Methodology-Potable Water/Firewater Network

Installation and Testing

A. Pre Installation
All activities for earthwork, trench excavation, pipe bedding in trenches, backfilling after
laying the piping, laying of marker tapes, and all associated jobs related to civil
discipline shall be done by the civil contractor.

Check & verify that the civil work is completed in compliance with all requirements for
installation as per approved shop drawing and handed over for mechanical works. Joint
inspection of the location shall be carried out by the consultant & contractor before
releasing the excavated trench for installation works.

Any over-excavation adjacent to a structure or beneath the formation level of a pipeline

either to be constructed under the contract or in a futures contract shall be backfilled
with grade 20 SRC concrete.

If during excavation the trench width exceeds one of the values listed in the table
below:

Nominal Bore mm Maximum Trench Width mm Nominal Bore mm Maximum Trench W

100 550 600 1350

150 600 800 1550

200 800 1000 2000

300 900 1200 2300

400 1000 1400 2500

 500 1250 1500 2700

A plain or reinforced concrete cradles and/or reinforced concrete arches shall be

provided to the requirements shown on the drawings and to the approval of the
engineer.

Check the pipe for transport damage prior to starting with any installation work; Check
that the inside of the materials is free from any foreign objects.

Transport and unload the pipe, fitting & support down to its intended installation place.

Pipe installers should be careful to prevent bending or torsion strains from being
applied to flanges or flanged appurtenances.

Ensure that proper and dry trench beddings are placed.

Verify that the invert levels of the trench are correct. Check the dimensions and
elevations based on the approved benchmark by the engineer.

Ensure trenches are free from obstruction, rocks, and other debris prior to laying of the
ductile iron materials.

All relevant documentation approved shop drawings, and material applicable to a

particular section of work will be checked by Site Engineer prior to commencement of
work.

Ensure that material received is in compliance with the project

specifications/authorities regulations and is approved.  Ensure that all required
materials and accessories are delivered, inspected, and approved by the consultant
and are readily available at the site to carry out the work.

Prior to the commencement of work, areas and access will be inspected to confirm that
site is ready to commence the work and coordinated with other trades and
subcontractors.

All relevant documentation (including MST and RA are approved, obtain necessary work
permits, fill up STARRT cards after completion of daily toolbox talk), will be checked by
Site Engineer prior to commencement of work.
The Site Engineer/Site Supervisor will give necessary instructions to mechanical
tradesmen and provide necessary approved construction/shop drawings.

The Site Engineer/Site Foreman will check that proper tools and equipment are
available to carry out the work and are in compliance with contract specifications.

The Site Engineer will explain to his team about HSE precautions to be observed.

The Site Engineer/Foreman ensures the cleanliness of the area.

Pre‐inspection arrangements for DI pipes, fittings, valves, and corrosion protection

materials: In order to facilitate the onsite inspection for Materials Engineers, the
following points are to be followed.

For any materials inspection, the items shall be segregated as per their type/sizes on
different pallets.

Each pallet shall have the description of the items clearly displayed on it.

There shall be appropriate spaces between the pallets so that the engineer/inspector
can freely go around them and inspect the materials thoroughly.

Staking the materials all over each other & in one corner is strictly not allowed.

All valves shall be kept under the shade away from direct sunlight. The valves shall not
be kept on the floor; they shall have wooden pallets underneath them.

Corrosion protection materials shall never be kept under direct sunlight or exposed to
a harsh site environment. They shall be stored inside the site warehouse.

If the items in one pallet are more than ten in number, do not arrange it on top of the
others, and provide space in between to inspect easily.

B. Procedure
All necessary work permits shall be obtained prior to the commencement of any
activity at the site and shall remain valid throughout the entire duration of the
operation.

Work clearance forms shall be submitted and approved prior to commencement of any
works at the site.

The work area shall be isolated by erecting suitable barricades.

At the completion of each day’s pipe laying, the ends of the pipe shall be covered to
prevent the ingress of dirty water or debris.

Prior to the start of excavation, make sure that the pipeline coordinates and elevation
have been certified by the surveyor. Pipe location, elevation, and slope shall be
maintained by a surveyor. A survey report shall be made after the final installation.

For the waterlogged areas, gabbro material as gravel shall be used.

Before the start of pipe laying, the bottom of the trench shall be dry, continuous,
smooth, and free of rocks and to the line and grade have shown on the drawings.

Ductile Iron Pipe Installation

Before commencing to place any side fill material, any leveling pegs or temporary
supports shall be removed.

Ductile iron pipes shall be supplied in 6.0 meters. lengths; Cut to the required size
using the cutting machine before lifting.

Lower the pipe into the trench. Don’t remove the lifting device (existing crane or chain
hoist) before the pipe is laid and aligned in the support.

Only remove caps and dummy plugs on-site just before the pipe is laid.

Check the horizontal level of the pipe longitudinally and in the cross direction.

Accurate axial alignment of the mating pipes prior to jointing will be done.

Pipe straightness will be achieved using cotton or nylon thread.

Install appropriate pipe thrust blocks where required. The excavation for thrust blocks
shall be carried out prior to laying the pipes except that a trimming margin of not less
than 150 mm shall be left to be removed by hand excavation. No pressure shall be
applied to the thrust blocks until the concrete has matured for at least seven days.

All activities related to the thrust block shall be performed by the civil contractors. All
concrete thrust blocks shall be cast against undisturbed soil.

All joints shall be kept exposed until satisfactory completion of the hydraulic pressure
test.

If trench dewatering is necessary, no pipe installation shall start until the design of the
dewatering system has been approved.
The wrapping operation shall preferably take place where low temperature can be
maintained in the summer heat period so as to avoid the tape degrading due to the
high temperature of the coated pipes.

The maximum time between wrapping of the pipe and installation/ laying into the
trench will be as per project specification and manufacturer recommendation.

Sluice valves, fire hydrants, air, and washout valves shall be installed as per approved
manufacturer recommendations/instructions, approved shop drawings, and project
specifications.

All equipment and accessories required for testing shall be calibrated and certified by
an approved third-party agency for its accuracy and shall process valid calibration
certification.

Step of Works
The installation operations to be adopted for connecting the DI pipe shall be in
accordance with the project requirements and as per manufacturer recommendations.
Installation operations shall be done by trained DI pipefitters.

The DI materials shall be suitable for use with the range of chemical characteristics of
the water and comply with guidelines suitable for using and storing in the
environmental condition and normal working water temperature at 50 degrees
centigrade.

All the potable water DI pipes shall be from approved manufacturers and the

engineer’s approval.

All the material shall be stored in accordance with the manufacturer’s storage
recommendations.

Prior to installation, the material shall be protected as per general specification for the
main laying contract:

Protection of Materials before installation:

Pipes
A suitable storage area shall be arranged for the duration of the project and subject to
approval.
The pipes shall be stacked neatly on timber battens in parallel method with spigots and
sockets laid to alternative ends and using wooden battens between rows (size and
location of battens shall be as manufacture specification) and the maximum
recommended number of layers as manufacture specification.

Valves & Fittings

Valves & fittings of any type shall be arranged in a suitable storage area and shall take
every care to prevent damage to valves & fittings and their ancillary equipment. These
items must not be in contact with the ground but shall be placed on timbers or planks
and provide adequate wedging between each fitting in the base layer and at the sides.

Valve headstocks, motor gearing, or indicators shall be adequately labeled for

identification stored carefully in weatherproof premises and be reconnected after the
erection of the valves.

Electrical equipment shall be protected from the dampness and the dampproofing
seals shall remain intact until the electrician is ready to connect up the equipment.

Air valves are to be stored under cover, in a vertical position with the top of the valve
uppermost. Under no circumstances are air valves to be stored such that the ball is
subjected to sunlight. Resilient seated sluice valves are to be stored in the same fashion
as air valves.

Other Materials
Rubber seatings, gaskets, polyethylene film, wrapping tape, adhesive tape, PVC coated
copper pipe, copper fitting, PVC duct, and other anti-corrosion materials and all other
equipment and materials liable to be adversely affected by the heat and sunlight are all
to be stored in end door cool place. Bolt, nut, the washer should be stored under cover
in dry conditions and before used should be lubricated.

All material like rubber seating, gaskets, adhesive tape, wrapping tape, and other anti-
corrosion materials shall be stored indoors and in an air-conditioned space prior to
starting installation.

All the interfacing of tie-in points with other packages shall be done according to
project specification and shall be as per approved shop drawings with coordination
with Engineer’s representative.
Corrosion protection shall be applied to the ductile Iron pipes, clean the surface from
dust then apply the primer to the pipe surface and wrap the pipe with approved color
self-adhesive wrapping tape.

Corrosion Protection
All buried pipes and related fittings shall be protected from corrosion by the
application of a PVC / bituminous corrosion protection tape and sleeving.

All pipes and fittings shall have the appropriate external corrosion protection.

Wrapping of Pipe Barrel

The entire external surface of the pipe shall be clean, dry, and free from all rust, dust,
grease, or any other deleterious matter.

Only touch up shall be done at the site.

No grit blasting or sandblasting shall be done at the site.

The clean, dry, primed prepared pipe surface is to be machine wrapped with the
approved tape.

The tape is to be applied spirally with a minimum of 25 mm overlap for the normal
area and 55% overlap for the waterlogged area using sufficient tension to ensure the
tape conforms and adheres to the pipe surface. End laps between successive rolls to be
a minimum of 200 mm. The wrapping shall extend as close to each end of the pipe as
practicable, so the pipe can be jointed in the trench damage to the wrapping.

After the pipes are jointed the step between the spigot and socket area is to be shaped
up with the tape manufacturer’s to give a smooth surface profile for wrapping. The
joints shall then be wrapped as described above and the joint wrap to extend a
minimum

150 mm onto the existing wrap on either side of the joint. Any transit damage to the
wrapping tape will be repaired before the pipe is wrapped in the sleeve and laid in the
trench.

Wrapping of Buried Flanges, Valves, and Other Fittings

Buried flanges, valves, and fittings shall be protected by approved PVC / bituminous
protection wrapping tape, plus primer and putty supplied by the tape manufacturer.
All exposed metal surfaces of the object to be protected and existing protective coating
at each extremely to be cleaned free of all rust, weld spatter, mill scale, dirt, dust, lime
wash, and other deleterious matter.

The clean, dry, prepared surface is to be brush primed with one thin continuous coat of
quick-drying primer and allowed to dry completely.

All pipe and fittings shall be wrapped with an approved polyethylene sleeve if required
by project specification.

The polyethylene film will be supplied in tubular form and it is to be placed around the
barrel of the pipe or fittings and fixed with sufficient overlaps as required and taped
with an approved tape of a minimum of 50 mm width.

All such sleeving is to be done before the pipes and fittings are lowered into the trench.

After the pipes and fittings have been lowered into the trench and jointed, the
polyethylene film shall be folded over the joints with an overlap of 300 mm.

Polyethylene Sleeving
All pipes and fittings shall be wrapped with an approved polyethylene sleeve if required
by the specification. The polyethylene film will be supplied in tubular form and it is to
be placed around the barrel of the pipes or fittings and fixed with sufficient overlaps
and taped with an approved tape of the minimum width of 50mm.

All such sleeving is to be done before the pipes and fittings are lowered into the trench.

After the pipes and fittings have been lowered into the trench and jointed, the
polyethylene film shall be folded over the joints with an overlap as directed by the
consultant.

The contractor is to ensure that the fold is positioned such that it is on the crown up
the pipe. The contractor is to ensure that there is a continuous film of polyethylene
between pipes and fittings and the surrounding backfill material. No backfilling of the
pipe is to take place until it has been checked and passed the integrity of the
polyethylene protection.

Before the pipes are laid, they are to be carefully brushed before the pipes through to
remove any soil, stones, or other matter, which has entered.
After the trench has been excavated and required elevation achieved, obtaining
approval to proceed with granular bedding and compacted as per project specification
for the main laying as follow: (Will be done by civil contractor)

i. Imported granular material shall comprise crushed clean hard limestone. The
crushed limestone shall be obtained from an approved source.

ii. Granular material shall contain no excessive quantities of dust, soft or flaky particles,
shells congealed lumps, nodules of soft clay, shell, alkali, or other contamination likely
to affect adversely the compaction of the material or to cause damage to pipes.

iii. Prior to commencement and during the progress of works the contractor shall
provide samples of the proposed granular material to be used in the works. This
sample will be retained for comparison with deliveries to the site during the works.

iv. The grading of fine aggregate, when determined by the method described in BS 812
(British Standard 812), shall lie within the respective limits specified.

Ensure that pipes and fittings to be joined are of the same nominal size, pressure, and
type, making sure that no stones or sharp ends in bedding.

Special attention needs to be given to the bedding, side filling and backfilling of the
trench. This provides the necessary support for the pipes.

The pipes shall be laid according to coordinates and elevations specified in the
approved drawing. The tolerances for elevation shall be strictly followed.

Before the pipes are socketed the joint shall be carefully cleaned and dried. No dirt or
water is to be allowed to enter before the joint is made. No packing of any kind shall be
used to locate the pipes in position in the trench.

All precautions shall be taken to avoid any foreign material from entering the pipe
during installation. Ensure no debris, tools, clothing, or other materials shall be left
inside the pipe.

Pipe installation shall start at low points towards high points.

Pipes will be lowered in the trench and installed/jointed in the specified slope, level,
and coordinates as per the approved shop drawings, seal the open ends of the pipes
with caps after completion of activities according to project specification of laying
contracts.
Sealing Ends of Pipes
Immediately after laying, the open ends of the pipes shall be sealed with unperforated
wooden plugs of appropriate size or approved expanding stoppers to prevent the entry
of extraneous matter or water which might contaminate or damage or affect the
working of the system.

These plugs are not to be removed until the end in question is no longer classified as
an open end.

Pipes, valves, fittings, and other materials shall be handled, moved, lifted, or lowered,
connected with the least possible impact, and handling equipment using slings with a
third-party inspection certificate.

Valves (washout, air release, etc.) and all fittings (tees, bends, reducer, etc.) and other
related materials (fire hydrants) shall be fixed according to manufacturer
recommendation, specification, and approved shop drawings.

All pipes, valves, fittings, and their ancillary equipment shall be protected before and
after erection against the collapse of earthworks, falls of materials, concrete and
cement droppings, wood, and other shavings, and all deleterious material.

When setting and assembling flange work, care shall be taken to ensure that the
flanges and bolts are correctly positioned and bolts are evenly tightened up in the
correct sequence.

Immediately after laying, open ends of the pipes shall be sealed with imperforated
wooden plugs or approved expanding stoppers to prevent the entry of extraneous
matter or water which might contaminate or damage and affect the working on the
system.

At curves on the pipelines; horizontal, vertical, or a combination of both bends and

elsewhere shall be provided with the thrust blocks, supports blocks, etc. as per
approved detailed shop drawings and requirements.

As-built surveying shall be taken and recorded prior to surrounding, the pipe surround
shall not be less than 250 mm above pipe crown.

Backfilling of the trench, after obtaining approval from the Engineer shall proceed
immediately after satisfactory completing of work. No backfill layer shall be covered by
the next layer of construction until it has been inspected, tested, and approved by the
Engineer.
Approved PVC marker tape shall be laid directly above the water main, 300 mm below
finished ground level, and 200 mm below the service connection line. Under
carriageways, marker tape shall be laid on top of the concrete protection to the water
main or as directed by the Engineer.

The remaining depth of trench above sand layers can be backfilled with approved
excavated material in layers of not less than 200 mm compacted thickness, each layer
will be compacted by roller or plate compactor. The final layer will be tested to 95%
proctor.

For the scenarios for pipe crossing new road work and other utilities.

Laying, Jointing Pipes and Fittings

Pipes and special castings will have flange joints, couplings, bolted glands, joints, or
similar. Before the pipes are laid they are to be carefully brushed before the pipes
through to remove any soil, stones, or other matter, which has entered.

Pipe laying shall commence at low points, i.e., washout branches, and proceed towards
summits, i.e., air valve location. Pipes are to be lowered singly into the trench brought
to proper inclination, firmly bedded, and made to rest throughout their whole length as
specified.

Before the pipes are socketed the joint shall be carefully cleaned and dried. No dirt or
water is to be allowed to enter before the joint is made. No packing of any kind shall be
used to locate the pipes in position in the trench.

Pipes, valves, fittings, and other materials shall be handled, moved, lifted, or lowered,
connected with the least possible impact, and handling equipment using slings made of
terylene, nylon, or other suitable synthetic fibers capable of withstanding the required
loads.

Joints
When setting and assembling flange work care shall be taken to ensure that the flanges
are correctly positioned as required that the component parts of the joints are clean
and dry that the faces and bolt holes are brought firmly together that the bolts are
evenly tightened up in the correct sequence and that the protection of the flanges is
made good.
All jointing out strictly in accordance with the manufacturer’s instructions and prior to
jointing a demonstration may be given by the manufacturer’s supplied skilled pipe
jointer/representative or a trained pipe jointer of the contractor.

Flexible Mechanical Joints

The spigots and sockets of all types of flexible jointed pipes shall be thoroughly cleaned
before jointing rings are placed and jointing completed.

Notwithstanding any flexibility provided in the pipe joints, pipes must be securely
positioned to prevent movement during and after the making of the joints and no
person shall be employed on the jointing of pipes who is not thoroughly experienced
and skilled in the particular work in hand.

No deviation from a straight line will be allowed without approval. Any such deviation
shall be provided with thrust blocks if so instructed.

Cutting Pipes
Pipes shall be cut by a method, which provides a clean square cut of pipe and lining
and then chamfered where required without being shattered or separated.

All cut or trimmed ends and the parts of any pipe on which the coating may have
suffered damage shall be re-coated as per manufacture specification.

Collars and Closers

Where loose collars are used to join pipes cut for closers special tools shall be
employed to keep the inside of the pipes flush and the collars concentric with the pipes
while the joint is being made.

Sluice Valves and Fire Hydrants

Faces and Seating

Gunmetal faces and seatings of all sluice valves shall be kept clean and free of dirt. No
valve shall be laid and operated without first wiping the gunmetal faces with a clean
cloth dipped in clean non-mineral oil.

After such cleaning, every care is to be taken to ensure that no extraneous matter
enters the valve during the laying process.
The gate groove in the base of the valve is to be thoroughly cleaned by hand before
laying the valve. Should bitumen, cement, or any other matter be deposited on the
gunmetal faces or seatings it shall be dissolved using proprietary solvents or carefully
removed by methods that do not involve scraping the gunmetal faces.

Oiling of equipment

Before any sluice valve or hydrant is commissioned, all gears, bearings, and spindles
should be oiled with approved oil as recommended by the valve manufacturer. Oil
baths are topped up to the appropriate levels and all grease nipples are charged with
the grease of the approved manufacturer.

Stuffing Boxes

Every stuffing box shall be examined when the main is under pressure test and leaking
boxes shall be adjusted or repacked with square plaited lubricated packing, or ‘O’ rings
of approved manufacture. The stuffing box shall not be so tightly adjusted or packed as
to materially affect the friction of the packing on the spindle.

Air Valves

Air valves shall be checked before the main is tested to ensure that the balls and faces
are not damaged and that there is no dirt or other deleterious material in the cavities
of the body.

All air nozzles shall be probed to see that they are clean. Air relief valve assemblies
shall not be installed directly to any storm drain or sanitary sewers system.

Connections to Existing Live Water Mains

Where no tee has been left for future development, the connection shall be made
using an approved cutter or under pressure drilling tee and drilling machine.

The pipe where is to be fitted will be clean, dry, and free from all rust, dust, grease,
wrapping tape, or any other deleterious matter and shall be painted with the quick-
drying primer. After fitting and drilling the whole tee shall be protected as per
specifications.

Protection of Equipment during Laying

All pipes, valves, fittings, and their ancillary equipment shall be protected before and
after erection against the collapse of earthworks, falls of materials, concrete and
cement droppings, wood and other shavings, and all deleterious material.
Sealing Ends of Pipes
Immediately after laying, the open ends of the pipes shall be sealed with unperforated
wooden plugs of appropriate size or approved expanding stoppers to prevent the entry
of extraneous matter or water which might contaminate or damage or affect the
working of the system. These plugs are not to be removed until the end in question is
no longer classified as an open end.

Anchor Blocks, Thrust Blocks, Support Blocks, etc.

At curves on the pipelines, either horizontal, vertical, or a combination of both bends or
elsewhere, the pipes must have thrust blocks of concrete Grade SRC 20 to the
dimensions shown on the drawing.

Concrete work shall be done by civil discipline.

Thrust blocks shall be cast against un-disturbed soil and shall be cast at all socketed
bends, tees, and tapers/ reducers.

Service Connections
This specification covers the laying of MDPE pipes with associated fittings for the size
range 20 mm (1/2”) up to 63 mm (2”) underground and aboveground.

Excavation & Backfilling

Excavation and backfilling for MDPE service connection will be in accordance with
general specifications for main laying contracts noting that pipe depth shall be 600 mm
as detailed in the specifications of the project.

MDPE service pipe shall have 100 mm sand bedding, 150 mm selected backfill material
with 100% compaction, and backfill material of varied depth up to ground level, all in
accordance with road depth highways maintenance section requirements.

The minimum width of trench excavation is to be service pipe duct diameter (either 100
mm or 150 mm) used plus 200 mm and the maximum width of trench excavation is to
be service pipe duct diameter used plus 300 mm.

Materials

All materials supplied shall conform to the project specification for materials used in
pipe-laying construction and service connection work.
Service connection size

The sizes of service connections will differ, in no circumstances shall the sizes of the
connection exceed the following values:

Diameter of Main Maximum Size of Connection with Saddle

80mm 20mm

100mm 25mm

150mm 32mm

200mm 40mm

300mm 50mm

MDPE pipes and fittings Installation Instructions

Trench marker tape with an aluminum strip in the middle shall be laid at a minimum
450 mm depth below ground level along the route of pipe.

The contractor shall tap the distribution main at depth of a minimum of 900 mm and
bring MDPE pipe from ferrule to a higher elevation without the use of any fittings, as
far as possible, so that MDPE the pipe could be laid at a minimum depth of 600 mm
from ground level, from the distribution main till it reaches customer boundary wall.

When laid above ground along with customer wall premises or elsewhere, polyethylene
pipe shall be protected with GRP duct of minimum thickness 3 mm.

Two sizes are allowed; 2” duct for 20mm (1l2”), 25mm (3/4”), 32mm (1”) & 40mm (1 ¼”)
and 3” duct for 50mm (1 ½”) & 63mm (2”).
The GRP duct shall start from ground level and be extended to an appropriate height to
secure the exposed MDPE pipe near the water meter service cabinet. The GRP duct
shall be of a semi-circular shape and be firmly fixed to the wall with brackets.

Hydraulic Testing
The pipelines are to be subjected to the following hydraulic tests:

Test to a pressure of one and half time the working pressure or to a pressure of 9 bars
which is the greater and is to be carried out on the section of main during laying.

After completion of all sections of similar diameter, a test shall be carried out at the
specified pressure on the completed pipeline.

After completion of service connection, a test of 6 bars shall be carried out on the
completed pipeline.

The first test is to be to a pressure of 9 bars and is to be carried out on sections of the
main during laying. The second test (final) is to be 6 bars, carried out on the competed
pipeline, and is designed to test the service connections. However, in case no service
connections are installed, the second test (final test) shall be 9 bars, not 6 bars.

In general, testing should not be carried out against closed valves, the final 9-bar test
can be carried out in sections against closed valves.

Initial Test
This test will be carried out on a short section of the main, maximum length to be 1.5
km with joints left exposed, with in-service connections installed, and against proper
stop-ends. Under no circumstances this test be carried out against closed valves.

Each section of the pipeline is to be tested to a specified pressure, such pressure being
recorded at the lowest point on the test section.

The contractor is to supply all necessary pumps, water, approved blank suitably drilled
and tapped for use as the temporary test ends, small bore pipework to fill the main
supplying the test hand, pressure gauges, isolating cocks, measuring vessels for
measuring the quantity of water lost during the test period and all other materials
necessary to ensure successfully testing of the section.
Final Testing
This test will be carried out when the pipeline has been fully completed i.e., all service
connections made fully backfilled and reinstated, all valve chambers complete, etc.

The pipeline is to be tested to a specified pressure, such pressure being recorded at

the lowest point on the test section.

Testing Method
Where pipes are being tested by sections, each section must be properly sealed off
with a stop and securely anchored to prevent any movement. Unless otherwise
specified, the maximum thrust on the stop ends for the 9 bar test shall be as per
project specification for the main laying as shown below.

Pipe Diameter mm Thrust Tons

100 0.7

200 2.8

300 6.4

400 11.3

600 25.3

900 57.2

1200 101.7
If the anchor is to be made of concrete, testing must not start until the concrete has
developed adequate strength.

After the contractor is satisfied that all stop-ends are adequately anchored, the section
under test is to be filled with water taking care that all air is displaced either through
vents at the high points or by using a swab.

After filling the pipeline, must be left under operating pressure for a period to permit
the lining to absorb water, pipeline movements, the release of any air still remaining in
the section, etc.

The test will last for a period of 24 hours after which time the pressure will be noted
and the seals removed.

If a drop in pressure occurs, the quantity of water added in order to re-establish the
test pressure should be carefully measured. Unless otherwise specified this quantity
should not exceed 0.1 liters per millimeter of pipe diameter per kilometer of pipeline
24 hours for each 30m head of pressure applied.

The requirements per kilometer per day shall be as per project specification for main
laying contracts or project specification and as shown below.

9 Bar Test Quantity of Water

Pipe Diameter (mm) Litres/km/24 hours

100 30

150 45

200 60

300 90

400 120
 600 180

1200 360

6 BarTest Quantity of Water

Pipe Diameter (mm) Litres/km/24 hours

100 20

150 30

200 40

300 60

400 80

600 120

900 180

1200 240
If the test is not satisfactory i.e., the amount of water to be pumped in to bring the
pressure back to the test pressure is greater than the quantities given in the tables
above, the fault is to be found and rectified.

Where there is difficulty in locating faults, the section under test, where it is in the initial
test should be sub-divided and each part tested separately. For the final test, such sub-
division can be done by closing valves. All fittings and other materials required for re-
testing are the responsibility of the contractor.

If no faults can be found, then one of the following methods can be utilized to find the
leak:

1. Visual inspection of each point not backfilled.

2. Use of a bar probe to detect signs of water in the vicinity of backfilled joints.

3. Aural inspection using a stethoscope or listening stick in contact with the pipeline.

4. Use of an electronic listening device, which detects and amplifies the sound of any
escaping fluid.

5. Injection of dye into the test water (only of use in the waterlogged ground).

6. Introduction of nitrous oxide into the test water and using an infra-red gas
concentration indicator to detect the pressure of any nitrous oxide that has escaped
through the leak.

All pressure tests on mains will be done using water pressure tests and under no
circumstances will pneumatic testing be permitted.

Swabbing and Sterilization

Before the final commissioning of the pipeline, the contractor shall swab and scour the
pipeline to ensure that this is free from obstructions, debris, and sediment.

Swabbing
One of the following methods shall be used to swab the pipeline.
Hydraulic swabbing

A foam plastic cylinder swab shall be inserted into the pipeline and driven by hydraulic
pressure through the pipeline. The dimensions of the swab shall be as follows:

a. Pipe diameter less than 300 m

Swab diameter = 1.25 x pipe diameter

Swab length = 2 x diameter

b. Pipe diameter greater than 300 m

Swab diameter = pipe diameter + 75 mm

Swab length = 1.5 x diameter

The pipe shall be swabbed in one length or in a series of sections.

Should the swab jam at any point, it will be the contractor’s responsibility to either
dislodge the swab or to locate it and remove a section of pipeline adjacent to facilitate
the removal of both the swab and the blockage. Swabbing will be continued until such
time as all obstructions are removed and swab freely through the main.

Dry Swabbing
A form plastic cylinder swab shall be inserted into the pipeline at the beginning of pipe
laying and pulled through each pipe as it is laid by means of the rope, thus providing an
effective dry swab.

To avoid contamination and infestation, an expandable plug shall be fitted at the end
of the pipe at each break in the working day and when pipe laying is suspended. The
swab shall be replaced at regular intervals to ensure a tight all-around fit.

Scouring
After the pipeline has been successfully swabbed, the pipeline is to be flushed with
clean water.

The scouring shall be continued until the water runs clear and the contractor shall
ensure that no erosion or silting occurs in the watercourses or drains into which the
water is discharged.
Sterilization of Water Mains
After the mains have been tested and approved, swabbed, and flushed out, the mains
shall be slowly filled with clean water containing a chlorine solution injected.

In general hypochlorite solution will be added to the water passing into the main such
that the measured chlorine residual is 20 mg/l (ppm). After all the mains to be sterilized
have been filled, the mains shall be left full of chlorinated water for a period of 24
hours.

After the period the main is to be emptied, filled with clean water, and left for a further
period of 24 hours. Then the biological test is to be carried out and the sample shall be
taken from the front points of the main as measured from the level of chlorine
residual.

If the tests fail, the procedure is repeated until satisfactory results are achieved.

10. Quality Assurance and Quality Control

A. Quality Assurance Requirements
The contractor shall provide the required documents for the consultant’s approval
prior to initiating the execution of this activity as per project specification.

The Quality Control requirement shall include related ITPs and other related
documents as applicable.

Refer to Inspection Test Plan.

B. Quality Assurance Process

The contractor shall notify the Engineer 24 hours in advance prior to the start of activity
and comments from the Site Instruction will be complied with the satisfaction of the
consultant.

The contractor shall consult the public utility authorities not less than one month
before it is proposed to commence work to ascertain whether any underground
installations will be affected by the proposed work, in which event the contractor shall
make all necessary arrangements with the public utility authorities to safeguard the
installation.
C. Follow up and Evaluation
Follow-up on quality performance shall be carried out through an in-house monitoring
system such as progress reporting to the planning department, daily, weekly, and
monthly reports generated by the planning department to closely monitor site
performance.

All the above shall be conducted in close coordination with the quality department to
monitor any deviations from the Quality Management System requirement and induce
corrective actions whenever required to eliminate non-conformance or quality
deviations.

D. Records
Checklists (CKL)

Inspection Request (INR)

Inspection and Test Record (ITR)

11. Attachments-Method Statement of Potable

Water/Firewater Network Installation and Testing
Appendices

Appendix A: HSE Risk Assessment for Installation and Testing of Potable/Firewater

Network

Appendix B: Inspection and Test Plan Installation and Testing of Potable/Firewater

Network

Appendix C: Checklist for Installation and Testing of Potable/Firewater Network

Appendix D: Ductile Iron Piping Leak Test

Appendix E: Ductile Iron Pipe Disinfection Checklist