FOREWORD

It is with immense pleasure and respect that I write this foreword for a man whose
dedication, expertise, and leadership have significantly shaped the landscape of
our water management projects—Mr. H.H. Navani.
As the General Manager of Water at LCC Projects Pvt Ltd, Mr. Navani's
contributions have been monumental. His deep understanding of water resources
and his innovative approach to project management have not only driven the
success of numerous initiatives but have also set a benchmark for excellence in
our industry.
Mr. Navani's career has been a testament to his unwavering commitment to
sustainable development and environmental stewardship. His ability to
seamlessly integrate advanced technologies with practical solutions has earned
him respect and admiration from colleagues, clients, and industry peers alike.
This book is a reflection of Mr. Navani's profound knowledge and experience. It
encapsulates the wisdom he has gained over decades of service and serves as a
valuable resource for current and future generations of engineers, managers, and
environmentalists.
On behalf of LCC Projects Pvt Ltd and the countless individuals who have had
the privilege of working with Mr. Navani, I extend my heartfelt gratitude and
congratulations on his retirement. We are confident that his legacy will continue
to inspire and guide us in the years to come.
May his book on engineering experiences inspire and enlighten many young
engineers

SHRI.ARJANBHAI RABARI
MANAGING DIRECTOR
LCC PROJECTS PVT LTD

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 FOREWORD

It is with great pleasure and profound respect that I pen this foreword for a
remarkable individual, H. H. Navani, who has dedicated his career to the
advancement of water management projects and significantly contributed to the
success of LCC Projects Pvt Ltd.
H. H. Navani's journey with us has been marked by unwavering dedication,
exceptional expertise, and a visionary approach to water resource management.
As the General Manager of Water Projects, he led with both passion and
precision, ensuring that each project was executed with the highest standards of
excellence and sustainability.
Under his stewardship, LCC Projects Pvt Ltd has achieved numerous milestones,
pioneering innovative solutions in water management that have set new
benchmarks in the industry. His leadership has not only driven the company
forward but has also inspired countless colleagues and young professionals to
aspire to greater heights.
H. H. Navani's retirement marks the end of an era, but his legacy will
undoubtedly continue to influence and inspire future generations. His
commitment to excellence, integrity, and environmental stewardship serves as a
guiding light for all of us.
On behalf of everyone at LCC Projects Pvt Ltd, I extend my heartfelt gratitude to
H. H. Navani for his invaluable contributions and unwavering commitment. We
are honored to have been a part of his illustrious career and look forward to
carrying forward the legacy he has built.
I hope that his book on engineering experiences will inspire and enlighten many
young engineers.

SHRI.LALJIBHAI AHIR
MANAGING DIRECTOR
LCC PROJECTS PVT LTD

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 FOREWORD

Mr. H. H. Navani, the author of this book is basically a civil engineer who had
vast experience in water sector of Government of Gujarat, after retirement he has
worked in private sector for more than 19 years.
Apart from engineering activity, he is Shiv Bhakt and was founder Chairman of
Om Shiv Mandli Adipur, I knew him since 1984 when I was appointed in Gujarat
Water Supply Board at Bhuj, so it’s now 40 years since I first met him, he was 17
years senior to me and during my initial years in my job, I learnt a lot from him.
Shri Navani has the experience of handling water scarcities, restoration during
cyclone, restoration during earthquake 2001 of Kachchh, there are few people
who have experience of disaster management along with planning and execution
experience.
I appreciate his passion for engineering, due to which he worked as civil engineer
in private firms even after retirement.
One day he shared his thought that he wanted to pen down his experience as
engineer and wanted to share the petty and huge mistakes which is done by civil
engineers during the design, planning and execution of the works.
Academic books don’t contain the experience of any person, experience is such
thing that the world won’t know unless you write down. Most of the lecturers
and professors don’t have field experience so they teach, whatever is written in
the books.
Sharing the experience in the form of a book, will be a boon to the young
engineers. Shri Navani has experience since 1970’s where there were fewer tools
of engineering, no GPS, no satellite images, no computers, no approach road, no
electricity, no telephones in the areas where he worked.
Shri Navani has unique style of working, he used to write down the list of
activities which were to be done in a day, as a junior to him, I used to get chit in
morning which mentioned the target activity of the day, he worked in a planned
manner.
I wish him that his book on engineering experience may enlighten lot of young
engineers.
SHRI.Deepak Ramchandani
Retired Chief Engineer
GWSSB
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 (DEDICATED TO MY GURU JI LATE SHRI YOGESH BUCH AND OUR
MD OF LCC SHRI ARJAN SIR)

AUTHOR OF THIS BOOK:

MR.H.H. NAVANI
INTRODUCTION
Myself being a water supply engineer in GWSSB from 7th April 1971 to 31st
August 2006. After retirement God gave me the opportunity to work in MANN
Anjar as GM Civil, for 6 months, Adani for 5 years as a HOD water and waste
water (as global head for whole India projects). M/s Octamech Bombay for 6
months, M/s Sadbhav Engineering for almost a year. Welspun projects for 3 years
and finally LCC projects PVT LTD for 2 and a half years for heading water
supply projects all over India. Looking to my vast experience of more than 50
years in water supply, I am suggested/advised to write a hand book on practical
tips for executives as well as O & M for water supply engineers. With the God’s
gift and assurance of Hon.Shri Lalji Bhai Ahir director and partner of LCC
projects pvt. ltd Ahmedabad for printing this book. I have started writing from
today on 4th June 2024 with the blessing of shri Radhakrishnan Murthy chief
general manager of LCC projects PVT LTD Ahmedabad and Good Wishes
of shri Lavji bhai Bambhania General Manager LCC projects PVT LTD and
shri.Deepak Ramchandani Chief Engineer GWSSB.

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TECHNICAL TIPS
(A book for field Engineers on water supply)
1.SURVEY
Any project is started by survey. In water supply projects survey and alignment
and levels play a major role, technically and financially.
(A)Alignment:
The route/the alignment of the line shall be straight as far as possible. We should
know the distance between 2 points measured shall be shortest when it is straight
without any bends and curves. Unless they are unavoidable, we should select the
straight alignment.
Benefit: Straight line is shortest hence minimum cost of pipes. The survey must
consist levels at max 30.0-meter interval, levels and location of adjoining utilities,
River, Nalla, Village boundary, all type of roads, economical route for crossings
of all existing structures etc. It will help to designer with best economical and
suitable design and to analysis the details and cost to cross the existing
structures/water body/utilities.

FIG.1 (ALIGNMENT)
The friction losses (head losses) per km will also be minimum with the
minimum length of pipeline. I shall like to share my real experience from 1980-
81. It was survey and alignment for a rural water supply scheme named Banni
WSS in Kutch Dist. Gujarat. The first line (main line) from source (ground water,
well and tubewells) from village Jhura to village Servo – 24 km straight distance.
It is plain ground 16 kms in Rann of Kutch and initial 6 to 8 kms in wasteland
fully covered with jungle/jhadi (bavad-babool trees). It was very difficult to align
straight with the help of only survey instruments – ranging rod and compass the
only instruments available in those days, 42-43 years ago from today 2024. While
having several rounds of alignment in jeep and foot, we noticed fire in the jungle
visible from a distance of 8 kms apart. We (me and MR. VM Jeswani) both junior
engineers returned to confirm the distance of fire by the help of speedometer of
jeep, really it was 8 kms around as per our judgement.

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We decided when the light of the fire is visible from 8 kms we should try to see
light from A to B (24 kms) or reverse B to A. we tried one night deploying 2
labours on top of slab and asking them to hold a 4-cell torch, tied in 20ft long
bamboo rod. Then we went to the other side and climbed on top of the roof of a
mosque. But from such height we could neither see from A to B nor from B to A,
due to Earth Curvature. We could see at 8-10kms of distance only. We decided to
fit a point ‘O’ 8 kms from ‘A’ (near source) and from where we could see B point
also as there was no jhadi no jungle between O to B and light could be seen we
fitted the compass and started seeing bearing of O to A and O to B the difference
was coming 182 degrees, again 178 then 179 – finally by trial and error we found
a point where difference between 2 bearings was 180 degrees. It meant that now
we were on a straight line AOB. Immediately we aligned 3-4 points from O to B
in that straight line. Thus, we found the solution of fixing alignment in straight
line for pipeline. This was an exercise for almost whole night as we started work
at 9pm and we were free about 3.30 am. But we were happy that a great job was
done. This was only an example and only starting. We finished the whole
alignment of main pipeline and branch pipeline in the same way. This saved
more than 48 kms (if I remember correctly) saving not only the cost of the
pipeline but also frictional losses. The things were spread, we got huge
appreciation from our superiors, subsequently this was communicated to our HO
Gandhinagar. They not only issued an appreciation letter but circulated it to all
the subdivisions and Divisions of Gujarat. This is called attitude and dedication.
Having no survey instruments, we could save a lot of pipe line. Why not we can
do it today when we have a lot of sources. Hence alignment of pipeline plays a
major role in a water supply project.
The other thing /second point is that we must be cautious for selecting the
alignment by avoiding rivers and mountain cliffs. There should not be major up
and downs in the alignment. To avoid this, we may allow to increase length of
pipeline. Major ups and downs, in levels cause water hammer and air locking,
frequently break down the pipeline. This increases the cost of pumping machinery
and cost of operation maintenance.

FIG.1A (ALIGNMENT)

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(B)Levels
The Levels play an important role in a water supply project. When we design 5.0
M or 7.0 M residual head at consumer point even then water may not reach due
to:
If location of ESR(OHT) is changed without revising NGL, the horizontal
distance may be 5-10-20 mts. from the original point but if vertical distance is
increased without notice of site engineer/ Execution Jr engineer, it may create
great loss/major change. Instead of water reaching by Gravity at consumer point,
it may be essential to Pump and to provide a pumping station by construction a
sump, PH, PM, electrification. Though the designer is not wrong the small/minor
changes during execution may create adverse results. Therefore, for each and
every change the Execution team should take designer into confidence. It is also
moral duty of a design engineer to make his project successful. He should be in
continuous touch with the execution team.
The change in levels not only in storage tank but in pipe line also, sudden rise in
elevation which was not in the original LS may play negative effect. If we check
the longitudinal section (LS) and hydraulic mean gradient (HMG)line, we find
nominal residual pressure say 1.0-3.0mt at certain point in hilly areas. Here if the
execution engineer is negligent and leaves marking of alignment upon labour
contractor, there are full chances of shifting the line 2-5-10mt horizontally and
thereby 2-3-5mt vertically. This creates negative head in pipe line. Water will not
move further. The site supervisor will be ignorant of this thing and will try for
testing and commissions. At the time of design, the Pumping/Gravity main pipe
line many times designer not check the levels of intermediate points and design
the same with levels of first and last point only. In undulating terrain, we must
have to take levels max @ 30.0-meter interval and designer has to consider the
same in while design the Pumping/Gravity main pipe line. Ignorance of in route
levels will fail the fully project or alteration like intermediate pumping station/ in
line booster pump is required to use the existing network.
Similarly, in pumping/rising main, suction head should be checked/measured
twice or thrice. If lower suction level (LSL) is reduced the pump will not lift the
water. This happen in Submersible pumps whose source is tubewell or wells.
In surface water source also if water reduces to the calculated suction level, we
have to dig/excavate approach channel and provide extra POT at lower level in
Intake well. Therefore, levels play a major role in a water supply project. The
Design engineer as well as execution engineer/supervisor must take care about
these issues. The engineer in charge should be an experienced one and should not
rely everything upon the site supervisor. The Senior engineer must make frequent
visits on site and ask for these things/points.

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 FIG.1B (LEVEL)
2.SOURCE
Source of water is very important in water supply projects.
A. Source-ground water
The source shall be assured, perfect and long lasting. Whether it is ground water
or surface water. It is seen by experience ground water source means well,
tubewells, etc. are not much reliable. In due course of time water table of
vicinity/surrounding area goes down/diminishes. It results in failure of source and
pumping machinery. Therefore, designer must survey the past record of 10-15
years and be ready to face the situation. Another well or tubewell with more depth
must not be ruled out. Also care should be taken in selection of point of wells
(borewells) geologically. That means permeable strata, sand stone shall be
selected to tarp the water. In case of excessive sandy strata or silt there are
chances of choking up the strainer pipes. The Proper filter media should be
placed.
Second precaution shall be taken for distance between 2 sources, 2 borewells. The
cone of depression must be considered. It should not overlap. We observe many
times that due to pumping in one well the water level of adjacent well reduces
(Diminishes)automatically. This is the effect of cone of depression.
Third precaution shall be taken for quality of water. The quality of water must be
fulfilling the WHO/CPHEEO standards. During survey sample must be collected
from surrounding source and get it tested from PHE or Other Government
laboratory.

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 FIG.2A(BORE WELL PUMPHOUSE)

B. Source – surface water

Here we select river, dam, lake, etc. and draw water by constructing intake well
and approach bridge. Care shall be taken in collecting details of last 25-30 years,
to predict lower suction level and location of POT in the intake well.
Approach/intake channel may also be proposed/considered to bring the water
from a distance say 100-200-300mts length of channel. In short source shall be
reliable whether ground water source or surface water source. The details of
Water Body are essential to fix the location of reliable source for drinking water
scheme. Data like FRL (Full Reservoir level), HFL (High Flood Level), MDDL
(Minimum Draw Down Level). Generally, in Dam the water is reserved for
irrigation purpose. For drinking water scheme, it is advisable to draw water below
MDDL and accordingly suitable location will be considered for Intake Well. For
reliable and economical design of Intake Well do survey for maximum possible
locations.

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 FIG. 2B (INTAKE WELL)
3.PUMPING MACHINERY FOR SOURCES
We must select and design the pumping machinery capable of discharging the
quantum of water as required at immediate stage, that is, after 15 years of project.
The life of pumping machinery is considered as 15 years. Though the pipe line is
designed at 30 years hence (Future)demand.
In case of ground water, the suction level is generally more than 15-30 meters
below the ground level in well or tube well. Therefore, generally submersible
pumps are selected with suitable discharge and head.
In case of intake well vertical turbine pumps (VT pumps) are opted for limited
pumping head and more discharge. The efficiency for VT pumps is generally
80% and that of motor is 90%, the combine efficiency is selected around 75%.
In case of submersible pump and motor the combine, efficiency comes to 65-
70%.
A. Working and stand by pumps.
In case of tube well, the tube well itself should be of 25% more capacity. For
example, for a scheme we require 4 tube wells as per design, we shall provide 5-6
tube wells and in case of 1 tube well it will be 1 only. The pumping machinery
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shall be 1 working and 1 stand by in case of 1 tube well. In other cases, 50%
stand by is provided, for example 6 sets against the requirement of 4 sets.
In case of VT pumps, the pumping machinery shall be 50% more in
Discharge/Nos.
The concept of 2 working and 2 standbys of 50% capacity is not correct. The
pumping machinery whether the VT pumps or the CF pumps shall be of same
capacity of working and standby sets. Instead of 2 working we should select at
least 4 working plus 2 stands by sets of all equal capacity. This has more benefit
in operation as we can replace any pump at any time. The repairs maintenance
becomes easy. The discharge capacity can also be adjusted/maintained by running
2-3 or 4 pumps. It is observed that many times the demand of water which was
anticipated after 15 years, raises after 2-3-5 years due to many reasons such as
fast growth of population or addition of more village’s/habitants’/ hamlets in the
project. Therefore, concept of equal capacity of working and stand by pumps
must be opted for easy and smooth operation and maintenance.
For easy and smooth maintenance, we should have sufficient spares, tools, and
tackles with skilled staff to save time in repairs.
The capacity of wires, cables, panels boards, MCB, cable trays, everything shall
be as per Design and standard make, to cause minimum failures.
B. Pumping machinery for clear water sump at WTP or at any
other locations like intermediate pumping stations.
The pumping machinery selected shall be with positive suction only with
underground pump house, having same bottom level which is lowest suction level
of sump. The details from reputed manufacturer/ supplier for HSCF Pumps will
be helpful for at the time of design and execution.
The Series of pump sets, suction header, delivery header with sufficient valves,
detachable joints, Nonreturn valves expansion bellows, shall be designed and
provided by experienced designer and Engineer. The involvement of senior
experienced engineer is must, to avoid any mistake or laps in design and erection
also.
C. Mechanical joints (CID joints)
In case of suction headers and delivery header it is always essential to provide
mechanical joints/detachable joints called cast iron detachable joints (CID joints).
The benefit of these joints is that they can be easily opened by opening a nut bolt and can
be refitted. In case of repairs or placing additional valve (SV or NRV) the header line can be
dismantled from mechanical joints. The work becomes easy without disturbing
the whole system.

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D. Expansion bellows
The expansion bellows have the benefit of reducing or increasing the length (the
space near valve) so that the sluice valve or Nonreturn valve etc., can be easily
opened, removed, replaced without disturbing the suction or delivery line/header.
Though it is costly but must not be avoided from maintenance point of view.
E. Pump house
The pump house shall be designed carefully. In case of Tube well the Opening
(Manhole)shall be given in Top Slab for lifting (Clearance) of Column pipes. At
many places, it is observed that civil designers suggest the size of pump house at
random, either small or big. There are no issues in big pump house except
financial cost. The small pump house creates problem. The pump house shall be
designed to accommodate the pump motor set with some clear distance between 2
pump sets. It shall be at least 1.50 M or as suggested by the pump manufacturer.
The layout of the pump motor panel board, crane, cable tray, etc. before
finalization of the size of the pump house. The pump house may be for intake
well or for clear water pump, care should be taken in both the cases. The height of
the pump house shall also be designed as per the height of the crane to lift and
move the pump sets. The height of vertical turbine pumps is generally 1.0m to
2.0m or as per capacity of pump sets. This plays a major role in deciding the
height of pump house over intake well. While doing structural design of the pump
house, the load of pumps, motors, and electrical equipment and vibration of
running pumps shall be considered. Proper drainage arrangement for storm water
shall be designed as per the topography of surroundings. The provision of
sufficient rain water spouts shall be made in the slab to drain out all the water.

FIG.3 (PUMP HOUSE)

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4.SURGE ANALYSIS/SURGE DEVICES
In case of Rising main/Pumping main, with high head, there is always, affect of
Water hammer. Due to water hammer the pipe of Pumping main near Pump
House, Sluice Valve and NRV usually burst. There is sudden Bombing with huge
noise, when breakage occurs due to water hammer/ Surge. This results in huge
loss of cost of water, repair cost and time loss. This may happen repeatedly until
unless proper design is done and suitable devices like PRV, Zero Velocity valve,
Air cushion valve etc. are provided. The pipe designer shall always take care of
surge. The total head in a Pumping main should be kept limited to 30 M as an
ideal case. Now a days to reduce the Capital cost of IPS (Intermediate Pumping
Station), the Pumping/Rising mains are designed at higher heads, say up to 150 M
head or so. In such a case proper survey with contour, LS, CS, etc. shall be done.
The surge shall be calculated to design the class of DI pipes. The DI pipes in
Pumping main shall always be kept of DI K-9 class from safety point of view. In
case of MS pipes the thickness of pipes shall be designed as per Surge/ Water
hammer.
There are several devices like, Pressure relief Valves, Zero Velocity Valves, Air
Cushion valves and Automatic Bye pass valves to resist the water hammer. The
Automatic bye pass Valve is most suitable/ Effective in my view. If there is a
ridge or highest point in alignment after which water flows through Gravity, we
may construct an open sump to release the Air and allow water to flow by Gravity
after that point. Another remedy is to increase the numbers of Air valve near
Pump house which is most effective and Economical. This is successfully done
by providing close Air Valves in one project in Kutch District of Gujarat
(Lakadia to Chitrod pipe line of GWSSB in the year 1989-90) and 2) In case of
Madia Project Dist. Sagar MP(MPJNM) for Rising main with 140 M head at
WTP (To MBR 1) and 112 M Head at IPS (To MBR 2) by Project manager Shri
Bhisham pal ji Rathod in my Guidance (GM of the Project). We saved the cost of
surge devices for more than Rs 9 lacs. The air valves shall be provided at 100 M,
distance, up to 500 M length. The first AV at PH at 0 CH, then at 100, 200, 300,
400 and 500 M. The Project is running smoothly since March 2024. All the
peaks, elevated ground in Pumping main shall be provided Air Valves.
These are some practical tips for fast and smooth work to save cost and time both.
5.ELECTRIFICATION AND SWITCH YARDS
We have to install the Pumping Machinery in Pump House at source of water.
The Pumping Machinery needs power connection to run. The suitable
Transformers/ switch Yards are to be provided. The load of Transformers shall be
calculated carefully considering power factor 0.85. The capacity shall be selected
as to next higher to designed capacity, available in the market. The care shall be
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taken for Earthing Pit, Gravel packing, fencing etc. The power connection shall
be through 11 KVA/ 33 KVA dedicated line for a water supply project to get
supply for 24 hours. (33 KVA is preferred as power supply must be assured for
water supply scheme) All the permissions shall be taken from Power supply
company/Electric Board so as not to waste the time in power connection.

FIG.4 (SWITCH YARD)

6.WATER TREATMENT PLANT

Site Selection: - In most of the WS Projects site for WTP is fixed by the client,
but in many cases due to one or other reason like land comes in forest area or
disputed land other options must be kept in hand for speedy decision. As the
WTP are with Rapid Gravity Sand filters and whole WTP runs by Gravity, a
location with gradual slope will be good as we can use the natural gradient to
design the WTP.
A. Soil bearing capacity
The SBC shall be taken in much advance so as not to delay the design. We should
plan for SBC and appoint the good/efficient agency for SBC to give exact and
correct results.
The SBC for all structures of intake well, WTP principal multi balancing
reservoir (PMBR), MBR, ESR, etc. WTP is the main structure (component) of
water supply project. The Plate load test is must for structures store/process huge
quantum of Water like Clariflocculator, Clear Water Sump, Filter House. It takes
about 12 months to complete therefore, well planning shall be done. Taking SBC
design, fixing agency, start work, takes too much time. All the structures (civil)
must be started parallelly. The Filter takes much time, especially procurement of
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filter media is also a time taking job. The execution team shall focus and plan at
micro level for completion of WTP. We should try not to waste a single day as
WTP takes time more than 12 months, sometimes 18 months. Filter House is the
key and most time taking component in whole WTP. It is general tendency to do
design of Filter house in last and start the execution in last. It must be started
from the day one to complete it within time. We can’t run WTP without
completion of Filter house. The Piping and Instrumentation (P&ID) Drawing
must be prepared parallel with GAD and Structure Drawing to analysis the
required material to save the time.
The work of compound wall, internal roads and landscaping shall be planned
when 75% civil work is completed. This work shall go along with the electro
mechanical work parallelly. The work of Quarters, Admin buildings Laboratory,
etc. shall be completed prior to WTP. We should appoint a lab technician in well
advance at the stage of trial run of project. The use of alum and chlorine shall be
monitored carefully. There should be sufficient stock of alum and chlorine
cylinder. The statutory permission for chlorine gas cylinder shall be applied well
in advance as it takes 12-18 months in getting permission.

FIG.5 (WATER TREATMENT PLANT)

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Process Flow Diagram for Rapid Sand Filter Water Treatment Plant

MADIA WATER TREATMENT PLANT

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7.RAW WATER PUMPING MAIN
In most of the cases we have to pump the raw water, from the source of water, say
intake well in river/dam, etc. The pumping main shall be designed at 20 hours
pumping but 16 hours is safe though costly. The discharge per hour, if 16 hours is
considered increases, resulting increase in size of pipe line.
The MOC (material of construction) of pipe shall be selected as HDPE, Ductile
iron (DI) or Mild steel (MS).
8.HDPE PIPE
The HDPE pipes are preferred when diameter is up to 500mm. Though light in
weight, easy to cart, easy in laying and unloading but the disadvantage is that the
cost in higher diameter is equal or more than DI pipes. Moreover, we should not
stock HDPE in huge quantity as it is affected by sunlight, becomes brittle. In case
of fire HDPE pipes are at ultimate risk. The fitting of HDPE pipe is also easy. It
is easy to lay and joint and fit any fitting like tee bend, etc. Therefore, HDPE
pipes are preferred for smaller diameters up to 300 mm.

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 FIG.6 (HDPE PIPE)
9.DUCTILE IRON PIPE
A. The ductile iron pipe has great properties. It is rust proof. It is not brittle.
Therefore, use of DI pipe is increased very much. More over laying and fitting is
also simple. In case of piece fitting, it becomes difficult to cut and make a piece
fit. The fittings of DI pipes need a big inventory hence becomes costly. During
O&M we do not know which fitting will be required. Whether both side socketed,
one side socketed, one side flanged, etc. The labor should be skilled for DI pipes,
during laying and fitting.
The DI pipes are costlier in comparison to HDPE (smaller diameter up to
300mm). DI pipes are costlier than MS pipes in bigger diameter especially more
than 700mm. the selection of pipe is a big skilled task having price back up of
market to compare the cost.

FIG.7 (HDPE PIPE)

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B. Maintenance of DI pipe
Generally, leakages occur due to crack in rubber gasket or twisting of rubber
gasket
in pipe. Special tools (like chisel) are prepared to fit, press, and move the gasket
to its proper place. The skilled fitters are also needed to repair these kinds of
leakages.
Sometimes use of lead wool helps, to stop small leakages from the joints. Even if
there is pin hole in DI pipe, we can fit it and close the hole with lead wool.
C. Avoidance of Leakage
To avoid leakages in DI pipes, care shall be taken in laying. The ring crack or
circumferential cracks in pipe can be avoided by supporting or resting the pipe on
a smooth ground. Due to increased size of sockets (joints) of DI pipes the rest of
pipe, doesn’t touch or rest on ground. The pipe rests on 2 ends only and there is
gap in the rest of pipe. In this case, it works as simply supported beam, resulting
bending movement, somewhere at centre of pipe, this results in ring crack in pipe
during hydro testing. The load of water and the load of earth affects the pipe,
increase BM resulting in ring crack. To avoid this type of crack/leakage, we
should fill the gap below the pipe with sand or soil. Alternatively, pipes end shall
be dug to rest the collar portion of pipe below the bed of pipe (invert level) and
the pipe shall touch the soil/earth resulting no gap between pipe and trench.
D. Longitudinal crack in DI pipe occurs due to air locking, excessive pressure, or
surge. Sometimes in rocky area if care is not taken in back filling and JCB dump
stones along with soil. These stones result in hammering effect and pipe is
cracked longitudinally. Note: These all possibilities are very well mentioned in IS
code of laying DI pipes. In most of the cases only few engineers refer to IS code
before or during execution. If all the engineers make it a habit to study well the IS
code, we can save much loss. We can improve quality of work. To study IS code
and follow it does not mean we create hinderance in the progress. An engineer is
supposed to know all the parameter, all the consequences. If we have full
knowledge of subject, we can follow the things, practically taking care of quality
of work as well as progress. The precautions are always better. The negligence to
quality leads to great damage. It affects loss of huge money in repairs and loss or
time. Even then we cannot bring it to the original quality. Therefore, adhere to
quality, workman ship, whether it is pipe line or concrete or plaster and/or
anything. Once again it is repeat that field engineer should fully refer to IS codes
before the start of work.

15 | P a g e
 FIG.8 (LONGITUDINAL CRACK)
10.MILD STEEL PIPES
The mild steel pipes shall be designed properly before placing order. The
thickness is the main factor. It affects cost of the project. The designer, the DPR
engineer should not allow minus tolerance in case of MS pipes though mentioned
in IS code.
Other things are mentioned in specification IS code for procurement and laying
jointly fitting welding of MS pipes. Even then field engineer shall be very much
cautious for rusting of MS pipes. A small negligence may invite rust in MS pipes,
especially at joints. We must take proper care for joints. After welding is done
inside and outside of pipe, the coating is generally food grade epoxy paint inside
the pipes and joints, must be assured by latest technology. The outside LPE
coating shall be done carefully, leaving no chance for rust/corrosion.

FIG.9 (MS PIPE)

A. Land acquisition
At the time of starting the work of WTP, and pipe line, we must focus the issues
of land acquisition, ROW (Right of work), etc. In most of the cases major portion
16 | P a g e
is forest land. The collector has the power to recommend the case, up to 1.0-
hectare only to sanction the alternate revenue land against forest land. The forest
department will recommend the case for sanction only when collector agrees to
spare the substitute revenue land. This procedure takes a long time; therefore,
project manager must arrange one liaison officer for all cases of land. The
lesioning officer, should have good knowledge of Government rules. Therefore,
project manager may appoint a retired Government officer or equivalent, to deal
with forest, panchayat roads, MDR (major district road), State highways, National
highways, and Railways. This work is more cumbersome and time taking hence
the liaison officer shall be a senior person with 2 or 3 assistants to follow up day
to day cases in Government offices. The execution agency may take help of local
political representative to resolve any issue – general or complicated. It is noted
that many big projects are delayed due to lack of proper lesioning in getting
statutory sanction.
B. Permission for road crossing/railway crossings and shifting of
electrical line from the alignment
It is noted that at many places electrical line with poles are either crossing the
alignment of pipeline or parallel to the pipeline. In this case the authorities must
apply for shifting the lines and arrange hinderance free front for work. The
project manager focuses these issues well in advance so that progress of work is
not affected.
Permission for state highways, national highways, and railways
The pipe line may cross the road at many locations. It shall be defined/ascertained
with proper survey and latitude longitudes of crossings. The project manager shall
take care and manage in their own way to start the work parallelly of getting
permissions. The application can be submitted on the online system of the
concerned department. Sometimes the alignment may be longitudinally parallel to
the road, either on shoulder or in land width depending on the availability of land
to lay the line. The project manager has to manage all the issues without wasting
time.
Land of farmers and crops
When the pipeline alignment is crossing through the fields and passing through
live crops, the project manager must, either wait up to ripping and cutting of the
crop or to pay the crop compensation to the farmer. The latter is suggested for
speedy work as delay in work is always costly. The project manager may appoint
a retired Talati, Patwari/tehsildar to deal with the farmers, for crop compensation
in reasonable amount without any issues. These are some suggestions for speedy
work.

17 | P a g e
11.AIR VALVES
The air valves are provided in the pumping main (rising main) as well as in
Gravity main.
A. In case of gravity main, once the pipeline if filled, tested, and run for a few
days then there are very less chances of air, entering in the pipeline unless and
until storage tank is empty. We should take care that outlet pipe shall always be
submerged with water so that even if the tank is empty the air will not enter in the
pipe. In case of gravity main when the pipe line is damaged by outside sources by
excavation, etc. by other agencies like another pipeline by other agencies, oil line,
road cutting, etc. the field engineer/site supervisor and/or labour shall take utmost
care against any kind of damage of pipeline due to any reason. We must empty
the pipeline before repairs and again recharge it after repairs. Thus, air will enter
the line and may give trouble for a few days again. In gravity main, air valves can
be easily put at 1km or even more on flat ground. When topography is uneven,
many rise and falls are there in L section then we have to provide air valves at
every rise, irrespective of horizontal distance. The average distance may be 300-
500mt.

FIG.10 (AIR VALVE)

B. In case of Rising main (Pumping main), Air valves play vital role as the pipe
line is emptied many times due to interruption of flow of water due to power
failure. To avoid this, we should manage assured power supply (33 KVA)/
Dedicated feeder. In short, care shall be taken to maintain continuous flow of
water in Pumping main. The entry of Air in pipe line results in breakage of line.

18 | P a g e
Therefore, sufficient Air valves shall be provided at 500 M at least. In case of Flat
ground, the distance between two air valves can be increased. In case of hilly
area, the Air valve shall be provided at each ridge point. (According to
topography). The L section shall be prepared carefully to show location of all the
valves, Air valve, Sluice valve and Scour valve. The Design Engineer as well as
Executive Engineer (Project Manager) shall take care of exact position of valves.
The care shall also be taken to avoid excessive Air valves also as there is
possibility of theft of water from Air Valve or breakage of Valves and wastage of
water. In many cases it is observed that shepherd break down the Air valves to
serve water to their cattle. The theft of water is done by Big Hotels, Restaurant,
Petrol pumps also where the alignment of pipe line is parallel to Road (SH, NH).
Generally, the water is taped by connecting Hose pipes to Air valves and those
pipes are removed at the time of checking or visit of higher authorities. It is
concluded that when the pipe line is old/well settled, the Air valves can be
reduced in Gravity mains, to avoid the theft of water. The frequent repairs shall
be done to Air valve to avoid leakages and great loss of water.
C. The size of the air valve is generally provided 25% of the main pipeline or
next nearest higher size available in market. The air valves are fitted on MS riser
pipe of height 1.80mt so as not to be tampered with and can be easily operated
and maintained. The MS riser pipes shall be encased with concrete M-150 or M-
200 with 150mm thickness around the pipe. The naked portion of pipe and air
valve shall be painted with black paint, every year to avoid corrosion (rust).
During O&M we may change the balls of air valves rather than changing the
whole air valve. Generally, rubber coating of wooden balls is damaged.
Therefore, we should have extra balls in our inventory.
12.SCOUR VALVES
When there is leakage in pipe line and we have to repair it, it is essential to empty
the pipe line for minimum length. To empty or evacuate the line, scour valves are
provided in valley portion, lowest level portion (if we see the L section). The
scoured water shall drain through nearby Nala (Drain) as we provide scour valve
at lowest level. The distance between two scour valves shall be normally 5km
approx. or the location available to drain the water in natural Nala/valley. The
scour valve shall be fitted with drain pipe 6.0 to 20.0 M length depending upon
the distance of Nala from the pipe line, to drain out the water away from the pipe
line. The care shall be taken that scoured water shall be away from the main
pipeline. The accumulation of water along the main line may result in settlement
of main pipe line resulting breakage and leakage. It is seen that due to settlement
of soil below the pipe line may cause, Ring crack /Longitudinal crack in DI pipe
line. Therefore, there shall not be water pit /Khada near the pipe line. The size of
Scour Valve is generally 2/3rd of diameter of main pipe line. It can be reduced to
½ D in case of big pipe lines say more than 600mm size.
19 | P a g e
 FIG.11 (SCOUR VALVE)
13. SLUICE VALVE
The sluice valve is generally provided at the location near to Scour valve. This
helps us to drain the water from one side only where repairing is to be done. The
other side of pipe line is filled, hence no wastage of water. It (SV) serves as break
valve of whole long pipe line. Generally, Sluice valves are necessary in Gravity
main to avoid empty of whole pipe line. In case of Rising main/ Pumping main,
there is no need to provide Sluice valve, as the water is stopped by shut down of
Pumping machinery. It is not advised to put sluice valve in Rising main, if the
valve is closed by mistake of any one, the pipe line will burst when pumping is
started. The closure of sluice valve can be by mistake or by Mischief of our own
staff. The Sluice valve is essential at the Pump House at the end of Header/at
Junction of Header and main pipe line. There shall be two sluice valves at every
branch pipe line in Gravity main. One on branch pipe and one on main pipe line
after the branch towards flow of water. This facilitates in controlling supply
quantity in Branch line. The valves can be closed in case of repair of pipe line. 12
A Non-Return valve (Reflex valve) NRV, IS code 5312.i.2004
The NRV or Nonreturn valve in Pumping main near Pump House or inside the
PH
is provided in suction header/ Delivery header, to restrict the back flow of water.
The water may return due to shut down of Pumping Machinery. This may happen
due to many reasons as Failure of power, breakage in pipe line or over flow of
Service reservoir. The velocity of return water is high resulting huge pressure at
20 | P a g e
lowest point near Pump house. The pipe line is liable to damage or dismantle
from joints. Therefore, NRV is must to withstand back pressure. The NRV shall
be heavy duty ISI mark. It is advisable to keep the NRV as stand by at Pump
House. There is always chance of damage of NRV in Pumping main. The NRV
are of two types.
Single baffle wall 2) Double wall system. (As in case of single shutter door and
double shutter door). The single wall NRV is more effective and durable in
comparison to double wall NRV. Over all it depends on quality of valve also.
A. Pressure Gauge in Pumping main
The pressure Gauge is important in any pipe line. It is equally important in
Pumping main and Gravity main. The pressure Gauge must be fitted at
source/Pump House, on Suction header and Delivery header. The pressure Gauge
shall also be fitted on pipe line near GSR/ ESR where pumping main ends. The
PG shall not be fitted on main pipe line in Rising main as the damage in PG will
result great loss of water.

FIG.12- (PRESSURE GAUGE)

B. Pressure Gauge in Gravity main
It shall be fitted at each and every junction of branch line. This helps to study
flow of water in Branch pipe line. The O&M Engineer controls Valve in
accordance to availability of Pressure in Branch line. This helps to know the
water is being supplied in branch pipe line at required pressure. During O&M if
pressure is suddenly dropped, it indicates the leakage in pipe line which is not
visible. There is possibility of blockage in line also. The pressure Gauge is useful
to the field Engineer same as Thermometer for a Doctor. Therefore, PG shall be
21 | P a g e
maintained well. (Generally, it is neglected). The dial of PG shall be preferred as
150mm size, rather than 100mm, to read it from distance. The range of PG shall
be 0 to 5 kg or 0 to 10 kg depending upon the site requirement. (As availability of
pressure in line). The vertical pipe shall be like the Riser pipe of Air valve.
Generally, it is of 25mm to 40mm, size to avoid chocking of pipe. Then PG may
be fitted by using a reducer. The vertical pipe is encased in RCC pipe of 150mm
size filled with sand. As pressure Guage plays important role in O&M, it shall be
preserved and well maintained.
14.SUMP (STORAGE TANK)
The Under-ground Sump is proposed where ever Storage is required and water is
to be supplied further by Pumping. We may call it IPS also, (Intermediate
Pumping Station).
Generally, a sump on main line is proposed of 6 hours capacity where continuous
supply is there by Pumping. In case of Rural area where sump is for branch line
for one or more villages, the storage shall be at least of 12 hours demand, for
assure supply. The slab of small sump up to 1 lac liter may be a Flat slab whereas
Dome slab shall be proposed in bigger capacities of sump. The benefits of Dome
type slab are, 1) water does not retain on slab, 2) The thickness of slab comes less
due to less Bending moment, as per Design. 3) We can avoid beams and Columns
under the slab. This reduces cost of Structure. In bottom of Sump construction of
Collection Pit/ Drain Pit shall be proposed to pump whole water. This helps in
cleaning of sump periodically. The care shall be taken that the 1) Foot valve in
the sump shall always be Flooded/ Submerged so as not to allow the Air in
Suction line. 2) The Foot valve shall be at least 300mm above the bottom level of
Suction pit so as Sludge/sand or any Debris is not entered in Foot valve. The
sump shall be cleaned by lime or Hypochlorite.
15.GSR/ ESR
The Service Reservoir where pumping water is stored /collected shall be at
sufficient high
level to serve the water at required residual pressure to end point/ tail end/last
village.
The pumping water shall have 5.0 to 7.0 M head over the FSL of GSR/ ESR. The
designer must consider not only static head and Frictional losses but losses due to
Tees, bends and leakages must also be considered to make the Project successful.
The losses due to unauthorized connection like cattle feeding in the route, slumps,
hutments which were not the part of the Project. For safer side the value of C for
frictional losses may be considered for old pipes rather for new pipes. The
Designers/Estimating Engineers and Clients shall take note for this point, to avoid
failure of the Project (Scheme).
22 | P a g e
A. The Piping in Service reservoir
The Inlet pipe shall have bell mouth or of increased dia. to increase the area of
discharge and reduce the velocity so that water may not touch the top slab and
damage it. The Free board in the reservoir shall be at least 400mm to avoid the
water to reach the slab level during over flow. The provision to escape the Air
from water tank shall be kept, 1) Cowl ventilators (The Nos shall be as per actual
design), 2) Provision of Shaft with Jali, on top of Dome to Escape the Air during
entry of water. It is noticed in many cases these things are clearly shown in the
drawing but are ignored by Site Engineers/ contractors. This affects the smooth
running of the scheme. All the down take pipes like, Inlet, out let, over flow and
Washout pipes of ESR shall be rested on Duck foot bends. All the 3 pipes Inlet,
out let and Washout pipes shall be provided by Sluice valves of same size that of
pipe, where as in case of Over Flow pipe, there shall not be any Sluice Valve.
The Over flow pipe shall be connected to equal size of Horizontal pipe of
sufficient length to lead it to nearby Drain/Nala.
16.FLOW METERS
The flow meters play equally important role in a water supply scheme. The flow
meters are used to measure the supply of water and collect revenue on quantity
basis in Urban and semi urban areas. Still flow meters are not fully successful at
consumer point due to lack of maintenance.
The Electromagnetic Flow meters (EMF HSN Code 90261020) if maintained
properly can be relied to bill the consumer. In Gujarat state GWIL is successfully
using EMF in big size and maintaining well to bill the consumers like big
Industries /Institutions etc. In rural areas Flow meters are not maintained well,
therefore the billing is on basis of size of connection. The Flow meters are
important to know the Flow, quantity of water, velocity, and pressure. It gives
cumulative readings also and are connected to PLC / SCADA system. The EMF
though precise but are costly. The use of EMF is increased now for revenue
collection system. The Installation of EMF meters shall be done as per
Instructions and directions of Manufacturing company. The flow meters shall be
fixed on smooth ground. The alignment shall be straight length without bends.
The pipe shall be straight 5 times of dia. of pipe on upstream side and 3 times on
downstream side. The length of cable from source of power for EMF shall be
minimum.
The Mechanical meters in Rural areas are not successful due to poor O&M.
Generally, the meters are choked up with sand, dust and any other debris. There is
Air locking also, that restricts movement of meter and suddenly when Air is
released the meter moves fast and shows unrealistic readings. The Ultra sonic
flow meters are fitted on outside of pipe. It works on concept of sensing the
23 | P a g e
velocity of water flowing in pipe. The flow can be computed by Q=A*V, as area
of pipe is fixed, the meter gives the flow. The condition for correct result is that
the pipe should run full (No partial). The advantage of these flow meters is that
when the pipe is already laid and is in running condition. The shutdown is not
possible but we have to measure the flow, then these Flow meters are useful.

FIG.13 (FLOW METER)

24 | P a g e
17.BENDS, THE USE OF BEND IN PIPE LINE, THRUS BLOCK.
As far as possible the alignment of pipe line shall be straight. The bends shall be
avoided. The frictional losses increase due to bends. Even then bends cannot be
avoided when turns or curves are there in alignment. Due to the bends, there is
circumferential force which pulls the pipe line on outer side. You might have seen
super elevation in case of Roads at curves / Turnings, to avoid over turning of
vehicle. Similarly, here, the joints of bend are liable to open due to
circumferential force. Therefore, at every bend RCC (M 20) Thrust block is
essential. The design depends upon, Flow, Velocity, Size of pipe and degree of
bend. The designer shall design the Thrust block for every bend (221/2, 45, 90
degree) and Execution team shall cast the thrust block as per design and drawing.
18.SUPERVISORY CONTROL AND DATA ACQUISITION
(SCADA)
Now a days all the major pump house, Treatment plants is Monitoring and
operated with SCADA. The data from all components according to project is to
be monitored and collected through SCADA. A proper designer/ vendor is to be
appointed for SCADA.
19. HOUSE SERVICE CONNECTION (HSC)
The final and most important component of “JAL JEEVAN MISSION” to
provide potable, regular and sufficient drinking water to each and every house
hold by giving House Service Connection. Basic details for number of houses are
required to collect at the time of Survey. Depends on the end user they will take
direct connection to their underground storage tank or kept a Stand Post inside the
campus of house hold. A 15 mm connection is provided with the help of Service
Saddle, MDPE Pipe, GI Pipe, Ferrule, Flow Control Valve, beds, Tap. Upmost
care must be taken during fusion of service saddle with HDPE Pipe or Clamping
with metallic pipes as there may be chances of failure of service saddle at the time
of water supply commissioning.

25 | P a g e
 MEMORIES
I am recalling my memories of past when I was working in field offices of
GWSSB. My much time was spent in Execution and Maintenance of the water
supply Projects. Here are some memories are mentioned which can be useful to
Field Engineers of water supply Engineers.

1.VARIETY OF PIPES USED IN THE SCHEMES. HERE I

MENTION A FEW.
A. RCC pressure pipes, P1, P2, and P3 of class 2kg/cm2, 4kg/cm2 and 6kg/cm2
were used in Banni water supply scheme of Taluka Bhuj District Kutch in the
year 1980-81. The Quality of pipes was very good and there was almost no
leakage. Subsequently, after sometime during maintenance, the leakages were
found in Joints. The joints were cement joints and there were cracks in cement
due to Thermal stresses. As the soil was clay type ordinary black cotton soil, it
was affected by even small leakages. There was unequal settlement in the soil
(Bottom of pipe) resulting more leakages in the joints. This became daily
headache for our team. Even minor leakage caused much damage to the pipe line.
The water supply became irregular. There were ring cracks in centre of pipe due
Shear stress due to settlement of pipes. Therefore, to run the Scheme smoothly,
concrete block at joints was done to stop the leakage from joints. As this Idea was
successful the supply was restored regularly. The MS Molds were fabricated with
opening hole on top to pour the concrete. Initially these RCC blocks were casted
on leaking joints and after successful trial run, it was proposed to do it on each
joint in the interest of Project (For long run). The RCC pipes are being used still
today in Irrigation /Lift Irrigation as Gravity main with low pressure. It is known
that Most of the RCC pipes are leaking from joints. We may apply this method of
Concrete with Mould system for an assured result.

Fig.14 RCC PIPE FITTING

26 | P a g e
B. Asbestos Cement pipes (A C pipes)
The asbestos cement pipes were generally used from 80mm to 400 mm dia. size.
These pipes were made up of Asbestos fibre and cement. The same material is
used in A C Sheets (Roofing) also. The joints of these pipes were cast iron
detachable joints with nut bolts. The A C pipes were available in 5kg/cm2, 10
kg/cm2 and 15 kg /cm2, known as class 5, class 10 and class 15. During O&M of
these pipes the Major problems were, 1) The nut bolts were kept loose due to
negligence of Contractor and Supervising staff.

Fig.15 AC PIPE FITTING

2)TWISTING OF RUBBER RINGS IN GROOVE OF CID
JOINT.
3) RUBBER TERMITE
Eating away of Rubber rings (As it was of organic rubber) by termite. This was a
major Problem. It was not easy to detect even, where the ring is damaged. This
generally came to notice after leakage and wastage of considerable quantity of
water. The Termite or Udhai (Called in local language) is generally in Roots of
plants and trees in the field. The termite always searches a safe cold place to live
in summer. The Food and water both were available in pipe joints. The damage
due to Termite attacks was in kilometres of length. This was a great damage and
loss to pipe line. It was a challenge to O&M of pipe line. There was no alternate
to excavate the pipe, open the joint, replace the Rubber ring and repair the pipe
line and commission again. This went on for few years and the problem was
discussed on higher level. The alternate was found as SBR Rubber ring which
was anti termite. The field Engineers must be aware of this problem.
4) CAST IRON PIPES
There was wide use of Cast Iron (C I) pipes in water supply projects, at that time
Ductile Iron pipes were not introduced.

27 | P a g e
 Fig.16 PIPE JOINT BY MELTING LEAD
I remember that I was deputed to Custom House of Kandla Port for Custom
clearance of DI pipes in 1974. At that time DI pipes were imported from Japan.
The DI pipes were manufactured by the Electro steel company, Kolkata
somewhere near the year 1998-2000. The CI pipes are brittle. The utmost care is
to be taken in Loading, Unloading and Laying of these pipes. The joints of CI
pipes were, cement joint or Lead joints. Please refer IS code for more details. The
cement joint also fails due Thermal stresses. The lead joint is flexible joint and
were placed after every 10th joint to handle the thermal variation of pipeline. The
CI pipes are manufactured with flanged joint which were used in inlet, outflow
and overflow pipes of ESR and some other type of fittings for manifold system,
similarly DI pipes are also manufactured with flanged joints for similar purpose.
This type of Knowledge is essential to an O&M Engineer.
5) USE OF LEAD WOOL
The lead wool is made from lead (Lead in form of threads). It is impervious. The
lead wool is used now a days also to repair not only pipes but water tanks also.
The main benefit is shut down of water is not required for repairing. The lead
wool is used to repair RCC, CI, DI or any other pipe where there is minor leakage
from joint. The leakage is mainly due to failure of cement joint, damage of rubber
gasket etc. The lead wool is inserted from where there is leakage and pushed
through caulking tool (just like chisel). The lead wool is soft and forms any
shape, inside the pipe by hammering with tool. In case of water tank, the lead
wool is pressed where there is minor crack this could be done even when tank is
filled with water.

Fig.17 USE OF LEAD WOOL

28 | P a g e
6) MILD STEEL PIPES
The MS pipes can be repaired by welding or Clamp fitting.

7) CHOKING OF PIPE LINE

It is observed that during laying of pipe line whether, PVC, CI, DI, MS or any
other pipe line, the ends are kept open. (Not closed at the end of day). This is due
to careless work of the contractor and Field engineers. It Is advisable to close the
ends of pipe with Gunny bags or any other suitable material. This helps in
preventing entry of foreign material like, earth, stones, rats, cats and snakes etc.
Generally, in summer season live creatures enter the pipe line to get shelter from
heat etc.
Here is my real experience of testing and commissioning of 100 mm diameter- 4
km pipe line. It was a branch line from main line of 200mm dia. There was
sufficient pressure in main line even then water was not reaching the other end at
the distance of 4km only. The pipe line was choked. We put our all efforts to find
out the location where line is choked. It was a great pressure from higher
authorities to supply the water to the village Gorevally of Banni Water supply
scheme of Kutch Gujarat. We tried to pump from one side and kept other side
open to remove any sand, earth, or debris. For two nights pumping was done and
in the day time leakages were repaired due to excess pressure but ultimately no
results were met. Then we started making a small hole at every 100 M distance to
locate the choke, physical line pressure was observed and it was thought process
that if there is considerable drop of pressure between two holes by which section
of choked portion could be identified. The pipeline was punchered by making
holes up to 3 km length and no choke up found. Our whole night was wasted and
we were tired, it was almost 3 am in night. Finally, we found that after a
particular pipe there was no flow, it means we located the choke up pipe. The
pipe was opened removed. It was fully choked up and Full of bad smell. The pipe
was broken and to our surprise, there was dead body of a cat. It was swollen and
had choked full pipe. This is lesson that how costly, it proved us, by keeping open
end of pipe after the day work. The contractor and Field Engineers must take care
and learn from this real story of 1981-82. Recently in Madia water supply
project, Dist. Sagar MPJNM, the Project Manager Bhisham pal ji told me that in
many pipe lines were choked up with stones and soil. It took much efforts and
time for commission of pipe line. The field Engineers and contractors must take
care of closing the pipe ends.

29 | P a g e
7 A. CHOKING OF PIPE LINE DUE TO ROOTS
In Rann of Kutch and many such other places where there Babool/Bavad /tress,
or any other Plants, trees on the route (Alignment), the roots of these trees enter
into pipe line and cause blockage of pipe. Initially the roots are so thin like a
string/thread, say 0.1 mm in size, that it enters the joint easily and gets expanded
inside getting favourable atmosphere (Perennial water). I shall mention here a live
example (Real Story) of Roots. There was a Sluice valve on the main line which
was completely choked up with Roots. It was 600mm dia. Valve. Even after
collective effort of 8-10 labors the valve could not be operated. The efforts were
made to remove the Roots from all the sides but it had grown like a tree. This was
tried for whole day. The supply of City was hampered as no water was passing
through. Ultimately, we had to break the Valve and replace with a piece of pipe
and restored the supply. This was a great experience that roots can play such a big
role in stopping the supply. It took us two days to repair and restore the water
supply of GandhiDham / Kandla city including many Industries like IFFCO, and
Kandla port. The roots of Babool or any other such trees affect highly. The Field
Engineers must be aware of this kind of Serious problem. Therefore, utmost care
should be taken to cut the trees along the Alignment of pipe line and discourage
growth of Roots. Periodically cutting of trees is essential. The O&M team shall
give priority to this task.

8. PRACTICAL WAYS OF REPAIRING THE PIPE LINE

I recall my memories, how we were repairing the pipe line1) The Running
condition of Flow, without taking shut down, 2) Urgently overnight repair, 3) In
absence of ample resources.
A. When the leakage was of the low, pressure zone (Generally in Gravity main),
the holes occurred in pipe line due any reason were repaired by putting rubber
packing on the hole and fixing MS Clamp over it, tightened by nut bolts. It was
bit difficult when the hole was found in the bottom of pipe. To stop the water, we
used to insert wooden pegs in the holes, cut it from top to the level of pipe, then
clamp it, even if there is no rubber packing available at site.
The wooden pegs have property of swelling which matches the size of opening
and becomes water tight during course of time. This was a great benefit to
complete the work without rubber packing, some times without clamp even. Only
Wooden peg would stop the leakage. The cycle tubes, tire tubes were also used in
absence of rubber packing. It was readily available, more effective, and cheaper
solution.

30 | P a g e
 Fig.19 (RUBBER PACKING)

Fig.18 (RUBBER SLEEPER PACKING)

B. When the leakage was at high pressure zone, bigger size of pipe line and high
velocity of water.
When there is sloping ground, big level difference, the velocity is more, we must
make arrangement of draining the leakage water coming out of pipe to see the
size and nature of hole/crack in the pipe. Due to huge volume of water coming
out from the pipe, the pipe is fully covered with water and it is difficult to
ascertain even, from where the leakage is there and nature and size of leakage. I
shall tell you a real story of such leakage. There was a phone call at night at about
11 pm at night.

31 | P a g e
It was about a leakage in main line RCC 600mm old pipe line. There was huge
volume of water from 20-25 tube wells flowing in pipeline. I called the driver,
took the jeep and arranged two three labors at night. On reaching at site, we saw
huge water coming from the pipe line as it was predicted. The leakage was to be
repaired over night as it was question of supply of water to whole city of Adipur
under Gandhidham Municipality. The leakage was hardly 300 meters away from
50 lac liter water tank at high ground level. We drained the water accumulated
around the pipe line. After two three hours of draining, we could find the nature
of leakage. There was a hole of about 250mm size on the top of pipe. The rubber
packing was there but clamps were of smaller size. It was not possible to control
the flow of leakage with 150mm size clamps. We required at least 300-400mm
wide clamps. The clamps could be fabricated next day. It was feared the water
supply shall be stopped for 2-3 days. At this crucial time one of my staff
suggested to bring a wooden log of 300-400 mm size to insert in this hole. It was
good idea and at the same time if such a big log could not be pushed inside, this
will further break the old RCC pipe and size of leakage may increase. Even then
we tried and brought a big log, trimmed it with Kulhadis (Axe) and pushed it with
big hammers. After the continuous efforts of overnight we succeeded to control
the flow about 90%. Only small quantity of water was coming from the periphery
of wooden log. At least we were sure that we could supply the water next day for
few hours. The leakage around the wooden log would reduce gradually as log
swells in size.
This is the practical approach with strong will power. Imagine how much water,
we could save and arrange supply to city next day with some reduced quantity.
Generally, we repair small pipe lines and small holes with wooden pegs which
subsequently swell and become water tight. The O&M keeps wooden pegs in
stock for immediate / urgent repairs.

9. THE DAMAGE OF PIPE LINE BY SHEPHERDS

(MALDHARIS)MICRO
It is common practice in Jungle/Rann or any other remote area where Maldharis
(Cattle owners) are feeding grass to their cattle. They require water also. The
Maldharis know the alignment of pipe line. The Air valves are usually leaking but
very small quantity. This quantity is not sufficient, for cattle, therefore, they
tamper the pipe line/ Air valve and try for bigger leakage for more water, this was
very serious problem. As the water is leaked, it may not reach to tail end
consumer. The shepherds create great problem. They require less water but waste
a huge quantity of water by damaging the pipe line / Air valves. This problem
was discussed at higher level. It was political support to Shepherds. The logic was
to feed the water to cattle in summer is the mercy (Jiv Daya). Finally, it was
32 | P a g e
decided to construct cattle trough at every 5km distance along the alignment of
pipe line. This way, the wastage of water could be controlled. This saved not only
water but lot of money and man power spent for repairs of pipe line. The O&M
team may take note of this point as same problems may come today even.

10. INTAKE WELL/ JACK WELL, CHOCKING OF ROSE PIPE

The holes kept in Intake well to allow the water inside from Dam/ River, are
called POT. Generally, jali/ Wire mesh is covered to these holes. In many other
cases, Rose pipes, (Perforated pipes) are fixed in Jack well to allow water. They
are fixed to prevent entry of wooden logs, Debris, Fishes, Shells, Dead bodies of
Animals, and many other refuses. It is common that these Rose pipes /Holes /
POTs are choked up due to many reasons. When the water in Dam is at its lowest
level, the water is tapped from bottom most hole, which is generally full of mud
etc. The velocity of water is also very less due limited difference in water level
(In summer). The site team is quite competent to tackle with cleaning the Holes/
Rose pipes. This was the case of Tappar dam of Anjar Taluka Dist. Kutch,
supplying water to Kandla, Gandhidham cities, and many villages along the route.
The Rose pipe was Fully choked up. The site team tried its hard but failed. The
water supply was stopped. Finally, Divers had to be called from Bombay to clean
and make possible the entry of water in Jack well. It is mentioned here as the
same condition may happen anywhere in any Project. The O&M team shall be
fully prepared and arrange the cleaning periodically to avoid such a huge havoc.
Therefore, every year, cleaning along the water route of bottom most hole must
be done before summer season.

CONCLUSION

This book is written by me depending upon my own field experience. It is not

claimed that everything, written here is Technically correct or Fool proof. This is
mainly for Field Engineers of water supply Projects. They are advised not to
solely depend upon this book but work according to Tender Specifications and
Conditions of contract. The IS code of each item must be referred and followed.
Thanks to God, thanks to all who supported me in this task.

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 PROJECT:GANDHISAGAR
TENDER COST: 1166.32 CR.
CONTRACTOR: LCC PROJECTS PVT. LTD

34 | P a g e
 LCC PROJECTS PVT LTD
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