PIPE LAYING English7 Mar06

7/21/2019 PIPE LAYING English7 Mar06

1/78

1

Pipe laying and service installation manual

1.

Introduction

This manual is made for workers at a construction site.

So this manual describes the procedure of pipe laying work at the site, points to note, etc.

But description of this manual is general in Lao P.D.R and does not necessarily correspondto every region.

Therefore please arrange this manual according to local regulation or local manner, and

make use of this manual.

2.

Flow chart of pipe laying

The site workers must construct based on design specifications.

This chapter describes a general flow of construction.

The site workers must confirm the flow chart and every part of work in all processes and do

pipe -laying suitably.

This manual does not describe the work of engineer section. If you learn it, refer to text-book for pipe-laying and service installation (after text book) chapter 1,5,6.

The choice of a new route.

The choice of pipe diameter.

Site studies.

Land survey.

Design plan drawing.

Estimation of construction costs.

Beginning and end point of works.

Commencement of work

Pipe laying plan

Preliminary survey

Design

Engineer

Section

Preparation forpipe materials

Draw out theprocess table

Preparation for

materials and equipment

of earthwork

Occupancyapplication

The site construction starting

Technician

Section


2/78

2

3.

Drawing out the process sheet

The site worker must complete his work within the planned budget and construction period

efficiently.

Therefore the site worker draws out the process sheet to manage each process.

The site worker checks the progress of process. If there is a delay, investigate the cause of

the delay, reconsider the present schedule and try to improve.

This chapter describes general process table in Lao P.D.R, and explains the contents.

If you learn it more in detail, refer to textbook chapter 9.

Measurement

(Offset of pipeline, pipe laying

length, earth cover and crossing

position)

Earthwork - 1

Water suspension Measurement (width

and depth of excavation)

Pipeline work

Water filling, water pressure test

Technician

Section

Earthwork - 2

Water drainage

Completion of construction

Measurement (Thickness of

pavement, Thickness of upperand lower of road bed)

Completion pipeline drawingEngineer

Section

Sand bedding

Pipe cutting, rubber ring

attachment, jointing,

installed valve, etc.

Sand covering


3/78

3

Table-1. Bar Chart process sheet (Sample)

Contents.

! The name of the construction work

! The planned construction period

! Address of the construction site

1. Preparation work2. Excavation and back-filling

3. Pipeline work

4. Installation of pipe equipment

5. Connect to existing pipe

6. Service installation replacement

7. Road recovery

8. Clean up and drawing

9. Completion

Bar chart construction schedule

Kind ofequipment

8

9

Air valve 1.0 place

hydrant 1.0 place

Installation of pipe

equipment

Gate valve(150) 2.0 place

Plan Actual

The

name of theconstruction work

Theplaned constructionperiod

Address of theconstruction site

Type of process

Item

1

Quantity Unit

m2

pavement

Clean up anddrawing

1.0 set

Completion

2

3

4

5

6

7 Road recovery Cutting pavement 210.0

Compaction ofroad bed

150.0

m

Service installationreplacement

2025 20.0 place

Connect to existingpipe

2.0 place

Pipeline-work K 150 100.0 m

Excavation andback-filling

1.0 set

Remark

Preparation work 1.0 set

month

0 10 20 0 10 20 0 10 20 0 10 20

August

0 10 20 0 10 20

September October November December

1

2

3


4/78

4

4.

Preparation for pipe materials, equipment and worker of earthwork

The site worker must prepare pipe materials, equipment and worker of earthwork based on

design plan drawing.

The site worker orders materials which are hard to be procured in no time, not so as to

affect progress.

In general, followings are materials and equipments which earthwork and pipeline workrequire:

1. Equipments of earthwork truck, backhoe, pick, shovel, pump, etc

2. Materials of earthwork backfill soil, earth stoppers, etc

3. Safety equipment safety fence, lighting, construction warning

sign, safety vest, etc4. Pipe materials pipe, valve, bend, socket, bolt, nut, lubricant,

glue, etc

5. Piping tool pipe wrench, monkey wrench, water pliers, joint

tool, cutting tool, etc

6. Other broom, clean cloths, etc

Truck

Cutter Tamping Machine

Backhoe

Equipments of earthwork


5/78

5

Dewater pump

Generator

Soil

Asphalt Earth stopper

Safety equipment

Shovel


6/78

6

PVC pipe PVC fitting

Steel pipe

Steel pipefitting

Valve

DIP

Pipe materials


7/78

7

Meter Box

Water! meter

Branch Saddle

Corporation cock

iping tool

Pipe wrench

Torque & Ratchet Wrench

Pipe cutter (Big size) Thread machine


8/78

8

5.

Occupancy application

The site worker must submit an occupancy application to road administrator.

In certain cases, it takes a lot of time to get permission takes long time. So you had better to

submit an application as soon as you can.

This chapter describes a general occupancy application in Laos.

Saw

Grinder

Pipe cutter (Steel pipe)

Engine Cutter

Drill

(For branch)


9/78

9

Table-2-1. Occupancy application (Sample

in case of Vientiane)


10/78

10

Table-2-2. Occupancy application (Sample

in case of Vientiane)

Submit document

1.Application (NPPs application form)

2.Process sheet or schedule.


11/78

11

6.

Safety control

The construction starts after all necessary equipments, workers, and documents ofconstruction are prepared.

First of all, securing safety of the site is very important during construction.

This chapter describes a general drawing of safety equipment position on road and presents

some safety equipments with photograph.

If you learn it more in detail, refer to textbook chapter 8.Fig-1.Safety equipments position

Safety fence

Lighting

Construction

Site

Warning signboard

Safety fence or Safety corn Lighting

Road

Construction Machine


12/78

12

Safety vest

Safety corn

Warning sign board

7. Earthwork

The site worker must excavate to lay pipe and backfill after securing safety of the site.

This chapter describes a general procedure for earthwork with photographs.

If you learn it more in detail, refer to textbook chapter 3, 4.


13/78

13

Earthwork-1

! Cutting the pavement Cut the pavement with cutter or pick.

! Breaking the pavement Break the pavement with backhoe or shovel.

! Excavation Excavate with backhoe or shovel.


14/78

14

Notice: In case of the excavating the part of existing pipe or around

underground facilities, use backhoe up to 50cm above the existing pipes.

The thickness of 50cm above the existing pipe, use a hand- excavation to prevent

existing pipes from being damaged

(b) Since uneven surface on excavation bed gives concentrated load to the laid pipes,

flatten the bed surface as much as possible.

(Concentrated load to the laid pipes will be cause of water leakage.)

(c) Pipe installation height must be properly controlled.

( If pipe installation height is not properly controlled, it often leads to air pockets)

(d)Earth stopper should be used depending on the soil condition of the site.

( Refer to textbook chapter 3 2.1)

! Dewatering

Drain water with pump or bucket.

(It is desirable for using pump.)


15/78

15

! Measurement of excavation

At the completion of excavation, check the top width, depth and bottom width of its cross

section.

Fig-2 Excavation Example for in case of bad

cross-section

soil/granite soil

Take two measurements between

measuring points.

(One measuring point 50m, generally)

Refer to textbook chapter 1 1.2.2 or

chapter 3 1.2(5).

Drawing of Excavation cross-section

B1

B2

H

B1: Top width

B2: Bottom width

H :Depth

Sand bedding

(10 20cm)

Pipe

Sand covering

( 20 30cm)

House sideRoadside

Distribution

Pipe

B1

B2 Sand bedding

B3

Service pipe

B1

B2 Sand bedding

B3

H1 H2

H3

Roadside House side

Water meter

Ground Line

Drain


16/78

16

Size of excavation(On H1, H2, H3, B1, B2and B3, See figures shown above.)

Nominal

Size (mm)

H1

(m)

H2

(m)

H3

(m)

B1

(m)

B2

(m)

B3

(m)Remark

Service

Installation

13

Min.

1.0

Min.

0.4

0.2

0.3 2025

30 0.3 0.5

0.1 0.140

Distr

ibutionPipe

50

Min.

1.2

0.5

0.60.1 0.1

75

100

150

2001.2

1.5

0.6

0.8 0.2 0.2250300

350 1.5 2.0

0.9

1.00.3 0.3

400

Earthwork-2

! Backfilling

(a) Backfilling-1

Backfilling of soil with backhoe or shovel.

(b) Compaction

Up to pipe top+ 30cm, the backfill should be tamped manually to avoid

damaging the pipes since mechanical tamping may be harmful.


17/78

17

(c) Backfilling-2

Backfilling of soil with backhoe or shovel.

Repetition

(d)Compaction

Over pipe top+30cm, apply mechanical tamping using a tamper, etc.

! Completion of backfill

! Road surface recovery

After natural compaction term (usually 30 days), backfilled surface should be restored

by wearing coat pavement. As for structure restoration, it should be based on discussion

with road administrator.


18/78

18

Reference :In case of Japanese standard

After completion of backfill, backfilled surface should be restored temporarily, as following.

(a)Backfilling of crushed stones (for lower of roadbed)

Thickness and structure depends on road administrator.

(b) Compaction

Compact with mechanical tamping.

(c) Backfilling of mechanically stabilized crushed stones Thickness and structure depends

on road administrator.


19/78

19

(d)Compaction

Compact with mechanical tamping.

8. Pipeline works

After earthwork-1 finished, the site workers carry out pipeline works.This chapter describes notice of installation of pipe, types of joints, joint connection method

(PVC, Ductile cast iron pipe) and notice of water filling and follow.

If you learn it more in detail, refer to textbook chapter 10,11,12.

! Handling and storage of pipes and valves.

(a) Handle pipes and valves with care and avoid giving impact to them, and be careful

not to damage the coating and lining on pipes.

(b)Always keep a good condition of the work, and place fences to prevent outsider

entering storage site.

(c) If storage site is outdoors, cover pipes and valves with sheet (plastic sheet etc) and

end of pipe with cap to prevent a foreign matter from entering inside of t pipes.

(d)Place sleepers or balance log under the pipes.(e)Always apply drags at both ends while stacking.

(f) While transporting, do not roll or drag pipes.

(g)At the time of hanging up or down pipes, apply 2 point hanging. Pay attention to the

center of gravity and use cushion materials so that housing tools do not touch the

lining parts directly.

Drag

Apply sleepers 1meter apart


20/78

20

Example

(h)Rubber parts deteriorate when pipes are exposed to ultraviolet lay, heat, etc. in the

air. Therefore store them indoors with packing.

(i) Make sure rubber rings not to touch any oil or solvent while storing or handling.

(j) Do not place bolts/nuts directly on the ground after opening the package.

! Notice of pipe installation

(a) Confirmation of pipe laying position (earth cover, crossing position) in the design

drawing.

(b) Confirmation if the pipes do not have scars, cracks and other faults.

(c) In case of hanging down the pipe, if earth stoppers such as wooden piles are put out

temporarily, after reinforcing and confirming safety, hang down the pipe carefully.

(d)Since uneven surface on excavation bed gives concentrated load to the laid pipes to

damage them, flatten the bed surface as much as possible.

If necessary, bed the sand or sleeper.

(e)After cleaning the inside of pipe, install the pipe accurately based on design drawing

using spirit level.(f) While installing the pipe, bed the good quality sand on side and bottom of the pipe

and tamp to prevent the pipe from moving.

(g) When installation of pipe is suspended by sunset, cover the end of pipe with the

wooden cap to prevent soil or spring water from entering inside of the pipes.

(h)Using straight pipes for bend part leads to reduction of room for joints to expand or

contract. Therefore such installation style should be avoided.

(i) The sequence of pipe installation is from the lower to the higher point and direction

of faucet is height.

(j) Confirmation of safety. (Especially, if the inside of excavation is safety or not.)

Cushion material

Tight the wire rope always

through the eyeLess than 60


21/78

21

! Characteristics of each pipe material

(a) Ductile cast iron pipe

Merits Demerits

Strong and durable Comparatively heavy

Tough and impact resistant Anti-escapement measures are necessary at

fittings

Because of flexible joints, the pipe will

follow the ground movements in an

earthquakes

Damage to the internal or external

anti-corrosion surfaces may lead to

corrosion

A variety of linings is available

(b) Steel pipe (Features as distribution pipe)

Merits Demerits

Strong and durable Installation of welded joints requires skilled

workers and special tools

Tough and impact resistant Measures are required to protect against

electric corrosion

The pipes can be one fixed line by

welded joints so that they will follow the

ground movements in an earthquakes

Damage to the internal or external

anticorrosion surfaces may lead to corrosion

A variety of linings is available

(c) Galvanized steel pipe (Features as service pipe)

Merits Demerits

Strong, resistant to external injury Natural of easily rusting

lower cost Drastic dropping of strength caused by

rusting

(d) Polyvinyl chloride pipe (PVC)

Merits Demerits

Featuresasdistributionpipe

Highly corrosion-resistant Reduction of impact resistance at lower

temperatures

Light-weight and easy to install Susceptible to certain organic solvents,

heat, and ultraviolet rays

Easily connected Consideration should be given to the

long-term strength, fatigue strength, and

creep strength

Internal surface roughness does not

change

Damage to the surface may reduce the

strength

Anti-escapement measures are necessary

at fittings

as Corrosion resistant, acid-resistant,

alkalinity-resistant

Weak in high temperatures, inadequate in

temperatures over 60oC


22/78

22

Merits Demerits

Resistant to electric corrosion Weak against ultra-violet rays and

freezing, and therefore, unsuitable for

outdoor-exposed piping

Inside smooth with no scale, no

contamination

Thermal expansion is more than metal

pipes. Light and easy to both handle and

construct

Weak against organic solvents

Inexpensive

Easy to construct

! Types of joints

This section describes a general joints used in Laos.If you learn it more in detail, refer to

attachment material.

(a) PVC pipe (Polyvinyl chloride pipe)

(i)Flexible Type (RR type) RRRubber ring

Fig-3 Cross section of Flexible Type (RR type)

(ii) Fixed Type (TS type) TSTaper socket

Fig-4 Cross section of Fixed Type (TS type)

Rubber ringS i ot

Marking of insertion depth

Socket

Spigot



23/78

23

(iii) Dresser type(Expansion joint)

Fig-5 Cross section of

dresser typeexpansion joint

(b) Ductile cast iron pipe

(i)Mechanical A-typeFig-6 Cross section of Mechanical A-type

(ii)Mechanical K-type

Fig-7 Cross section of Mechanical K-type

Bolt/Nut

Faucet

SpigotRubber RingPush Ring

Rubber Ring

Bolt/Nut

FaucetRubber Ring

SpigotRubber RingPush Ring

Bolt/NutFlan e

S i otS i ot

Rubber RinSleeve

Rubber Rin


24/78

24

(iii) T-type

Fig-8 Cross section of T-type

(c) Flange type of each material

Fig-9 Cross section of Flange type

Rubber Ring Spigot

Faucet

Rubber Ring

Bolt/NutHub type

RF type RF type RF type GF type

RF type gasket

Flange surface

GF type gasket


25/78

25

! Joint connection method

This section describes a general joints used in Laos.

(a)PVC- Flexible Type (RR type)

(i) Necessary tool as following

saw clean clothfile or grinder

meter stick

brush marker

lubricant

(From maker specification)

(ii)Mark the pipeMark the pipe where it is

to be cut.


26/78

26

(iii) Cutting pipeCut the pipe with a finely toothed saw along the marking.

Removal extra of pipe edge.

(iv) ChamferingChamfer with a file or grinder certainly.

Chamfering drawing

15 / 2

2


27/78

27

Table-3 t- size (Reference)

(v)Cleaning

Clean the outer parts of the pipe on the area which is going to be inserted and therubber ring groove.

Nominal Size (mm) 55 65 80 100 150 200 250 300

t(PVC 5)(mm) 1.8 0.2 2.2 0.2 2.5 0.2 3.2 0.25 4.6 0.3 5.4 0.35 6.6 0.4 7.8 0.45


28/78

28

(vi) Rubber Ring AttachmentMount the rubber ring.

Shape a rubber ring into heart, Mounting is easy.(As following drawing)

(vii)Marking of insertion depth

Rubber ring

Notice: Dont mistake direction of rubber ring.


L


29/78

29

Table-4 L- size (Reference)

(viii)Spreading of lubricantApply the pipe lube.(Do not apply the pipe lube to the ring groove)

Table-5 Lubricant consumption(

Reference)

Nominal Size (mm) 55 65 80 100 150 200 250 300

L (mm) 75 95 110 135 155 170 195 220

Nominal Size (mm) 55 65 80 100 150 200 250 300

Lubricant consumption(g) 3 4 5 10 20 25 30 35


30/78

30

(ix) Jointing

Place the pipe to be jointed into one straight.

Insert it to marking of spigot with the lever, the puller or hand.

Insert with the lever Insert with the puller

(x)InspectionCheck with a check gauge to

ensure that the rubber ring is

located properly.

Check gauge

Wooden panel


31/78

31

(b) PVC- Flexible Type (TS type)

(i) Necessary tool as followingsaw clean cloth file or grinder brush marker

solvent cement(maker specification)

puller or lever(if necessary)

(ii) Cutting pipe and ChamferingChamfer the angle, burr or ridge (flare) caused by cutting with file.


32/78

32

(iii)Marking of insertion depthMake alignment mark for connection.

(iv) CleaningRemove any moisture or oil sticking to the pipe surface where the cement is to be

applied with clean cloth.

(v)Spreading of solvent cementApply the solvent cement to the socket interior and the pipe end surface slightly all

over and uniformly.


33/78

33

(vi)Jointing

Immediately insert the pipe into the socket until it bottoms at alignment mark.

Turn the pipe or filling 1/4 turn during connection (but not after the pipe is bottom )

to distribute the cement evenly.Leave the connected pipe to stand alone for approximately 15 seconds.


34/78

34

(vii) Completion

Wipe the remaining cement off with a cloth, then let the solvent harden for 5 minutes

before put into use.

(c) Dresser typeexpansion joint

(i) Necessary tool as followingmarker ratchet wrenchclean cloths

(ii) Cleaning and set the flange,

rubber ringRemove any moisture or oil

sticking to the pipe surfacewith clean cloth.

Set the flanges and rubbers

ring on spigots straightly.

(Make sure it Flange and rubber

ring in the right direction.)

(iii)Set the sleeve and marking of insertion depthSet the sleeve

on one spigot.Make alignment mark

for connection.

L

L /2

Marking Sleeve

Set straightly

Set straightly


35/78

35

Table-6 L- size (Reference)

(iv) Jointing

Insert the one spigot into the sleeve.

(iv)Fitting the rubber ring and the flange

Fit the rubber ring until Fit the Flange until sleeve.

marking line.

(v) Fitting the bolt/nut and tightening

Be sure not to tighten

one more than the others.

Nominal Size (mm) 80 100 150 200 250 300

L (mm) 70 80 90 100 100 100

10mm

SleeveMarking

SleeveRubber ringSleeve

Flange


36/78

36

(d) Ductile cast iron pipe( A, K type)

(i) Necessary tool as followingratchet wrench clean cloths

torque wrench brush

lubricant

(maker specification)

(ii) Pipe fitting

Make sure the maker-mark is placed at the top.

Dig a temporary hole at the bottom to make tightening of the bottom part easy.

(iii)Pipe cleaning

Wipe outside the spigot from the edge to white line.


37/78

37

Wipe inside the faucet, especially the contact surface of rubber ring with cloth.

Clean inside and outside surface of the push ring.

(Sand, oil and other foreign matter should be removed)

Set the push ring on the spigot.

Make sure it faces in the right direction.


38/78

38

(iv)Clean the rubber ring and place the rubber ring on the spigot.

Wipe the rubber ring with cloth.

Fit the rubber ring onto spigot.

(use lubricant on the outside surface of the spigot to help fitting the rubber ring)


39/78

39

Make sure the rubber ring faces in the The rubber ring should be placed about

right direction. 20cm far from the end of the spigot.

A-type

K-type

(v)Application of lubricant

Apply a lubricant to surface of the spigot and the rubber ring.

(A solution of 70% water and 30% soap can be used as the lubricant.Apply a lubricant to thoroughly between the edge of pipe and a white line.

Never use a grease or petroleum oil.

Apply a lubricant to the internal surface of the faucet

Spigot

and rubber ring

20cm

20cm


40/78

40

Faucet

(vi) Connecting faucet and spigot

insert the spigot(faucet) to the faucet(spigot)

For pipes with less than 600mm diameter, two lines marked on spigot. Adjust the first

one to the edge of the faucet.

(vii) Fitting the rubber ring

Push the rubber ring by maintaining even clearance on both the spigot side and faucet side.

Be careful not to damage the rubber.


41/78

41

A-type

K-type

(viii) Setting the push ring

Adjust the bolt holes of the pipe to the holes of push ring.

Place a wedge between the push ring and spigot to ensure correct centering.

(If necessary)

Wedge


42/78

42

(ix)Fitting the bolt/nut and tightening

Be sure not to tighten one more than the others.

Even Clearance


43/78

43

(x) Check tightness of all bolts and nuts.

Finally, use a torque wrench to tighten to the standard torque.

Record the clearance between the faucet and the rubber ring, the condition of rubber ring,

and tightening torque of the bolt to the check sheet.(Refer to K type joint check sheet)

Fig-9 Final tightening and use of torque check

Table-7Torque (kg-m)

Nominal Diameter (mm) 80 100 600 700 800 900 2,600

Nominal size of the bolt M16 M20 M24 M30

Torque(kg-m) 6 10 14 20


44/78

44

(xii) Allowable bending angle and allowable displacement

4m 5m 6m

75 500 8 35 100 500 10 35 150 500 15 44 200 500 19 44 250 400 19 35 300 320 19 35350 450 31 50400 410 31 43

450 350

31

40500 320 31 35600 250 31 29700 230 32 26800 210 32 22900 200 32 211000 150 33 191100 140 33 171200 130 33 151350 120 33 141500 110 32 121600 130 43 10 13 1650 130 45 10 13 1800 130 48 10 13 2000 130 53 10 13 2100 130 55 10 13 2200 130 58 10 13 2400 130 63 10 2600 130 70 10

Allowable bending angle

Nominaldiameter(mm)

Allowablebending angle

()

Difference (X)

betweenmeasure of A1

and A2

Allowable displacement per one

pipe(cm)

(A-type and K-type)

Allowable

bending

angle()

Using straight pipes for bent parts lead to

reduction of room for joints to expand or

contract and thereore, such installation

style should be avoid. Istead, it is desiable to

use bent-pipes for bent parts of a pipeline.

If there is no other choice than connecting

straight pipes for bent-parts, do so within

the rage of allowable angles and use more

than one joint to attain desired piping

results.

Place a pipe straightly

Tighten the bolts to certain tightness

Bend within allowable bending angle

Tighten to reach the standard torque.

A1

X=A1A2A2Xmm


45/78

45

Check sheet for type K joints

All joints must satisfy following conditions or disassemble and joint again.

i. The torque is within -20Nm and +30Nm of the specified torque.

ii. Condition of rubber gasket is good.iii. The difference between max. and min. of the gland-socket clearance a at each joint is within

3 mm.

(e) Ductile cast iron pipe(T type)

(i) Necessary tool as followingclean clothsbrush lubricant(maker specification)

puller lever(if necessary)

kg/m


46/78

46

(ii)Pipe fitting

Make sure the maker-mark is placed at the top.

(iii)Pipe cleaning and rubber ring

Wipe outside the spigot from the edge to white line.

Wipe inside the faucet, especially remove the foreign matter such as sand, mud, gravel, dirt

and paint flakes from the groove using a driver, etc.

(If there is foreign matter left, water leakage may occur. )

Clean the spigot


47/78

47

Clean the faucet

Clean the groove

Clean

the rubber ring


48/78

48

(iv)Fitting the rubber ring

Insert the rubber ring into the faucet.

Form a heart-shape with the rubber ring.

Make sure the rubber ring is correctly

seated in the faucet.

FaucetRubber ring

Rubber ring

Faucet


49/78

49

Confirm the condition of the rubber ring.

(v)Application of lubricant

Apply lubricant to the internal surface of the rubber ring, and the outside surface of the

spigot end


50/78

50

(vi)Connection

Place the spigot in the faucet.

Make sure the two pipes forms a straight line.

Lubricant LubricantWhite line


51/78

51

The other line should be visible outside

This white line should be in the faucet


52/78

52

Insert with the lever Insert with the Puller

(vii) Inspection

Confirm the proper position of the rubber ring all around the socket by inserting a

check gauge into the gap between the spigot and faucet.

Record the clearance between the faucet face and the rubber ring, the clearance between

the faucet face and white line to the check sheet. .(Refer to T type joint check sheet)Check gauge

Wooden panel


53/78

53

(viii)Allowable bending angle and allowable displacement

4m 5m 6m

75 500 8 35 100 500 10 35 150 500 15 44 200 500 19 44 250 500 22 44 300 400 21 42350 400 24 42

400 330 24 37450 300 24 31500 300 26 31600 300 31 31700 230 31 26800 230 35 26900 230 39 261000 200 35 211100 200 38 211200 200 42 211350 200 47 21

1500 200 52 211600 200 56 14 18 1650 200 58 14 18 1800 200 63 14 18 2000 200 70 14 18

Allowable bending angle

Nominaldiameter(mm)

Allowablebending angle

()

Difference (X)between

measure of A1

and A2

Allowable displacement per onepipe(cm)

(T-type)

It is desiable to use bent-pipes for angle-

pipeing in case of T-type pipes also.

Apply angled-piping only when there is no

other choice and within the allowable angles.

Further, use more than one pipe to divide

the pipeline into segment which form a

desired bending shape eventually.Place a pipe straightly

Bend within allowable bending angle

Allowable

bending angle()

X=A1A2A2

XmmA1


54/78

54

Check sheet

T-type joint Check sheet

DateWork Name

Project

Joint work process executedby

( )

Chiefof

pipin

gwork

Instructor

Personin

chargePiping system Drw. No.

Measuring point No.

Nominal diameter,Type of the pipe

Pipe No. and shapeSchematic drawing

Joint No.

CleaningLubricant

Check at the groove of socket

The clearance betweenSocket face and rubber

gasket

1

2345

678

The clearance between

Socket face and white line

1

23

45

678

Judgment

*! On each joint, if one of the measuring points is 9mm or larger than other 7 points, the rubbergasket may be twisted. Disassemble immediately for re-assembling.

(Note)If the nominal diameter is less

than 300mm, four positions1,3,5,7 should be measured.

Thickness gaugeSocket groove

Rubber gasket

Arrow view

White lines

Measuringpositions


55/78

55

(f) Flange type (RF type)

(i) CleaningClean the flange surfaces, bolts, nuts, and gasket to remove foreign matter that may be

sticking.

(ii) Installation of the gasket

Accurately center the gasket relative to the pipe. Temporarily secure it with a thin strip ofadhesive tape (or adhesive) to prevent movement.

(iii)Contact the flanges surface

Install several bolts at equally distances around the periphery.

Contact the flanges surface.

(iv)Temporary tightening

Tighten the bolts installed until temporary tightening while taking care not to dislocate

the gasket and bolt holes.

Order for temporary tightening

Gasket


56/78

56

(v) Final tightening

Install the remaining bolts and tighten them all. Order for final tightening

Until nearing the specified torque,

tighten a bolt and then retighten

the previous bolt all the way

around the periphery so that the

gasket will be evenly compressed.

Table 8

Torque

(For reference)

(vi) Checking the tightened joint

Visually check that the flanges are properly and parallel mated to each other and the

gasket is not dislocated.

(g) Flange type (GF type :Flanges on both pipes touch)

(i) Cleaning

Clean the flange surfaces, gasket groove, gasket, bolts, and nuts to remove all foreign

matter.

(ii) Installation of the gasket

Set the GF gasket in the gasket groove. Adhesive is not needed at this time. If the

gasket comes out of the groove, apply cyanoacrylate adhesive at four to six equally distant

points depending on the pipe diameter.

Application of adhesive

Bolt sizeTighten

torque(kg-m)

Applicable pipe

diameter(mm)

M16 60 75 200M20 90 250300

M22 120 350400

M24 180 450 600

M30 330 700 1200

Notes:

1. Do not use the following adhesives as

they may adversely affect the gasket.

Acetic acid plastic adhesives

Synthetic rubber adhesives.2. When an adhesive is used, check that

the gasket is firmly attached.AdhesiveAdhesive

View from the above


57/78

57

Set the gasket in the groove so that the outer diameter of the gasket is in contact with

outer diameter of the groove.

Install in sequence at points 1, 2, and 3.

(iii)Contact the flanges

Install several bolts around

the periphery. Contact the GFand RF flanges straight to

each other with care not to

twist the gasket.

(iv)Temporary tightening

Order for temporary tightening

Tighten the bolts installed until

temporary tightening while taking

care not to dislocate the gasket

and bolt holes.

View from the above

View from the above

Straight forward.


58/78

58

(v) Final tightening

Install the remaining bolts and Order for final tightening

tighten them all. When nearing the specified

torque, tighten a bolt and then retighten

the previous bolt all the way

around the periphery so that

the gasket will be evenly compressed.

Refer to Table 8 for torque.

(vi)Checking the tightened joint

Insert a clearance gauge between the flange surfaces from the outside at four equal distant

points around the periphery. It should not be possible to insert a 0.9 mm thick gauge

between the flange surfaces.

! Notice of water filling and follow.

(a) Place a temporary saddle corporation cock on the pipe.

(b) When water fill pipe, open the valve slowly with hearing water flowing sound.

(c)Vent the air in the pipe from a temporary saddle corporation cock.

(d) Check the water leakage from pipe joint and valve.(e) Drain water and check the water cloud from a temporary saddle corporation cock.

(f) Check the residual chlorine from a temporary saddle corporation cock.

Correct location of gasket


59/78

59


60/78

60

9.

Service installation

Service equipment refers to service pipes installed by branching from the distribution pipe

installed by water supplier and auxiliary devices are directly connected to such service pipes.

For general household use, small caliber service pipes ranging from 13mm to 25mm in

diameter are used. For factories and larger building, there are service pipes from 30mm to75mm diameter.

Service devices directly connected to service pipes means such devices are connected to

service pipes in such a manner that they are not easily removed.

They are such devices as saddle corporation cocks, curb cocks, water meters, service cock, etc.

This chapter describes general flow chart of service pipe installation,general branching

method and notice of service pipe installation.

If you learn it more in detail, refer to textbook chapter 13.

! Flow chart of service pipe installation

Water use

The number of people using water

The number of outlet

Calculate the total head loss including

the height of the supply equipment

Comparison with the pressure head

provided as the design minimum dynamic

water pressure at the water distributiontakeoff pipe

Selection of Water meter size

Equipments of earthwork

Materials of earthwork

Safety equipment

Pipe materials

Piping tool

Earthwork - 1

Service pipe installation

Water meter installation

Design EngineerSection

Pre aration

Technician

Section

Calculation of designwater consum tion


61/78

61

! Safety control

Refer to chapter 6.

! Earth works

Refer to chapter 7.

! General service pipe installation

Show an example of standard service equipment used for normal households.

Fig-10 General service pipe

installation

Technician

SectionEarthwork - 2

Completion of installation

Branch saddle

Corporation cock

Stop Valve (Bronze)

Distribution

Elbow 90Nipple

Union

Valve Fitting

Meter Box

Service Tap

Pipe

(GSP)

Meter

Interval of more than 30cm

Pipe (GSP)

Stop Valve (Bronze)

Pipe (GSP)

Pipe (GSP)

42cm

50cm

Pipe

(GSP)

26cm16.5cm

40cm

GSP=Galvanize steel pipe

for water supply is blue

mark because it is the

medium qualified


62/78

62

! Joint connection method

This section describes general joints used in Laos! (steel pipe and PVC).

(a) PVC (RR-type, TS-type)

Refer to chapter 8 (a), (b)

(b) Steel pipe (GSP)

(i) Cutting pipe

With cutting machine or pipe cutter.


63/78

63

(ii)Making taper thread

With thread machine or dies.(Using cutting oil, which dose not affect the water quality)

Table-9 Number of thread (Reference)

Diameter

(mm)

Number of thread

(N)15 11.0

20 12.0

25 10.0

32 11.0

40 11.0

50 13.0

65 15.0

N


64/78

64

Example. Bad threads

(iii)Treatment on the pipe end

Deburr the pipe end using a file if necessary.

(iv)Jointing

tape a pipe with seal tape. screw a pipe into a fitting by hand

flat

Inflection thread One side thread

Polygon thread

Seal tape

File


65/78

65

Table-10 Insert Number of thread (Reference)

screw a pipe into a fitting with pipe wrench.

Diameter

(mm)

Number of thread

Insert number(L) Remain

number(M)

Total

number(N)screw a pipe

with manual

screw a pipe

with wrench

15 4.5 1.5 5.0 11.0

20 5.5 1.5 5.0 12.0

25 4.5 1.5 4.0 10.0

32 5.5 1.5 4.0 11.0

40 5.5 1.5 4.0 11.0

50 7.0 2.0 4.0 13.0

65 7.5 2.5 5.0 15.0

N

L M


66/78

66

(v)Anti-corrosion treatment

Apply an adequate amount of anti-corrosion agent or sealer to the outer threaded portion of

the joint (4 5 threads from the inner).

Repair the outer surface of the pipe using anti-corrosion sealer.

! General branching method

(a) Instrument

Branch saddle Corporation cocks

Tools

Apply an adequate amount of

anti-corrosion agent or sealer.

Repair the outer surface of the

pipe using anti-corrosion sealer.

scar

4 5 threads


67/78

67

(b) Cleaning

(c) Mounting the saddle


68/78

68

(d) Mounting the corporation cocks to saddle

(e) Setting the drill


69/78

69

(f) Drilling

! Connecting pipes of Steel pipe and PVC pipe! (For example)

! Meter installationHandle meter with care and avoid giving impact to it

Prevent a foreign matter from entering inside of meter.

Check the meter position.

Check the meter flow direction.

Check the horizontal installation of meter.


70/78

70

This section describes only about water meter installation. But there are various kinds of meter.

If you learn it more in detail, refer toattachment material.

! Notice of service pipe installation.

This section describes general notice of service pipe installation.

If you learn it more in detail, refer toattachment material.

(a)At the place where external forces cause strain in the ground surrounding service pipes or

where the ground is not firm, the pipes should be flexible enough to absorb the stress and

prevent damage that leads to water leakage.

(b)To maintain water quality, the service pipe can not be connected to a pipe or

equipment that may cause a reverse flow of contaminated water.Example of prohibited piping

(b) Distributing pipe end connector shall be located more than 30 cm away from the end

connector of other service installation.

(c) The end connector diameter of water supplying pipe to distributing pipe shall not be

Do not connect.

LiaisonValve

Tap water

Service pipe

Well water or

industrial water

Do not connect.

Cooling tower

CoolerHeatgeneratingwater

Service pipe

Tap water

Heatradiating

water

Liaison

valve

Ball tap

Meter flow direction


71/78

71

excessively large as compared to the water consumption rate of the relevant service

installation.

! Determining for the service pipe size(a) Designed water usage

For the direct connection water service system, the water usage should be determined from

the instantaneous flow rate expected with the possibility of simultaneous usage of taps. In

general, it is determined from the relationship between the total number of taps and those

used simultaneously, (see Table 11 ) or between the number of taps and the usage ratio (see

Table 12 ). The water delivery by tap-type and size, should be considered and reflected in

the total water usage (see Table 13 ).

Table 11 Number ofsimultaneously used taps Table 12 Usage ratios

Totalnumber of

taps

Number ofsimultaneously used

taps

Total number oftaps

1 2 3 4 5 6 7

Usage ratio 1 1.4 1.7 2.0 2.2 2.4 2.6

1 1Total number of

taps

8 9 10 15 20 30

2 4 2 Usage ratio 2.8 2.9 3.0 3.5 4.0 5.45 10 311 15 416 20 521 - 30 6

(b) Guideline for determining the pipe size

The service pipe should be big enough to ensure the designed water usage at the minimum

water pressure expected for the distribution pipe and it should also be cost-effective.

The pipe size should be such that the sum of the height of the tap and the total head loss

relative to the water usage does not exceed the head of the minimum dynamic water

Table 13 Water usage by application and

applicable tap sizes

ApplicationWater

usage

Applicable

tap sizeNote

Sink for kitchen 12-40 13-20

Sink for washing machine 12-40 13-20Wash basin 8-15 13

Bathtub (Japanese) 20-40 13-20

Bathtub (Western) 30-60 20-25

Shower 8-15 13

Urinal (flush tank) 12-20 13 Usage at onetime (4 to 6seconds):

2 to 3 liters

Urinal (flush valve) 15-30 13

Water closet (flush tank) 12-20 13

Water closet (flush valve) 70-130 25 Usage at onetime (8 to 12seconds):

13.5 to 16.5

liters

Hand wash basin 5-10 13

Fire hydrant (smaller one) 130-260 40-50

Sprinkler 15-40 13-20

Car wash tap 35-65 20-25For industrial

use


72/78

72

pressure for the distribution pipe. A larger size should be selected with respect to both the

possible increase in future demand, and the minimum operating pressure for water heaters

and other devices.

Care should be taken to prevent an excessive water velocity in service pipes

(c) Calculation of the total head loss

(i) Weston's formulaThis formula is applied when pipe size is less than 50mm.

And material of pipe is PVC, GSP, Stainless steel pipe, and Polyethylene pipe.

h

{0.0126

(0.01739

0.1087d )/

v }

l/d

v

2

/2g

Q=(

d

2

/4)

v=Q/A=Q/(d2/4)

I

(h/l)

1000(0/00)

h: Total head loss( m )

l : Length of service pipe(m)

g: Acceleration of free fall( 9.8m/s

2

)

v: velocity in pipe( m/s )

d: Diameter of pipe ( m )

I : Hydraulic gradient(0/00)

Refer to drawing of Weston's formula flow curve(P-48)

(ii) Hazen-Williams' formula

This formula is applied when pipe size is more than 75mm.

v 0.35464CD

0.63

I

0.54

Q 0.27853CD

2.63

I

0.54

d 1.6258C

0.38

Q

0.38

I

0.205

(h/l)

1000 = I

{10.666

C

1.85

D

4.87

Q

1.85

}

1000

h: Total head loss( m ) l: Length of service pipe(m)v: Velocity in pipe( m/s ) Q: Flow(m

3

/s)

d: Diameter of pipe ( m ) I : Hydraulic gradient(0/00)

C: Coefficient of Velocity(110)

Refer to drawing of Hazen-Williams' formula flow curve.(P-49)

(iii)Conversion of head loss of service device

Head loss of Service devices, such as saddle corporation cock, water meter, stop valve,

and service cock are converted into head loss of straight-line pipe.

Head of designminimumhydrodynamicwater pressure (H)

Lift head h

Hydraulic gradient lineTotal head loss

Surplus head

h + h < H


73/78

73

Refer to following table.

Table 14Conversion of head loss of service device(Reference)

Application

Nominal Size

Saddle corporation

cock stop valvewater meter service cock

13mm 1.5m 4.0m 3.0m

20mm 2.0m 11.0m 8.0m

25mm 3.0m 15.0m 8.0m

40mm 6.0m 26.0m

50mm 8.0m 35.0m

(iv)Calculation of the total head loss {(l

l

)I} h H

H : Head of design minimum hydrodynamic

water pressure (m)

h : Lift head ( m )

l

:

Length of service pipe(m)

l

:

Head loss of service device(Conversion )(m)

I : Hydraulic gradient(0/00)

(v) Example for Calculation

Case-1

Nominal Size 20, Pipe length=15m, Flow=0.6/sec, Total head loss(h) =

h = lI=15(240/1000)=3.6m

l=15m

I=240/1000(Get I at drawing of Weston's formula flow curve.)

Case-2

Nominal Size 13, Pipe length=35m,

Distribution pipe pressure=1.0kg/cm2=10m

Lift head (m)=3.0

Flow (Q) = /sec

h = 10.0 3.0 7.0

I h/l = 7.0 / 35.0 = 200 / 1000

Get flow at drawing of Weston's formula flow curve

Q = 0.18/sec

3.0m

35.0m

Distribution pipe

pressure:1.0kg/cm2

Distribution pipe


74/78

74

How to get I or flow at drawing of Weston s formula flow curve

Case-1

Case-2

(vi)Number of branch for service pipe

If a service pipe is branched into many service pipes (as following drawing), allowance

number of branch should be limited to certain numbers according to pressure, diameter

and so on.

Refer to the table of number of branch for service pipe (For reference, P-)

10.

Postscript

Description of this manual is for general use in Lao P.D.R.

Proper construction work is very important to lead to reduce future water leakage accidents.

On pipe-laying, you should carry out the construction work according to this manual.

Description of pipe materials is also for ordinary use in Lao also. But in the future, when water

supply technology progresses in Lao, high quality and high performance materials will be

required.And as living standard and life-style change in Lao, water use and form will change also.

This manual is not satisfactory for receiving these changes.

Therefore please revise this manual timely by yourselves.

And if you have some questions in this manual or you would like to know other water

supply equipments that are not included in this manual, please ask WASA (Water Supply

Authority) or NPNL (Nampapa Nakkhone Luang) .

0.6

Flow(/sec)

I: Hydraulic gradient(0/00)

240

20 0.18

Flow(/sec)

I : H draulic radient(0/00)

200

13

service pipe 20

Distribution pipe

100

Main service pipe 25

service pipe 20

service pipe 13

Main service pipe 40


75/78

75

Drawing of Weston s formula flow curve


76/78

76

Hazen-Williams formula flow curve


77/78

77


78/78

PIPE LAYING English7 Mar06

Documents

Transcript of PIPE LAYING English7 Mar06