SPECIFICATION FOR SURGE VESSELS

1 06-04-2009 Changes in section 5

0 02-02-2002 Approved Issue
rev. date Description/issued for prepared authorised
client: ADWEA
project: STANDARD SPECIFICATIONS FOR WATER WORKS
title: SPECIFICATION FOR SURGE VESSELS

tender: project: document: W-M-SS-006 rev: 1 sheet: 1 of: 12

 Table of Contents page

1. SCOPE .................................................................................................. 3

2. APPLICABLE STANDARDS AND CODES .......................................... 3

3. SITE CONDITIONS ............................................................................... 4

4. DESIGN CONSIDERATIONS................................................................ 4

5. FABRICATION REQUIREMENTS ........................................................ 5

5.1 Compressed Air Type Surge Vessels.......................................... 5

5.2 Diaphragm Type Surge Vessels.................................................. 7

6. INSPECTION AND TESTING................................................................ 9

6.1 Manufacturer's Shop ................................................................... 9

6.2 Manufacturing Data Record Books ........................................... 11

7. SPARE PARTS ................................................................................... 11

8. SPECIAL TOOLS & TACKLES........................................................... 11

9. PACKING AND SHIPMENT ................................................................ 11

10. VENDOR DOCUMENTATION............................................................. 12

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR SURGE VESSELS

tender: project: document: W-M-SS-006 rev: 1 sheet: 2 of: 12

 1. SCOPE

This specification covers the minimum requirements, for design, manufacture, testing at
manufacturer's works, supply, site testing and commissioning of the surge vessels. This
specification shall be read in conjunction with the relevant data sheets, drawings and other
relevant sections of the Tender Documents.

Compliance with this specification shall not relieve the CONTRACTOR from any of his
contractual obligations and responsibilities towards fulfilling the performance requirements.

No deviation from this specification shall be allowed, unless specifically approved in writing by
ADWEA/ENGINEER.

This specification and the associated drawings shall be considered the absolute minimum
requirements for performance & quality and shall be considered in extension of "not in
limitation".

The Contract drawings indicate the general arrangement of the surge vessels and all the
auxiliary equipment required for a complete surge vessel package. The CONTRACTOR
should review all Contract drawings so that all items effecting the operation of the complete
system are considered in the design and supply of the engineered package.

2. APPLICABLE STANDARDS AND CODES

All materials and workmanship shall comply with the latest edition of the applicable standards
and codes which shall include but not be limited to the following :

ASME Sect. II Part C Welding Rods, Electrodes and Filler Metals

ASME Sect. V Non Destructive Examination

ASME Sect. VIII Div. 1 Pressure Vessels

ASME Sect. IX Welding and Brazing Qualifications

API 5L Specification for Line Pipe

ASTM A 516 Specification for Plate Material

ASTM A105 Standard Specification for Forgings, Carbon Steel for Piping
Components

ASTM A106 Seamless Carbon Steel Pipes for High Temperature

ASTM A234 Piping Fittings of Wrought Carbon Steel and Alloy Steel for
Moderate and Elevated Temperature

ASTM A193 Alloy Steel and Stainless Steel Bolting for High Temperature
Service

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR SURGE VESSELS

tender: project: document: W-M-SS-006 rev: 1 sheet: 3 of: 12

 ASTM A194 Carbon and Alloy Steel Nuts for Bolts for High Pressure and
High Temperature Service

ANSI/ASME B16.9 Factory Made Wrought Steel Butt Welded Fittings

ANSI/ASME B16.10 Dimensions and Weights of Seamless and Welded Steel Pipes

BS 4504 Sect. 3.1 Circular Flanges for Pipes, Valves and Fittings (PN
designated). Specification of Steel Flanges

ISO 8501 Preparation of Steel Surfaces before Application of Paints and

Related Products

ISO 9000 Quality Management and Quality Assurance Standards -

Guidelines for Selection and Use

3. SITE CONDITIONS

The surge vessels and associated equipment shall be designed and suitable for operation in
the climatic conditions of the United Arab Emirates.

The surge vessels shall be suitable for handling desalinated potable water, well water and/or
a mixture of both with residual chlorine content of 1 - 1.5 p.p.m. unless specifically mentioned
otherwise.

The CONTRACTOR is referred to the General Technical Requirements which details the
climatic conditions that may be encountered at site. However the offered equipment shall be
suitable for the below mentioned conditions as a minimum:

- Maximum ambient conditions in the shade : 52oC

- Minimum ambient temperature : 1 oC

- Maximum ambient relative humidity : 100%

4. DESIGN CONSIDERATIONS

Surge vessels shall be designed, fabricated, tested and inspected in accordance with ASME
VIII Div I code.

Corrosion allowance of 3 mm shall be considered for the vessel.

Steel plates shall be in compliance with ASTM A516 Gr 70 and shall be normalised. The
pipes shall be to API 5L Gr B/ASTM A106 Gr B. seamless; fittings shall be to ASTM A234 Gr
WPB and flanges shall be to ASTM A105 normalised. The completed vessel shall be stress
relieved if required by the code for the design conditions and material used. No welding shall
be permitted after stress relieving of the vessel.

Code stamping is not required for the vessel.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR SURGE VESSELS

tender: project: document: W-M-SS-006 rev: 1 sheet: 4 of: 12

 The vessels shall be sized such that one vessel can be taken out of service for maintenance
reasons and the remaining vessels shall have enough capacity to cope with the surge
problems. The capacity of the vessels shall be based on the worst scenario i.e. power outage
when maximum number of pumps are running or valve closure at the terminal point when
maximum number of pumps are running.

The sizing of the surge vessels shall be based on the findings of the surge analysis study.
The surge analysis shall utilise an approved computer software package. The computer
results shall also show location of the air valves/vacuum breaking valves along the pipeline
route.

The CONTRACTOR shall provide full surge protection for the system in accordance with the
recommendations of the surge analysis.

The surge protection equipment shall be located as shown on the drawings unless alternative
locations are approved. These alternative locations shall be based on new surge study
showing better performance of surge protection system. It is not anticipated that the
alternative locations will be approved unless the alternative locations are shown to have
substantial advantages in the surge protection systems.

5. FABRICATION REQUIREMENTS

5.1 Compressed Air Type Surge Vessels

The surge vessels and associated piping/nozzles shall be of welded steel type internally lined
with vulcanised hard rubber of minimum thickness of 3mm. The rubber lining shall be
complete with non-toxicity certificate from a reputed international authority indicating suitability
for use with potable water. In addition the requirements of the Regulation and Supervision
Bureau in respect to water quality have to be met. Furthermore ADWEA requirements on non-
toxicities certification and coating protection shall be met.

The surge vessels shall be fitted with the following fittings and connections as a minimum:

a) Water delivery pipe to pumping main with isolating valve with interlock facility to prevent
pump starting if the valve is not fully open.

b) Non-return valve and by-pass on the water delivery pipe (if required) or non return valve
with bleeding capacity (if required).

c) Direct reading level gauge (differential pressure type).

d) Level transmitter

e) Level switch (minimum 3 No.) for local control.

f) Level switch (high level alarm)

g) Level switch (low level alarm)

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR SURGE VESSELS

tender: project: document: W-M-SS-006 rev: 1 sheet: 5 of: 12

 h) Direct reading pressure gauge

i) Drain point with drain valve

j) Safety pressure relief valve

k) Lifting lugs

l) Suitably sized Manhole/door with davit arm/hinges

m) Compressed air supply pipe with isolating valve and solenoid valve

n) Access ladders and platforms

o) Solenoid air vent valve with isolating valve

All solenoid valves should have manual control capability.

All nozzles emanating directly from the air vessel shall be flanged and have a minimum
internal diameter of 100 mm.

All safety valves shall be fitted with manual isolation valves.

All isolation valves and solenoid valves shall be of the same size wherever possible for
reduced spares stocks.

The surge vessel and all fittings shall be rated at a pressure equal to or greater than the
pressure rating of the main pumping line and shall be tested both at the works and on site to
the appropriate test pressure.

A common back up LCP shall be provided for surge control system. The normal control of the
surge vessel shall be from the DCS, in case of DCS failure the control shall be automatically
transferred to the LCP. Override switch shall be provided in the LCP take over the controls for
testing purpose.

Level switches shall function into time delay circuits to ensure that the detected condition is
not transient before the appropriate alarm or control circuits are operated. These timers are
to be set such that the alarms and controls are only activated as a result of changes in
quantity of air in the vessel and not as a result of surge conditions.

In the event of the low level switch being activated the solenoid air vent valve shall open until
the level rises above that switch and further to the normal level switch.

In the event of the high level switch being activated the solenoid air inlet valve shall open until
the level decreases below that switch and further to the normal level switch.

The drain valves and pressure relief valves shall be piped to discharge into a site drainage
manhole.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR SURGE VESSELS

tender: project: document: W-M-SS-006 rev: 1 sheet: 6 of: 12

 Surge vessels on the pumping stations sites shall be provided with complete automatic air
charging systems with manual control capability as specified.

The access ladders and platforms shall allow access to all instrumentation valves and the
manhole cover.

The isolating valve for the surge vessel shall be manually operated and shall be provided with
position indicator to indicate if it is fully open. The isolation valve for the vessel shall be
locked in the fully open position.

The surge vessel shall be grit blasted to SA 2.5 and coated externally using 4 coat
anticorrosion system as follows:

Primer Coat: Inorganic zinc silicate primer to a DFT of 75 microns.

Second Coat: Polyamide cured tie coat to a DFT of 40 microns.

Third Coat: Amine or Polyamide cured high build epoxy to a DFT of 125 to 175 microns.

Top Coat: Polyurethane high gloss finish to a DFT of 50 to 75 microns.

Total dry film thickness 325 microns.

The third party inspection authority shall be nominated by ADWEA/ENGINEER.

5.2 Diaphragm Type Surge Vessels

The vessel shall be manufactured as a welded carbon steel envelope containing a food
quality butyl rubber interchangeable bladder. The bladder shall be subject to a current
certification issued by a recognised laboratory guaranteeing compatibility for use with potable
water. The bladder shall be designed to withstand the initial pre-charge pressure when the
vessel is empty.

All equipment and materials making up the diaphragm type surge vessels shall be compatible
and shall comprise but not necessarily be limited to the following:

a. Steel surge vessel having a minimum working pressure as required by the surge study to
include:

- manhole with lifting arm for cover.

- all nozzle flanges for air charging valve, drain valve, level tube etc.

- air charging, vent, drain and relief valves.

- tank supports.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR SURGE VESSELS

tender: project: document: W-M-SS-006 rev: 1 sheet: 7 of: 12

 b. The main flanged outlet of the vessel shall be equipped with an anti-extrusion grid to
reduce turbulence and to avoid expulsion of the bladder during the initial pre-charge. The
head losses through the grid must be as little as possible.

c. An attenuator shall be installed to allow full discharge of water from the surge vessel and
restriction of water returning to the vessel when the pump stops. The calculations for
sizing of the attenuator shall be carried out by the manufacturer and submitted for
ADWEA/ENGINEER approval.

d. A security level gauge system shall be installed on each vessel. This system shall be
made up on a non-magnetic steel tube connected via isolating valves to the top and
bottom of the surge vessel. A magnetic float in the tube registers the water level in the
vessel and the float position is detected by external magnets, some of which activate
micro-switches connected to any control loop which may be located at any level on the
tube. A special assembly of non-return valves and electrovalves are to be included and
shall be designed to close if high rate water discharge is detected in the tube. This
aspect of the system allows the level tube to operate continuously even in transient
conditions with no risk of loss of gas through the tube by venturi suction effect. Two
additional micro switches are to be located on the level tube to detect high and low water
levels in the surge vessel and a corresponding signal sent to the respective annunciator
panel. A separate level tramsmitter shall also be installed on the surge vessel.

e. A cross-piece shall be fitted to the top of the vessel to facilitate the following:

- Nitrogen filling of the vessel.

- Fitting of 100 mm stainless steel pressure gauge.

- Connection at top of security level gauge.

f. The CONTRACTOR shall supply initial charge for all vessels and reserve nitrogen
cylinders for an additional charge of all vessels.

The surge vessels may be located vertically or horizontally subject to ADWEA/ENGINEER

approval.

The diaphragm type surge vessels shall have the same external coating as the compressed
air type surge vessels.

The surge vessels shall be coated internally using food quality powder coated epoxy system
to a total dry film thickness of 300 microns minimum. The paint must be certified compatible
for use with potable water by recognised international authority. The external coating system
shall be the same as the one applied on the compressed air type surge vessels.

The third party inspection authority shall be nominated by ADWEA/ENGINEER.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR SURGE VESSELS

tender: project: document: W-M-SS-006 rev: 1 sheet: 8 of: 12

 6. INSPECTION AND TESTING

6.1 Manufacturer's Shop

ADWEA/ENGINEER reserve the right for shop inspection/stage inspection by their authorised
representatives.

The surge vessels shall be subjected to heat treatments and tests (including NDT) as
required by the specific applicable code of construction.

The material certificates indicating above details shall be inspected and certified by
ADWEA/ENGINEER's inspectors prior to starting shop tests of the component.

he VENDOR/CONTRACTOR shall provide full assistance and co-operation for any such
inspection, when required by ADWEA/ENGINEER.

The vessels shall be hydro tested to a pressure 1.5 times the design pressure.

The CONTRACTOR/Manufacturer shall make suitable provisions for detailed shop testing of
the surge vessels and intimate ADWEA/ENGINEER sufficiently in advance to enable their
representatives to witness the tests.

ADWEA/ENGINEER and/or Third Party Inspection Authority shall be informed of all defects
arising during manufacture and fabrication of the surge vessels and only the above shall
authorise repair or rejection of faulty material or workmanship.

The programme for the tests shall be prepared by the CONTRACTOR and shall be subject to
ADWEA/ENGINEER approval.

The CONTRACTOR shall produce material test certificates for all components making up the
surge vessels in accordance with ISO EN 10204 3.1 certificate.

If any defect is detected during the tests before completion or during the warranty period, the
faulty equipment shall then be rectified immediately by the Vendor/CONTRACTOR at his
expense. If the fault cannot be rectified, the VENDOR/CONTRACTOR must then replace the
defective equipment which must also be proven to be free from defect.

The factory tests for each surge system shall include, but shall not be limited to:

a) Visual examination of the surge vessels to ensure compliance with specifications.

b) Hydrostatic test of the surge vessels.

c) High voltage test for rubber lining before vulcanisation at 5 kV/mm.

d) After vulcanisation, the following tests shall be conducted on rubber lining:

- visual inspection

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR SURGE VESSELS

tender: project: document: W-M-SS-006 rev: 1 sheet: 9 of: 12

 - adhesion test

- dielectric test with sparkling device

- Shore D hardness test.

- Thickness test by electronic device.

e) Coating thickness check.

The below mentioned requirements shall apply to the Quality Control Plan/Inspection Test
Plan which shall be submitted by the CONTRACTOR and approved by ADWEA/ ENGINEER.

a) The following mill certificates to EN 10204 3.1 shall be submitted for the steel plates
indicating:

- Heat treatment (if any)

- Chemical analysis.

- Physical analysis

b) Welding procedure specifications together with procedure qualification records.

c) Welder qualification records.

d) Non-destructive testing procedure.

The above certificates shall be subject to review and approval by Third Party Inspection
Agency/ADWEA/ENGINEER.

The below mentioned tests shall be included in the quality control plan as witness/hold points
for TPIA/ADWEA/ENGINEER.

a) Tests on rubber lining before vulcanising.

b) Tests on rubber lining after vulcanising.

c) Hydrostatic test.

d) Coating thickness checks.

Certificates type 3.2 to EN 10204 shall be issued for all tests mentioned above.

The above certificates shall be reviewed and certified by the respective inspection authority.

After shop test, the surge vessels shall be opened and visual inspection shall be carried out
for any possible defects/deformations. Any defects/faults/ deformations detected shall be
promptly repaired/replaced by Manufacturer, prior to dispatch. ADWEA/ENGINEER's decision
in this regard, within tender specifications, shall be final and binding on the CONTRACTOR.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR SURGE VESSELS

tender: project: document: W-M-SS-006 rev: 1 sheet: 10 of: 12

 6.2 Manufacturing Data Record Books

The test certificates, material certificates, mill certificates, etc. for all items related to the
surge vessels shall be entered into the manufacturing data record books, as an ongoing
procedure and must not be left until the end of the manufacturing programme. The
manufacturing data record books including the witnessed tests documents shall be submitted
to ADWEA/ENGINEER prior to the despatch of the equipments.

The CONTRACTOR/Manufacturer shall guarantee the availability of spare parts for a duration
of 10 years.

7. SPARE PARTS

The CONTRACTOR shall include in his bid, as a minimum, consumables and spare parts for
commissioning and spare parts for guarantee period. The Contractor / Manufacturer shall
guarantee the availability of spare parts for a duration of 10 years.

Any spares over and above the specified minimum shall be listed and priced separately by
the CONTRACTOR for ADWEA/ENGINEER's approval/acceptance.

Spare parts lists with detailed specification of each component are to be provided separately.

The CONTRACTOR shall supply the following spares (as a minimum) for each type and size
of surge vessels supplied and installed under the contract.

- Level switch 2 Nos.

- Level gauge 1 No.
- Pressure gauge 2 Nos.
- Drain valve 2 Nos.
- Safety pressure release valve 1 No.
- Solenoid valve 1 No.
(each size & type)
- Isolation valve 1 No. (each size & type).
(air pipework)

8. SPECIAL TOOLS & TACKLES

The CONTRACTOR shall furnish a list of special tools and tackles, considered essential for
the normal maintenance of the installation (if any) and define what is to be supplied with the
equipment.

Trouble shooting and maintenance schedules shall be provided by the CONTRACTOR.

9. PACKING AND SHIPMENT

The surge vessels shall be packed in wooden type seaworthy crates having sufficient strength
to withstand normal ship handling and transport.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR SURGE VESSELS

tender: project: document: W-M-SS-006 rev: 1 sheet: 11 of: 12

 The crates shall be marked with ADWEA name and address, contract no., project tittle, order
number, type of equipment, hoisting points etc.

Enclosed with the shipment, the following documents shall be included in suitable wrapping:

 Packing list.

 General arrangement drawing.

 Foundation plan including foundation loadings (where applicable).

 Operation and maintenance manual.

 Installation instructions.

10. VENDOR DOCUMENTATION

The CONTRACTOR shall furnish following vendor data as a minimum, along with the bid:

- Detailed reference list.

- Catalogues/Brochures for quoted models/types.

- Cross section drawings with detailed parts list for vessels.

- Complete calculations of all vessel components, structural, etc.

- Detailed material specifications for all vessels.

- Completely filled-in and stamped data sheets.

- Dimensioned general arrangement drawing.

- Recommended list of consumables and spares parts.

- Complete details of testing facilities available at manufacturers works.

- Local (UAE) agent name and address.

Bids not accompanied by all of above-mentioned information/data shall be considered

incomplete and liable to be rejected.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR SURGE VESSELS

tender: project: document: W-M-SS-006 rev: 1 sheet: 12 of: 12