 The newly constructed manholes shall be equipped with the following

Hinged type Manhole Cover and Ring according to Drawing No. TX: 481A.

Steel Ladder.

Cable Racks.

* Cable Supports.

Steps.

Anchor Iron and Sump hole Cover. 27


Number Plate.

* Each Cable Rack shall be equipped with Cable Supports in all positions (Full capacity).

3-6.23 The newly constructed handhole shall be equipped with hinged type handhole cover and its frame

(Drawing No. TX - 482 A), cable rack for handhole and number plate. 3-7 LEAD-IN DUCT 3-7.1 The Contractor shall lay lead-in duct (for laying the lead-in cable to the subscriber’s premises or building

from manhole, handhole or pole) to the subscriber’s intake duct or draw box fixed on the boundary wall and shall joint the lead-in duct with the intake duct or draw box.

The lead-in ducts shall be of UPVC from the manhole, handhole or pole to the draw box, except the exposed portions. The exposed portions near the draw box or pole• shall be of galvanized iron in accordance with material specifications. Suitable adaption according to the size of the ducts must be provided by the Contractor to connect the G.I. and PVC ducts with the approval of the MOC Engineer.

If there is no draw box on a boundary wall in the subscriber’s premises, as most of the subscribers have lead-in duct ready upto the outside of their premises, the Contractor shall carry out the field survey at the site, locating the existing duct by excavation, if necessary, and shall arrange to have the new PVC ducts effectively coupled to the existing duct, adopting a coupling and have the proposed method of coupling approved, by the MOC., securely tied to its hardware A draw rope of thermoplastic material of minimum 5 mm dia shall be provided throughout the full length of duct from handhole to Draw Box, in order to lay cable at a later stage at each end.

3-7.2 In case, no lead-in duct exists in the subscriber’s premises, the Contractor shall obtain the subscriber’s

consent on the position of Draw Box to be fixed on a boundary wall, and with the approval of the MOC Engineer, the Contractor shall lay lead-in duct from manhole, handhole or pole to level wherever possible, along the boundary wall. the boundary wall of the subscriber and shall fix Draw Box to the end of the lead-in duct raised to 160 Cms from the ground Alternatively, if so required by the Engineer, the Contractor shall inform the subscriber, in writing, to install the lead-in duct. In case there is no boundary wall, leading in duct shall be terminated in a draw box 300 x 300 x 75 mm at a place approved by the Ministry.

3-7.2A Incase of rehabilitation of area along with other services, the Contractor has to install a new leading in pipe along with draw box to each house.

3-7.3 The route of the lead-in ducts shall be shortest. In footpaths, care is to be taken of other services and

standard reservations as shown in Drawing No. TX: 320/G. 3-7.4 The lead-in duct shall bend smoothly at radius more than 6 times the outer diameter. The depth from

ground surface to the top of the duct should be 40 Cms. The ducts shall be so coupled throughout the whole length that there will be no difficulty in laying of the lead-in cable.

Joints of leading in PVC ducts shall be made with PVC couplings and sealed with solvent cement (BS 4346).

Coupling for jointing PVC duct to 50 mm G.I. duct should be made of PVC and have one end threaded and the other end shall be suitable for sealing with solvent cement.

In case of existing subscriber duct having different diameter, a reducing coupling shall be used.

The Contractor shall in these cases, submit sample for approval of MOC.

Premade bends should have a minimum radius of 6 times the outer diameter of the duct (See MOC

28


Standard G20:10:001:32) 3-7.5 All galvanised steel ducts to be buried, should be given a protective coating of bitumen. 3-7.6 The Contractor shall write the D.P. Number on the D.P. Box cover, installed on the pole or boundary

wall as well as draw box, as instructed by the Ministry of Communications. 3-7.7 Any damage to subscriber’s property during the work shall be made good by the Contractor at his own

expense. 3-7.8 After laying the ducts, both ends shall be carefully sealed with removable sealing compound to prevent

insects and reptiles getting entry into the building. 3-7.9 The Contractor shall reinstate all trenches for laying lead-in duct in paved or unpaved footpath and all

other places to match the original surface. 3-7.10 In case that lead-in duct is newly laid or replaced in manhole or handhole, regardless of existing

conditions, in general principle, the duct should be fitted on the same side as main duct.

However, in case it is not possible to fix the duct on the same side, Contractor should take approval from the MOC Engineer.

3-7.11 The cost of leading intake shall include all accessories, Draw Box / DP Box, Duct Termination in

Box and Handhole Coupling to existing subscriber’s ducts, numbering etc. 3-8. CLEARANCE TO UNDERGROUND SERVICES AND FACILITIES 3-8.1 Storm water and Sanitary Sewers, Water and Gas Mains and other Services Duct lines - Subject to the

requirements of other service Ministries, Authorities and Companies, a minimum clearance of 150 mm shall be provided between telephone installations (ducts, ducts and cables) and storm water and sanitary sewers, water and gas mains and other services duct lines.

3-8.2 Electricity Supply Poles and Pylons, Road Lighting Poles and Masts, Traffic Sign and Signal Poles,

Gantries and Overhead Supports - A minimum of 150 mm shall be provided from the above facilities and their foundations to any telephone installations.

3-8.3 Electric Cables — The minimum clearance between telephone cables and electrical cables shall be as

follows

(i) High Voltage Single Core Cables of Voltage greater than or equal to 650 V, but not more than 132 KV. ... 450 mm.

(ii) High Voltage Multicore ‘Cables of Voltage greater than or equal to 650 V, but not more than l32 KV. (with resistance earthing of neutral for 132 KV). ... 300 mm.

(iii) Low Voltage cables of Voltage less than 650 V. ... 150 mm.

Exceptionally, with the permission of the MEW Engineer and the MOC Engineer, the clearances given in (i) and (ii) above may be reduced at crossings of electric cables to a minimum of 150 mm. In such cases, a 75 mm. thick layer of K-140 concrete shall be placed between the electric cables and the telephone cables. The concrete layer shall be sufficiently wide to overlap the electricity cables by 75 mm on either side and be not shorter than the width of the telephone plant.

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The minimum clearance between telephone installations and electric cables of voltage of 132 KV with direct earthing of neutral and all cables carrying voltages greater than 132 KV shall be determined as a special case for each location.

No reduction of the clearance shown on the drawings will be permitted without prior approval of the MEW Engineer and the MOC Engineer.

The Contractor shall be responsible for obtaining details of the type of electric cables to be crossed by or to run adjacent to the telephone plant to be installed under the contract.

3-9 INSTALLATION OF DISTRIBUTION CABINETS

In case distribution cabinets are required to be supplied and installed by other Ministry’s Contractor, the following specifications shall be applicable.

3-9.1 Distribution Cabinets of size 2400 pairs shall be supplied and installed by the Contractor. The locations

of these Cabinets will be shown in the Drawings of T.P. F.D. enclosed. The Cabinet shall be of such a size that it can be installed on any type of manholes.

3-9.2 It shall be installed on a reinforced concrete base in accordance with Drawing 347/6B/D, or as approved

by MOC according to the type of Cabinet used, to be cast along with the roof of the Manhole (while the manholes being newly constructed) or the base may have to be cast over an existing manhole.

3-9.3 The foundation bolts suitable for the make of the Cabinets shall be fixed while casting the concrete.

Special care shall be taken to ensure that the articles shall be securely fixed/embedded with correct position and the Contractor shall, at his own expense, provide all necessary templates, temporary supports and other plant and labor required.

Items to be embedded in the concrete shall be clean and free from oil or foreign matter that would weaken the bond of concrete to these items.

The Contractor shall make the distribution cabinet watertight, by sealing all apertures in the cabinet base.

3-9.4 The distribution cabinet shall normally be installed at the down side corner of the Manhole, on the

building line side, so that it is parallel to the road and facing the building side. In case of cabinets with doors on both sides, the side facing building will be front side (Face A) and side facing road will be back side (Face B). The position and type of the Cabinet shall be got approved from MOC before execution.

3-9.5 The Contractor shall write the cabinet number at front and back on each cabinet as instructed by the

MOC. The lettering shall be 100 mm block lettering. 3-9.6 The Contractor shall install guard posts around manhole cabinets newly installed and existing cabinets as

shown in Drawing No. TX: 449/1 to protect the cabinet from vehicles etc.

The Contractor should investigate about manholes for which guard posts are to be installed at the time of field survey, and should get approval from MOC.

3-9.7 The cabinets shall be earthed as specified in MOC Standard G20:10:001:24. The earth wire entry duct

installed in the Cabinet base shall be sealed properly after installation of earth wire, to prevent entry of water. The Contractor should include in his field survey report the details of existing cabinets which are to be earthed.

3-10 CONTRACTOR’S RESPONSIBILITY FOR PROTECTION OF THE INSTALLED PLANT

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The Contractor shall be solely responsible for maintenance and protection of plant installed by him until such plants are provisionally handed over to the Ministry. In case any damage is caused to MOC Plant before provisional handing over, due to work by other Contractor / Agencies, it is the responsibility of the Contractor himself to get the plant repaired without delay and any cost incurred due to such damages should be settled with such Agencies / Contractors and any of the above responsibilities shall not be transferable to MOC in any manner.

3-11 COMPLETION REPORTS AND DRAWINGS 3—11.1 On completion of work, the Contractor shall prepare a written report of the final acceptance testing

including the tabulated results of all mandrel, pressure and compaction tests carried out, to the MOC Engineer which shall be accompanied by

(a) Set of completion drawings 3 copies with newly installed plant marked in red and As-built

Drawings to scale 1:2000 and conforming to A-l size showing actual status of As-built facilities. As-built drawings shall include three sets of prints and one set of Auto CAD polyester film of 75 Microns (0.003”), from which prints can be taken out along with CD with latest version of Auto Cad. Write on CD Project no. and Detail of Areas/ Road name .

(b) All As-built drawings must be Geographic Information Compatible pro-forma

with Coordinates as per WGS 84 GPS Projection system in decimal degree.

(c) Key map to a suitable scale showing clearly the location of Area / Street / Road.

(d) The as built drawing should include the following information

(i) Name or number of main road, street name / number.

(ii) Width of road / footpath. (iii) Distance of central line of plant from Kerbstone or centre of road.

Road Name Road No. Width of road Foot Path

Width

MOC’s centre line from kerb

stone

31


Where, A - Width of Footpath. B - MOC centre line from Kerb Stone. T.L - Telephone Line. K.S - Kerb Stone. B.L - Building Line.

(iv) Manhole No., Handhole No and drawing numbers. (v) Type of MH S1, S2 etc. and if ordinary or R.C.C. (vi) MH Span, HH Span (from Centre to Centre of HH or MH).

240.00 (9) UPVC

(vii) Cabinet No., Draw Box No., DP No. (viii) Nos. and types of ducts.

(ix) Depth of top level of ducts if it exceeds 1 M. (or complete profile drawings).

(x) Details of protection of ducts (concrete surroundings).

(xi) Size of drawing.

59.4cm MOC’s monogram

as per standard 2cm 84.0 cm

(xii) Direction of north may be marked on location plan & detail plan.

(xiii) When depth of top level of ducts if it exceeds 1M, complete profile drawings

should be submitted.

(xiv) Details of protection of ducts ( Concrete Encasement ) to be marked.

(xv) As built quantities:

MOC’S

STANDARD SIZE DRAWING

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Legend Quantities

Existing Hand hole

Existing Manhole Type S-1

Existing Manhole Type L-1

Legend Quantities

Pipe laying 1 way

Pipe laying 2 way

( 2 ) Pipe laying 4 way

( 4 )

When the Engineer is satisfied that the work is complete, that all testing as specified have been carried out, and all documents have been submitted, he will inform the Ministry of Communications, who will carry out a final acceptance inspection for the provisional acceptance of the plant.

(d) In case of partial inspection also the above drawings and details must be submitted by the

Contractor to MOC.

3-12 INSPECTION AND ACCEPTANCE TESTS 3-12.1 The Inspection and Acceptance Tests specified herein shall be made after the physical completion of the external

plant facilities and shall not replace the normal supervision, inspections and tests to be made by the Contractor and the Engineer during the progress of the construction work. All Inspection and Acceptance Tests specified herein shall be performed by the Contractor at his cost under the supervision of MOC Engineer. Any reinstatement after the inspection is to be done by the Contractor at his cost.

3- 12.2 The main items of Inspection and Acceptance Tests by Ministry of Communications are given below: Inspection Acceptance Tests (1) Structure. (1) Mandrel Test. (2) Sump Hole. (2) Pressure Test for (3) Accessory Material. PVC Ducts. (4) Pulling Bolt (Anchors) (3) Proctor Compaction (5) Step. Test. (6) Ladder. (7) Cover Greasing.

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MOC TND Specification No. 4 (8) Cleaning (9) Duct Laying and Termination. (10) Manhole No. Plate. (11) Cabinet. (12) Draw Box. (13) Lead – in Duct (14) Handhole No. Plate. (15) Wayer tightness of MHs/HHs. (16) Break Inspection (To Ascertain the depth of duct, concrete encasement, pointing, providing of spacers) and any other required information. 3- 12.3 “The physical completion of External Plant facilities” means:

(A) Manholes and Ducts for Feeder Cables.

After all works concerning Manholes and Ducts for the Feeder Cables to the farthest point from the Exchange in each Subscriber direction are completed.

(B) Handholes and Ducts for the Distribution Cables. After all works concerning Handholes and ducts from a Cabinets to its dead-end for the Distribution Cables are completed , including leading- in duct.

3- 12.4 Necessary equipment, laborers and costs for the Acceptance Tests and for any other tests required under this specification shall be provided by the contractor. Written reports including the tabulated results of the tests made by the contractor shall be prepared, signed by the contractor and the Engineer and submitted to MOC upon completion of the work.

3- 12.5 The Contractor shall perform Mandrel Test by using hard wooden mandrel of 90 mm in diameter and 300 mm in

length. The Contractor shall also perform Pressure Test as per Para 3-4.6(b) of this specification. Ducts to be tested shall be designated by the Ministry of Communications.

In case the test mandrel cannot be pulled through the duct or failure of pressure test during the acceptance tests

the ducts shall be rejected. 3- 12.6 The Contractor should repair all defects in the plant and re-offer for second inspection within 21 days from the

date of first inspection. If the work is again rejected in the second inspection or if the contractor fails to repair the defects within 21 days , MOC reserves the right to accept the work with due compensation from the contractor to the ministry for repairing the defects. If third inspection is required MOC may charge the contractor an inspection fee which will be decided by MOC. These compensation and other charges are with prejudice to any provision contained in the contract or penalty for delay etc.

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1. SCOPE OF SPECIFICATION ................................................................................................................................................... 3 2. ASSOCIATED DOCUMENTS .................................................................................................................................................. 3 3. DESCRIPTION AND APPLICATION OF ITEMS ....................................................................................................................... 3 4. MATERIAL REQUIREMENTS ................................................................................................................................................ 3 5. MECHANICAL STRENGTH REQUIREMENTS.......................................................................................................................... 4 6. TESTS AND INSPECTIONS .................................................................................................................................................... 4 7. PACKING AND MARKING .................................................................................................................................................... 4

Drawing References Item MOC Drawing Reference

Cable Support (2 Cables) TX 368/1 Cable Support (4 Cables) TX 368/1

Cable Rack Manhole TX 368/1 Cable Rack Hand hole TX 368/1

Ladder Manhole TX 368/1 Step Manhole TX 368/1

Anchor Cable Pulling (Anchor Iron) TX 368/1 Sump hole Cover:

Hook Bolt Rack Bolt

TX 368/1

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1. SCOPE OF SPECIFICATION This specification covers the steel hardware used in the mnaholes and handholes of the local distribution network in Kuwait i.e.:

i. Cable Supports ii. Cable Racks in Manholes and Hand holes iii. Ladders in Manholes iv. Manhole Steps v. Anchor Irons vi. Sump-hole cover, Hook Bolt, Rack Bolt.

2. ASSOCIATED DOCUMENTS Standards of the International Organistion for Standardisatic (ISO) have been used when available. Where International standards are not available Standards in accordance with the British Standards Institute (BS) have been specified. A Tenderer proposing any other standards shall include the standards in his proposal for approval. The following standards have been referred to in this specification.

MOC G 30:10:03 Test and Inspection Manufacture MOC G 40:10:03 Tests and Inspections - Local ISO R 1459 Metallic Coatings: Protection against corrosion. Guiding principles ISO R 1460 Metallic Coatings: Hot dip BS 729 Part (I) Galvanised Coatings of Ferrous Metals ISO R 1461 Metallic Coatings: Hot dip galvanised Coatings on Fabricated Ferrous products ES 4360 Mild Steel; Composition MOC Drawing No.368/1 Iron Works and Construction of neck for Hand holes and Manholes

3. DESCRIPTION AND APPLICATION OF ITEMS

No. Description Of Item MOC Detail Drawing No. Application



3 Cable Rack Manhole TX-368/1 Used Together With Cable Racks In Manholes For Cable Support

4 Cable Rack Hand hole TX-368/1 Cable Support In Hand Holes

5 Ladder - Manhole TX-368/1 Provided In Manhole To Aid Descent And Ascent

6 Step - Manhole TX-368/1 Provided Inside The Neck Or Slab To Hook The Ladder

7 Anchor - Cable Pulling (Anchor Iron) TX-368/1 For Anchoring Guide Block Chain When

Pulling Cable 8 Sump Hole Cover And Bolts TX-368/1

Table 1

4. MATERIAL REQUIREMENTS 4.1. The material used for hardware shall be mild steel conforming to BS 4360 or equivalent. 4.2. The surfaces of the hardware shall be given a uniform galvanised coating of 610 g/m2 for steel items having a

thickness of 5 mm or more, 460 g/m2 for items aving thickness less than 5mm and 305 g/m2 for threaded items of 10 mm diameter and over. The galvanising shall be applied by dipping the products into molten zinc in accordance with ISO Standards R-1459, R-1460, R-1461, BS 729 Part I and LSO Standards or equivalent.

4.3. Anchors cable pulling must be secured to a plate, which is cemented into the concrete in non-re-enforced manholes and shall be secured to reinforcement bars in re-inforced manholes. They should be installed in such a way that they shall withstand a pulling force of 3O KN.

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5. MECHANICAL STRENGTH REQUIREMENTS 5.1. Cable supports and racks shall be able to support a dead weight of 120 Kg applied to their outer extremity

(non-wall side of manhole or hand hole) when tested in situ. 5.2. Ladders shall be able to support a vertical weight of 200 kg applied on any of the rungs without any cracking,

buckling, or bending of the whole ladder assembly or individual rungs.

6. TESTS AND INSPECTIONS All items must conform to the Tests and Inspection requirements detailed in MOC Standards G 30:10:03 and G 40:10:03.

7. PACKING AND MARKING Where supplied externally to Kuwait all items shall be suitably packed for overseas transportation. Where manufactured within Kuwait the method of packing and delivery shall be agreed with MOC. All packing shall be clearly labelled as follows:

i. Ministry of Communications, Kuwait plus Order number ii. Name of Supplier and Country of Origin iii. Description of items iv. Quantity of Items v. Gross Weight

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1. SCOPE ................................................................................................................................................................................. 3 2. ASSOCIATED DOCUMENTS .................................................................................................................................................. 3 3. QUALITY OF MATERIALS .................................................................................................................................................... 3 4. MANUFACTURE AND WORKMANSHIP ................................................................................................................................. 3 5. DIMENSIONS ....................................................................................................................................................................... 3 6. INSPECTION AND TESTING .................................................................................................................................................. 4 7. PACKING AND MARKING .................................................................................................................................................... 4

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1. SCOPE

1.1. This technical specification describes Medium Duty ductile Iron Manhole and Handhole Covers. 1.2. Each complete manhole cover shall consist of the cover and its frame. 1.3. Each complete handhole cover consists of two pieces called the “Upper Cover” and “Lower Cover” and the

receptacle called the “Frame”. 1.4. The Handhole cover must be double hinged type as per approved MOC’s drawing . The gasket has to be

provided in frame to stop entry of water . 1.5. MOC is studying the proposal to upgrade existing metallic manhole and hand hole covers to Glass reinforced

plastic (GRP) as soon as it is finalized. Hence, MPW/NHA/consultant /contractor should confirm MOC’s approval of GRP covers before quoting or supplying manhole and hand hole covers

2. ASSOCIATED DOCUMENTS Kuwait Standards (KS) , American standard and British Standards (BS) have been used where applicable and are

detailed below: G 30:10:03 MOC Tests and Inspection - Manufacture G 40:10:03 MOO Tests and Inspection - Local KS 22 1971 Kuwait Standard relating to Manhole and Handhole covers

BS – 2789 Grade 500/7 standard relating to Manhole and Handhole covers

En 124 Method for the Loading verification of testing machines MOC Drawing No. TX: 481A Manhole Covers and Frames MOC Drawing No. TX: 482A Handhole Covers and Frames

3. QUALITY OF MATERIALS The covers and frames shall conform to Kuwait Standards Specification No. KS22-1971 and BS-2789 Grade 500/7 and ASTM A 536 and MOC Requirements detailed in the following Paras. The metal used for these items shall be suitable for the method of manufacture, and shall be of a quality no less suitable than those specified in BS 2789 Grade 500/7 and ASTM A 536 (Ductile Iron).

3.1. The tensile strength shall not be less than 19 Kg/mm3 i.e. 12 tons/in2 in case of 30.5 mm diameter of Test Bar as cast (US 1452).

3.2. The weight shall be corresponding to the dimensions as specified in KS 22-1971and tolerance of + 5 % is permissible.

3.3. All covers and Frames shall be coated with black bitumen paint and greased after treatment by heat for anti~rust protection. The paint coating shall be smooth and tenacious and shall not flow or chip when exposed to temperatures of between –10 °C and 85 °C.

4. MANUFACTURE AND WORKMANSHIP All covers and frames shall be cleanly cast and shall be free from air holes, sand holes, cold shuts and chill. They shall be neatly dressed and carefully fettled. All castings shall be free from voids whether due to shrinkage, gas inclusion, or other causes. The covers shall fit the frames properly and tightly and shall not leave any crack. Any crack or defect is not acceptable.

5. DIMENSIONS The dimensions shall be according to KS 22-1971 and up dated as per ductile iron material and approved drawing and are detailed in the following drawings: Manhole Cover Frame Drawing No. TX: 481A Manhole Cover Drawing No. TX: 481A Handhole Cover Frame Drawing No. TX: 482A Handhole Upper Cover Drawing No. TX: 482A Handhole Lower Cover Drawing No. TX: 482A

5.1. Tolerance of + 2.5 % for all dimensions except the gap between the cover and the ring which must not exceed 5 mm in the case of manhole cover and 2 mm in the case of handhole covers, tolerance between 0.8 mm and 1.5 mm in the upper edge of the inside of the frame and respective tapering position of the cover and + 0.5 mm in the case of keyholes, are permissible.

5.2. On the top of each cover shall appear the letter Telephone Net work in Arabic and English and on the backside the manufacturer's name and year of manufacture.

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5.3. The handhole covers shall indicate the difference between upper and lower covers , “UP” and ‘DN’ may be written on respective cover .

5.4. The manufacture/ Supplier has to obtain Manhole and Handhole cover drawing approval for ductile iron from MOC before manufacturing .

6. INSPECTION AND TESTING

6.1. Inspection and Testing shall be carried out in accordance with MOC Standards G 30:10.03 Test and Inspections Manufacture and G 40:10:03 Test and Inspection - Local. These tests shall include the load test detailed in Para 6.2 below.

6.1.1. The covers shall be available for inspection and testing at any time during manufacture or after finish, by the MOC appointed Inspector. The manufacturer shall provide necessary equipment and testing facilities.

6.1.2. One cover and frame in every 50 of each type manufactured, shall be tested by the method and to the requirement specified in Para 6.2 for test loading. In the event of any one of the Articles in the batch of 50 failing to meet the requirement of the standard, the articles in the batch shall be rejected, unless all the particular articles are individually tested.

6.2. Loading Test 6.2.1. The covers shall be required to satisfy the necessary load test and shall be considered satisfactory if they

sustain a 20 tonne force for a manhole cover and 15 tonne force for a handhole cover for period of 30 sec without fracture. The diameter of the bearing block used shall be 300 mm.

6.2.2. The procedure for loading test shall be as follows: 6.2.2.1. The apparatus required for the loading test shall consists of: 6.2.2.2. A supporting frame which shall be a standard frame or a specially made support, used solely for

testing purposes which shall provide the same conditions of support as a standard frame. 6.2.2.3. A bearing block, of 300 mm diameter. It shall be made of hardwood faced with hard rubber, or other

resilient material, and sufficiently rigid to ensure that the load on the cover is evenly distributed over the full area of the block.

6.2.2.4. A device preferably a hydraulic testing machine for applying the load. The device shall be capable of applying a load at least 25 % greater than the appropriate load specified in Para 6.2.1. If a testing machine is used, it shall comply as regards accuracy with Grade B of BS 1610 (Method for the Loading verification of testing machines). If any other load-measuring device is used, it shall be accurate to within two per cent of the indicated load.

6.2.3. The load test shall be carried out as follows: The cover or grating shall be supported in the frame and the bearing block shall be placed centrally over the cover. The appropriate load specified in Para 6.2.1 shall be applied without shock and shall be sustained for a minimum period of 30 sec.

7. PACKING AND MARKING Frames and covers shall be securely packed for overseas transportation when ordered from outside Kuwait. When ordered locally the method of packing and delivery will be agreed between MOC and the Supplier. All packages must be securely labelled with the following information:

i. Ministry of Communications, Kuwait plus Order Number ii. Description of Item iii. Quantity or Length of Item iv. Gross Weight of Item v. Manufacturer's Name and-Country of Origin

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1. SCOPE ................................................................................................................................................................................. 3 2. ASSOCIATED DOCUMENTS .................................................................................................................................................. 3 3. TEMPERATURE AND ENVIRONMENT ................................................................................................................................... 3 4. MATERIALS ........................................................................................................................................................................ 3 5. MECHANICAL, THERMAL AND ELECTRICAL PROPERTIES ................................................................................................... 5 6. TESTS AND INSPECTION...................................................................................................................................................... 6 7. STORAGE ............................................................................................................................................................................ 6 8. PACKING AND MARKING .................................................................................................................................................... 6

Item Description Of Item Use 1 UPVC Duct 100 mm 0 × 6 m 2 UPVC Duct 50 mm 0 × 4 m 3 Couplings for 50 mm Ducts 4 Cement Solvent Compound 5 Spacers for UPVC Ducts 6 Bends

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1. SCOPE This specification covers the manufacture, testing, and supply of UPVC ducts and accessories for use in the cable ducting network in Kuwait. 1.1. The ducts fall into two categories i.e.

i. 100 mm diameter duct for manhole and hand hole linkage. ii. 50 mm ducts for lead-in facilities to subscribers premises when small size cables are used.


Society for testing and materials (ASTM) are applicable in this specification the latest issues shall apply and deemed to be an integral part of this specification. Where equivalent international or other standards are used details shall be submitted with any tender.

2.2. The following standards have been referred to in this specification. BS 2782 BS 3505 Un-plasticised UPVC Duct/Spacer BS 3506 BS 102c Softening Point BS 4346 Cement Solvent ASTM D 2564 - 73A Solvent ASTM 792 Density ASTM D 1708 Modulus Elasticity ASTM D 2240 Hardness ISO R 174-E Modulus of Viscosity

3. TEMPERATURE AND ENVIRONMENT 3.1. The ducts are for installation in excavated trench works throughout Kuwait. They shall be capable of meeting

the following temperature requirements. Installed: -10 °C to +55 °C Ambient Temperature During Storage & Transportation

i. –100 °C to +550 °C Ambient Temperature ii. +89 °C maximum sun Radiation Temperature for period of days

3.2. The ducts shall be resistant to any corrosive elements found naturally in the ground in Kuwait. They shall be unaffected by water, oil, oxidising Agents, salinity, aggressive soil, sand, fungi growth and bacterial or electrolytic actions.

4. MATERIALS 4.1. The duct compound shall be rigid UPVC without plasticiser, lubricants, and stabilisers. Anti-oxidants and

pigments may be added. 4.2. No constituent material shall be used which will adversely affect the long-term mechanical strength of the

UPVC. All constituents shall be uniformly and fully dispersed. 4.3. The tenderer shall state in his proposal the name of the manufacturer of the UPVC compound and also its name

or code number. 4.4. The colour of the material shall be light grey. Pigments shall be titanium oxide and carbon black. The

maximum pigment and filler content shall be 5 %. 4.5. Ducts shall be homogeneous throughout. All surfaces shall be clean smooth, and without any visible cracks,

grooves, blisters, wrinkles, dents, beat marks or foreign inclusions. Ends shall be square and free from sharp edges.

4.6. UPVC Ducts For MH And HH Route The UPVC ducts shall be supplied in 6 m lengths. The ducts shall have minimum 100 mm internal diameter and minimum 4.5 mm thickness. The UPVC ducts shall have one end plain and the other end a 100 mm expanded socket for spigot coupling. The expanded end shall have a wall thickness not less than that specified for the duct, and the tolerance on the fit of the spigot and socket shall be compatible with the requirements for jointing specified herein. Bends shall mainly conform to Figure 3-a. The spigot end of each duct shall be indelibly marked with a continuous circumferential black line 100 mm from the end of the duct. This line shall be used as a measure of the penetration of the spigot into the socket of the adjoining duct, so that joints, which show in the opinion of the Ministry Engineer, inadequate penetration may be rejected. The manufacturer’s name and year of manufacture shall be clearly marked on each duct.

4.7. UPVC Ducts For Leading-In The ducts shall be supplied in 4 m lengths. The ducts shall have a minimum 3 mm wall thickness and external diameter of 50 mm. Bends shall mainly conform to Figure 3-b.

4.8. 50 mm ducts shall be jointed with couplings and cement solvent. The coupling pieces shall be made of identical UPVC material to the ducts and shall be 98 mm in length.

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4.9. Cement Solvent 4.9.1. All joints for UPVC ducts are to be made with cement solvent. 4.9.2. The cement solvent shall be in accordance with BS 4346 or equivalent. The cement solvent shall be

supplied in sealed containers with the manufacturer’s name, date of manufacture and date of expiry of the solvent clearly marked on them. The cement solvent shall be uniform in quality and shall contain no precipitation or floating agent.

4.9.3. If the cement solvent is to be used with a primer, the contractor should also supply the primer along with the cement solvent. The solvent shall be stored with the containers tightly closed in a dark and cool place away from fire.

4.9.4. The joint made with the cement solvent shall have a min. shear strength of 6 Kg/cm² after one hour and 20 Kg/cm² after 24 hours and 50 Kg/cm² after 336 hours. The joint shall not leak when tested for long-term pressure of 47 bars for 25 hours and 40 bars for 1000 hours at 20 °C in laboratory conditions.

4.9.5. 50 mm UPVC ducts for leading in shall be jointed with a coupling and cement solvent. The coupling shall be made of UPVC and 98 mm long. The coupling for jointing with GI duct shall be made of UPVC and have one end threaded, and the other end shall be sealed with solvent cement. Suitable reducing couplers shall be used for jointing 50 mm UPVC ducts with subscriber’s duct of different sizes.

4.9.6. The number of joints that can be made with 1 Kg of solvent and one kg of cleanser shall be indicated. Shelf life and any special precaution to be taken during use must be clearly stated. Solvent cement and cleanser shall be packed in airtight tins of 1 Kg and 0.5 Kg respectively. The contractor shall submit the test result of shear strength and long-term hydrostatic pressure for approval.

4.10. Spacers For UPVC Ducts Materials for spacers for UPVC pipes/ducts should be made of synthetic Resin or UUPVC conforming to clause 5 below and should be hard. Spacers supplied shall be suitable to hold the pipe nest together without any deformation or damage in the various duct configuration (max. 8 rows × 6 pipes) shown in MOC Civil Drawing No. TX: 47/4D-1. Two types of spacers shall be supplied:

1. Intermediate Spacers (Figure 1). 2. Top and bottom Spacers (Figure 2).

The width of the rim supporting the duct shall be 28 + or - 0.2 mm all around. The inner diameter of the rim shall be minimum 111 mm with a maximum tolerance of + 0.5 mm / -0.0 mm. The spacers supplied for UPVC Ducts shall conform with the MOC Drawings shown above and shall be grey in colour. The spacers shall be provided with interlocking facilities such that it can be used with any duct configuration. The spacers should be capable of withstanding a minimum compressive load of 500 Kg and shall take a minimum tension load of 150 Kg without break. The minimum tensile strength of interlocking portion shall be 50 Kg/cm². Certified test data from KISR or any International Testing Organisation shall be submitted and the Spacers shall require MOC approval before use in MOC Plant.

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5. MECHANICAL, THERMAL AND ELECTRICAL PROPERTIES 5.1. MOC Requirements for the UPVC material and the finished products are as detailed in Table 1.

Item Description of Quality MOC Requirements Test Method

1 Density (without filler) 1.4 – 1.5 gm/cm³ ASTM D 792 2 Co-efficient of viscosity (without filler) 57 – 70 ISO R174-1961E 3 Modulus of Elasticity 27-32 KP/cm² ASTM D 1708 4 Hardness Shore D 80 - 85 ASTM D 2240 5 Tensile Strength Min. 500 KgF/cm2 BS 3505/6 6 Softening Point Min. 85°C BS 102/C 7 Flexural Strength 950 KgF/cm2 +/- 10% BS 3505/6 8 Compressive Strength 560 KgF/cm2 (Min) BS 3505/6 9 Impact Strength 4.5 Joules/M BS 3505/6

10 Co-efficient of Linear Expansion 5X 10-5 °C BS 3505/6 11 Insulation Resistance at 60 degrees C 600 MΩ MOC Requirement 12 Dielectric Strength at 270C 1000 V/mil(min) MOC Requirement 13 Specific Heat 0.25 Cal./°C/gm BS 3505/6

Table 1

5.2. The ducts, couplings and spacers shall not ignite or support their own combustion.

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6. TESTS AND INSPECTION 6.1. Manufacturers will be expected to supply certified test data in respect the required qualities detailed in Table 1.



6.3. Test and Inspections will be as defined in MOC Standards G 30:10:08 and G 40:10:08. 6.4. Where ducts are delivered directly to a contractor it is his responsibility to advise MOC so that inspection may

be carried out and a materials acceptance certificate issued. No materials may be utilised by a contractor prior to the issue of this certificate.

7. STORAGE Ducts shall not be stored in direct sunlight for long periods and shall be stored in such a manner that sagging and bending is prevented.

8. PACKING AND MARKING The method of packing and delivery of ducts shall be agreed between MOC and the Manufacturer / Supplier in case of ducts manufactured in Kuwait. When the ducts are supplied from outside Kuwait, a label indicating the following information shall be fixed on each packing.

i. Ministry of Communications Kuwait and Order Number ii. Size of ducts iii. Quantity of Ducts iv. Manufacturer’s name

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M A T E R I A L S

F O R

C I V I L W O R K S

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I N D E X

1. SCOPE ................................................................................................................................................................................. 3 2. ASSOCIATED DOCUMENTS .................................................................................................................................................. 3 3. CEMENT.............................................................................................................................................................................. 3 4. SAND .................................................................................................................................................................................. 3 5. WATER ............................................................................................................................................................................... 3 6. AGGREGATE ....................................................................................................................................................................... 3 7. STEEL RE-ENFORCING BARS .............................................................................................................................................. 3 8. TESTS AND INSPECTION ..................................................................................................................................................... 4 9. PACKING AND MARKING .................................................................................................................................................... 4

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1. SCOPE This specification defines the required standard for materials used in the civil works involved in the installation of outside plant. Materials covered are as follows:

i. Cement ii. Sand iii. Aggregate iv. Water v. Steel Re-enforcing bars.

2. ASSOCIATED DOCUMENTS MOC G 30:10:09 - Tests and Inspections - Manufacture MOC G 40:10:09 - Tests and Inspections - Local AST C 150 BS 410 BS 812 BS 882 BS 4449 BS 4482

3. CEMENT 3.1. Cement shall be sulphate resistant type 5. 3.2. The cement shall meet the requirements and satisfy the tests contained in ASTM C-150. 3.3. The cement shall consist of a uniform fine powder with no evidence of bonding of the powder articles. Any

cement showing traces of particle bonding shall be rejected.

4. SAND 4.1. Sand shall be clean, sharp, gritty and free from loam, organic matter or adherent coatings. It shall not be shore

sand taken from a seashore. 4.2. The sand shall conform to BS 410, 812, and B82. 4.3. The sand shall be well grained. Grains shall be of varying size upto a maximum limit of 2.36 mm, and the

percentage by mass passing through a 2.36 mm sieve shall be betwwen 60 % and 100 %.

5. WATER Water from the potable (drinkable) supply system of Kuwait shall be used. No other source is permissible without specific agreement from MOC in writing after an analysis of the proposed supply has been carried out at the cost of the proposer.

6. AGGREGATE The aggregate for concrete should be clean-screened ballast, gravel or stone conforming to BB 410, 812, and 882. The material should be in the form of cubes or spheres (not flakes) and should be uniformly graded from 2 cm upwards to the maximum size of 4 cm. It should be free from dirt, floury stone dust, loam and earth or other like materials. Clinker, brick, sandstone or other porous stones shall not be used.

7. STEEL RE-ENFORCING BARS All reinforcing steel bars shall comply with the requirements of AASH TO M 31 (ASTM - 615) and shall be grade 60 deformed steel bars and shall be minimum requirements as detailed below

Property Grade

Tensile Strength (minimum) 6327 Kg/cm² Yield (minimum) 4218 Kg/cm²

Elongation In 200 mm Length Bar size up to 20 mm 9 mm

21 to 24 mm 8 mm 25 to 30 mm 7 mm

Table 1

7.1. The reinforcing bars shall be free from mill scales, cracks, heavy rusting or other deformities. Only light rusting is acceptable.

7.2. The reinforcing bars shall not suffer any impairment when bent. 7.3. The reinforcing bars shall be made in accordance with the shape and measurement given in the design

drawing, by a method, which is not detrimental to the quality of materials being used.

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7.4. Re-enforcing bars shall be free of all heavy rust, mud, oil, paint ore prior to use. Only light rusting is acceptable.

8. TESTS AND INSPECTION Test and Inspection shall be carried out in accordance with MOC Standards G 30:10:09 and G 40:10:09.

9. PACKING AND MARKING 9.1. Cement shall be delivered in sealed branded bags. The bags shall be of adequate strength to withstand handling

during transportation and storage. Bags shall be marked with the Manufacturer’s name and the grade of cement.

9.2. Sand and Aggregate may be delivered in loads in open vehicles. A certificate of quantity shall be supplied at the time of delivery.

9.3. Steel reinforcing bars shall be delivered in such a manner that they are not subject to excessive bending or crushing during transportation.

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G A L V A N I S E D P I P E S A N D T R O U G H S

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Description Of Items

Item Description Of Item

1 Steel Pipes 50 & 100 mm 2 Coupling Pieces for Steel Pipe 50 & l00 mm 3 Right Angle Bends for Steel Pipe 50 mm 4 Steel Troughs 30 mm2, Length: 300 cm 5 Steel Troughs 55 mm2, Length: 300 cm 6 Steel Troughs 105 mm2, Length: 300 cm 7 Right Angle Couplings for Steel Trough 30 mm2 8 1 Right Angle Couplings for Steel Trough 65 mm2 9 Right Angle Coupling for Steel Trough 105 mm2

I N D E X

1. SCOPE ................................................................................................................................................................................. 3 2. ASSOCIATED DOCUMENTS .................................................................................................................................................. 3 3. MATERIAL AND MANUFACTURE ........................................................................................................................................ 3 4. DIMENSIONS ....................................................................................................................................................................... 3 5. COMPLIANCE ...................................................................................................................................................................... 4 6. INSPECTION ........................................................................................................................................................................ 4 7. PACKING AND MARKING .................................................................................................................................................... 4

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1. SCOPE This specification covers the requirements of galvanized steel pipes and steel troughs.

2. ASSOCIATED DOCUMENTS 2.1. The latest issues of standards shall apply and deemed to be integral parts of this specification. A Tenderer

applying any other Standard, which is equivalent or better, shall submit the standard for approval with their proposal. The following standards are referred to in this specification: MOC G 30:10:11 - Tests and Inspections - Manufacture MOC G 40:10:11 - Tests and Inspections - Local ISO R 630 - Steel Quality ISO R 228 - Threads ISO R 1459 - Hot Dip Galvanizing ISO R 1460 - Hot Dip Galvanizing ISO R 1461 - Hot Dip Galvanizing

3. MATERIAL AND MANUFACTURE 3.1. Steel Pipes

3.1.1. The steel quality for the steel pipes shall be in accordance with ISO R 630, FE 37A, BS 21, 427, 1387. 3.1.2. The pipes shall be Medium Duty seamless, free from dents and internal roughness. The ends of the tubes

shall be reamed to prevent abrasion against the cable. 3.1.3. The outside ends of the pipes shall be threaded with a pipe thread to ISO Recommendation (International

Standardisation Organization) R 228. 3.1.4. The pipes shall be joined together by means of a coupling of the same material as the pipes. 3.1.5. After completion of forming operations the pipes and couplings shall be hot dip galvanized to meet the

requirements of the ISO Recommendations R 1459, R 1460 and R 1461. The zinc coat shall have a minimum thickness equivalent to 305 g/m².

3.2. Steel Troughs 3.2.1. The troughs shall be made of hot-rolled steel. 3.2.2. After completion of the forming operation the troughs shall be hot dip galvanized to meet the

requirements of the ISO Recommendations R 1459, R 1460, R 1461, and BS 729 Part (I). The zinc coating shall have a minimum thickness equivalent to 610 g/m².

4. DIMENSIONS 4.1. Steel Pipes

4.1.1. The pipes shall have the dimensions as stated in Table 1.

Nominal Inside Diameter (mm)

Nominal Wall Thickness (mm)

40/50 3.25/3.65 100 5.40

Table 1 4.1.2. Straight pipes shall be supplied in lengths of 2 – 6 m as specified. 4.1.3. Bends shall be provided for 900 angle. The bending radius shall be approximately 500 mm.

4.2. Steel Troughs 4.2.1. The troughs shall have dimensions as stated in Table 2.

Incise Wall

Thickness (mm)

Width (mm)

Height (mm)

30 30 1 55 55 1

105 105 1

Table 2 4.2.2. The troughs shall be supplied in lengths of 300 cm. 4.2.3. 900 bends of steel to fit the troughs shall be provided.

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5. COMPLIANCE The Tenderers shall state their compliance with the specification. Any deviations suggested by the Manufacturer, shall be fully documented and presented in the form of an alternative offer.

6. INSPECTION Inspection shall be performed as described in MOC Standards G 30:10:11 and G 40:10:11.

7. PACKING AND MARKING Pipes and troughs shall be delivered in such a manner that no damage is incurred during transportation. Banding of pipes into bundles will be allowed but not for troughing. Consignments shall be clearly labelled with the following details:

i. Ministry of Communications Kuwait plus Order Number ii. Description of Items iii. Quantity of Items

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H D P E S U B D U C T S A N D A C C E S S O R I E S

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I N D E X

1. SCOPE.................................................................................................................................................................3

2. ASSOCIATED DOCUMENTS ...................................................................................................................................3

3. TEMPERATURE AND ENVIRONMENT ....................................................................................................................3

4. MATERIALS...........................................................................................................................................................3

5. HDPE SUB DUCTING ACCESSORIES......................................................................................................................4

6. TESTS AND INSPECTION........................................................................................................................................4

7. STORAGE...............................................................................................................................................................4

8. PACKING AND MARKING...............................................................................................................................4

Item Description of Item Use 1 HDPE Subducts 32(OD)/28(ID)mm 2 HDPE Subducts 25(OD)/21(ID)mm 3 HDPE Subducting accessories

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1. SCOPE This specification covers the manufacture, testing, and supply of HDPE Subducts and accessories for use in cable ducting network in Kuwait. 1.1. The ducts fall into two categories i.e.

i. 32mm OD Subduct for feeder and junction routes. ii. 25mm OD Subducts for feeder and distribution route.


Society for testing and materials (ASTM) are applicable in this specification the latest issues shall apply and deemed to be an integral part of this specification.

Where equivalent international or other standards are used details shall be submitted with any tender. 2.2. The following standards have been referred to in this specification.

ASTM 1238 DIN 8074 & 8075

3. TEMPERATURE AND ENVIRONMENT 3.1. The subducts are for installation inside 100mm (ID) PVC ducts throughout Kuwait. They shall be capable of

meeting the following temperature requirements. Installed: -10 °C to +55 ° C Ambient Temperature During Storage & Transportation.

i. -10 °C to +55°C Ambient Temperature ii. +89°C maximum sun Radiation Temperature for period of days

3.2. The Subducts shall be unaffected by water, oil, oxidising Agents, salinity, aggressive soil, sand, fungi growth and bacterial or electrolytic actions.

4. MATERIALS 4.1. The duct compound shall be HDPE. Anti-oxidants and pigments may be added. 4.2. No constituent material shall be used which will adversely affect the long-term mechanical strength of the

HDPE. All constituents shall be uniformly and fully dispersed. 4.3. The tenderer shall state in his proposal the name of the manufacturer of the HDPE compound and also its

name or code number. Test certificate for HDPE compound shall be submitted from Kuwait Institute of Scientific Research (KISR) for MOC’s approval.

4.4. Subducts shall be homogeneous throughout. All surfaces shall be clean smooth, and without any visible cracks, grooves, blisters, wrinkles, dents, beat marks or foreign inclusions. Ends shall be square and free from sharp edges.

4.5. The subduct 32mm OD and 25mm OD shall be supplied in coils of specified lengths. The colour shall be as per the requirement on the basis of configuration in Para 4.6

4.6. Subduct size, manufacturer’s name and length shall also be indelibly marked on the outer surface.HDPE single subducts are supplied in coil along with Nylon draw wire (1mm Φ) with length up to the requirements of MOC contractor.

Feeder/main route 4 way Sub ducting 1ST 32mm OD - Black 2nd 32mm OD - Green

3rd 32mm OD - Yellow 4th 32 mm OD – Orange

Distribution route 5 way Sub ducting 1st 25mm OD - Black

2nd 25mm OD - Grey 3rd 25mm OD – Green 4th 25 mm OD – Orange 5th 25mm OD – Yellow

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4.7. Requirements of Tests for the HDPE material and the finished products are in Table 1 7 2 below.

Table 1: Properties of HDPE material Properties Test Method Requirement

Density DIN 53479 0.95 g/cm3 Melt Flow Index ASTM D 1238 0.5 g/10 min

Coefficient of linear expansion DIN 8075 1.5X10-4 m/m (k)

Crush Resistance

ASTM D 2412

Recovery shall be more than 95% within

2.5 minutes Tensile strength at Yield ASTM F 2160 >20 N\mm2

Elongation at break ASTM F 2160 >500% Impact Strength ASTM D 2444 No crack/Split

Di-Electric Strength at 27°C - >500 Volt/mil Insulation Resistance at 60°C - >600 Mohm

Vicat softening Point ASTM D 1525 110-128°C Brittle Temperature - -86°C

Hardness ASTM D 2240 60-80 ShoreD

Table 2: Dimensions of Subducts Outer dia (mm) Inner dia (mm) Wall Thickness (mm)

25 21 2.0 32 28 2.0

5. HDPE SUB DUCTING ACCESSORIES The Contractor shall supply suitable rubber plugs for plugging 100mm ID PVC pipes subducted with different configuration stated in Para 4.6 The plugs shall withstand the climatic conditions and soil/water contents. The plugs for subducts (empty and occupied) shall also be supplied by the contractor. The plug used for empty subduct shall be suitable for tying the vinyl pulling rope specified in Para 4.6

6. TESTS AND INSPECTION 6.1. Manufacturers will be expected to supply certified test data as per the requirements detailed in table 1 & 2.



6.3. Where Subducts are delivered directly to a contractor, it is his responsibility to advise MOC so that inspection may be carried out and a materials acceptance certificate issued. No materials may be utilised by a contractor prior to the issue of this certificate.

7. STORAGE Subduct shall not be stored in direct sunlight for long periods.

8. PACKING AND MARKING The method of packing and delivery of subducts shall be agreed between MOC and the Manufacturer/Supplier in case of ducts manufactured in Kuwait. i. Ministry of Communications, Kuwait and Order number ii. Size of subducts iii. Quantity of subducts iv. Manufacturer’s name The Contractor shall submit samples of HDPE subducts 32mm OD and 25mm OD, different subducting configuration using sealing plugs 100mm ID PVC pipe and end plugs for HDPE subducts of 32mm OD & 25mm OD. The manufacturers test certificate for raw material as well as finished products shall be submitted with the samples.

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