Pipeline Contruction and Design Standards 200907

8/22/2019 Pipeline Contruction and Design Standards 200907

1/43

Busselton Water

Pipeline Construction and DesignStandard

July 2007


2/43

BUSSELTON WATERPipeline Construction and Design StandardJuly 2007

INDEX1. INTRODUCTION...................................................................................................... 5

2. REFERENCE MATERIAL ........................................................................................ 5

3. GLOSSARY OF TERMS.......................................................................................... 5

4. STANDARD ABBREVIATIONS ............................................................................... 6SECTION 1

5. PRELIMINARIES TO CONSTRUCTION ................................................................. 7

6. MAJOR WORKS ...................................................................................................... 7

7. MINOR WORKS (EXEMPT WORKS).................................................................... 12

SECTION 2

8. DESIGN GUIDELINES........................................................................................... 14

8.1 REDEVELOPMENT OF EXISTING AREAS ...................................................... .................. 148.2 WATER RETICULATION PLANNING FOR SUBDIVISIONS............................................... 148.3 LAND REQUIREMENTS......................................................................................................14

9. TECHNICAL REQUIREMENTS (MAINS).............................................................. 15

9.1 DESIGN BASIS....................................................................................................................159.2 BW BASIC DESIGN CRITERIA...........................................................................................159.3 ADDITIONAL DESIGN CONSIDERATIONS........................................................................159.4 ALIGNMENT CONSIDERATIONS.......................................................................................169.4.1 VALVES...............................................................................................................................16 9.4.2 LOCATION OF VALVES......................................................................................................169.5 LOCATION OF HYDRANTS................... ........................................................... .................. 179.6 AIR VALVES........................................................................................................................179.7 SCOUR VALVES........................................................ ......................................................... 179.8 FLUSHING POINTS ................................................... ......................................................... 179.9 PRESSURE REDUCING VALVES ........................................................... ........................... 179.10 SERVICES...........................................................................................................................189.11 CONNECTIONS OF WATER RETUCULATION...................................... ............................ 18

10. DRAWINGS............................................................................................................ 18

11. CONSTRUCTED INFORMATION ......................................................................... 18

12. PRODUCTS AND MATERIALS ............................................................................. 19

13. CONSTRUCTION REQUIREMENTS .................................................................... 19


3/43


16. PIPE LAYING AND JOINTING .............................................................................. 2316.1 PREPARATION PRIOR TO INSTALLATION.......................................................................23

17. JOINTING............................................................................................................... 23

17.1 PVC TO PVC PIPES AND FITTINGS..................................................................................2317.2 PVC TO DI PIPES AND FITTINGS......................................................................................2317.3 DI TO DI PIPES AND FITTINGS .................................................... ..................................... 2317.4 JOINTING OF STEEL PIPES AND FITTINGS.....................................................................2417.5 PE TO PE PIPES AND FITTINGS.................................................. ..................................... 24

17.6 PROTECTION OF STEEL PIPES FROM CORROSION..................................................... 2418. LAYING OF PIPES AND INSTALLATION OF FITTINGS...................................... 25

18.1 DI PIPELINE SYSTEM ......................................................... ............................................... 2518.2 PVC PIPELINE SYSTEM.....................................................................................................2518.3 PE PIPELINE SYSTEM ........................................................ ............................................... 2518.4 MAJOR ROAD CROSSINGS...............................................................................................2518.5 BRIDGE, TUNNEL AND RIVER CROSSINGS............................................................ ........2618.6 BENDS AND PIPE DEFLECTIONS.....................................................................................2618.7 INSTALLATION OF FITTINGS AND VALVES.....................................................................26

18.8 HYDRANT RAISERS.................................................. ......................................................... 2618.9 FLUSHING POINTS ................................................... ......................................................... 2618.10 VALVES...............................................................................................................................27 18.10.1 COVERS, FRAMES AND SURROUNDS .......................................................... .................. 2718.11 TEMPORARY BLANK ENDS...............................................................................................2718.12 CONNECTION TO EXISTING WATER MAINS........................................................... ........27

19. THRUST SUPPORTS AND ANCHORS ................................................................ 28

19.1 STEEL PIPE ANCHORAGE ........................................................... ..................................... 28

20. BACKFILL .............................................................................................................. 2920.1 BACKFILL AROUND VALVES, HYDRANTS, FLUSHING POINTS AND SERVICECONNECTIONS ........................................................ ........................................................... .................. 2920.2 RESTORATION OF ROAD RESERVES AND ACCESS WAYS.................................. ........29

21. TESTING OF MAINS AND SERVICE CONNECTIONS........................................ 30

21.1 PREPARATION .......................................................... ......................................................... 3021.2 FILLING MAINS FOR TESTING..........................................................................................3021.3 TEST EQUIPMENT .................................................... ......................................................... 31

21.4 OFFICIAL PRESSURE TEST..............................................................................................3121.5 TEST PROCEDURES .......................................................... ............................................... 3121.5.1 STEEL, PVC, DI AND COPPER PIPELINE SYSTEMS INCLUDING PE IN CUL-DE-SAC .3121.5.2 PE PIPELINE SYSTEMS.....................................................................................................3121.5.3 WATER SERVICE CONNECTIONS....................................................................................3121.6 TEST COMPLIANCE CRITERIA .................................................... ..................................... 3121.7 RE-TESTING.................................................... ........................................................... ........3221.8 POST-TEST REQUIREMENTS...........................................................................................32


4/43


SECTION 425. CONTRACTOR REQUIREMENTS........................................................................ 41

26. JOB SAFETY ANALYSIS....................................................................................... 42

TABLE 1. MEASURES OF LIKELIHOOD OR EXPOSURE TO HAZARD.............................. 42

TABLE 2. MEASURES OF CONSEQUENCE OR IMPACT.................................................... 42

TABLE 3. RISK ANALYSIS MATRIX RISK LEVEL.............................................................. 42


5/43


1. Introduction

Busselton Water (BW) Pipeline Construction and design standard provides staff,contractors and consultants with guidelines and technical standards for the designand installation of water supplies within Busselton Waters License area. Thestandard has been produced to complement existing standards implemented byWSAA Water Supply Code WSA03-2002 and the Water Corporation of WA for thedesign and construction of water reticulation assets. In the event of conflict betweenthe WSAA Code, the BW Standard shall take precedence.

2. Reference Material

WSAA Water Supply Code of Australia (Water Services Association ofAustralia) WSA03-2002Water corporation Design standard DS 63 and DS 60Polyethylene Pipeline Code WSA 01 1998 (Water Services Association ofAustralia)Utility Providers Code of Practice for Western AustraliaSteel Pipeline System Design Manual (Tyco Water)Steel Pipeline System Handling and Installation Reference Manual (Tyco

Water)Pipe Fittings Standard Drawings (Water Corporation and WSAA)

3. Glossary of Terms

Within the standard the following highlighted in bold expressions shall have thefollowing meaning.

As Constructed Information and measurements provided to locate worksrelative to existing assets and other supplied survey information.WSAA Code The Water Supply Code of Australia WSA03-2002, aspublished by the Water Services Association of Australia.BW Busselton Water.


6/43


4. Standard Abbreviations

AC asbestos cement L litre

AHD Australian Height Datum mg milligram

AS Australian Standard m metre

B/END blank end GRP glass reinforced plasticBL building (property) line mm millimetre

BV butterfly valve MSCL mild steel cement mortar lined

BW Busselton Water NI not installed

CI cast iron OD outside (external) diameter in mm.

CU copper ID Internal Diameter in mm.

DAV dual orifice double air valve PAW pedestrian access wayDI cement lined ductile iron PE polyethylene pipe

DN nominal diameter in mm. PN pressure nominal

E&Cexpanded & collapsed (slip-in)-steel pipejoint

POS Public Open Space

EXIST existing PVC polyvinyl chloride

FP flushing point RC reinforced concreteFW fullway gate valve ROW Right of Way

HYD hydrant RRJ rubber ring joint

kg Kilogram S Steel

kL kilolitre SC scour

kPa Kilopascal SV sluice valve


7/43


5. Preliminaries to Construction

Section 41 of the Water Boards Act 1904 refers to Preliminaries to construction forother than exempt works, requiring BW to undertake the following:

Carry out all necessary surveys and levels of lands to be made and taken.Prepare plans of the proposed works, and cause certified copies of the plansto be available at the front counter of BW.Undertake advertising to publish the proposed works in the GovernmentGazette and in one or more locally circulating newspapers. Theadvertisement is to specify the:

Description of the works.Locality at which the works will be constructed.Purpose for which the works are to be constructed.Times and places at which the plans may be inspected.

For the purposes of this document activities to be undertaken prior to constructionactivities will be called Prelims (Preliminaries to Construction).

6. Major works

Where major works are undertaken BW shall carry out prelims as set out in section41 of the water Boards Act 1904:

Major works are to be submitted to the following Government departments andutilities as required:

Department of Environment and Conservation (DEC):Within BWs Licence area DEC is the referral body for state issues relating to flora

SECTION 1


8/43


Department of Indigenous Affairs (DIA):DIA is the centre of expertise for heritage issues and maintains a register ofaboriginal sites within BWs license area. Where construction is undertaken inproximity to a wetland and or Aboriginal site BW will initiate a section 18 under theAboriginal heritage Act 1972 prior to the commencement of works.

Department of Environment and Water Resources (DEW):Within BWs Licence area DEW is the referral body for Federal issues relating to floraand fauna and wetlands. Referrals to DEW are to be made when carrying out workson nationally protected wetlands. When requested, BW is to undertake all thenecessary surveys. EPBC referral/process shown as per attachment 1 and 2 (pages9 and 10)

Department of Water (DOW):The DOW is the licensing body for bores around the state. BW shall submitapplication for new bore to proposals to the department. DOW is also the agency thatissues a water providers licence.

Main Roads WA (MRWA):The MRWA is the controlling body for all major roads within the state. Advice relatingto works and issues relating to traffic management on major roads shall be submittedto MRWA for comment.

ORGANISATION ADDRESS PHONE

Department of Environmentand Conservation 14 Queen Street, BUSSELTON WA 6280 9752 5555

Shire of Busselton Locked Bag 1, BUSSELTON WA 6280 9781 0444

Western Power GPO Box L921, PERTH WA 6842 1300 769345

Alinta 12 -14 The Esplanade PERTH WA 6000 131352

Bunbury Tower


9/43


Main Roads WA PO Box 5010 BUNBURY 6231 138138

Customer AdviceOnce clearances are obtained for the works proposed from the neceassraygovernment departments all affected and or adjoining landowners are to be advisedof the works via a letter drop prior to construction. Domestic users shall be given aminimum of 24 hours notice and commercial and industrial users a minimum of 7

days notice (rear attachment 3 page 11).


10/43


ATTACHMENT 1


11/43


ATTACHMENT 2


12/43


7. Minor works (Exempt works)

Section 45A of the Water Act 1904 describes Minor works and or exempt works asactivities undertaken for reticulation works:

That are in or over private land where the works are requested by the owner.Roads and reserves being works that are required to link other exempt and orexisting works.

Exempt works are not subject to provisions as set out for Major Works, howeverutility information is to be requested for these works via Dial before your dig.

Prior to the construction of exempt works all affected and or adjoining landowners areto be advised of the works via a letter drop. Unless works are carried out in anemergency domestic users shall be given a minimum of 24 hours notice andcommercial and industrial users a minimum of 7 days notice (rear attachment 3

page 11).


13/43


ATTACHMENT 3

IMPORTANT NOTICE REGARDING YOUR WATER SERVICE

Dear Customer,

Please be advised that Busselton Water will be undertaking mains maintenance on . Water will be turned off from approximately to at the following locations:

With such events, Busselton Water regrets the inconvenience and we seek yourtolerance in this matter.

You may find that this interruption to the water will cause either discolouration or aslight smell of chlorine. Chlorine is used as a mild disinfectant following maintenanceworks on the water reticulation system. To overcome the problems, simply run yourtap for a few minutes before you use the water.

For further information please contact Joanne Kooloos on 97810508.

Yours faithfully,

Keith White

CHIEF EXECUTIVE OFFICER


14/43


8. Design Guidelines

This Part of the Standard sets out Drafting and design requirements of BusseltonWater (BW). It shall be read in conjunction with Part 1 of the WSAA Code. In theevent of conflict between the WSAA Code and this standard, the Standard shall takeprecedence.

8.1 Redevelopment of Existing Areas

The condition and adequacy of existing water supply mains in redevelopmentproposal shall be assessed in consultation with BW.

8.2 Water Reticulation Planning for Subdivisions

BW will determine the reticulation layout plan including reticulation main sizes andclass, location of distribution main valves and hydrants, and capacities of otherelements of the system to ensure the supply to and within the subdivision isintegrated with the overall water supply scheme.

Where required BW will request its hydraulic consultant to undertake the design ofreticulation and trunk mains. Prior to the request for hydraulic design BW will requesta quote from the consultant and submit this to the developer. Works will notcommence until payment is received.

8.3 Land Requirements

Fee simple ownership is BWs preferred land tenure for all it facilities. Where facilities

are identified for a particular development land identified for those facilities is to beceded to BW free of cost. In built up areas BW will negotiate with individual owners.

SECTION 2


15/43


9. Technical Requirements (mains)

9.1 Design Basis

The design methodology provided in the WSAA Code is acceptable to BW, howeverdesign criteria in this Standard shall take precedence over the criteria in the WSAACode.

BW requires the developer to pay a design fee for the hydraulic design, thedevelopment is then assessed to ensure the pipe network and pipe size meetsminimum water licence requirements for the all stages of the development.

9.2 BW Basic Design Criteria

Under BWs existing customer charter BW must supply a minimum static head of

15m and a maximum static head of 100m to every serviced lot within its licence area.BW require all developments to be reviewed hydraulically in context with the watersupply system as a whole, the BW consultant will review developments as follows:

Elevations used to meet minimum pressure requirements for an urbanproperty is the ground level found within the front 30 m of the property, thehighest contour is to be used to calculate the minimum head. Maximum headis to be calculated using the lowest contour. For larger lots where building

envelopes are clearly defined, the elevation used for maximum and minimumhead calculations may be restricted to the area of the building envelope.Water reticulation mains shall be sized by BWs hydraulic consultant. Ingeneral the consultant will size mains such that flow velocities are kept below2 m/sec. Distribution, trunk and supply mains are to assessed on an individualbasis however flow velocities generally will not exceed 4m/sec with headlosses of between 2 to 3 meters per kilometre considered acceptable.

9.3 Additional Design Considerations

BWs consultant will design BWs water supply with the following guidelines:

Reticulation mains shall be mains smaller than DN 250.In urban, special rural and or High density development, BW requires aminimum pipe size of DN 100 63 MDPE may be considered in cul de sacs


16/43


9.4 Alignment considerations

Mains are to be located within road reserves on an alignment of 2.1mmeasured from the property boundary in accordance with the Utility ProvidersCode of Practice Western Australia.where road reserves are not available, easements are to be negotiated andprovided within Developments on Crown land and or Public Open Space.Easements shall have a minimum width of 3m and shall where required aspart of the subdivision process and shall be transferred to BW free of cost.Where road reserve vegetation requires clearing BW may request aneasement over adjoining private property (eg farmland paddocks). Thedeveloper shall consult with the owner for the provision of an easement.Where possible the number of long services are to be minimised thus roadreserves greater than 30m wide shall have mains located on both sides of theroad.If a road crossing is unavoidable, each main should cross the road

perpendicular to the road reserve boundary at 2.1m off the lot boundary andin line with property truncation point.Where a main is to cross a river via a bridge or other structures such astunnels and or culverts. BW is to be presented with drawings of the proposaland a methodology outlining construction and maintenance issues.For river crossings where security of supply is considered an issue maincrossings shall be above ground.

9.4.1 Valves

Sluice Vavles shall be RSTC Clock Close Fig 500.Within a reticulation network,valves are required to isolate the mains for operational and maintenance purposes.Set out below are guidelines for the installation of valves such they create a minimalaffect on residents within an area. The network is to be designed to enable thesupply of water through alternative mains if the primary main is isolated, withoutaffecting a large number of lots. A primary reticulation main supplies water to a

number of secondary reticulation mains. The primary reticulation main is normally a200mm or 250mm diameter main and supplys 150mm and 100mm (secondaryreticulation) mains.

9.4.2 Location of valves


17/43


9.5 Location of Hydrants

Hydrants shall be WA pattern 100mm screw-down type with intergral `yoke SPS 292with built-in isolation valve and installed only on DN100 or larger pipes. Hydrants

shall be located:

So that the maximum distance between a hydrant and the rear of a buildingenvelope, (or in the absence of a building envelope the rear of the lot) shallbe 120m and the hydrants shall be no more than 200m apart.A maximum of 100m spacing in Industrial and Commercial areas.Where appropriate at the truncation of road junctions or intersections so thatthey can serve more than one street and can be readily located.In proximity to a boundary to allow it to readily located.Hydrants shall be located centrally only when driveways create a problem

9.6 Air Valves

Generally Air valves are not required throughout a reticulation system. However Airvalves may be required on supply mains and or trunk mains number, where requiredAir valves are to as follows:

Air valves, where used in reticulation systems, shall be of DN 50 dual orificeinstalled with a flanged or threaded isolating valve

9.7 Scour Valves

Scour valves are generally located along reticulation mains located in undulatingterrain, or where installation of flushing points are not practical.

Where required, scouring assembly shall include a DN 100 flanged sluicevalve and installed to the BWs requirements.

9.8 Flushing Points

All temporary blank ends and dead ends of mains shall be provided with flushing


18/43


Pit type installation is not preferred and will only be approved in specialcircumstances.

9.10 Services

No services shall be connected directly to a distribution / Trunk main in adevelopment area.The number of long services shall be minimised wherever practicable.

All new development shall have prelaid water services installed to isolationTap.All services shall be 25mm MDPE single services. Long services shall be2x25mm MDPE single services in a conduit.Loackable service locators to be used on all services.

9.11 Connections of Water Reticulation to Distribution / Trunk Mains

The location and size of a water reticulation mains connected to distribution /trunk mains shall be determined by BW.For industrial subdivisions, the smallest connection shall be minimum DN200.If more than 250 services are to be supplied from the connection, then theconnection shall not be smaller than DN 300.

10. Drawings

Drawings shall show sufficient detail to clearly indicate the design of the reticulationat a scale of either 1:1000 or 1:2000, drawings are to include the following:

A legend indicating the symbols and abbreviations.A north Arrow.

Water reticulation Boundaries.Street names, Cadastral boundaries, lot numbers and the total number of lotsserved (Detailing short and long services).land use, e.g. duplex, POS, school, multi- residential etc.Land required by the BW, Easements etc.Spot levels or contours.


19/43


Text indicating the drawing is an As Constructed is to be paced on thedrawing along with the surveyors name and date the As Constructed wasundertaken.The final design plan is to indicate, length of mains, type and class, the finallot layout and location of prelaid services, valves and hydrants etc.A digital copy of the plan is to be supplied in either DGN (Preferred) or DWG /DXF format. The as constructed in to be spatially correct using MGA94

coordinate system and all levels are to be based on AHD.Non standard alignments are to be indicated on the plan in brackets eg (1.8)

12. Products and Materials

All water reticulation products shall be new and shall have mechanical, corrosionresistant and operational characteristics that render it fit-for purpose in live service.

The product shall be packaged such that when it is installed in accordance with themanufacturers installation guidelines, it will operate in pressurised water networkwithin the specified operating parameters for at least 50 years prior to any majorrehabilitation and or replacement.

All elements of water reticulation product in contact with drinking water shall complywith the requirements of AS/NZS4020. All water reticulation systems shall be handedover to BW in a hygienic and disinfected condition.

Water reticulation products shall comply with the requirements of the relevantAustralian Standard.

13. Construction Requirements

Water reticulation shall be constructed to the requirements of BW and to the WSAA

Code as required. Construction activities that may impact directly or indirectly onexisting BW infrastructure are not permissible unless agreed in writing by BW.

13.1 Contractor Accreditation Requirements

Water reticulation construction personnel shall be accredited in accordance with the


20/43


Australasia Limited (IMEA) Certification Program forPlastics Fusion Welding.Contact: Licensing Officer, Telephone (03) 9326 7266,facsimile (03) 9326 7272, e-mail [email protected] least one person in each pipe laying crew shall be accredited except that,for PE pipeline welding work, all welders shall be accredited.

14. Prevention of Contamination

During the construction of water reticulation, all materials, components andinstallation shall be configured so as to prevent any contamination of system water. Ahigh standard of hygiene shall be maintained with respect to the personnel engagedand all materials, tools and equipment used in the construction of the work. Inparticular materials, tools or equipment used previously on live sewerage work shallnot be permissible on water reticulation work. Staff and contractors are to follow BWdisinfection processes and procedures as set out in the asset manual (file No WP41).


21/43


SECTION 3

15. Construction

15.1 Survey and Setting Out

Water reticulation shall be set out in accordance with the design drawings. Anydeviation from the accepted drawings shall be subject to the approval of BW. Oncefinal finished levels are achieved on lot boundaries after the completion of roadreserve clearing and road earthworks:

Sufficient cadastral survey pegs and temporary pegs along curved lotboundaries shall be installed to enable the proper construction of thewater reticulation. All pegs shall be uniquely marked so as to be clearly

identifiable in relation to individual lots.Cadastral survey pegs installed for the water reticulation work shallremain uncovered and undisturbed and shall be available for the JointFinal Inspection. Any disturbed cadastral survey pegs shall be re-established by a Licensed Surveyor.

15.2 Handling of Pipes and Fittings

All pipes and fittings shall be handled and installed in a manner that will preventphysical or structural damage to pipes, coatings, linings and elastomeric seals.Pipeline components including coatings and linings that are damaged, includingscored pipe surfaces, and cement lining cracks larger than 0.1mm shall be rejected.Pipes and fittings that have coatings or linings of polymeric or plastic materials shallnot be exposed to the external environment for more than 12 months. Prior to use allpipes are to be checked to ensure they are not out of date. Out of date materials willbe rejected by BW.

15.3 Pipe Alignment and Depth

15.3.1 Alignment

Installation of Pipe shall not commence until the cadastral survey pegs required todetermine the pipe alignment are in position The following requirements shall apply


22/43


15.3.2 Depth (Minimum Cover)

Generally pipes shall be laid as straight as practicable and in compliance withmanufacturers recommendations while maintaining the appropriate minimumcover of 700mm. Where a change in grade occurs the mains shall be laid toavoid exceeding the maximum allowable deflection allowed under themanufacturers recommendations.A minimum clearance of 100mm all around shall be maintained where themain is to be installed in close proximity to existing and or proposed services.The depth to the top of the pipe from the final verge level and the gutter levelshall be established at intervals not exceeding 50 metres and recorded on theAs Constructed Drawings.Concrete encasement or protective cover slabs are not permissible asalternatives to maintaining minimum pipe cover.

15.4 Excavation and Bedding

Prior to excavation works all utility facilities are to be located and potholed and anyservice clashes reported to BW before installation of the mains.

15.4.1 Excavation

Where open trench excavation is proposed, pipe trenches shall be excavated toalignments, depths and widths required by the design drawings. The followingrequirements shall also apply:

Where necessary trenches shall be dewatered until each section of main hasbeen completed and tested.Groundwater shall not be allowed to enter pipes.Over excavation of the trench shall be backfilled and compacted with suitablebedding material.

Where open trench excavation is not practicable, such as across major roads,

freeways and railways, under major obstructions, and wherever shown on theDrawings, the pipeline shall be installed by trenchless technology. The methods shallbe to the requirements of the controlling authority (eg MRWA) and acceptable to theBW.

15.4.2 Bedding


23/43


16. Pipe Laying and Jointing

16.1 Preparation Prior to installation

Pipes shall be examined for cracks, scoring, gouges or any other defects.Where defective pipes are identified they will be rejected by BW.Sand and other foreign materials shall be removed from the pipe bore.And jointing pipe spigots, socket surfaces and elastomeric rings are to be

cleaned.

17. Jointing

17.1 PVC to PVC Pipes and Fittings

Joints between PVC pipes and fittings shall be made with elastomeric seals in

accordance with the manufacturer's instructions:

Pipes are to be installed in a straight line prior to making the joint.Only jointing lubricant specified by the pipe manufacturer is to be usedSocket joints are to be adequately restrained to prevent movement during thejointing processSpigot Joints are to be pushed home in a manner recommended by the pipemanufacturer until the witness mark is just visible.Pipes damaged during the jointing process are to be removed and replaced.Where PVC pipe is cut on site, the cut end shall be chamfered and witnessmarked in accordance with the manufacturers instructions.

17.2 PVC to DI Pipes and Fittings

PVC socket ends shall be jointed with matching PVC spigot ends only inorder to achieve a watertight joint.No metallic pipe or pipe fitting spigots shall be jointed to PVC socket ends.

Where a PVC pipe is cut on site, the cut end shall be chamfered and witnessmarked in accordance with the manufacturers instructions without damagingthe pipe.

17.3 DI to DI Pipes and Fittings


24/43


17.4 Jointing of Steel Pipes and Fittings

Elastomeric seal jointed steel pipes shall be installed in compliance with themanufacturers instructions. Fittings shall be welded as for weld-jointed steel pipes.Where steel pipes are weld-jointed, installation shall be in accordance with the SteelPipeline System Handling and Installation Manual and the following requirements:

All pipe welding shall be in accordance with AS 4041 Pipe work Class 2P,Corporation Welding Specification WS-1 and the Drawings;Pipe flanges for valve connections shall be welded to pipes in accordancewith the Drawing AY58-15-1 of the Pipe Fittings Standard Drawings;Welding procedures and qualification of each welder and welding operatorshall be in accordance with AS4041 and the requirements of CorporationWelding Specification WS-1;Where the cement mortar lining of a pipe or fitting cannot be readily reinstatedat the welded joint, a convex band shall be welded over the joint. When theband has cooled, it shall be fully injected with cement grout through a hole in

the bottom or side which is then sealed with a welded cap once the grout hasset;All cut ends and welded areas shall be protected as required by sub-clauseProtection of Steel Pipes from Corrosion under 5.4.5.Welded joints may be subject to visual examination by BW for acceptance ofwelding work.

17.5 PE to PE Pipes and Fittings

PE pipes and pipe fittings and their jointing shall comply with therequirements of, and including limitations in Table 3.1 of Part 3 of the WASSStandard.Where butt fusion weld jointing is expressly permitted, the pipes shall beprepared for welding in accordance with pipe manufacturersrecommendation.

17.6 Protection of Steel Pipes from Corrosion

Damaged pipe coating shall be primed, filled with butyl mastic and wrappedwith a 2mm thick reinforced bitumen mastic with PVC backing (Densopol 80,Rockrap 4000 Tape System or approved equivalent), in accordance with themanufacturers application specification.

BUSSELTON WATER


25/43


18. Laying of Pipes and Installation of Fittings

Pipes shall be laid to the following general requirements. At the end of each day'swork or at any time when pipe laying is suspended, every open end of eachincomplete pipeline shall be plugged with a tapered stopper or an acceptable endcap matching the pipe. No tools or any construction materials shall remain in thepipes.

18.1 DI pipeline system

Purpose made polyethylene sleeving shall be installed in accordance with thepipe manufacturers recommendations.Any rupture in the sleeving due to damage shall be overwrapped andsecurely taped.

18.2 PVC pipeline system

PVC pipelines shall be laid in accordance with manufacturers instructionsand in accordance with the practices recommended in the PVC pipe layingaccreditation course.

18.3 PE pipeline system

PE pipelines shall be laid in accordance with manufacturers instructions andpractices recommended in the PE butt welding accreditation course.Allowance shall be made for the likely pipe movement due to temperaturechanges during installation and commissioning. A final service temperature of205C may be assumed unless otherwise specified in the Drawings. Pipelengths and bend locations shall be adjusted for changes in length that willoccur when the temperature stabilises at the final service temperature.The trenches shall not be backfilled unless the ambient temperature is within5C of the final service temperature.PE pipes within the trench may snake if the final snaked alignment at the

final stabilised service temperature is within 100mm of the correct alignment.

18.4 Major road crossings

The pipes shall be laid continuous under road pavement and extend 1.5 metresbeyond the road shoulder The pipeline under the road pavement shall not

BUSSELTON WATER


26/43


18.5 Bridge, tunnel and river crossings

Each crossing proposal shall detail the construction methodology togetherwith the approval of relevant authorities and shall be submitted to BW forconsideration and acceptance.

18.6 Bends and pipe Deflections

A pipeline required to follow a long curve may be laid and jointed withdeflections at the joints. The maximum angular deflection at a pipe joint shallnot exceed the pipe manufacturers recommendations. Bending of pipes toachieve a curve or for any other purpose is prohibited, except for PE and CUpipes.PE pipes may be laid in a curve of radius that is not less than themanufacturers recommendations.An acceptable pipe-bending tool shall be used to bend CU pipe. Crimped ordistorted pipes shall be rejected.

Where the required angle change exceeds the permissible joint deflection,standard bend fittings shall be used.Bends shall be installed opposite cadastral survey pegs unless otherwiseshown on the Drawings and or accepted by BW.Where a bend is required on a truncation at which a valve is also required,the bend and the valve shall be separated by an 800mm minimum length ofstraight pipe.

18.7 Installation of Fittings and Valves

The mating flanges of all flanged joints where dissimilar metal contact mayoccur shall be electrically isolated by means of acceptable flange insulationkits.The inside of all valves, hydrants and fittings and the mating surfaces of thespigot ends, collars, flanges and rubber rings shall be cleaned immediatelyprior to installation and before jointing.

Pipes shall be cut to ensure installation of fittings in the correct location. Theminimum pipe length between adjacent elastomeric seal jointed fittings shallbe 1000mm without anchorage and 800mm with anchorage.

18.8 Hydrant Risers

BUSSELTON WATER


27/43


18.10 Valves

All valves and fittings that are non-compliant or defective shall be rejected.

18.10.1Covers, Frames and Surrounds

Covers, frames and service chamber assemblies for sluice valves, gatevalves, stop valves, hydrants and flushing points shall be installed so that thecover level is flush with the final surface level and to the requirements shown

on the Drawings.Vave Box to have BWB moulded in top painted Bermuda Blue. BusseltonWater own pattern and request valve boxes to be purchases from BusseltonWater.

18.11 Temporary Blank Ends

Temporary blank end caps shall be installed on new pipelines to be

connected to existing water mains. The end caps shall be installedapproximately 4m from the existing water main and shall be clear of anypavement.Temporary blank ends shall be adequately anchored to withstand testpressure.

18.12 Connection to Existing Water Mains

Work on or connection of new pipelines to existing water mains is not permissibleunless:

Written acceptance has been obtained from WB.All required pressure testing of the new water reticulation has beensuccessfully conducted and accepted.The new water reticulation has been disinfected in accordance with section22 of the standard.

New mains shall be laid at the specified depths and alignments afterascertaining by manual excavation methods the positions of other existingservices in the vicinity.Interference with, or operation of any existing main or valve or fitting is notpermitted unless approved by BW.

BUSSELTON WATER


28/43


19. Thrust Supports and Anchors

Thrust supports for permanent installation shall be of concrete. For temporaryinstallation, repairs and where concreting work is impracticable, jarrah timber may beused. Thrust supports for multiple or compound bend arrangements shall be ofconcrete only.

Flange bolts shall be installed with the washers and nuts furthest from any concretethrust support. Bolt heads must not be encased by the concrete. Corrosion protectionof the flange bolts shall be carried out prior to construction of concrete thrustsupports.

Thrust supports shall not extend more BW. Thrust supports shall be installed and thetrench backfilled and compacted prior to commencement of pressure testing.

19.1 Steel Pipe Anchorage

Buried Steel Pipeline

Where buried steel pipes are used, thrust supports may be replaced by weldedpipeline sections installed on both sides of the fittings as indicated in Table 1.

Min Length of Weld (m) each side of pipeSize DN(mm)

45 Degree Bend 60 Degree Bend 90 Degree Bend

100 6 10 30

150 6 10 30

200 6 15 40

250 6 15 40

Table 1

At service tapping points and around service risers to the agreed final ground level

BUSSELTON WATER


29/43


20. Backfill

Initial backfill shall be selected fill material placed and compacted to providecontinuous support to the pipe as shown in the standard drawings.

Initial backfill at the sides and up to 150mm above the pipe shall be well compactedso that no joints or pipes are disturbed or damaged. All joints shall be left exposed

until the preliminary pressure tests have been successfully completed.

Final backfill of pipe trenches shall be carried out to the requirements of theDrawings.

Where the excavated soil is not suitable for final backfill, imported granular materialcomplying with the requirements shall be imported for backfill.

Except where thrust support by backfill is required for pressure testing, final backfillshall not be carried out until:

the As Constructed measurements have been taken for pipes and fittings inpipe trenches;The Official Pressure Test is accepted, and height and position have beencomplied with for service risers.

Where backfill is required to provide thrust support, for pressure testing, it shall becarried out only after the As Constructed measurements have been taken.Any backfilling carried out prior to complying with the above requirements will berejected and the reticulation may be required to undergo a further pressure test.Compacted final backfill shall be finished as follows:

In a road verge - levelled to the final verge level.Within a pavement area - to the levels meeting the road authoritysrequirements for the pavement construction.

At service tapping points and around service risers to the agreed final ground level.Sections of water reticulation damaged and repaired during backfilling will requireanother official pressure test after reinstatement

20 1 B kfill d V l H d t Fl hi P i t d S i

BUSSELTON WATER


30/43


21. Testing of Mains and Service Connections

Each pipeline and service connection shall be subjected to a successfulpreliminary pressure test before carrying out the Official Pressure Test. OfficialPressure Tests shall be witnessed by the Construction Engineer. Details of eachOfficial Pressure Test shall be recorded on a Pressure Test Record Sheetincluded in this part of the Standard. Each record sheet shall be kept and a copy

submitted to BW for its records.

Water service connections may be pressure tested separately to, or incombination with reticulation mains. The tapings and all riser joints and fittingsshall remain exposed to allow viewing during the pressure test.

The use of sealant or similar products to plug any detected leakage is notpermitted.

21.1 Preparation

Mains shall not be tested until at least 24 hours after concrete thrust supportshave been constructed. The following requirements shall be met prior to testing:

The difference in elevation between any two points on the section of the mainunder test shall be not greater than 30 metres;At least 300mm of suitable fill material shall be placed over the initial backfillfor the section of pipeline to be tested, leaving all meter risers, stop tap, waterservice tapings and hydrant tee flanges exposed to view;The pressure test gauge shall be located as close as practicable to the lowestpoint of the test section.All water service tapping points and riser joints included for the pressure testshall be exposed for inspection. All property service stop taps shall be in theopen position and have their outlets plugged at the time of testing;Where a valve is shut to form one end of a test section, suitable temporary

supports shall be installed to prevent the valve moving due to unbalancedhydraulic thrust.No pressure testing against valves on live mains shall be conducted prior toapproval from BW.

21 2 Filling Mains for Testing

BUSSELTON WATER


31/43

Pipeline Construction and Design StandardJuly 2007

shall be removed upon completion of the test and the tapping point sealed with asuitable plug.

21.3 Test Equipment

Main or isolated sections of the main shall be pressure tested by means of apump capable of raising and maintaining the hydraulic pressure for the durationof the test.

A calibrated pressure gauge of minimum diameter 100mm and maximum 50kPapressure graduation intervals shall be connected to the pipeline to be tested.

21.4 Official Pressure Test

Each test section shall be subjected to a hydraulic pressure test of 1.25 times thedesign pressure (H) for the section under test (1.25H), or 1200 kPa (120m headof water) whichever is the higher, as measured at the lowest point of the test

section, unless otherwise requested by BW.

21.5 Test Procedures

For all water reticulation systems the test shall be carried out with the testpressure maintained for as long as necessary to inspect all joints and fittingswithin the test section. The duration of the test shall not be less than one hour.

21.5.1 Steel, PVC, DI and Copper Pipeline Systems including PE in Cul-de-Sac

The test shall be carried out as outlined in the Code generally except that nowater loss or pressure drop during the test shall be acceptable.

21.5.2 PE Pipeline Systems

The test shall be carried out as outlined in Section 2.13 of WSA 01 as in the

Extract attached at the end of this Part, except for the test pressure and testduration requirements herein.

21.5.3 Water Service Connections

Each water service shall be flushed for its full length with water from the main to

BUSSELTON WATER


32/43


There is no visible leak or evidence of leakage from all water service tappingpoint or riser joint during testing.

21.7 Re-Testing

If a test section fails the pressure test, the cause of failure shall be determinedand rectified. The section shall be re-tested until an acceptable test result isachieved.

21.8 Post-Test Requirements

After satisfactory completion of the pressure test, the test section shall be leftcharged. All sluice valves and section gate valves shall be left fully opened andall hydrants, flushing points and tapping at temporary dead ends shall remainclosed.

After successful pressure test and before backfilling of a pipe trench, the stop tap

in the service connection shall be turned off. The stop tap shall then be fitted witha fabricated stand-up service protector in accordance with BW New DrawingRequired BW-?-? and the stop tap outlet fitted with a security plug in accordancewith drawing New Drawing Required BW-?-?

BUSSELTON WATER


33/43


22. Disinfection of Water Reticulation

The water reticulation shall be disinfected as part of the filling and pressure testingprocesses, unless otherwise accepted. Water reticulation disinfection work shall notproceed until a Disinfection Plan has been submitted to and accepted by BW. EachDisinfection Plan shall provide the following details:

Disinfectant and dilution water quantities proposed for each disinfection batchor operation.The progressive stages of disinfection operations as defined by the valvingsequence proposed.The disinfection dilution and injection equipment proposed;The timing of each disinfection operation.The methodology proposed for flushing of disinfectant waste and the disposalarrangements acceptable to the local and environmental authorities.

At any stage during the filling and testing of mains, BW may request that allmains to be tested be flushed until the water is clear of all foreign material.During filling, disinfectant shall be added to the main in accordance with therequirements in of section 22.1, ensuring that the disinfectant is thoroughlymixed with the filling water and evenly distributed.Where practicable, the common reticulation valves shall be operatedprogressively after two or more adjoining sections have been successfullypressure tested. The disinfectant shall be progressively introduced until thereticulation has been fully disinfected.The diluted disinfectant shall be retained in the water reticulation for as longas practicable which shall not be less than 24 hours. The main shall then bedrained and flushed with potable water. All waste and flushed disinfectantshall be disposed of in an environmentally acceptable manner in accordancewith the requirements of the local and the environmental authorities.

22.1 Disinfectant

Disinfectant shall be calcium hypochlorite powder rated to yield 65% availablechlorine, or sodium hypochlorite liquid rated to yield 12% available chlorine.The disinfectant shall be diluted with water for injection into the waterreticulation to be disinfected so that the effective strength of the dilutedproduct provides a dosing rate of 20mg/L measured as free chlorine.

BUSSELTON WATERPi li C i d D i S d d


34/43


Table

NOTE: For a dose rate of 20mg/L: 10kg of calcium hydrochloride will treat 325 KL ofwater/ 20 L of sodium hydrochloride liquid will treat 120 KL of water

NominalVolume in Pipe

CalciumHypchlorite

Powder (65% C12)

SodiumHypochlorite

Liquid (12% C12)Nominal Pipe

Diameter(mm)

kL of Waterper 1000m of

Pipe

kg used for1000m of Pipe

Litres used for1000m of Pipe

50 2 0.06 0.4

100 7 0.20 1.2

150 17 0.50 2.8

200 33 1.00 5.5

250 49 1.51 8.2

300 68 2.10 11.3

BUSSELTON WATERPi li C t ti d D i St d d


35/43


23. Prelaid Water Service Connections

Prelaid water service connections in new subdivisions shall be installed inaccordance with the Drawings.

23.1 Alignment and Depth

Water services shall be installed where shown on the Drawings in accordance withthe typical arrangements shown on the Drawings contained in Part 4 of the Standard.Where it may prove impracticable to comply with the requirements due to concealedobstructions, alteration will require BW approval.A minimum of 100mm clearance all round shall be provided for all water servicepipes relative to other services.

23.2 Road Crossings

Road crossings for service connections shall be installed prior to the construction of.Immediately after installation the ends of the service pipes shall be temporarilyenclosed with a plastic bag securely fastened with adhesive tape.

23.3 Tapping Reticulation Mains

Service tapping locations on water reticulation mains shall be located within 100mmof the standard service alignment unless constrained by the following:

A minimum of 300mm from a pipe or pipe fitting socket.A minimum of 300mm from an adjoining tapping.When tapping PVC and PE mains, the swarf and coupon shall not bepermitted to fall into the main.The tapping band shall be installed so that the off-take is centrally positionedover the tapping hole in the main and in accordance with the Drawings in Part4 of the Standard.90 Brass elbow (male to female) must connect from tapping band to servicepipe work.Fittings shall be assembled and jointed in accordance with the manufacturer'srecommendations.Each threaded joint shall be sealed with PTFE thread tape or Teflon jointing

BUSSELTON WATERPipeline Construction and Design Standard


36/43


24. Miscellaneous Works

24.1 Road MarkingsRoad markings shall be provided to indicate the location of valves, permanentflushing points and hydrants. The kerb marking, shall be placed adjacent to thefittings. Blue catseyes required to indicate Hydrants shall be installed by FESA.

24.2 Marker PostsWhere there is no kerbing, metal marker posts shall be provided and installed toindicate location of to indicate the position of valves, flushing points and hydrants.



37/43


WATER RETICULATION OFFICIAL PRESSURE TEST RECORD SHEET

Subdivision Estate Name/Description of Main:

.....

.

Busselton Water File No.WAPC No:..

Busselton Water DrgNo: .

Busselton Water Assessment Officer:

..Contractor:

Mains Tested in accordance with the requirements of Busselton Waters WaterReticulation Standard.

MAIN DIA. TYPE LENGTH REMARKS

NOTE: There are no allowable leakage rates for any type of pipe.

Date Tested:

PASSED/FAILED



38/43


EXTRACT (SECTION 2.13) FROM WATER SERVICES ASSOCIATIONSPOLYETHYLENE PIPELINE CODE WSA 01-1998

TESTING AND COMMISSIONING

GeneralThe traditional testing procedure used for most pipeline materials throughout thewater industry requires the pipeline to be filled with water, raised to the test pressure

and then sealed. The pressure in the pipeline is then monitored, and the pipelineinspected for any leakage or failure of any pipeline components. A maximumacceptable water loss rate or loss volume is specified for acceptance purposes.These procedures are strictly not applicable to viscoelastic materials such as PEsince PE pipes exhibit creep and stress relaxation. When a PE pipeline is sealedunder a test pressure there will be a reduction in pressure, even in a leak freesystem, due to the creep response of the material.Two pressure tests have been described below. The basic pressure test (visual) is

recommended for pipe sizes20

0

C)temperatures during testing. In such cases the multiplication factor adopted shouldbe reduced to say 1.2 to 1.3.

Basic Pressure Test (Visual)For completed line testing, a test pressure of 1.25 times the maximum

working pressure shall be applied for a minimum of 15 minutes withoutleakage, or for sufficient time to permit visual inspection of the line.

Test water shall be introduced to the pipeline and time allowed for thetemperature to stabilise in the pipe to overcome any volume change effect.Test pressures shall not exceed the design safety factor for the material.

Compressed air testing shall not be permitted for pressure pipe.



39/43


Applications, produced by the Water Research Committee (WRc). The test

procedures set out below are based on the procedures in this standard.

Test PrincipleThe principle of the testing procedure is that the plot of the log of pressure versus thelog of time, for a pressurised pipeline will result in a straight line, if there are no leaksand no entrapped air. The slope of the line should be within a certain range, basedon experience in the UK.

Test Pressure

For PE pipe systems the recommended test pressures at


40/43

p gJuly 2007

t1

c=t1

+ O.4tL

t2c=t

2+ O.4t

L

(vii) The measurement of the slope of the pressure decay curve between t1and t

2is

then calculated as the ratio n1:

n1=(logP

1-logP

2)/(logt

2c-logt

1c)

Enter results in table (refer to table below)(a) For an acceptable main, experience suggests that n

1should be between 0.04 to

0.05.For pipelines that are unconstrained, eg. slip lined or pipe cracked, n

1should be

between 0.08 to 0.10(b) If value of n

1is significantly less than in (a), there is too great a volume of air in

the main.

(c) If the value of n1is significantly greater than in (a), it is likely that there is a leak.

The third pressure reading P3is taken at a decay time t

3not less than 15 t

L. The

corrected value for t3is:

t3c=t

3+0.4t

L

The measurement of the slope of the pressure decay curve between t2and t

3is then

calculated as the ratio n1

n2=(logP2-logP3)/(logt3c-logt2c)

The value n2should be between the same ranges as n

1(see (a) above).

The sensitivity of the analysis can be increased by extending the value of t3(ie.

extending the test duration).The results (log P versus log t

c) when plotted should yield a straight line if there are

no leaks.

If the test results when plotted shows that there may be leaks, the pipeline route shallbe inspected for leaks which, when detected, shall be rectified. The pressure in themain shall be released slowly to pre test conditions. The pipeline shall then beretested after a period equivalent to at least 5 times the previous total test period.

Commissioning



41/43

p gJuly 2007

25. Contractor Requirements

This section is to be read in conjunction with section 3 and sets out contractorsobligations and requirements in relation to works undertaken for and on behalf of

BW.

In general works undertaken by contractors will be either within the road reserve oron freehold BW sites. In all cases the contractor will be required to adhere to thehighest possible standards for Occupational Health and Safety.

The contractor will need to demonstrate to BW that all the necessary procedures,accreditations and insurances are in place as follows.

Provision of up to date copies of insurances relating to Workerscompensation and Public Indemnity.Certificates required to undertake the works to be carried out (eg working atheights, working in confined spaces etc)Relevant experience in similar size and type of work.Submission of a Job Safety Analysis (JSA) reviewing risks and proposals toreduce risk (See attachment for BW JSA).Any relevant licenses specific to the works to be undertaken.

The contractor at all times will be required to enure the site is kept clean, tidy, safeand secure and that appropriate bunting , signage, traffic management and trafficcontrol is in place. Contractors are to enure all the necessary PPE are madeavailable to its employees. Failure to comply with one or of the above willresult in the issue of a stop work notice.

SECTION 4



42/43

July 2007

42

26. Job Safety AnalysisTable 1. Measures of likelihood or exposure to hazard

Level Descriptor Description IntervalA Almost Certain The event is expected to occur in most circumstances DailyB Likely The event will probably occur in most circumstances Bi-MonthlyC Possible The event should occur at some time YearlyD Unlikely The event could occur at some time 2 YearlyE Rare The event may occur only in exceptional circumstances < Once per 5 years

Table 2. Measures of consequence or impact

Consequence Injury Property Damage Process LossInsignificant First Aid Injury Low financial lossMinor Minor Injury Medium financial loss

Moderate Medical Treatment Injury High financial lossMajor Loss Time Injury Major financial lossCatastrophic Fatality or Permanent Disabling Injury Huge financial loss

Table 3. Risk analysis matrix Risk level

Consequence

Likelihood Insignificant Minor Moderate Major Catastrophic(A) Almost Certain S S H H H(B) Likely M S S H H(C) Possible L M S H H(D) Unlikely L L M S H(E) Rare L L M S S

Risk Levels: L = Low, M = Moderate, S = Significant, H=High

BUSSELTON WATERPipeline Construction and Design StandardJ l 2007


43/43

July 2007

43

Job Number: Date: Page: of

Allocated to: Checked By: Approved By:(Contractor) (Supervisor) (Appropriate Manager)

Job Stepsor Task

Hazard IdentificationInclude risk assessment details i.e.likelihood x cons = high, significant,

moderate or low risk

RiskLevel(H,S,M,L)

Recommended Control MeasuresEach hazard is to have specific control measures. They may be more thenone control per hazard. The hierarchy of control is elimination, substitution,

engineering, administration and PPE.

Common Hazards Strain/ Sprain Slip/trip/fall Crushing Equipment failure Weather Falling (personal) Electricity Suspended load Inexperience Radiation Lacerations Ventilation Uneven ground Noise/vibration Chemical/gas Struck by Unauthorised access Access/egress Visibility Confined spaces Fire/explosion Biological Hazards Vehicles/traffic Buried services Inundation

Animal/insects

Physical condition (worker)

Operating equipment

Acc equipment starts

Atmosphere

Pipeline Contruction and Design Standards 200907

Documents

Transcript of Pipeline Contruction and Design Standards 200907