AT MICROFICHE REFERENCE
ATMICROFICHEREFERENCELIBRARYA project of Volunteersformterin AsiaSvstemfi an-eWorksby: Andreas Bachmann and Nirman JoshiPublished by:Swiss AssociationP.O. Box 113KathmanduNepalFree to seriousfor TechnicalAssistancefor TechnicalAssistancegroups.Availablefrom:Swiss AssociationP.O. Box 113KathmanduNepalReproduced by permissionfor Technical Assistance.of the Swiss AssociationReproduction of this microfichedocument in anyform is subject to the same restrictionsas thoseof the originaldocument.
‘.WATERPIPEFORSYSTEMSWORKSI
ABRIEFCOURSEINTRODUCTIONFOR THE ESTABLISHMENTSOF RURAL WATER SUPPLIESINNEPAL.c‘PREPAREDBY:ANDREAS ,BACHMANN,NIRMANJOSHI,DRAFTSMANSS ASSOCIATION FOR TECHNICALASSISTANCEBOX113K A T II M A N D U /NEPALS A T A,P,0,SATA
PREFACEAs ruralwater suppliesbecame one of the prime tasks forthe Himalayan'Kingdomof Nepal it was soon recognisedthatplasticpipes would play a major role for the mostly quitedifficulthillyterrain.The firstmanual was worked out for Peace Corps workersin autumn 1974. It shows the basic principlesof pipe work.It has since then been severaltimes reprinted,also at thespecialrequest of the Nepal Government,Water Department.It is hoped that this new editionwillbe usefulformore fieldworkers willingto assistin improvementslivingconditionsin ruralareas.AndreasBachmannS A.T A / KathmanduJune 1980manyof
CONTENTS\1.Introduction1.1.1.2.Importanceof water.,.,.,11.‘.,,,.Development of sources,qualityand m.Pumpa .GravitySystem.HydraulicRam.Loss of Head\ / Chart.3.Water3.1,3.2.3.3.,3.3,3.4,3.5.3.6.Trenches and Pipelines.Manhole, SpecialStandpipe.Water PreventionDevice.Water PreventionDevice / Sketch.Water Place, Standpipe.ValvesSpecialValves.78910111213Use, rules,pipe measurements,length of threads,Thread, cutting,watertightjointsand thread&.Nipple cutting,.connectiontb concrete. .* . . . . .Galv. it.
5.Plastic5.1.c 75.4.Introduction.Transportand Storage.Preparationof Trenches and Laying of PipesConnectionof Galv. Pipes and PlasticPipes6.PVC6.l6.2.6.3.Use, rules,preparingof a spigotend .Solvent cement joints,pointsto remember.Sockets and Bends.7.HDFE7.1.7.2.7.3.7.4.7.5.7.6#7.7.use p Rules.Handlingof Pipe Coils.Wel.ddng .'Branch450.Branch600.Branch900.e.Bends and Elbows450 900 15.Endcap.ConicalReducer .reducer 1 ,,Endcap ( and 1st. step for low-pressureReducer( low pressure) .Reducer, for small differencesin diametersReduced Branch.HDFE - Tools.Blow Lamp.*.*.i."32333435363738395, ‘Pipes.18192021- Pipes-222324Pipes
1.1.- IINTRODUCTIONImportanceof Water-Water is essentialfar:Water is essentialforWater is the princfpalWater is importantforand on thtl farm- Water conservationandIeveryonelifehealthand sanitationraw materialfor food productionmany uses outsidethe homesanitationare importanttoThe Water Cycle.SSW DWART. W. SPRINGSSPRINGSARTESIAN OR WELLSWELLP POROUSSTRATAX Y WATERTIGHTSTRATAA cross sectionof a possiblearrangementof the earth crusf: showing how water may be distributedover and through it,A part of the rainfallruns off at the surfaceformingcreeks andrivers;a part may soak into the ground and returnto the surfaceat springsor wells.Yet another portionmay percolatedeeper through cracks and faults.( A-A and B ) into a porous strata(F) where it may be carriedmanykilometersto the ocean or to artesianwells.Sourcesof water- Rain Waterfordomestic- NaturaluseSurfaceWater- Ground Water-l-
1.2.INTRODUCTIONDevelopmentof sourcesof waterAny new or untriedsource of water should be examined for qualitybefore expensivedevelopmentis undertaken.For wateringanimals,spryingand irrigationit should at least beclear and free of any materials,minerals,tastes or odors, whichwould be harmfulor objectionableto plantsor animals,QualityThe watermust be or odorssediment to be clear,temperaturelow (appr.withoutcolor10 C (50 OF)Quantityneed. forlifeneed forlifeDefinations- 15per- 50peras appliedltrdayltrday(appr. 31/2 gallons)and person(appr. 11 gallons)and personto waterWhen used in connectionwith handelingwater,head refersto theverticalheightof a column of water above a certainpoint,nnd isconsideredas causing or countekactingthe flow of watei.For example, if water stands at a height of 6 meters (20 feet),there willbe 6 meters (20') of head in the bottom of the pipe,This pressureis expressedin terms in kg per cm2 (or pounds persquare inch, psi).A column of water with 10 meters of height(10 meters head) willhave a pressure'of 1 kg/cm2 (At 6 m L 0,6kg/aQ).GravityheadPressureSl;ctionis the actualverticalheightabove the referencepoint.of a columnof waterPressure head is the verticalheightin meter (feet)to which any given pressurewillforce water.Cne kgper cm2 willforce water to a heightof 10 m.(or one pound to a heightof 2.3 feet).heada term appliedto pumps, is consideredas the totalquivalenthead1 in meter (feet)on the suctionsideof the pump againstwhich the pump must work in orderto get water.The quivalentsuctionhead is made up ofgravityhead frictionhead-.Most pumps are guaranteedto work against'7 m (22')of totalsuctionhead at sea level(As more the altitude as less can be the suctionhead)!
2.1.W LBW,OPEN OUTLETNOT FIX ANY VALVE 1-(DO-‘----4fiCATCHMENTBASIN/STRAI NEd/KEEPSTRAIGHTPIPEFOR EASYCLEANONG.FORGzjzi ,Spring catchment must be in a waythat the water: always can flow out,withoutdamming up the water level.Ther? must also be an overflowwithout any valve.The outletshave to be covered withscreen,so that no dirtor animalcan block the pipe.GravityTypeA gravitywater. system is one having a tank or a storage reservourlocatedhigher than the faucetsfrom which tank or reservoirwaterflows to the faucetsby the force of gravity.systems.One is "natural"There are two common types of gravitygravitywhere the source of the water is high enough above the -faucets to providea satisfactoryflow,The other is the 'pumped" system where a pump is used to elevatethe water to a gravitystoragetank located above the faucets.,NaturaiGravitySystemThe natural gravitysystem shouJ& be consideredonly when the s or buildings); .'I to g'ive adequate flow,' ;,,',;'-':;Unle&s the spring has a strong flow, a catchment basin should beas shawn. For a satisfactoryUS',,' .;buil .below the: springflow there may,':,:,, 'be&at least 7 meters (22') of elevationon the highestfaucets.Ifthe'systemhasagreatdistance,more then'7 meters is desirable.1:.shoulc'provi@an adequate year-roundI j /.',i:: A'souxce to beldeveloped,,(, : supp ly of good qualitywater.Specialattentionshould be given toI ,cM hment basins, size and materialof pipe to use, and protection I from contaminationor pollution.',t- ,-2,,,I
2.2.'-'y ,,,r';,);:a;,I,',%:2. .,’.2,::I.j ” P“.:;.;.* ’; OR HEIGHTW. GRAVITYCLEAR WATERi CHAMBERVALVEFOR CLEANI”?NGAND CHECKiNGOF FOOT VALVEWELLSCREENOR PERFORA7’EDPIPE.//a;.,:1::.- :,,::.,y .'2 ).- ' SH Suction Head, Has to be as low and short as possible.headAsmadeupofgravityandfriction( loss).Theabsolutely'j/(f.8 I."maximum of head !GH FH) is 7 m (2211 at sea level.Pumped GravitySystems;a:',P,): ::.I. ,i,.#.I1:Y,,.‘ / " If 'there is no lrossibilityfor a naturalgravitysystem, there re;,-,c:L, mains the pump& gravitysystem.,.,7.s'But they are not always recommend,"j, able: pumps are expensive,needquitesome pensivefuel,with the exceptionof,'it,he,.BydraulicRam.y?:: ; ,," ,,'.,,,; Hoq& , for big quantitiesand/or if there Is only this possibility'1'.;:.' I' t‘ L:i,averysatisfactorysystem.i :'I.,'I,. ,,,Q5;j;i r &:.& ;a @Istorage' 'cipacityis desirableto providewater for days , it;.J,;: ::.::, .needs,"alossfrequentstartingoftheengine.0,",-' j , 8: 6%q, .;.,::,',t.,i,c::,,'.,:""-,,,,. :‘:,, ';.:,,.,. ":,,.;,:":.!I;, ,!.,;,,'j,.' ,"*;,';;,:/ ,-4- ,LI! ,"Z,I,, !'.' :i /,/,/ ,i.jJ';,'i i '-:/'a ,'c,,i,.,I, ,*i*
t.\-‘The HydraulicRam is an automaticpump which by means of a lablespringor stream water*12:toamuchhigherpoint.J2'.7.Example: The spring or stream water is being collectedin a reser.1% 'voir. From here a part of this water is to be liftedtothe supply.Y !*.;rQ iFor this purpose the water is being fed through a pressurev;.,li.,1. ,I reservoir.pipe into the ram. A part of this volume is then being raisedthrough.:'1 '.;thesupplypipetothereservoir,.i3:’Iii,‘.! .The proportionbetween pressure pipe quantity supply pipe quantity-.can be:.:ti.,:from:100 !% up to3 %,( ‘100LSupto24%'A', 'I:,:.i31l.t ,tL LENGTH OF PRESSUREA 30-40cm(12-16”)B AT LEAST10 CM INGANDPIPERAMFREEFLUSH(ESSENTIAL)OUTwater availableis collectedin a reserthe water is taken from a stream, this latthis purpose. The collectingtank can beIt is however essential;that the pressurewayb, covered under at least 30-40 cm (12-16').servoir must furthermorebe construcetdin a wayy possibilityof air bubbles enteringthe pressure,in the pressure pipe would hamper the proper oper-“ installationd.knowledge. of a ram is a very particularBefore ordering a hydraulicmatter,itram, contact
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3.1.W A,';r E RCONDCIT,PipelineS:don'tbringdrinkingwaterto a placei.S assured!(MOISTURE bringsinsects,IPIPE MARKING/PIPE WITHOR BIGGER,FILLEDWITHMARKSOF DIRECTIONbeforetheand illness).drain,2quSAMEDIAMETERCEMENT,WITHKEEP FREE FOR WALKINGANbTO PREVENTSTONESFALLINGON THE PIPEEXCAVATEDI&I5DEPTH OF TRENCHAT LEAST1 M (3’04’)AT ALTITUDESWITHFROST EVENMORE!SOIL, WITHOUT STONESI0TRENCHF-lBOTTOMsure that the pipe system iswaterproof:tight,-make a plan how the pipe lies in theground.againstmePipes should be in the ground, where they are protectedalso willbe better.chanicai damage. The temperatureThe depth of a trench may be at least 1.0 m (3’-4”),otherwisethere could be the risk that they willbe dug out by the farmersBeforerefillinga trench:-makefor irrigatioq.before the trench,, Don’t let pressure in the pipelineremains the risk,thati kz fiitecorrectway. Otherwise'*.IAlways lookthroughthe pipes beforeand if itthe open ends immediately,you installis only foris filledupit willneverthem and closea few minutes!-7-
WATER3.2.CONDUITManholeBy changing the directionin the ground make always big bends.The best solution(by low pressuredistributiononly) is a manhole.This for the reasons of cleaningand also for blocked pipelines.Pipelinesin the ground should have a diameterof at least 1 1/4".(Excepetions:branchlineto standpipes).FRONTTOP VIEWVIEWIS CUTHALFELFGStandpipewithreservoirand pumpWater shortage,remains a good possibility;ascause there is not enough water,or becausethe valve.shown. Shortage bethe people don't ��ry‘PECONSTRUCTIONSEE19 MINPIPEr I.SEPARATE1”)W. CAP (MIN. 2’#)PAGE!
This shows an idea for a waste preventionstandpipe.This is lessapplicableto the type of hand-pumped supply,but for gravityorpiped systems.The principleis based on the fact that most common water containerused in many parts of the world is a kerosene tin which holds littlfless than 20 liters,A standpipeconstructedof a pipe with 150 mmdiameter(6"),inside which slidesa free piston.The capacit;lofthe 150 mm pipe in the appr. 1 meter length between the top of thepistonin its lowest positionand the outlettop is 20 liters. 's pistonincorporatesa short length of small diameterpipe, say;‘ mm diameterwhich, by passing water from below to above permitsthe pistonto sink slowly by Its own weight when the pressureonthe two sides is equal,so that its normal positionis at the bottorof the standpipe.Its weight is adjustedso that it willraise underthe pressureof incoming water when the tap is opened, and sink asdescribedwhen the tap is closed.When villagersopen the tap, water from the tog side of the pistonruns into her container,and the pistonis raised by the water pressure below, When 20 litershas been withdrawn,the pistonred&esits highestposition,and the mouth of the 10 mm pipe seals itselfagainstthe rubber stop. As long as the tap remains open, the waterpressurebelow holds the pistonin this position,and no more watercan be drawn off.In order to fillanothercontainer,it is necessar.,.to close the tap long enough for the pistonto sink its lowest position,where another cycle starts.( see ref.WHOJSelfClosingHydrantThe idea is brilliant.When the hydrantis made by professionalsitsurely works to perfection,but when made at home by a more or lessskillfulmechanic,it is not quite succesful.Unless the mechanic hasthe necessarytools to make the insideof the tube perfectlysmooth,and to give the pistonthe very close yet free runningfit,the hydrant willleak. This has been the experience.We would suggest a slightchange. Insteadof having the outletpipeat the side of the tube to be blocked by the pistanput it in thecenter at the top of the tube. This way the very outletis plugged,and tubeand even if some water does leak past between the pistonmerely goes above the piston,but simply cannot flow out,Another usefulsuggestion:eliminatethe tap. Taps manufacturedinthe Orient are a perpetualsource of trouble.Four of our taps thatworked well were stolen,one afterthe other.The open end of theoutlet can quite easilybe blocked by the user'shand tillthe pi-ston drops.i tee ref, MINI TECHNOLOGY.I
3.3.WATERc 0 N 1) ti I 7Waste Water Prevention2%I1) left:Pistonat bottom of standpipe,before drawoffcommences.2) right:Pistionraising as water is drawn.mm pipePiston slidein standpipetap?iT!:tttt3) Outletsealed afterwater in standpipehasbeen drawn off.4) Piston sinkingbyits own weight whentap closed.not to scaleSchematic,GJHO:( set8 ref.cl
,J.x.,).,,,,'.':/1.i""I.,;;L,4 .,,';!i'?WATER3.4.--PLACEStandpipeA bad water ,place makes bad, situationworse!Take great care for the place itself,and the place around. Thewaste water outlet(drainage)is absolutelyobligatory(Moistureinsectsand sickness).brings dirt,Don't open the system before every work is finished,tile riskthat it willnot be done afterwardsis very possible.iPLASTICORPLASTICPIPEMIN. 60 MM QWIT HOUT ANYOPEN I.,.; /t,‘,,,,.‘:,;;,.Ip‘. ECEOF PLASTICPIPE
VALVESve1.- The seat openingsare usuallyof the same diameteras theinsideof the pipes.Theyhave very littleresistanceto the flow of water,whenthe valveis completelyopen.Use: in main-pipelines,beforethe taps,There wherewatertightnessis not so important,Not to be used:as outflushvalve,(too hichspeed in therJipeline,and not real.lvwatertight)thereforetake agood tap (withrubberwasher).1iIIIIIGlobe - -- Ivalve (stop -.cock, -- fern1This vaJve has to be installedwiththe waterpressureunderthe valveseat.A globevalvecan be repairedquiteeasilywiththe changeof the rubberwasher,and iswatertight.But the frictionlossis quitehigh.Use: for smallerdiameters.Not to be used:as ck - -(tap,-Spindle --!cz@ Gland ------ faucet).The bib cock closeagainstthewaterpressure.When it isthe passageis relativelyopen,freefor the water.The spoutthreadedspoutmay or may not be(forhose connection).
3.6.V A L V E S/EXAMPLESFoot- - .- .valves. .Use:forsuction-pipesUse:inpumped-systemspumped systems,on theend by suctionpipesPlug - .valve--.-. Use : for-.-only.( Theyare nat watertightandthe waterflowis stoppedtoofast.That may producewaterhummersand damagethe piptinstallat:onsJ.non- nof returl,ingof the water;where thewater has to remain in the pipes.By pumped gravitysystems and by installationof the hot water storagetanks(boilers,geysirs),but al.scJ with safetyvalve (or vent.-pipe)only,Use the check if possiblewith swing-plate,wherelow pressuresystem is made. It has a big passageand littlefrictionloss.-13-
4.1.GALV.PIPESG.I.Use:Pipes (galvanizediron pipes)insidebuildings(high mechanicalresistance),electricalconducting mechanicalresistance- high friction(loss of head reductionof pressureand quantity) fittingsavailable- no possibilityto make thefittings(because of gaJ.v.1 good for smallerdiameters- no resistanceagainstchemic‘?l*corrosion(rust) few extensionwith changes- pieces up to 6 m (20')onlyof temperature many joints-t good connsctionwith cement- withoutflanges,only good(aftertheremovingof thejointsup to the Idi-lmetergalvanization).of max. 2"- quiteheavyNever put union's(or flanges)in the ground or wall(Because therewillbe no chances of inspectionand maintenance)Paintingin ground and wallsis necessaryas protectionagainstcorrosion(danger of rusting).By using 6.0 m piecescut of the halfof the factory-madethread(with a hacksaw)and cut a new, fulllengththread.No bends of G.I. pipes to be made withoutusing the properfittings(By bendingthe pipes the galvanizationwillsplitoffrisk ofrusting.pll/23141"lU411122"outsidefi in mm/ mapw . weightinkg *21.326,933.742.448,3--1.2.% li lengthof thread(unscrewlength)in mm13/liil.21123"* the weightof the pipe is dependingon its qualitythickness.Pressureresistance:(dependingon the quality)l/2- 3/4ww . 25 kg/cm2 (max)1"4"appr.16 kg/cm2 (max)-14-resp.wall-
4.2.G.1.GALV.pipes/ ThreadPIPEScuttingCheck the qualityof the pipe,(corrdchwelded seam, propergalvanization,diameteraccurate)2.fix the pipe in pipe vice3. cut tha lenghtand afterthe thread(Never cut threadswithoutUSil'cJ oil)4. chdck the lengthof the threadsplitters5. clean it from oil and steel6. put hemp and joint-paste(puttyor animal grease)Checking:if the threadis properlycut, it should be possibleto screw appr.65% of the threadedportioninto afittingby hand.Plumber threadsare iconical.The fittingswillspoilif they are urr.screwed the whole lenght;appr.two turns of the threadshould remain visible,Protectionagainstrust:apply a layerof paint.Caution:Gate valves,globe valvesand similaritems should be easiL,removeablefor overhaulor replacement,withoutdismantelingmuch oithe line.For this purposelong threading,unionsor flangesshouldbe fittedclose to such parts.Cuttingpipes with pipe-cutterrequiresthat the pipes be reamed forburring,Betteruse only hacksaw for cutting.1,CROSSThe burr made bya pipe ointson threadsUse dry hemp only (candlewicking)and non-poisonousjointpaste,(puttyor animal grease).Paint as jointpaste is not recommecdable.b&cause it drieshard.1. Turn hemp in clockwisedirection,startingat the beginning(enciof the pipe)of the thread,coveringthe entirethreadwith hem!2.Put pipe jointpaste on the hemp of the thread,check that nooilorjointpasteisinsidethepipe.hew Ithefittingon the pipe by hand and tightenwith the pipi3. St
AT MICROFICHE REFERENCE LIBRARY A project of Volunteers in Asia formter Svstemfi an-e Works by: Andreas Bachmann and Nirman Joshi Published by: Swiss Association for Technical Assistance P.O. Box 113 Kathmandu Nepal Free to serious groups. Available from: Swiss Association for Technical Assistance P.O. Box 113
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AT MICROFICHE REFERENCE LIBRARY A project of Volunteers in Asia Workshop Exercises Metal, Fundamental Skills, Part A edited by H.N.C. Stam Published by: INTEMS b.v. Available from: TOOL Entrepotdok 68a/69a 1018 AD Amsterdam THE NETHERLANDS Reproduced by permission. Reproduction of this microfiche document in any
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