Handbook on Pipes and Fittings for Drinking Water Supply

Scope & Key Specifications from IS SP Part 57 (QAWSM) : 1993

1. Thickness & Dimensions (Clause 3.00)

• Flange thickness formula: [ \text{Flange thickness} = 3.00 + 0.05b ] where (b) = nominal flange thickness (mm).

• Tolerances on dimensions:

• Mass tolerance:
  • Bends & fittings with >1 branch: ±12%
  • Other fittings: ±8%
  • Nominal mass tolerance: ±3%

2. Hydrostatic Test (Clause 1.05)

• Air pressure: 1.05 MPa (10.5 kgf/cm²) under water or light oil immersion.
• No leakage allowed after wrench-tight assembly with lubricant/sealant.
• Length tolerance:
  • Socket fittings & flange/spigot ≤450 mm dia: ±20 mm

  • 450 mm dia: ±38 mm

  • Flanged fittings all dia: ±10 mm

3. Water Carrying Capacity (Clause 1.2)

• Use Hazen-Williams formula for flow capacity: [ h_f = \frac{10.67 \times L \times Q^{1.852}}{C^{1.852} \times d^{4.87}} ] where:

  • (h_f) = head loss (m)
  • (L) = pipe length (m)
  • (Q) = flow rate (m³/s)
  • (C) = Hazen-Williams coefficient
  • (d) = pipe diameter (m)

• Recommended 'C' values:

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Handling and Off-Loading of Pipes (IS SP Part 57)

Key Specifications & Practices:

• Ductile Iron Pipes:

  • Use cranes preferably; for pipes ≤ 400 mm NB, skid timber & ropes allowed.
  • Lift smoothly without jerks; use guide ropes to prevent pipe damage.
  • Hooks must engage pipe ends positively, passing over protective packing.
  • Avoid slings around bundles; use broad webbing sling for single pipes.

• Cast Iron Pipes:

  • Do not throw pipes from trucks or drag on hard surfaces.
  • Use timber skids and steadying ropes to prevent bumping.

• Mild Steel Pipes:

  • Avoid distortion or coating damage.
  • Use canvas or non-abrasive wide slings; no throwing or dragging.

• Concrete Pipes (Cement, SCRC, Prestressed):

  • Use chain block with shear legs or crane with spreader beams.
  • Slings around circumference, not through pipe bore or ends.

• Asbestos Cement Pipes:

  • ≤ 60 kg handled by two persons.
  • Heavier pipes unloaded via ropes on planks ≤ 45° slope.
  • No throwing or dragging.

Pipe Support During Laying:

• Pipes may rest on ground if soil is non-aggressive.
• Ground must match pipe curvature over 120° arch length.
• Alternatively, use saddles, rollers, or rocker supports.

Important Tables & Figures:

Handling Safety Tips:

• Use sufficient

IS SP Part 57 - Jointing Methods Key Points

1. Clause 8.2: Jointing Techniques

• Specifies methods ensuring leak-proof, flexible, and durable joints.
• Common types: rubber ring joints, cement mortar joints, and mechanical joints.

2. Clause 6.4: Joints for Concrete Pipes

• Cement Mortar Joints:
  • Use 1:2 cement-sand mortar.
  • Thickness: 10-15 mm.
  • Surfaces must be clean and moistened before application.
• Rubber Ring Joints:
  • Provide flexibility and watertightness.
  • Rubber rings must comply with IS 5382.

3. Clause 3.9.5: Cement Joints

• Cement joints should have:
  • Mortar mix: 1 part cement to 2 parts sand.
  • Proper curing for at least 24 hours.
  • Joint thickness: 10-15 mm.
• Ensure no gaps or voids to prevent leakage.

4. Clause 9.2: Jointing Techniques for PVC Pipes

• Use solvent cement welding or rubber ring joints.
• Solvent welding involves:
  • Cleaning pipe ends.
  • Applying primer and solvent cement.
  • Joining within 30 seconds.
• Rubber ring joints ensure flexibility and easy assembly.

Summary Table: Joint Types & Specifications

flowchart LR
    A[Pipe Ends] --> B{Joint Type}
    B --> C[Cement Mortar Joint]
    B --> D[Rubber Ring Joint]
    B --> E[Solvent Cement Joint (PVC)]
    C --> F[Mix 1:2 cement:sand, 10-15 mm thickness]
    D --> G[Use IS

IS SP Part 57: Installation and Laying of Pipes - Key Specifications

1. Minimum Cover & Clearance (Table 2.3.3)

¹ If cover < 900 mm, increase impact factor in design.

2. Laying Procedure (Clause 3.3)

• Center spigot end in socket, force pipe home, align to gradient.
• Secure pipe with approved backfill, tamped on sides except socket.
• Prevent dirt entry; close open ends with watertight plugs when idle.
• Caulk joints not suitable for pouring to ensure watertightness.

3. Trench Bedding Types (Fig. 1)

• Earth/murum trench
• Hard rock with cement concrete or sand bedding
• Pipes must rest evenly on bedding, not on joints or humps (Fig. 2).

Summary Diagram of Pipe Laying:

flowchart TD
    A[Excavate Trench] --> B[Prepare Bedding]
    B --> C[Place Pipe Length]
    C --> D[Align & Connect Spigot to Socket]
    D --> E[Backfill & Tamp Sides (except socket)]
    E --> F[Close Open Ends if Idle]
    F --> G[Caulk Joints if Required]

This ensures structural safety, proper alignment, and durability of pipe installations per IS SP Part 57.

IS SP Part 57: Testing and Disinfection Key Points

1. Testing of Pipes (Clause 6.4)

• After charging the system with water and expelling air, apply test pressure.
• For thermoplastic pipes (PE, PVC), initial pressure drop occurs due to expansion.
• Make-up water needed to maintain steady pressure over 12 hours (approximate values):

• Test pressure should not fall more than 0.02 MPa (0.2 kgf/cm²) after 1 hour.

2. Flushing and Disinfection (Clauses 7.1.3, 7.2, 7.4)

• Flushing: After pressure testing, flush with water at sufficient velocity to remove dirt.

• Disinfection Methods:

  • Continuous Feed (Clause 7.2):
    • Inject chlorine (liquid or hypochlorite) at ≥ 20 mg/l concentration continuously.
    • Maintain chlorine residual of ≥ 10 mg/l after 24 hours contact time.
    • Operate all valves/hydrants for thorough disinfection.

• Precautions (Clause 7.4):

  • Prevent backflow of strong chlorine solution into supply.
  • After contact period, flush until chlorine residual matches rest of system.
  • Conduct bacteriological tests; if

IS SP Part 57: Backfilling and Trench Requirements - Key Points

1. Trench Zones for Backfilling (Clause 2.4)

• Zone A: Bottom of trench to pipe centerline
• Zone B: Pipe centerline to 300 mm above pipe top
• Zone C: 300 mm above pipe top to trench top

2. Trench Width & Bedding (Clause 2.3.2)

• Minimum clearance on either side of pipe as per Table 1 (not provided here, typically 150-300 mm depending on pipe size).
• Trench bottom must be trimmed for uniform support.
• For pipes >1200 mm diameter, trench bottom curvature should match pipe curvature subtending ~120°.
• For rock/boulder beds, provide 100 mm lean cement concrete or sand cushion below pipe barrel.
• Steel pipes require extra excavation (~600 mm depth × 900 mm length) around joints for welding.

3. Backfilling (Clauses 1.4.2 & 2.4.7)

• Partial backfill allowed before testing except at joints, with authority permission.
• Excavated material can be used in:
  • Zone C when settlement is not critical.
  • Any zone if material is suitable (loam, clay, sand, fine gravel).

Typical Trench Clearance Table (Example)

Trench Cross-Section (Mermaid Diagram)

graph TD
    A[Trench Bottom]
    B[Pipe Centerline]
    C[300 mm above Pipe Top]
    D[Trench Top]

    A -->|Zone A| B
    B -->|Zone B| C
    C -->|Zone C| D

Summary: Ensure trench width and bedding provide uniform support and protection, backfill in defined zones with suitable material, and allow for welding space in steel pipes. Always consult project-specific drawings and authority approvals.

Pipeline Corrosion and Incrustation: Key Points from IS SP Part 57

1. Corrosion Overview:

• Corrosion is a chemical/electro-chemical attack on metals.
• Rusting is specific to iron alloys forming hydro ferric oxides.
• Non-ferrous metals corrode but do not rust.
• Prevention includes proper material selection, avoiding irregular profiles, and ease of maintenance (Clause 2.5).

2. Incrustation:

• Deposition of mineral matter (mostly calcium/magnesium carbonates) inside pipes.
• Occurs regardless of pipe material.
• Leads to reduced water carrying capacity.
• Requires periodic cleaning (e.g., swabbing).

3. Water Carrying Capacity & Roughness:

• Depends on pipe roughness, friction factor, Reynolds number.
• Hazen-Williams formula commonly used:

[ h_f = \frac{10.67 , L , Q^{1.852}}{C^{1.852} , d^{4.87}} ]

Where:

• (h_f) = head loss (m)
• (L) = pipe length (m)
• (Q) = flow rate (m³/s)
• (C) = Hazen-Williams coefficient
• (d) = pipe diameter (m)

4. Hazen-Williams Coefficient 'C' Values (Table 1):

5. References for Detailed Corrosion Study:

• IS 8062 (Parts 1 & 2): Cathodic protection of steel structures.
• IS 10221: Coating and wrapping of underground mild steel pipelines.

flowchart LR
    A[Water Quality] --> B[In

Special Considerations for Plastic Pipes (IS SP Part 57)

Key Specifications (Clause 8.85 & Table 4.4)

• Material Types: LDPE, HDPE, UPVC, GRP (Glass Reinforced Plastic)
• Wall Tensile Strength: Minimum 8.85 MPa for thickness <5 mm
• Elongation at Break: Min 350% (LDPE), 200% (others)
• Opacity: Wall must not transmit >0.2% visible light (to prevent algae growth)
• Chemical Resistance: Good for all plastics; specific limits on toxic substances (Pb, Cd, Hg, etc.)
• Impact Strength at 0°C: No failure in 14 strikes or ≤4 failures in 42 strikes (UPVC)
• Working Pressure (at 27°C):
  • LDPE: 0.25 to 0.60 MPa
  • HDPE: Up to 1.00 MPa
  • UPVC: Up to 1.00 MPa
  • GRP: 0.3 to 1.5 MPa (depends on class)

Important Tables

Design Considerations

• Temperature Correction: Working pressure must be adjusted for temperature using multiplication factors (see Fig. 2A & 2B in IS SP 57).
• **

Welding Procedures for HDPE Pipes (IS SP Part 57, Clause 8.2.4.2)

• Heating Mirror Temperature: Maintain at 210 ± 5°C (target 200°C at pipe surface).
• Contact Pressure on Heating Mirror: About 20 kPa (0.2 kgf/cm²).
• Heating Time: 1 to 5 minutes depending on pipe wall thickness and diameter until a molten rim forms.
• Post-Heating Welding Pressure: Apply 0.1 to 0.2 MPa (1 to 2 kgf/cm²) for 2-3 seconds immediately after removing pipes from heating mirror.
• Pressure Maintenance: Maintain pressure until joint is lukewarm; then allow to cool fully without pressure.
• Temperature Control: Use crayon chalk test—color changes within 2 seconds at 210°C indicates correct temperature.
• Quality: Butt weld strength factor should be 1 (full strength).

Key Specifications

Precautions

• Avoid excessive molten rim.
• Maintain pressure until joint cools to lukewarm.
• Ensure constant temperature with regulator.
• Use thin crayon dot for temperature check.

flowchart LR
    A[Align pipe ends] --> B[Apply contact pressure on heating mirror (20 kPa)]
    B --> C[Heat at 210°C for 1-5 min until molten rim forms]
    C --> D[Remove pipes from mirror]
    D --> E[Apply welding pressure (0.1-0.2 MPa) for 2-3 sec]
    E --> F[Maintain pressure until lukewarm]
    F --> G[Allow joint to cool fully without pressure]

This procedure ensures a strong, permanent butt fusion weld for HDPE

Expansion Joints and Anchorage per IS SP Part 57

1. Thermal Movement (Clause 8.1.2):

• Provide for thermal expansion/contraction between anchors/supports to avoid stress.

2. Anchorage Requirements (Clauses 4.8, 7.6.3):

• Anchorage needed at dead ends, tees, bends, valves to resist internal pressure thrust.
• Cast iron joints do not grip pipe ends firmly; anchorage is essential to prevent slipping under pressure.
• Design anchors considering max service/test pressure and soil bearing capacity.
• Use concrete thrust blocks shaped for joint access (Fig. 8 in code).
• Follow IS 5330:1984 for anchor/thrust block design.

3. Spacing of Transverse Anchors for Steep Pipelines (Clause 4.8):

4. Deflection & Radius of Curvature for Pipe Lengths (Table 6, Clause 7.4.4):

Displacement and radius vary with pipe length (1m to 4m).

flowchart LR
    A[Internal Pressure] --> B[Thrust Developed]
    B --> C[Anchorage Required]
    C --> D[Concrete Thrust Blocks]
    C --> E[Transverse Anchors (Ste

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Care and Maintenance of Pipes as per IS SP Part 57 (QAWSM : 1993)

Key Points:

• Water Carrying Capacity depends on:

  • Relative roughness,
  • Friction factor,
  • Reynolds Number.

• Hazen-Williams Formula (empirical, widely used):

[ V = k \cdot C \cdot R^{0.63} \cdot S^{0.54} ]

Where:

• (V) = velocity (m/s),
• (C) = Hazen-Williams coefficient (depends on pipe material and condition),
• (R) = hydraulic radius (m),
• (S) = slope of hydraulic grade line,
• (k) = constant.

Hazen-Williams Coefficient 'C' for Pipes (Table 1)

Maintenance & Repairs (Clause 1.7)

• Consider material selection based on:

  • Maintenance needs,
  • Leakage losses,
  • Pipe behavior over service life.

• Losses in smaller pipes are more rapid due to rust, incrustation, erosion.

• Use well-designed bends and tees to reduce losses from fittings.

Additional Specifications for Plastic Pipes (Clause 8.85)

• Wall tensile strength: Min 8.85 MPa (<5 mm thickness).
• Elongation at break: Min 350% (typical), 200% minimum.
• Wall opacity: Should not transmit more than 0.2% visible light.

Summary Diagram: Pipe Care & Maintenance Factors

flowchart LR
    A[Pipe Material & Condition] --> B[Water Carrying Capacity]

Water Carrying Capacity & Hydraulic Considerations (IS SP Part 57)

Key Points from Clause 1.2:

• Capacity depends on relative roughness, friction factor, and Reynolds number.
• Hazen-Williams formula is widely used for practical design:

[ V = k \cdot C \cdot R^{0.63} \cdot S^{0.54} ]

Where:

• (V) = velocity (m/s)
• (C) = Hazen-Williams coefficient (depends on pipe material and condition)
• (R) = hydraulic radius (m)
• (S) = slope of hydraulic grade line (m/m)
• (k) = constant (usually 0.85 for SI units)

Hazen-Williams Coefficient 'C' (Table 1):

Additional Notes:

• Capacity reduces over time due to slime, incrustation, rust, etc.
• Smaller diameter pipes lose capacity faster.
• Losses in distribution lines are higher due to valves, fittings.
• Regular cleaning (flushing/swabbing) is essential (Clause 2.8.1).

flowchart LR
    A[Pipe Material] --> B[Select C value from Table]
    B --> C[Calculate velocity using Hazen-Williams formula]
    C --> D[Determine water carrying capacity]
    D --> E[Consider losses due to roughness & deposits]
    E --> F[Plan periodic cleaning to maintain capacity]

This concise framework ensures effective hydraulic design and maintenance per IS SP Part 57.

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