SECTION 3.

0 - LPG SERVICES

1.0 General

The equipment, materials and workmanship of the installation shall comply with the
requirements of the following standards, rules and regulations: -

- Malaysian Standard MS 830;

- Malaysian Standard MS 930;

- M/s Jabatan Bekalan Elektrik Dan Gas;

- All Welders certification shall be approved by M/s Jabatan Kesihatan Dan

Keselamatan Pekerjaan (JKKP);

- Gas supply Act (Act 501) 1993;

- AGA 205 Approval requirements for regulators with LP Gases;

- API Codes;

- SME Codes; and

- ISO 1217

1.1 Submittals

The Contractor shall submit the following item after award of the Contract: -

- Design calculations and schematic diagram of the system;

- Manufacturers catalogue and equipment Technical Specifications;

- Shop drawings indicating pipes, valves and equipment layout;

- Valve details to be used for approval; and

- As built drawings upon completion of installation

1.2 Base reference of Equipment and Materials

The following base standard list provides the names of Manufacturers or brand of equipment
and materials that are acceptable and shall be used as the basis for tender submission.
Equipment not listed shall be of the type suitable for the intended design and all technical
details to be submitted for the Engineers approval.

Valves Toyo
Kitz
Keystone
Centerline
Bestobell-Tomac
Fisher

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Regulator Fisher
Rego
Rockwell
Taylor

Instrument Kent
Budenberg
Johnson
Ashcroft
Nagano
Bailey
Yamamoto

Paint Jotun
ICI
Dimet
Berger
Nippon Paint

2.0 Gas Cylinders

2.1 General

The low-pressure gas of 52 kg each cylinder shall be provided as required in the drawing
attached.

The cylinders shall be arranged in two (2) banks with an automatic change over regulator with
built-in relief valve and remote indicator.

The cylinders shall be installed in upright position so as to facilitate their quick removal and
easy access to fittings, valves and regulators. The “tail” coupling of the cylinders shall be
suitable for connection to cylinders of installation c/w non-return valves.

2.2 Cylinder Manifold

The individual component parts of the cylinder manifold, i.e. piping, fittings, pigtail, valves,
etc. which are subjected to cylinder pressure shall be suitable for low pressure gas and shall be
capable to withstand, a test pressure of 20 kg/sq. cm or 2.5 times the maximum pressure
(corresponding to the assessed temperature) of the cylinder, whichever is the greater.

The manifold pipe shall be rigidly supported and shall be of 32 mm nominal bore seamless
steel pipe to ASTM API 5G or Grade C Schedule 40 and steel fittings to BS 1740.

Joints in manifold headers, which do not have to be broken in normal use, shall be welded or
brazed using a material, which have a melting point of at least 540 degrees centigrade. Other
joints shall be screwed tapers to taper threads to BS 21. The jointing compound shall be of a
type, which is resistant to low pressure gas and remains plastic, and shall be applied on the
male thread only. Hemp and similar materials must not be used in pipe joints.

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The manifold should also carry pressure gauges to indicate the inlet and out-going pressures.

3.0 Gas Pipings And Fittings

3.1 General

In general, all pipes to be installed shall be fully welded and supply complete with Hydraulic
Testing Certificates for steel pipes.

Pipings shall not be run in/along drains to avoid damage to the pipes by acids and other
corrosive chemicals.

Pipings or risers shall not be run in walls but along the surface.

Gas piping shall not be run in rooms containing electrical equipment such as transformers,
switchgears, switchboards or the like, or through air ducts, chimney or gas vent, or fire
protected areas.

Piping and valves should be suitably dimensioned and installed in such a way that burners are
supplied with the required gas rate and pressure and any likely increase in the estimated gas
off take should be allowed for.

The open ends of pipings or fittings shall always be made gas tight by means of a plug,
welded or brazed in position. Hammering over the ends of the pipes or plugging with wood
as a means of sealing is prohibited.

Pipings shall be free internally and externally of cuttings burrs, loose scales, dirt, dust or other
foreign matter and the pipe work have to purged before the installation is completed.

Pipes with threads, which are stripped, chipped, corroded or otherwise damage shall not be
used.

Pipings shall be located or protected so as to avoid extremes of temperature, which might give
rise to condensation, or cracking of the low-pressure gas.

Provision must be made to avoid damage to the piping by its expansion, contraction, vibration
or by settlement of the building on which it is carried.

The installation of piping shall in no way weaken significantly the building structure.

No device shall be placed inside the piping or fittings that will reduce the cross-sectional area
or otherwise obstruct the free flow of gas.

Pipings shall be adequately supported with a free air space between the piping and the wall or
structure. The pipings must be securely positioned to prevent them being moved from their
original place. The maximum interval between pipe supports is 2 meter for vertical and
horizontal run.

All materials shall be new and shall not show rust, corrosion, or any evidence of deterioration
caused by prolonged or improper storage or rough handling. All unacceptable materials shall
be removed from Site at the direction of the Engineer.

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Piping from the gas store to the building shall be buried at least 610 mm deep and inside the
building it shall be at least 40 mm deep below the finished floor level. Underground piping
from the gas store shall be run in a galvanized steel pipe sleeve of 100 mm diameter.

Where pipes are allowed to be installed in groove in cement screed, the material shall be steel
pipe Schedule 40. Any bend shall not be done at site but specially factory made to suit. All
buried pipes of Schedule 40 shall be applied with two (2) coats of approved rust inhibitive
primer and then wrapped with an approved tape with 55% over wrapped.

3.2 Gas Pipings

Pipes shall be seamless steel pipe to ASTM API 5G or Grade C Schedule 40 ASTM B42
Seamless Copper Pipe, or Brass Pipe ASTM B43 Seamless Red Brass Pipe. The jointing
compound must be of a type, which is resistant to low pressure gas and remains plastic, and it
shall be applied to the male thread only. Hemp and similar material must not be used in pipe
joints. In under-ground, or in inaccessible places, all joints shall be screwed welded or
brazed. Pipe work that is buried in a solid floor shall be factory wrapped or sheathed in PVC
pipes to avoid corrosion.

Where applicable, the pipes shall conform to the following standards: -

i. MS 862 Specification for welded and seamless steel pipes for general pressure purposes;

ii. MS 863 Specification for welded and seamless steel pipes (6 mm - 150 mm), screwed
type;

iii. ANSI/ASTM A53 Specification for black and hot-dipped zinc-coated welded and seamless
steel pipe;

iv. ANSI/ASTM A120 Specification for black and hot-dipped zinc-coated (galvanized)
welded and seamless steel pipe for ordinary uses; and

v. API 5L Specification for seamless and welded steel pipe.

Underground pipes shall be of Medium Density Polyethylene Pipes to MS 1096 and ISO
4437. Polyethylene pipe made to other standards shall include the ISO method of
determination of long term hydrostatic strength at 20°C derived from 80°C testing.

Copper and brass pipe shall not be used if the gas contains more than an average of 0.1 grain
of hydrogen sulphide per standard cubic metre of gas. This is equivalent to a trace as
determined by the following applicable standard: -

i. ANSI/ASTM D2385 Test for hydrogen sulphide and mercaptan sulphur in natural
gas, (Cadmium sulphate-iodometric titration method); or

ii. ANSI/ASTM D2420 Test for hydrogen sulphide in liquefied petroleum LP gases
(Lead acetate method).

Threaded copper, brass or aluminum alloy pipe in iron pipe sizes may be used with gases not
corrosive to such material.

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3.3 Pipe Fittings

All joints, bends elbows and tees in copper or steel pipes shall be made strictly using the
appropriate fittings. Bending, drilling, welding of pipes to create tees or bends are not
allowed. Pipings shall be located or protected so as to avoid extremes of temperatures, which
might give rise to cracking, or condensation of the gas.

Cast iron fittings and valves must not be used.

3.4 Gas Pipe Pressure

All pipings, tubings, fittings, valves and similar equipment (not subject to cylinder pressure)
shall be suitable for low pressure gas and shall be capable of withstanding a test pressure 35.5
psi or 2.5 times the maximum operating pressure to which they may be subjected to under
normal use.

4.0 Valves, Regulators And Specialities

The successful Tenderer shall install all necessary gas pipes complete with appropriate valves,
regulators and specialties suitable for Low Pressure Gas from the automatic change-over
regulator to the individual food stalls as detailed in the Tender Drawings.

4.1 Pressure Regulator

Pressure regulator shall be “Fisher”, “Rego” or “Rockwell” or other approved type capable of
handling the likely off take of the gas to the required pressure, and conforming to ANSI
B31.8.

The automatic changeover of not less than the required gas consumption capacity shall have
an adjustable range of between 0.2 kg/sq. cm to 1 kg/sq. cm (maximum). It should also has a
built-in relief valve.

The outlet pressure of the first stage regulator shall not exceed 5 psig and the second stage
regulator shall reduce this pressure to 11” water gauge.

One second stage regulator of not less than 240,000 Btu/hr shall be installed in each of the
food stall with a shut-off ball valve upstream of it.

The pressure regulator shall be rigidly installed and provided with a vent line to the outside air
with the discharge outlet not less than 1 m horizontally away from any building opening
below the discharge outlet.

4.2 Gas Meters

Gas meters shall be of diaphragm displacement type, in accordance with ANSI B109.1 or
equivalent, suitable for installation under indoor or outdoor conditions. Meters for domestic
applications shall be of Class 50, and temperature compensated.

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Meters supplied under this Contract shall be typed tested at works for meter class, maximum
operating capacity, accuracy, accelerated life test and sustained accuracy. All test certificates
shall be countersigned by an approved Testing Agency. Three (3) copies of the Test
Certificates shall be sent to the Engineer for approval before shipment of meters. No meters
shall be sent unless its Test Certificates has been approved in writing by Engineer.

4.3 Isolating Valves

Isolating valve shall generally be flanged or welded ball type.

All valves shall be fire safe and of anti static design conforming to BS 5351 and BS 5146.

Provision shall be made for extension of valve hand wheel for valves buried below ground or
at high level.

4.4 Quick-Closing Valves

Each building shall be install with quick-closing valve designed for local and remote isolation
of supply gas to that building.

The valve shall be spring-loaded type suitable for rapid actuation and shutoff.

Valve shall be complied to fire code and UL/FA listed. Location of valve shall be to M/s
Jabatan Bekalan Elektrik Dan Gas requirement and protected by housing.

4.5 Flexible Joint

Flexible joint shall be installed to absorb pipe movement or stress, isolate vibration and
protect against surges.

The flexible joint shall be flanged connected type suitably sized and classed to match the pipe
flanged.

4.6 Pressure gauges

Provision of socket outlet for installation of pressure gauges shall be provided at all pipe
termination at food stalls and when indicated in the Specification drawings..

Pressure gauges shall be 4” diameter dial indicator type suitably ranged to cover the measured
operating range.

Accessories for isolating and carrying the measured parameter to floor standing level shall be
provided as well, which includes fittings, gauge stand and syphon.

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5.0 Hangers, Supports and Anchors

The Contractor shall furnish and install sufficient hangers, structural supports, cantilever
supports, beam clamps, inserts and mounting devices to support all piping, installed under this
Contract.

Piping shall be anchored sufficiently to prevent undue strain on connected equipment and
shall not be supported by other piping. Special care shall be taken to support vertical pipe
works.

All hangers, supports and brackets shall be adequately sized and located at proper intervals.
All hanger, bolt and nut shall be submitted for approval.

Cantilever and trapeze support shall be fixed to RC concrete roof of beams wall with
adequately sized expanding bolts.

Supports shall generally consist of the following structural shapes such as angles, channels
and I-Beams.

The installation of supports shall be adhered to MSS SP-58.

Contraction and expansion shall be accommodated by sufficient bends or fitting of flexible

joint so as to minimizes excessive stresses in either piping or connected equipment.

All permanent and temporary support structures, support brackets, U-bolts, studs, bolts, nuts,
gaskets, etc. shall be deem included in the Scope of Work.

6.0 Painting And Labelling

Immediately prior to applying priming paint, all mill scale, rust, oil and grease on pipe work
shall be removed by thorough hand brushing or other satisfactory means. Should rust foam or
contamination of the cleaned surface occur between cleaning and painting, the surface shall
be re-cleaned.

The painting scheme shall be an approved five-coat system comprising of one (1) coat of red
lead primer, one coat of grey-green zinc chromate primer, two coats of micaceous iron-oxide
paint and the finishing coat of high gloss paint. The color of the finishing coats shall be
identified by the Superintending Officer.

Primers and paints shall be ICI or an approved equivalent. Painting shall only be done in
suitable weather. Tarpaulins, sheets and coverings to protect floors, walls, etc. shall be
provided by the Sub-Contractor. All surfaces to be painted shall be clean and dry.

Each coat of paint shall be applied by brush and well worked into joints, edges and corners.
When the paint is sufficiently dry, it shall be smoothed down with suitable abrasive paper or
cloth before the next coat is applied. Successive coats shall have different shading for easy
identification.

The minimum dry film thickness of each primer coat shall be 25 m and the minimum dry
film thickness of the micaceous iron-oxide coat shall be 50 m.

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Should any corrosion or signs of faulty paint work become apparent during the Defects
Liability Period, the Contractor shall be required to remove the defective paint work at his
own cost and retreat and/or repaint as directed and to the satisfaction of the Superintending
Officer.

All screw heads, nuts and other means of fixing shall be painted at the time of installation and
refinished after the final Testing and Commissioning.

All areas, which are not accessible after erection, shall be painted prior to erection.

The Contractor shall submit full details of the proposed Paint System including type of paint,
Manufacturer’s name and brand, thickness of each coat, and the minimum and maximum
permissible periods between application of successive coats, for approval.

Labeling on piping shall be painted in contrasting colors and shall be in centre of bands.

The labeling shall be indicated in the drawing.

7.0 Testing And Commissioning

7.1 General

The services of a qualified Supervisor shall be provided for the testing on the completed LP
Gas pipeline at the Site. The Contractor shall prove to the Engineer/Purchaser that all
completed section are pressure tested and leak proof against installation defects. The
Contractor shall provide all equipment necessary for reliable and efficient testing. If a Third
Party is to be engaged for testing, the cost shall be borne by the Contractor. The Contractor
shall record all test carried out and prepare a report after obtaining the final results.

All painting and Site insulation work shall not commence on the welded section as long as the
pressure test is not completed. Contractor shall provide alternative requirement of Witness
Test of completed section by Third Party or M/s Jabatan Keselamatan Dan Kesihatan
Pekerjaan and M/s Jabatan Bekalan Elektrik Dan Gas Inspectors.

7.2 Pressure Testing

Prior to testing, pipes are to be visually inspected during or after manufacture and fabrication.
he piping installation shall be carefully tested to ensure that it is leakage free. Piping Systems
may be tested as a complete unit or as the construction progresses. Where any part of the
installation is to be enclosed or buried, the test should be carried out prior to concealing them.
A valve is not to be subjected to a test pressure unless it is determined that it can safely
withstand the test pressure.

7.3 Test Medium

Test medium shall be air or inert gas. Oxygen or low pressure gas shall never be used.
Where possible pipe joints including welds shall be left uninsulated and exposed for
examination during the test unless they are previously tested. Prior to testing the interior of
the pipe shall be cleared of all foreign material. Pressure shall be measured with a manometer

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or equivalent devise calibrated to read in increments of not greater than 0.5 kPa (0.1 psi). The
source of pressure shall be isolated before tests are made.

7.4 Test Pressure

The following test pressures must be held for at least thirty (30) minutes: -
i. All parts of the installation subjected to cylinder pressure;
ii. Test pressure of 1.5 times the pressure corresponding to the maximum assessed pressure of
the product being carried.
iii. Portions of installation not subjected to cylinder pressure but carrying gas at pressure in
excess of 510 mm of water column shall be subjected to a test pressure of 35.5 psi; and
iv. Portions of installation subjected to gas pressure of 510 mm of water column or less, shall
be subjected to a test pressure of 2.5 psi.
In any part of the installation as protected by safety relief devices or valves then the test
pressure shall be that at which these relief devices or valves operate.

7.5 Test Precautions

Naked flames must never be used for checking the gas tightness of installations.
Defective pipes or fittings shall be replaced and not repaired.

7.6 Nitrogen Purging And Commissioning

The Contractor shall conduct a proper purging of the pipeline upon pressure testing.
Basically the sequence shall be as follows: -
- Displacement of air by inert gas i.e. Nitrogen;
- Displacement of inert gas by LP Gas; and
- Surveillance of the system.

All labor and equipment required in conducting the purging procedure shall be deem included
in this Tender.

After the procedure is completed and the pipeline is confirmed air free, then the
commissioning may proceed with the next stage of introducing the gas into the pipe.
Contractor shall be responsible in adhering to all precautionary measures required during this
period in averting unnecessary incident.

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8.0 Service And Maintenance

8.1 General

The work covered by this Specification is for the supply of all materials, appliances, labor and
necessary incidentals for the service and maintenance of the Gas Piping System and Ancillary
Equipment.

All work to be performed under this Specification shall be in accordance with the best
commercial practice and must be in strict accordance with this Specification.

8.2 Workmanship and Materials

The work described in this Specification shall be performed by Workmen skilled in the
service, maintenance and repair of Gas Piping System and Ancillary Equipment and shall be
executed in accordance with the best commercial practice.

All materials to be supplied in connection with work under this Specification shall be new and
unused and shall generally be of the best quality as regards manufacture and performance.

8.3 Supervision

The Contractor shall have a Foreman in charge of service, maintenance and repair work to be
carried out under this Specification. This Foreman must be thoroughly competent in
supervising the service, maintenance and repair of the Gas Piping System and shall be in the
direct employ of the Contractor and acceptable to the Superintending Officer.

The Contractor shall have in his direct employs, Workmen who are especially skilled in the
service, maintenance and repair of Gas Piping System and Ancillary Equipment.

8.4 Scope of Work

All machinery and equipment comprising the complete Gas Piping System and Ancillary
Equipment shall be serviced and maintained.

The service and maintenance of the complete Gas Piping System and Ancillary Equipment
shall be in strict accordance with the Servicing and Maintenance Schedule as set out below.

The Contractor shall advise the Superintending Officer of any defects in any part or parts of
complete Gas Piping System and Ancillary Equipment observed during routine inspection and
service and shall repair such defects if required to do so by the Superintending Officer.

The Contractor shall also provide emergency repair service during normal working hours and
also during overtime hours if required to do so by the Superintending Officer.

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8.5 Servicing and Maintenance Schedule

The Contractor shall inspect and service all machinery and equipment comprising the
complete Gas Piping System and Ancillary Equipment at the above premises at least once a
month, except where otherwise directed by the Superintending Officer.

At each such monthly inspection and service of the complete Gas Piping System and
Ancillary Equipment, the work detailed below shall be performed by the Contractor.

i. Pipe work

a. Check all pipe work for mechanical damage, rectify as necessary;

b. Check all seals, gaskets and connections for leaks and rectify as necessary;
and

c. Check all valves, regulator, etc. for correct function and rectify as necessary.

Instruct the Operators responsible for the operation of the complete Gas Piping System and
Ancillary Equipment and on the maintenance points to be watched.

Report in writing to the Superintending Officer any defect/s observed in any or parts of the
complete Gas Piping System and Ancillary Equipment. The report shall state the cause/s of
the defect/s observed, and shall include an estimate of the cost of repairs required.

8.6 Repairs

The Contractor shall repair defects in the complete Gas Piping System and Ancillary
Equipment on the instruction of the Superintending Officer.

The cost of such repairs shall not be included in the fixed monthly rate quoted by the
Contractor for the service and maintenance of the complete Gas Piping System and Ancillary
Equipment but shall be charged for separately by the Contractor.

All repairs on the complete Gas Piping System and Ancillary Equipment shall be guaranteed
by the Contractor against defects in workmanship and materials for a period of one year to
take effect from date of completion of the repairs. During the guarantee period, the
Contractor shall rectify defects in repairs carried out by him with no additional charge to the
Government.

8.7 Service and Maintenance Records

The Contractor shall provide a service and maintenance record book for the complete Gas
Piping System and Ancillary Equipment being services and maintained by him. This record
book shall be kept in the Pump House of the Gas Piping System being service and
maintained, and brief details of all services, maintenance and repairs carried out on complete
Gas Piping System shall be entered by the Contractor into this book for checking purposes.
The address and telephone number of the Contractor’s service station shall be entered into
this record book to facilitate emergency service call.

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The Contractor shall also keep an accurate detailed record in duplicate of all service,
maintenance and repair work carried out by him on the complete Gas Piping System. This
record shall be in the form of a Maintenance/Repair Sheet, and shall be countersigned by the
Superintending Officer each time the Gas Piping System is attended to by the Contractor.

8.8 Rates for Services and Maintenance

The rates for the service and maintenance of the complete Gas Piping System and Ancillary
Equipment shall be as shown in the Schedule of Prices for this Contract.

This rates shall be quoted for by the Contractor at the time he submits his tender, and shall
hold good for the period as tested commencing from the end of the free maintenance period.

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