National Guidelines for Small Scale Irrigation Development MOA

4 INSTALLATION AND TESTING OF DRIP SYSTEM

4.1 RECIEVING AND HANDLING OF PIPES AND FITTINGS

4.1.1 Receiving, unloading and handling guide

Pipes and fittings are delivered to aproject site in rolls or pieces depending on the type of product.
When a load of pipes and fittings arrives at the site, it is the responsibility of the engineer to check
it thoroughly. If possible, it is required to inspect each piece for damage. It is quite necessary to
check quantities against the delivering list. Note missing or damaged items on bill of loading; set
aside any damaged items and notify the supplier.

In order to avoid any damage to pipes and fittings, the person in charge of the site must adhere to
the following recommendations.
 The storage surface must be flat, stable, and free of stones and debris.
 Unload the truck, being careful to avoid any movement, which could cause injury to the
personnel or damage to the product and make note if any missing products in the
delivery lot.
 Unload layer by layer, ensuring they do not fall to the ground.
 Do not discard damaged materials; rather identify them carefully for later inspection and
notify to the supplier on time.
 Do not return damaged product before the authorization of the supplier.

4.1.2 Storage of received materials

Pipes and fittings delivered in rolls or pieces must be stored appropriately as described below.
 Deposit the products on a clear, flat surface, and far away from any source of fire
hazard.
 Specially fittings must be stored inside shelter and take care not to be lost.
 The maximum pipe storage height is preferable not to exceed 1.5m.
 Use chocks to prevent the pile of pipes from falling down which could result in damage
to the pipes, or worse still, cause injury to a person.
 If the pipes are stockpiled along the trench, they should be as close as possible to the
trench, on the opposite side from the backfill, to minimize loading, unloading and
transportation.

4.2 INSTALLATION OF PIPE LINES AND FITTINGS

Installation of mains and submain pipes

Mains and submain pipes in drip irrigation are buried. For installation of main and submain pipes,
first make sure that the pipes, fittings and valves are free from defects impairing strength and
durability and be of the best commercial quality for the purposes specified. All pipes, valves and
pipe fittings shall conform to the relevant standards. As the pipes are usually buried, to protect
them from farming operations and traffic hazards, the following guide may be used in their
installation.

4.2.1.1 Trench excavation

Proper layout, demarcation and pegging that guides the excavation line has to be carried out
before commencing excavation works. According to the volume of earth work, labor availability

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and accessibility the excavation works can be carried out by labor or excavator. During the
excavation works, the excavated material should not block sidewalks, utility outlets and back
falling of excavated material to the trench. The excavation of trenches for pipelines shall at any
one time be limited to lengths approved by the design engineer.

The width of the trench varies based on pipe size, soil type and other site specific conditions. The
minimum clear width of the trench measured at the center line of the pipe is generally specified at
least 300mm greater than the outside diameter of the pipe to enable backfill material to be
installed in the pocket area. For pipes with outside diameter of 200mm up to 400mm commonly
500mm width is recommended to allow free movement of human being shoulder during excavation
and installation.

The pipes should be buried at depth of 350mm-400mm below the deepest recorded penetration of
plough depth. Therefore, the commonly used depth of excavation is 500mm plus the pipe outside
diameter.

Adequate dewatering system to lower the existing ground water table below the level of the trench
bottom and to keep the trench dry until pipes are assembled and back filled. If during the progress
of the work the trench in part or in whole becomes flooded, the contractor shall immediately stop
all relevant work until the trench is dry.

4.2.1.2 Installation

After excavation of the trench, installation follows. Installation of pipelines includes construction of
beddings and foundation, laying and jointing of pipes and fittings, manholes and other structures in
the line, testing, and backfilling of trenches, surface restoration and commissioning.

i) Pipe laying, jointing and cutting

For laying the pipes, first granular bedding of sand for pipes shall be placed by spreading and
compacting granular bedding material over the complete width of the pipe trench. Where pipes are
jointed, bell holes of ample dimensions shall be formed in the bedding to ensure that each pipe is
uniformly supported throughout the length of its barrel and to enable the joint to be made and
inspected during testing. After pipe laying, additional material shall be placed and compacted by
hand rammer in 150mm layers equally on each side of the pipe as side support for the pipe.

Where pipes are laid on granular beds in ground with high groundwater level, puddled clay stanks
shall be constructed at 25m intervals at the mid-point of an individual pipe. The stanks shall be
0.5m long and shall be recessed 300mm into the sides and base of the trench, and shall extend by
a minimum of 150mm above the top level of the granular material.

Hydrants must be installed out of the way and must be painted with a bright-coloured paint to
prevent them from being run over. All mainlines and submains must be flushed after installation to
get rid of dirt that may have entered the pipes during installation. Pressure measuring points must
be installed after each control valve at a block or hydrant so that the design operating pressure of
the system can be set at those points.
While laying pipes, all joints shall be flexible joints and comply with the relevant provisions of the
appropriate standards and shall be made to the manufacturer's recommendations.

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Flanged joints shall be properly aligned before any bolts are tightened. Gaskets for flanged joints
shall be of the inside-bolt-circle type. Gaskets may be secured temporarily to one flange face by a
minimum quantity of clear rubber solution. Unless specified otherwise joints having exposed mild
steel components shall be cleaned and all loose rust shall be removed. The internal lining in a gap
which has been left for the joint to be made shall be completed in accordance with the
recommendations issued by the manufacturer unless specified otherwise. The external protection
shall comprise bitumen applied to a thickness of not less than one millimeter onto the external
surface of the joint, followed where appropriate by a spiral wrap of heavy duty glass fiber tape
bonded with hot bitumen.

For closing lengths, it may be necessary to cut pipes of various materials. Pipes shall be cut by a
method which provides a clean square profile without splitting or fracturing the pipe wall, and
which causes minimum damage to any protective coating. Where necessary, the cut ends of pipes
shall be formed to the tapers and chamfers suitable for the type of joint to be used and any
protective coatings shall be made good.

In general during pipe laying and joining works the following guides shall be adopted:
 When pipes are supplied in rolls properly transport the roll to installation trench, unroll
and stretch straight off side of the trench length.
 Immediately before being laid and jointed, each pipe and fitting shall be carefully
examined for flaws, cracks, or any other damage and all dust, dirt and foreign matter
must be removed from the pipe. Therefore, sufficient care shall be taken to ensure that
each pipe and fitting remains clean during the laying.
 If the Engineer deems the defective pipe as being suitable for use, the defective pipe
shall be cut back at least 150mm beyond any visible flaw and prepared for jointing.
 All pipe lining and jointing shall be carried out by experienced pipe layers, well skilled in
their work, to the grades, levels and lines shown on the drawing
 Joint the HDPE pipes using welding machines or compression fittings off side of the
trench.
 Before pipe laying to the trench clean all stone, soil and other debris that might have
fallen to the trench.
 Drag the pipes carefully section by section to the trench and laid on a natural bed over
the trench formation when there is no rocky or stony ground exists.
 HDPE pipes with small diameter pipes may be laid to curves, not exceeding 1.3 times
the minimum diameter.
 For the installation of valves and other fittings where required, pipes shall be cut and
prepared using proper tools.
 Additional care should be taken during the laying of pipes by using suitable caps or
plugs to cover open ends in the event of a prolonged interruption on completion of the
work.
ii). Installation of fittings

As presented in section 1.6, there are several types of PVC and PE fittings. The most common
fittings used in PVC pipes are Solvent Weld and threaded fittings. There are, however, different
options of connecting HDPE pipe with fittings and the most commonly used are described below.

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a) Flanged fittings
Flanged fittings are used mostly in large sizes exceeding 90mm size and when there is a need to
use flanged fittings and pipes. All flanged connections are face to face dimension by using backing
rings, bolts, nuts and gaskets.

b) Butt weld fittings

All pipes are going to be joined face to face by welding or by using weldable fittings such as
reducer, tee, elbow and etc. Also there is an option of using electro fusion fittings mostly during
maintenance work and some special cases like welding that to be carried above ground level on
roof and other raised areas. All weldable fittings are carried by using standard welding machines.

c) Compression fittings (Sleeve connection)

These types of fitting connections represents for joining of PE pipes and all of the compression
fittings and shall be consist the following parts:
 Body and lock nut- with great rigidity and low moisture absorbency
 Grip/splits ring- strong, hard, highly crystalline and is known as plastic engineering.
 Thrust ring/Bushing – with a characteristic of chemical resistance to solvents, acids and
alkaline, toughness and flexibility.
 „O‟ rings – made of rubber.
During installation of these types of fittings the following guide points shall be adopted:
 Level the end of the pipe to be inserted in to the fitting.
 Disconnect the lock nut from the body by rotating anti clock wise and remove the grip
ring.
 During installation clean the pipe surface that to be inserted in to the fitting and the
internal surface of the compression fitting.
 Insert the nut and the grip to the pipe which is ready for connection.
 Insert and push the pipe end to the bushing ring.
 After ensuring proper insertion of the pipe to the bushing ring push back the grip until it
connects to the bushing ring and then locks the nut to the body by rotating clock wise.

d) Threaded fittings

This can be referring to any types threaded fittings.

 Use adequate teflon on external threaded part of the fitting during connection thread to
thread.
 Connect at right position of the fitting thread to ensure tight connection.
 Be care full not to damage the peach of the thread.
iii) Curves and Bends

The pipes shall be laid in straight lines where possible. Curves of long radius shall be obtained by
deflection at the joints. The deflection of the joints for this purpose shall not be more than 50% of
the maximum deflection as specified by the pipe manufacturer for the relevant type of joint.
Concrete thrust blocks shall be provided where ordered by the engineer. Concrete for thrust blocks
shall be placed carefully against undisturbed earth or rock and shall in no case give less than
150mm of cover to the pipe. Concrete shall be grade C25. When casting thrust blocks, no
couplings or joints shall be covered, and where timber shuttering has been used such timber shall
be removed before backfilling.

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Figure 4-1: Thrust blocking for PVC pipes

Figure 4-2: Example of control head installation

Figure 4-3: Example of end line of submain pipe installation

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iv)Testing of main and submain pipes and fittings

As soon as pipes have been placed on their bedding and before backfilling they shall be tested for
leakage. Before any testing, the contractor shall ensure that the pipeline is anchored adequately
and that thrusts from bends, branch outlets or from the pipeline ends are transmitted to solid
ground or to a suitable temporary anchorage. Open ends shall be stopped with plugs, caps or
blank flanges properly jointed.

The Contractor shall not cover up any pipe except uPVC pipe until it has been inspected, tested
and approved. uPVC may be covered to a depth of 150mm to reduce thermal movement if
immediate inspection and testing is not practicable.

Before testing, valves shall be checked and sealed, the sections of main filled with water and the
air released. After having been filled, pipelines shall be left under operating pressure for the period
of not less than three (3) hours, so as to achieve conditions as stable as possible for testing.

The pressure shall then be raised until the test pressure being 125 % times the maximum working
pressure, is reached in the lowest part of the tested section, and the pressure shall be maintained
at this level, by pumping if necessary, for a period of one hour. The pump shall then be
disconnected, and no further water shall be permitted to enter the pipeline for a further period of
one hour. At the end of this period the original pressure shall be restored by pumping and the loss
measured by drawing off water from the pipeline until the pressure at the end of test is reached
again.

v) Filling and Protection

After testing, the pipe must be surrounded by fill for proper protection. Back filling can be done by
using selected soil from the excavated native material in the trench provided, which is free from
large stones, and free of debris or other organic materials up to 500mm height over the crown of
the pipe in which it is up to the maximum depth of the plough. The purpose of the backfill is to
protect the pipe from damage and floating over during water filling condition. It is not necessary to
compact the backfill directly over the top of the pipe for the sake of the pipe‟s structural strength.
However, it may be necessary for the sake of roadway integrity.

The pipe shall be protected with concrete encasement from live traffic loads at road crossings.
Filling and protection to pipes shall extend fully to the sides of the excavation. The Contractor shall
provide and maintain an adequate support system for upholding the ground actually encountered,
and the safety of adjacent structures or utilities shall not be affected.

All support systems shall be properly maintained until the permanent work is sufficiently advanced
to permit it to be removed. No gaps or voids are permitted as a result of the removal of the support
system. Gaps and voids that may be created upon removal of the support system shall be properly
filled with an approved granular material or Sand or other approved means.

The trench above the so finished pipe surround shall be filled with fill and shall be compacted flush
with ground level.

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Manifolds, laterals and drippers installation

After installation of main and submain pipes, the manifolds and lateral pipes are installed as per
the design and arrangement of the fields. The manifolds are HDPE pipes which should be carefully
connected to the submain pipes at riser points. Each laterals connected on a manifold in a given
block/BDU shall carefully be laid along the crop rows or between rows depending upon the
arrangement decided during design. The inlet end shall be connected to the manifold with suitable
size of connectors and the other end of the laterals shall be closed by end plugs. For inline
emitters, it is important to assure that each emitter positions are at exact locations of the crops.
For online emitters, carefully place the emitters at desired spacing. Be careful that the first emitter
is placed on the lateral at designed spacing.

4.3 TESTING OF THE SYSTEM

The purpose of a drip system is to distribute water uniformly. Right after installation and successful
testing of pipes and fittings, the uniformity of the emitter discharges in the system shall be tested.
Mostly non-uniformity in drip irrigation systems is caused by: (1) emitter plugging, wear, and
manufacturing variations; and, (2) non-uniform pressure distribution in pipes and hoses. Emitters
of the same type have variations in discharge (at the same operating pressure) due to small
differences from manufacturing tolerances. Manufactures normally specify the coeffiecient of
variation (CV) of their products.

In practice, the degree of uniformity of emitters discharges can be computed from field
observations of the depths of water collected in open cans placed at sampled emitters in a subunit.
The operating time used for testing is for at least 30minutes. The common index for indication of
application uniformity in drip irrigation is distribution uniformity, DU which is given by:
Q25%
DU   100
Qn ---- (4.1)
Where,
DU = coefficient of uniformity
Q25% = the average flow rate of 25% of the emitters with the lowest flow rate
Qn = the average flow rate of all the sampled emitters.

To calculate DU, the flow rate of a representative sample (40 to 100 emitters in the subunit) is
measured. DU values above 90% is a very good uniformity; 75 to 90% is good uniformity and
below 75% is unacceptable.

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