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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
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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
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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
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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
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Dewater pump
Generator
Soil
Asphalt Earth stopper
Safety equipment
Shovel
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PVC pipe PVC fitting
Steel pipe
Steel pipefitting
Valve
DIP
Pipe materials
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Meter Box
Water! meter
Branch Saddle
Corporation cock
iping tool
Pipe wrench
Torque & Ratchet Wrench
Pipe cutter (Big size) Thread machine
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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)
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Table-2-1. Occupancy application (Sample
in case of Vientiane)
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Table-2-2. Occupancy application (Sample
in case of Vientiane)
Submit document
1.Application (NPPs application form)
2.Process sheet or schedule.
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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
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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.
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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.
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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.)
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! 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
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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.
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(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.
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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.
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(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
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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
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! 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
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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
Marking of insertion depth
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(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
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(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
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! 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.
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(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
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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
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(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.
Marking of insertion depth
L
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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
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(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
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(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.
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(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.
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(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.
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(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
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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
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(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.
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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.
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(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)
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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
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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.
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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
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(ix)Fitting the bolt/nut and tightening
Be sure not to tighten one more than the others.
Even Clearance
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(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
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(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
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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
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(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
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Clean the faucet
Clean the groove
Clean
the rubber ring
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(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
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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
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(vi)Connection
Place the spigot in the faucet.
Make sure the two pipes forms a straight line.
Lubricant LubricantWhite line
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The other line should be visible outside
This white line should be in the faucet
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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
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(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
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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
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(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
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(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
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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.
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(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
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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
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! 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
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! 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.
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(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
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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
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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
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(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
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(b) Cleaning
(c) Mounting the saddle
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(d) Mounting the corporation cocks to saddle
(e) Setting the drill
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(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.
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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
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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
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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
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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
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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
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Drawing of Weston s formula flow curve
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Hazen-Williams formula flow curve
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