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MSIG Jilid 3 PDF
MSIG Jilid 3 PDF
Industry Guidelines
Volume III
SEWER NETWORKS AND
PUMP STATIONS
Third Edition
National Water Services Commission (SPAN)
© Copyright National Water Services Commission
ISBN 978-983-44456-0-7
Third Edition
January 2009
Published by
Suruhanjaya Perkhidmatan Air Negara (SPAN)
(National Water Services Commission)
Prima Avenue 7, Block 3510
Jalan Teknokrat 6
63000 Cyberjaya Selangor
Malaysia
FOREWORD
BY THE CEO OF SPAN
The National Water Services Commission (SPAN) has completed the exercise
initiated by the Sewerage Services Department to review and improve those guidelines.
The new revised documents were renamed as the “Malaysian Sewerage Industry
Guidelines” which comprise of five (5) volumes.
Section 1 Introduction
1.1 Purpose of This Volume 3
1.2 Who Should Use This Volume 3
1.3 Related Reference Material 3
i
2.2 Manhole 50
2.2.1 General 50
2.2.2 Manhole Location 52
2.2.3 Pipe Lengths from Manhole 53
2.2.4 Structural Design Considerations for Manhole 53
2.3 Manhole Covers and Frames 55
2.3.1 General 55
2.3.2 Load Class 55
2.3.3 Material 55
2.3.4 Dimensions, Marking and Surface Finish 55
2.3.5 Seating 55
2.3.6 Casting 56
2.3.7 Protective Coating 56
2.3.8 Water-tightness 56
2.3.9 Safety Features 56
2.3.10 Product Certification 57
2.4 Design of Network Pump Stations 57
2.4.1 Specifying of Network Pump Stations 57
2.4.2 General Requirements 58
2.4.3 Buffer Requirements 58
2.4.4 Pipework Requirements 58
2.4.5 Wet-well Requirements 59
2.4.6 Dry-well Requirements 60
2.4.7 Structural Requirements 60
2.4.8 Ventilation Requirements 61
2.4.9 Odour Control 61
2.4.10 Requirements for Lighting and Electrical Fittings 62
2.4.11 Acceptable Pump System (Fixed Speed Pumps 62
Only)
2.4.12 Valve Requirements 63
2.4.13 Requirements for Level Controls 64
2.4.14 Requirements for Alarms 64
2.4.15 Requirements of Hydraulic Design and Performance 64
2.4.16 Maintenance Considerations 65
2.4.17 Hazard and Operability 65
2.4.18 Other Requirements 65
ii
2.5 Interceptors 68
2.5.1 Oil Interceptors 68
2.5.2 Grease Traps 68
2.6 Concrete and Reinforcement Requirements 69
2.6.1 Concrete 69
2.6.2 Cement 69
2.6.3 Steel Reinforcement and Falsework 70
iii
3.6 Special Requirements For Sewer 88
3.6.1 Thrust Blocks for Pressure Pipelines 88
3.6.2 Pipe Restraints and Bulkheads on Steep Slopes 89
3.6.3 Pipe Embedment and Overlay 89
3.6.4 Sleeving of Ductile Iron Pipe 90
3.6.5 ‘Rocker’ Pipe Connections to Manholes 90
3.7 Reinstatement 90
3.8 Connections to Public Sewers 91
3.8.1 General 91
3.8.2 Junction Connections 92
3.8.3 Saddle Connections 92
3.8.4 Manhole Connections 93
iv
4.10.2 Technical Requirements and References 107
4.10.3 Equipment Specifications and Test Devices 108
4.10.4 CCTV Inspection Requirements 108
4.10.5 CCTV Inspection Implementation Procedure for 110
New Sewer Network
4.10.6 Interpretation Of Results From CCTV Inspection 111
4.10.7 Follow-Up Action to Be Taken 112
4.11 Infiltration Test 114
4.11.1 General 114
4.11.2 Procedure 114
4.11.3 Handling Test Failures 114
4.12 Water-tightness Test 114
4.12.1 General 114
4.12.2 Procedures 115
v
List of Tables
vi
Figure A13(b) Typical Details of Inverted Siphons or Depressed Sewer 132
Figure A14(a) Typical Details for Force Main – Scour Valve and Receiving 133
Manhole (Sheet 1 to 2)
Figure A14(b) Typical Details of Force Main – Air Valve (Sheet 1 to 2) 134
Figure A15 Typical Detail of Force Main Crossing 135
Figure A16(a) Standard Pipe Beddings (Sheet 1 to 2) 136
Figure A16(b) Standard Pipe Beddings (Sheet 1 to 2) 137
Figure A17 Vacuum sewage collection system 138
Figure A19(a) Example of vacuum station with housed collection vessel 139
Figure A19(b) Example of vacuum station with housed collection vessel 140
Figure A20(a) Collection chambers with interface valves vented through 141
breather pipes
Figure A20(b) Collection chamber with interface valve activated by float 141
Figure A20(c) Multi-valve collection chamber 142
Figure A21 Vacuum sewer profiles (not to scale) 143
Figure A22 Example of vacuum sewer profiles for uphill and downhill 143
transport (not to scale)
Figure A23 Y-branch for vacuum sewer 144
Figure A24 Method of joining crossover pipes and branch sewers to 144
vacuum mains
Figure A25 Typical details of dry-well pump station 145
Figure A26 Typical detail of wet-well pump station 146
Figure A27 Buffer Zone for Pump Station with Super Structure 147
Figure A28 Buffer Zone for Pump without Super Structure 148
Figure A29 Standard Symbols and Abbreviations 149
Appendix B Tables
vii
Section 1
Introduction
Introduction
This volume sets out the requirements of the National Water Services
Commission (SPAN) (referred to as the Commission in this document)
for the design, construction and testing of sewer networks and network
pump stations.
The owner must comply with the requirements set out in this volume
when submitting an application for the approval of the Commission.
This volume generally does not cover internal plumbing systems within
buildings. However, some guidelines are provided on the provision of
interceptors to protect public sewers from the discharge of oil and grease
from garage workshops, hotels, restaurants, canteens or any premises
that collect such matter.
This volume does not cover all aspects of design and construction of
sewer networks and network pump stations. Where information is not
covered in this volume, the designer shall follow the requirements given
in MS 1228.
MS 1228 shall take precedence over other foreign standards in the event
when there are discrepancies on the requirements.
a) Malaysian Standards
b) British Standards
d) German Standards
e) International Standards
The Commission will, from time to time, specify additional standards to be used in
the design and construction of sewerage works. These standards shall be referred
to as appropriate for the design and construction of sewer networks and network
pump stations.
All standards used in the design and construction of sewerage works shall be the
latest or the most updated. When any one of the above mentioned standards is
withdrawn or superseded, the latest or updated standards shall be referred to as
appropriate. This shall be the same for any applicable act, guideline, by-law, etc.
related to sewerage works endorsed by the government.
2.1 Sewers
1) Gravity sewers
a) Rigid pipes b) Flexible pipes
i) VC i) GRP
ii) RC ii) Ductile Iron
iii) HDPE (Profile)
2) Force mains (Rising mains)
i) Ductile Iron
ii) GRP
iii) ABS
iv) HDPE (Solid)
v) Steel
3) Vacuum sewers
i) ABS – for internal use
ii) HDPE (Solid) – for external use
There are specific requirements such as pipe class, joint type, linings
etc. which the above approved pipe materials must meet in order to
suit the above applications. Also, there are certain limitations for use of
each pipe type. These requirements and limitations are specified in the
following sections.
From time to time, the Commission will publish sewer selection guides
which will provide more detailed direction on the selection and use of
sewer materials.
For other pipe materials not listed above, their use will be given
considerations in special circumstances. However, only pipes and fittings
I) Gravity Sewer
a) VC
i) Only size 150 mm or above shall be used.
ii) The minimum size for public sewer shall be at least
225 mm.
iii) Pipe shall not be used in unstable ground.
iv) Flexible joints are recommended.
b) RC
i) Pipe protection linings are required.
ii) Only sizes 600 mm or above are allowed in compliance to
the policy.
iii) Flexible joints are recommended.
c) GRP
i) Pipe shall not be used in ground contaminated with high
concentration of chemicals such as solvent that can degrade
the pipe.
ii) Pipe shall not accept any industrial or other aggressive
discharges that may affect the pipe integrity.
iii) Pipe shall be used only when no fittings are required.
iv) Only sizes 600 mm or above are allowed.
d) DI
i) The use is only allowed for applications needed high pipe
strength.
ii) Pipe protection linings and coatings are required.
iii) P o l y e t h y l e n e s l e e v i n g i s r e q u i r e d f o r a l l b u r i e d
applications.
e) HDPE
i) Pipe shall not be used in ground contaminated with high
concentration of chemicals such as solvent that can degrade
the pipe.
a) DI
i) Pipe shall not be used in unstable ground.
ii) Pipe protection linings and coatings are required.
iii) P o l y e t h y l e n e s l e e v i n g i s r e q u i r e d f o r a l l b u r i e d
applications.
iv) Flexible joints are recommended.
b) GRP
i) Pipe shall not be used in ground contaminated with high
concentration of chemicals such as solvent that can degrade
the pipe.
ii) Pipe shall not accept any industrial or other aggressive
discharges that may affect the pipe integrity.
iii) Fittings shall be made of ductile iron.
iv) Only sizes 600 mm or above are allowed.
c) ABS
i) Where VC or RC pipes are not suitable.
ii) Only for nominated projects or as permitted by the relevant
authority.
d) HDPE
i) Pipe shall not be used in ground contaminated with high
concentration of chemicals such as solvent that can degrade
the pipe.
ii) Pipe shall not accept any industrial or other aggressive
discharges that may affect the pipe integrity.
e) Steel
i) Pipe is allowed only for sizes 700 mm or above.
ii) Pipe protection linings and coatings are required.
Vitrified clay pipe has extra chemical resistance that is suitable for
sewerage applications. The VC pipe may be used even under very
corrosive sewage environment. However, the potential for infiltration is
great and must be minimised by careful laying procedures on site.
Vitrified clay pipes are permitted for gravity sewers. The minimum
permissible size for public gravity sewer shall not be less than 225 mm
and for service connection shall not be less than 150 mm.
Pipes shall have flexible joints, i.e. spigot-socket rubber seal joints or
mechanical joints, except for pump station pipeworks and valve connections
where flange joints shall be used.
Polyethylene sleeving shall be used for all the buried pipe and
fittings.
Steel pipes will undergo corrosion when in contact with aggressive soil
and sewage and, thus, require an internal lining and an external coating.
Pipe internal linings normally include high alumina cement mortar, coal
tar enamel, coal tar epoxy, sulphate resistant cement lining, or bitumen.
Pipe external coatings often include coal tar enamel, bitumen enamel or
asphalt enamel and glass fibre.
Steel pipes are permitted only for inverted siphons (depressed sewers)
and internal pump station pipework. For force main larger than 700
mm, steel pipe may be used if the approval from the Commission is
obtained.
The internal and external surfaces of the pipes and fittings shall be
coated with thermosetting (epoxy paint or powder or epoxy tar resin)
or thermoplastic (polyethylene or polyurethane) material. The type of
external protection shall be determined by the Qualified Person based
on soil condition. Following the completion of pipe jointing, exposed
steel at the joints shall be protected from corrosion by manually applied
external tape wrap and internal cement mortar lining.
A spigot and socket joint welded both externally and internally shall
be used for pipe joints except for pump station pipeworks and valve
connections where flange joints shall be used. Mechanical joints are
only permitted for cut pipe lengths, where internal cement mortar lining
at joints is not possible and where movement of the pipeline is to be
allowed for.
Solid wall HDPE pipes are suitable for buried pressure sewer and buried
vacuum sewer installations. Butt fusion joints shall be used for PE pipe.
uPVC fittings are not permitted for force mains. Solid wall pipe for
pressure main application shall be of minimum PE80-PN10. The use
of specific strength shall depend on the depth and nature of the soil as
confirmed by the Qualified Person. Solid wall pipes for vacuum sewer
shall be minimum of PE80-PN8 and at least PN10 for heavy vehicle
loading.
A profiled wall pipe is a pipe with a plain inside surface and with a
ribbed or corrugated outside surface. The ribs or corrugations are normally
either aligned circumferentially or helically. These corrugated or ribbed
profiles optimise the pipe ring stiffness to weight ratio. The pipe can be
designed with double-wall profile or triple-wall profile.
There are two principal manufacturing methods for GRP pipes, centrifugal
casting and filament winding. The centrifugal casting GRP pipe incorporates
silica sand in the wall structure in addition to resin and chopped strand
mat glass fibres. The silica sand shall have a maximum particles size
of 10 mm. The centrifugal casting GRP pipe shall be according to AS
3751.
The filament winding GRP pipe does not normally incorporate sand, which
permits centrifugal casting GRP pipe to have a much thicker wall, and
thus much higher ring stiffness than the filament winding GRP pipe. The
filament winding GRP pipe uses continuous glass fibres wound helically
about the pipe. The design of filament winding GRP pipe shall be in
accordance with BS 5480.
Centrifugal casting GRP pipe is available in sizes from 200 mm to 2400 mm and
standard length of 6 m. The inner surface of the pipe is usually finished
with a resin rich lining which is resistance to attack by sulphuric acid
that may result from septic sewage. Centrifugal casting GRP pipe has a
rubber sealing sleeve joint which is supplied fitted to one end. So jointing
is similar to a spigot-socket joint. These pipes can also be supplied with
flange joints, sleeve-locking joints and sleeve recessed joints for special
applications such as pipe jacking and pipeline towing.
rich inner surface although the thickness of this resin surface layer is often
limited by the manufacturing method. Some filament winding GRP pipe
manufacturers incorporate corrosion resistant glass fibres. This feature can
be essential with this GRP pipe because its resin rich surface (gelcoat)
is thinner or, sometimes, removed for fabrication purposes. Filament
winding GRP pipe currently being offered can be jointed using a sleeve
and two rubber O rings. Filament winding GRP pipe does not have a
smooth outer surface like centrifugal casting GRP pipe. Machining may
be required for the outer surface where rubber sealing rings are used.
Flange joints and mechanical couplings are also available for special
applications.
Approval for the use of GRP pipe shall be sought from the Commission
for each project intending its use. GRP pipes are permitted for gravity
and pressure sewers. For gravity sewers, GRP pipes are only permitted
for sizes of 600 mm nominal diameter and larger where no fittings
are required. The minimum pipe stiffness shall be SN 5000 with the
appropriate stiffness determined in accordance with structural design
to AS 2566. For pressure sewers, fittings must only be of ductile iron
meeting the coating, lining and other requirements.
ABS, like uPVC and PE, is resistant to corrosion in the most corrosive
sewage environment that could occur. ABS is used in a range of
applications requiring pressure pipe. Because of its excellent resistance
to abrasion and UV degradation, ABS has found use in industrial and
mining applications and also in treatment plants for sewage and water.
ABS pipes may be permitted for force mains under special circumstances
which require the benefits of such pipes. If used, the approval of the
Commission is required. ABS pipes may be permitted for use in buried
forced mains and buried interconnecting pipe-works within pump
stations.
I) Average Flow
The flow used to determine the diameter and gradient of the pipeline
is the peak flow. Peak flow is the most severe flow that could occur
on any day when considering daily flow fluctuations and infiltrations.
The peak flow is derived from the average flow by applying a peak
factor for daily flow fluctuations. The peak factor shall be estimated
from the following formula:
III) Infiltration
I) Sediment Cleansing
Except for very high velocities, slime will always be present, which will
increase the pipe roughness. Abrasion by sediments will also impart a
permanent increase in roughness. Pipeline roughness decreases as the
velocity increases. However, there is insufficient data to accurately
determine the pipeline roughness for a wide range of velocities or at
small incremental changes in velocity. In addition, the velocity of the
sewage flow varies due to the factors such as daily fluctuations, different
type of catchment, different stage of catchment maturity, etc. Therefore,
it is not possible to select the pipe roughness with great accuracy.
Roughness, ks (mm)
Pipe Material
New Old
Vitrified Clay 0.06 1.5
Concrete: 0.15 3.0
Plastic 0.06 0.6
Old and new roughness values shall be used to determine the sewer
cleansing and maximum design velocities respectively.
Table 2.1b Normal Pipe Roughness for Force Mains for All
Pipe Materials
Unless special arrangements have been agreed for the structural protection
of pipes, the minimum depth of soil cover over the sewer shall be
1.2 m. Sewers are not to be constructed under buildings.
The design shall be based on the worst case scenario. The selection of
the gravity sewer diameter and gradient to cope with the peak flow shall
be based on the following equations:
Typical ks values for various types of sewer pipes are presented in Table
2.2 below:
2. Manning Equations
= 5 6
9
Q
ZKHUH
9 YHORFLW\PVHF
6 K\GUDXOLFJUDGLHQW
5 K\GUDXOLFUDGLXV
Q 0DQQLQJFRHIILFLHQW
Typical n values for various types of sewer pipes are presented in Table
2.3 below:
3.
Hazen - Williams Equations
9 &56
ZKHUH
9 YHORFLW\PVHF
6 K\GUDXOLFJUDGLHQW
5 K\GUDXOLFUDGLXV
& +D]HQ:LOOLDPVFRHIILFLHQW
Typical C values for various types of sewer pipes are presented in Table
2.4 below:
For long and undulating force mains, hydraulic pressure transient analyses
may be required to ensure that the force main can cope with water
hammer pressures.
Retention times in force mains must not exceed 2 hours without special
precautions to mitigate septicity.
All force main shall be designed to withstand at least 1.5 times the
working pressure. Approval from the Commission is required if any
force main is to be designed to withstand pressure less than the pressure
stated above.
Where retention times in the force mains exceed two hours and where
concrete pipe are laid downstream of the force mains, an induct vent
shall be provided at manholes receiving pumping discharges.
1. Darcy-Weisbach Equation
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Force mains shall be designed to handle the full range of flows from
present minimum to future peak.
The design velocity shall fall within the range of 0.8 to 3.0m/sec over
the full range of design flows.
The hydraulic resistance of force main fittings and bends shall be included
in the hydraulic design.
2.1.19.1 General
The vacuum sewer discharges into the vacuum vessel at the vacuum
station. The vacuum is maintained by vacuum pumps at a predetermined
level. The sewage is generally pumped from the vacuum station by
sewage discharge pumps.
b) Vacuum Station
pre-cast concrete. The two sections (the valve compartment and the
collection sump) may be mounted vertically one on top of the other
as shown in typical drawings in Appendix A. The diameter of the
sections may be as small as 1200 mm or as large as 1500 mm.
Some vacuum interface valves inhale and exhale air during their
operation. This is accomplished through a screened air pipe known
as a “breather”.
Each breather pipe shall be fitted inside the “breather bell” located
at the top of the collection chamber in an accessible location to
allow their removal for maintenance purposes.
I) General
The interface valve shall fail safe in the closed position and shall
prevent backflows from the crossover pipes to the collection sump.
When the valve is open, the flow path shall not be obstructed by the
valve mechanism. The valve shall evacuate at least the batch volume
each time per cycle. Valves installed in the sump shall be capable
of operating when submerged provided that the breather pipe is not
submerged.
The controller shall open the valve only if there is a minimum partial
vacuum of 0.2bar below atmospheric available and shall maintain the
valve fully open until at least the batch volume has been evacuated.
If the design provides for the introduction of air after the sewage
has been evacuated, the controller shall maintain the valve open for
a further period. The controller shall be adjustable so that a range of
air to sewage ratios can be obtained. Controllers installed in sumps
shall be capable of operating when submerged.
I) General
a) Minimise lift.
b) Minimise length.
c) Equalise flows on each vacuum main.
d) Provide adequate access for operation and maintenance.
When sewers are not buried, they shall be protected from extremes
of temperature, ultra-violet radiation and possibility of vandalisms.
a) Design Tolerances
b) Lift Design
Crossover pipe shall initially fall away from the interface valve
and shall connect into the top sector of the vacuum sewer contained
within the angle of ± 60° about the vertical axis as shown in
Appendix A.
d) Branch Connections
e) Water-logging
a) Pipe Size
The suction pipe DN/ID shall not be greater than the DN/ID of the
interface valve. The minimum diameter of crossover pipe shall be
DN/ID 50 and shall be greater than the DN/ID of the suction pipe.
Vacuum sewer shall have a minimum diameter of DN/ID 80.
c) Warning System
V) Isolation Valve
The isolation valve clear opening shall be not less than the DN/ID
of the pipe, and be capable of sustaining a vacuum pressure of -0.8
bar(g).
Isolation valves shall be resilient seated gate valves with the body,
bonnet, gate and bridge fabricated from ductile or cast iron. The
stem shall be stainless steel, and the gate shall be encapsulated with
Ethylene Propylene Diene Monomer (EPDM). End connections to
the valves shall be flanged.
When isolation valves are buried, they shall have extension spindles
and surface boxes.
I) General
The floor level of the dry well shall be designed to suit the invert
levels of the incoming sewers, the vacuum vessel diameter and the
dimensions of the selected sewage discharge pumps.
The vacuum vessel, the sewage discharge pumps, valves and pipework
associated with the sewage discharge pumps and a small sump to
collect washdown water shall be located in the dry well.
The plant room shall contain the vacuum pumps, control panel,
standby diesel generator, vacuum pressure gauges, and moisture
trap.
Sewer inlets shall be provided with short radius elbows inside the
vessel to direct the sewage inflow away from the sewage discharge
pump suction connections and the vessel walls.
V) Vacuum Pumps
a) Evacuation Time
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The system evacuation time, which is defined as the time period between
the vacuum pump start and stop, shall be between 2 and 5 minutes.
c) Vacuum Pipework
valve and a resilient seated gate valve on the discharge side. Where
the discharge pipework is manifold, the final discharge pipe shall
also be fitted with a non return valve. The valves shall be able to
be operated from the vacuum station floor.
X) Odour Control
b) Level Control
The level control system shall respond to the following sewage levels
in the vacuum vessel:
The controls shall permit the selection of duty, duty assist (where
provided) and standby vacuum pumps and sewage discharge pumps
and shall provide for the automatic introduction of the standby units
in the event of failure.
Inverted siphons are introduced along a gravity sewer line in order to pass
Longer siphons shall be provided with hatch box with access for
maintenance and cleaning. These siphons shall have independent washout
facilities.
The structural design of a buried sewer can be divided into the following
two categories:
a) Rigid pipe.
b) Flexible pipe.
All two structural designs shall take account of how the sewer is supported
to determine the loading which the sewer can safely withstand.
the structural integrity of the pipe cross section, the considerations for
the ground conditions and sewer installation practices that will affect
the longitudinal structural integrity shall not be omitted.
There are many design approaches for each of the two structural design
categories. However, there are only minor alterations among these
different approaches. Some design approaches tend to give a more
favourable prediction of performance for a particular pipe material than
other approaches. The use of standard design approaches given in this
guideline will prevent the selection of a particular design approach purely
to favour one material over another. Also, the following recommendations
are only meant for general design aspects. Any design aspects that are
not covered by this Volume, the designer shall refer to BS EN 752 or
any other standards deemed appropriate by the Commission.
When a buried rigid pipe is supported, the load which the pipe can
safely withstand is higher than the load which caused failure in the
three point loading test.
By varying the pipe ring strength and the pipe support, different
load resistance can be achieved.
The pipe support designs permitted by this Volume are limited to those
in typical beddings in Appendix A. They include the following:
Where vehicles will pass over the sewer and the sewer is laid with
a cover depth of less than 2.5 m, the sewer will be subjected to
additional loads from such vehicles. The Boussinesq Theory should
be used to determine the loads from vehicles in the design.
Loads on buried rigid pipe for field conditions and for main roads
can be found in Simplified Tables of External Loads on Buried
Pipelines published by the UK Transport Research Laboratory.
i) PE pipe
ii) GRP pipe
iii) ABS pipe
iv) Steel pipe
Similar to rigid pipe, the loading which a flexible pipe can withstand
can be increased when the pipe is supported. For flexible pipes, this
external ring support is more critical. Without it, a flexible pipe
would fail under the loads applied by usual soil cover for gravity
sewers and under vehicle loads for shallow cover force mains.
The soil load used for structural design for flexible pipe support shall
be the prism load or the weight of the column of soil directly above
the pipe. Marston Load Theory mentions that this column of soil
Where vehicles will pass over the sewer and the sewer is laid with
a cover depth of less than 2.5 m, the pipe will be subjected to
additional loads from such vehicles. The Boussinesq Theory should
be used to determine the loads from vehicles in the design approach
in this guideline.
2.2 Manhole
2.2.1 General
Brick manholes shall not be used, due to the high risk of excessive
infiltration.
Note:
a) These sizes apply to straight-through pipes; larger sizes may be
required for turning chambers or chambers with several side branches or
where specific maintenance requirements are necessary, e.g disconnecting
traps.
2.3.1 General
Manhole covers and frames shall comply with the specifications in this
Guideline and BS EN124. Where the specifications in this Guidelines
contradict the specifications given in BS EN124, the specifications in
this Guidelines shall take precedence.
2.3.3 Material
The production, quality and testing of spheroidal graphite cast iron shall
comply with ISO 1083.
The manhole covers shall be free of defects which might impair their
fitness for use.
2.3.5 Seating
2.3.6 Casting
All cast units shall be cleanly cast and free from air holes, sand holes,
cold shuts and chill. They shall be neatly dressed and carefully fettled.
All castings shall be free from voids, whether due to shrinkage, gas
inclusions or other causes.
All surfaces of manhole covers and frames shall be supplied coated with
either a:
2.3.8 Water-tightness
No visible leakage shall occur between the manhole cover and its seating
in the frame when tested in accordance with Appendix E of AS 3996.
a) Locking Devices
b) Hinge
The quality control of the certified manhole covers and frames shall
meet the requirements given in Clause 10 of BS EN 124. However, the
final inspection and tests and the frequency of tests/inspection shall not
be as shown in Table A3 of BS EN 124. Instead, the specifications as
shown in Table 2.7 below must be followed. All final inspection and
test documents shall be retained for at least 5 years.
Under conditions where there exists the potential of odour nuisance to the
nearest habitable building property line within residential and commercial
development despite having the minimum buffer zone, such odour shall
be minimised to the lowest possible level and in compliance with the
Environmental Quality Act.
equal to 2 to 3 times the peak flow into the wet-well in litres per
minute merely to protect the starting equipment from overheating
and failure caused by too frequent starting and stopping.
xiv) Emergency bypass shall be provided either at any suitable manhole
or wet-well. The discharge of the bypass is preferred to the nearest
watercourse and not to the perimeter drain of the pumping station.
However, if this is not available then discharge to the nearest surface
drain is allowed.
xv) All wet-well shall be opened and come with stainless steel or other
non-corrosive handrails. If stainless steel tubing is used, it shall be
in-filled with concrete.
vii) The penstock spindle shall extend to pump station ground level and
shall be suitably positioned to allow unrestricted operation of the
penstock.
viii) Access platforms shall be provided at all locations where dismantling
work takes place.
ix) Access covers shall be hinged with a lifting weight not exceeding
16 kg.
x) Internal walls shall be made resistant to sulphide corrosion by
coating with high alumina cement mortar lining, PVC lining or
epoxy coating. Other materials used under special circumstances
are subjected to approval from the relevant authority.
xi) Penstock greater than 610 mm x 610 mm shall be motorised and
come with manual overwrite switches. The actuator shall be located
above ground level and above flood level for easy access in the
event of flooding.
xii) Protection against falling shall be provided by means of handrails at
walkways and other working areas, where the fall equal or exceeds
1.5 m.
xiii) Edge protection by means of kick plates of at least 50 mm in height
shall be provided, where the drop is equal or exceeds 2.0 m.
xiv) Proper drainage shall be provided at the collection bin area to ensure
that liquid collected could be channelled back to the pump sump.
i) The potential for odour generation, its impact and treatment, shall
be considered in all aspects of design.
i) Centrifugal
ii) Screw
iii) Screw Centrifugal
Guide rail, lifting device and other wet-well fittings must be fabricated of
stainless steel, that is corrosion resistant. The use of hot dip galvanised
iron is not recommended.
2.4.12.1 General
v) Type non-slam Check valve shall be of the full body type, with a
domed access cover and only on moving pant, the flexible disc.
vi) Disc of Check valve shall be of precision molded Nitrile Butadiene
Rubber (NBR) to BS EN 681-2: 2000. the disc shall be of one-
piece construction, precision molded with an integral o-ring type
sealing surface, and contain alloy steel and nylon reinforcement in
the flexible use area.
vii) In the absence of check valve, the reverse rotation of the pump
shall not exceed 150% of the rated speed or limit set by the
manufacturer.
viii) Tapping (12 mm British Standard Parallel (BSP)) shall be located
upstream and downstream of check valves.
i) System curves.
ii) Pump curves.
iii) Operating point of pumps with respect to flow and total dynamic
head (TDH).
iv) Operating characteristics such as efficiency, horsepower, motor rating
and Net Positive Suction Head (NPSH).
Design Parameters
Description Unit PE ≤1,000 1,000 < PE ≤ 5,000
Volume 3
mm 100 100
openings
Pumping cycle start/ 6 - 15 6 - 15
(average flow conditions) hour
Lifting device* lifting davit lifting beam and block
Industry Guidelines
Malaysian Sewerage
Table 2.8 Recommended Design Parameters for Pump Stations
Design Parameters
Description Unit 5,000 < PE ≤ 20,000 PE > 20,000
Type of station wet-well or dry-well up to 10 000 PE wet-well and dry-well
10,000 PE above – wet well and
dry-well
Number of pumps 4 (2 sets) 6 (3 sets)
(all identical and work sequentially) 1 duty, 1 assist, 1 duty, 1 assist,
Volume 3
Minimum suction and discharge mm 100 100
openings
Pumping cycle start/ 6 - 15
(average flow conditions) hour 6 - 15
67
Planning, Material and Design
2.5 Interceptors
Oil interceptors shall be designed in such a way that pollutants that are
lighter than water liquid are trapped in a chamber and are prevented from
being discharged to the public sewer. The chamber shall be normally
fitted with a device to trap sediments and heavy particles that settle to
the bottom. The removal of these sediments is required periodically.
Intercepted oils shall be capable of being drained off for storage from
suitable draw off points on a continuous operational basis.
Grease traps shall be provided in drain lines from areas such as restaurants,
canteens, food processing and animal product or feeds factories, where
grease and fat are likely to present in wash down waters or sullage.
Grease traps shall be designed in such a way that solidified grease and
fats are trapped in a chamber prior to discharge and may be skimmed
off by means of a perforated strainer or bucket.
2.6.1 Concrete
2.6.2 Cement
3.1 Introduction
a) The pipe and fittings storage area shall be away from traffic and
shall not obstruct any property access or pedestrian route.
b) The pipe and fittings storage area shall be at a location that allows
lifting machinery to position easily and safely for lifting pipes and
fittings.
c) Pipes shall be stacked on a flat and level firm ground or the base
of the pipe stack shall be made level using additional solid timbers
under base bearers.
d) There shall be no rocks, tree roots, etc. under the pipe stack, which
may cause point load.
e) The sockets shall be alternated to different ends for each pipe stack
layer. The sockets shall be protruded out of the stack.
f) The base timber bearers shall be sound and without protrusions. The
cross section of each timber shall be at least 75 mm by 75 mm. The
base bearers shall provide support near the pipe ends, but placed
behind sockets. The placement of base bears shall not be more than
1.5 m apart.
g) VC, RC, DI, Steel and GRP pipe layers shall be separated using
timber spacers of at least 50 mm wide and 50 mm thick. These
spacers shall not be placed more than 1.5 m apart. These spacers
will prevent pipes in each layer from touching pipes in the next
layer.
h) For VC and RC pipes that are not crated, the pipes shall not be
stacked more than 3 pipes high. The pipe stacks shall be wedged
to prevent them from rolling off the stack.
i) Thermoplastic pipes (PE and ABS) shall be stacked in such a way
to prevent them from being twisted or bowed.
j) Thermoplastic pipes shall be either stacked in a pyramid with no
more than 1 m high or in a square with vertical side supports for
more than 2 pipes high.
k) Plastic pipes and fittings shall be kept under a cover that prevents
direct exposure to sun light.
l) Plastic pipes and fittings shall not be covered with plastic
sheeting.
m) Plastic pipes and fittings shall be stored away from oils, greases,
solvents and other aggressive chemicals.
n) Plastic pipe shall be stored away from sources of heat such as engine
exhausts.
o) Care shall be taken to prevent scoring and scratching of plastic pipe
and fittings.
p) Joint lubricants, rubber rings and other jointing materials shall be
stored in a secured area that cannot be accessed by the public.
q) Any safe pipe stacking procedure not covered above, but recommended
by the manufacturer, shall be adopted.
r) The rubber rings that are not delivered fitted to the pipe socket or
sleeve shall be stored away from direct sunlight or continual artificial
light. Also, the rubber rings shall be stored in a cool area that is
away from oils, greases or other petroleum products.
s) When rubber rings are delivered fitted to a pipe socket or sleeve,
the pipe ends with the rubber ring shall be shielded from sunlight
using a hessian cloth.
t) Rubber rings shall be retained in the original sealed packaging until
they are required.
h) PE and ABS pipes with damage in the barrel, shall have the damaged
section and at least 100 mm either side of the damage cut from the
barrel.
i) Repaired pipes and fittings shall be used only after the approval for
reuse from the Commission is granted.
a) The required line of the sewer and manhole locations shall be set
out using accepted surveying practices.
a) The bore shall be on the line, level and grade and of sufficient
diameter to allow pipes to be inserted without over-stressing the
joints or damaging the pipes.
b) The bedding material shall be placed as soon as possible after the base
of the trench is prepared and excess water has been removed.
c) Granular bedding shall be placed, compacted and graded so that
it offers continuous support to the sewer. The compacting, where
required, shall achieve a uniform density.
d) A small hole shall be left in granular bedding for each socket, jointing
sleeve, flange, etc. that may project into the bedding. The holes
shall be of size that is just sufficient for projections to be clear of
bedding. Long and large holes that may undermine the pipe barrel
support are not allowed.
e) A recess shall be made in the bedding to permit the withdrawal of
the sling without disturbing the remaining bedding.
f) Where the bedding is disturbed, the pipe shall be raised again to
repair the bedding.
g) Pegs or other temporary aids to levelling shall be removed before
pipe laying.
a) Before lowering the pipes into the trench, pipes shall be placed
next to the trench away from the trench edge. The pipes shall be
placed on the opposite side of the spoil beside the trench with their
sockets facing upstream. Where required, the pipes shall be blocked
or chocked to prevent any rolling.
b) Pipes and fittings (including linings, sheathings and protective
paintworks) shall be checked for damage before and after laying in
the trench.
c) VC pipes shall be carefully tapped at mid length and either end
with a wooden mallet or, otherwise, a metal bar. This is to detect
a clear ring that indicates soundness. This is best undertaken while
each pipe is lifted in free air with a lifting sling.
d) Pipe and fittings shall not be dropped into the trench. Instead, pipes
shall be lowered into the trench using approved slings.
e) Pipes shall be laid from the downstream end towards the upstream
end.
f) The laying of pipes shall proceed carefully to ensure the line, level
and grade are within the specified tolerances.
g) Pipes shall not be dropped or impacted forcefully into the bedding
to obtain the specified level or grade.
h) Concrete pipes with elliptical reinforcement shall be laid with the
load line on the vertical axis at the top or bottom position.
i) Holes made in granular bedding for projections of sockets, flanges,
etc. shall be lightly filled where necessary without pushing the pipe/
fitting off line, level or grade.
c) The setting out of the guide rails for the pipe and the actual jacking
operation shall maintain a high accuracy level of line and grade.
d) The direction and grade for jacked sewer shall not deviate from the
designed alignment for more than 100 mm for every 100 meters of
sewer.
e) All the joints used for connecting the jacked pipes shall be watertight
and durable.
a) Only VC, HDPE, ABS and DI pipes are permitted to be cut in the
field. However prior approval from the Director General is required
should the HDPE helically wound profile wall pipe needs to be
cut in the field. All pipes shall be cut in accordance to approved
methods.
b) Rough edges and burrs shall be removed from inside and outside of
HDPE and ABS pipe with a rasp or file.
c) Pipes shall be cut in a neat and skilful manner by workers experienced
in pipe cutting.
d) Pipes shall be cut perpendicularly to the pipe axis.
e) Any damage to the cement lining of DI pipe shall be repaired to
the satisfaction of the Commission.
a) The socket and spigot shall be checked for damage before and after
jointing.
b) Damaged spigot ends shall be cut from the pipe with 100 mm
clearance to the damage. The spigot end shall be cut perpendicularly
to the pipe and any burrs shall be removed.
c) The spigot shall be inserted up to the witness mark.
d) If a witness mark is not already on the pipe, the mark shall be made
to ensure that the spigot is inserted to the appropriate length.
e) Witness marks drawn on site shall be made with a soft pencil or
felt pen marker that would not score or scratch the pipe.
f) The witness mark shall be of the depth of the socket and shall be
measured from the pipe end.
g) A dry fit of the joint shall be made before the jointing.
h) Jointing surfaces shall be wiped clean and dried with a clean
cloth.
i) Jointing surfaces shall be primed using an approved priming solution.
The priming shall be applied with a clean cloth or swab freshly
dipped in the fluid immediately before jointing.
j) A thin and even coat of solvent cement shall be applied to the socket
and the spigot, which should then be inserted up to the witness
mark.
k) The jointing surfaces shall not be contaminated with water, dirt,
etc.
l) The jointing shall be made immediately after the application of
solvent cement.
m) After the spigot is pushed firmly into the socket, the joint shall be
hold in the same position for at least 30 seconds without moving.
n) The jointed pipes shall not be moved for at least 5 minutes after
jointing. The jointed pipes shall be handled with extreme care for
at least another hour.
o) Joints shall be left to dry for at least 24 hours before pressure
testing.
p) Containers of solvent cement and primer shall be kept tightly sealed
when not in use.
a) The welded joint shall use a socket-spigot joint with taper sleeve
wherever possible.
b) Welding surfaces shall be cleaned to a bright metallic finish before
welding.
c) Welders shall be qualified in accordance with the requirements of
British Standard BS 4515 Specification for welding of steel pipelines
on land and offshore.
d) Welding procedures shall be tested, qualified and approved in
accordance with BS 4515.
e) Welds shall be inspected and tested in accordance with BS 4515.
f) After welding, exposed external surfaces shall be cleaned by sand
blasting or wire brushing. The dry surfaces shall be wrapped in
an approved manner with an approved wrapping tape to provide
corrosion resistance.
d) The thrust block shall bear firmly against a recess at the side of the
trench.
e) The trench face which the thrust block bears against shall be freshly
cut and undisturbed.
f) Each thrust block shall have sufficient bearing area.
g) Thrust block shall be cast-in-place with 20 MPa concrete.
h) For plastic pipe or pipe with a protective coating, a compressible
membrane of rubber, felt or cork shall be placed on the pipe to
protect it from damage from its movement in the thrust block.
i) Formwork shall be used to cast the thrust block to the required
dimensions.
j) Formwork shall be removed before any testing.
k) Reference shall made to the standard drawings for thrust block to
ensure proper shape and size, which must be designed for each
individual thrust blocks.
a) The embedment material type and its grading shall take considerations
of the sewer type or length.
b) Reference shall be made to the approved longitudinal and cross-
sectional drawings of the sewers showing the bedding types, which
shall be designed based on supporting soil reports.
c) Embedment material shall not be contaminated with other soils.
d) Embedment material shall be brought up evenly in layers on each
side of the pipe.
e) Each embedment layer shall be placed to a depth that permits the
compaction equipment to achieve the specified density.
f) The pipe shall not be pushed off alignment, level or grade while
placing the embedment.
g) Where the embedment requires tamping, tamping equipment shall
not come into contact with the pipe.
h) Temporary trench wall support shall be lifted when the embedment
is compacted.
i) While placing the embedment for the pipe haunches, unnecessarily
voided areas shall be avoided.
j) At least 300 mm of cover shall be placed over the pipe before
light mechanical compaction, such as a hand operated whacker, can
commence.
3.7 Reinstatement
3.8.1 General
a) The owner must seek the approval of the Commission for any
connections that involve physical work to an existing public sewer.
The initial notification must be made on the appropriate form.
b) Once approved, the owner may make the connection only if his
contractor is licensed by the Commission for this category of
work.
c) The type and location of connections shall be determined by the
Commission. The type of connection could be a connection to a
manhole or a connection to a sewer through junction or saddle
fittings.
d) The cost of the work in making the connection shall be borne by
the owner, regardless of whether the work is undertaken by his
licensed contractor or a licensed contractor employed by Services
Licensee.
e) The connection must be correctly made by the licensed contractor
under the supervision of an authorised inspection person.
f) When the connection is ready for inspection, the owner must notify
the Commission on the appropriate form. At the same time, he must
The hole prepared for the saddle connection on the existing sewer shall
not have any rough edges that might cause blockage. The location of
the hole on the pipe shall be at a 45° to 60° angle to the horizontal.
The hole shall be made at the middle of the pipe to avoid damages or
excessive loading to the existing sewer pipe joints. The existing pipe may
require extra strengthening by additional concrete surround to withstand
the extra load from the connection pipe and fittings.
The connection pipe must not protrude into the existing sewer.
Any debris falling into the existing sewer during the connection shall
be removed.
Sewer Testing
Sewer Testing
4.1 General
Sewers and ancillary works shall be tested and inspected for water-
tightness to prevent infiltration and exfiltration and to ensure the pipes
are laid correctly according to the designed straightness and grade. The
testing of the sewers and ancillary works before backfill will facilitate
the replacement of any identified faulty pipes and joints. The testing of
the sewers and ancillary works after backfill will reveal the leakages
caused by the displacement of joints and subsequent damage. The testing
shall be supervised by consultants and their testing certificates issued
by the consultants shall be submitted to the Commission before final
approval.
I) Before Backfill
a) Gravity Sewer:
i) Exfiltration Test (either low pressure air or water tests).
ii) Check for straightness, obstruction and grade.
b) Force Main:
i) Exfiltration Test (when required).
ii) High pressure water test.
iii) High pressure leakage test (following high pressure water
test).
iv) Check for straightness, obstruction and grade.
For pipe or part that is made of material that will deteriorate under the
sun, the exposed parts of the pipe shall be shielded from direct exposure
to the sun during testing.
The concrete used for supporting the pipe or resisting thrust shall be
cured for at least seven days prior to testing.
Gravity Sewer:
Before and after any test, the sewer pipeline to be tested shall be clean,
which shall be flushed clean when necessary. Any leaks or defects
identified from any test shall be located and repaired. After testing has
been completed, the cleaned sewer shall be plugged at open ends to
prevent dirt or soil from getting into the sewer.
An exfiltration test, which can be either a low pressure air test or a water
test shall be performed on the sewer before any concrete pipe encasement
or backfill. After backfilling, an exfiltration test is required again on the
sewer laid. In addition, an infiltration test shall be conducted if:
When infiltration has been confirmed by the infiltration test, light and
mirror method or CCTV may be used to isolate the locations of leaks.
If a CCTV inspection is conducted, a video and written record of the
CCTV inspection shall be provided to the Commission no later than 7
days after the inspection.
For gravity sewers, the sewer length to be tested shall be the length
between manholes or proposed manhole locations. The test length for
water test may be shorter where the gradient is so steep as to cause too
high a head at the downstream end. The pressure head on the sewer being
tested shall not be less than 2 m above pipe crown at the upstream end
and shall not be more than 7 m above pipe crown at the downstream
end.
When desired, the air and water tests may be undertaken on shorter
lengths of the laid sewer before backfill. This is to prevent any faulty
joint to go unnoticed until it is revealed by a test on the complete length,
which will be more costly and time consuming to rectify the defects.
Testing of shorter lengths may also be necessary where it is required to
backfill the sewer to surface level quickly. This early backfill may be
encountered when there is wet weather, traffic crossings or site safety
requirements.
For the high pressure water test, the test length will depend on:
4.5.1 General
Low pressure air test is one of the two sewer exfiltration tests recommended
for sewer testing. The air test is quicker to conduct than the water test.
Furthermore, no large quantity of water needed to be disposed off after
the test. This test provides a quick mean for checking any damage pipe
or joints. Sometimes the test is conducted on a short length to prevent
damage pipe or joints from passing without noticed until the final sewer
test, which could be more costly and time consuming to rectify. However,
these tests on the shorter length should not replace the final test.
a) Seal the open ends, including sideline ends, using approved plugs.
Strut the plugs to prevent movement. Provide temporary bracing
where necessary to prevent pipeline movement during testing.
(One of the end plugs will require a connection point to permit
injection of air).
b) Connect a hand or motorised pump to the pressure injection line
at the end plug. Pressurise the test length at a slow and constant
rate.
c) Use dial pressure gauges to measure pressure. Apply an air pressure
of:
i) 30 kPa for vitrified clay and reinforced concrete pipelines.
ii) 50 kPa for all other pipelines.
(Two gauges in series shall be used so that the accuracy of one
gauge can be confirmed by the other. The dial gauges shall be able
to be read to an accuracy of ± 0.1 kPa).
d) Wait five minutes for air pressure to stabilise due to temperature
absorption into pipe wall and other effects. Adjust the pressure to
the required test pressure during this period.
e) Check for leaks at plugs and test apparatus. Release the air pressure
where leakage occurs. Make necessary repairs and adjustments of
apparatus to prevent leakages. Repressurise the sewer pipeline in
accordance with the preceding steps again.
f) Start the test and record the pressure loss for the test duration after
the final gauge adjustment to the test pressure. Conduct the test for
the test duration given in Table 4.1.
g) Pass the test if the pressure loss over the test duration does not
exceed:
I) Before Backfill
a) Readjust the pipe pressure to the specified test pressure and examine
for leakage by pouring a solution of soft soap and water over the
exposed joints if the test fail.
b) Repair leaks and repeat testing where leaks are found at joints.
c) Where leaks are not found at joints, move the plug, the one that is
not used to exert air pressure, along the pipeline to isolate lengths
with leakage. Uncover pipe barrels in the isolated lengths where
leakage in pipe barrels is suspected. Replace leaking pipe lengths
and repeat testing.
d) Conduct low pressure water testing to verify that the air test was
not erroneous where the test length fails the air test but no source
of leakage can be identified.
a) Move the plug up from the other end along the sewer pipeline to
isolate the lengths that fail the air test.
b) Exhume the failed length of pipeline and replace pipe lengths.
c) Repeat the air test.
d) Conduct water testing to check that the air test was not erroneous
when failed lengths could not be isolated using the air test.
e) Use CCTV, when required or available, to identify the leakage if
the fail section can not be isolated by the air test or water test.
4.6.1 General
The low pressure water test is commonly used for checking the water-
tightness of the joints and the integrity of the sewer pipes. Unlike the
high pressure water test, this test can not be used to check the mechanical
strength of the sewer pipe. Compared with low pressure air test, this test
requires more time to set up the test. Also, the water used for the test
4.6.2 Procedure
a) Seal the open ends, including sideline ends, using approved plugs.
Strut the plugs to prevent movement. Provide temporary bracing
where necessary to prevent sewer movement during testing.
b) Establish appropriate arrangements involving a standpipe to apply
the water head at the upstream end.
Acceptable arrangements include:
i) temporarily fitting a 90° bend to the upstream end, which should
then be connected with a vertical riser of straight pipe to used
as a standpipe.
ii) sealing the upstream end with a plug which has a connection
point for a hose, which can be connected to a tube acting as a
standpipe.
d) Fill in water from the upstream end. Ensure water head is not less
than 2 m above pipe crown at the upstream end and not greater
than 7 m above pipe crown at the downstream end. Shorten the test
length if the sewer gradient is so steep as to cause these water head
requirements not to be met.
e) Fill the sewer slowly to the required head and bleed air from behind
the upstream plugs.
(Air may be released by slightly loosening the plug and pushing in
a piece of wire between the seal and the pipe.)
f) Maintain the water head for two hours. Top up the water as
required.
g) Check for leakage at the plugs and the test apparatus during the
pressurising period and the constant pressure holding period. Release
the water pressure if leakage occurs. Make the necessary repairs and
adjustments before repressurising again.
h) Commence the test immediately after the last adjustment of water
head in the preceding two hours period.
i) Add water to maintain the starting water head every 5 minutes
during the test period of 30 minutes. Record the total amount of
water required for readjustment.
j) Pass the water test if:
i) the loss of water does not exceed 1 litre per hour per linear
metre per metre internal diameter for vitrified clay and reinforced
concrete pipes.
ii) there is no loss of water for pipe other than vitrified clay and
reinforced concrete pipe.
iii) these is no visible leakage at the joints for all pipe types.
I) Before Backfill
a) Readjust the internal water head to the specified test head if the
test section fails the water test. Examine visually for leakage at the
external surface of joints.
b) Uncover pipe barrels and inspect for leakage if leakage is not evident
at joints. Drain the water and move the downstream plug towards
upstream, where necessary, to isolate pipe lengths that fail the water
test.
c) Repair or replace pipes before repeating the low pressure water test
until the sewer passes the test.
a) Isolate pipe lengths that fail the water test by moving the downstream
plug towards the upstream end in sections when the test sewer fails
the water test. Alternatively, conduct a CCTV inspection, where
required, to identify the source of leakage if the source of leakage
can not be isolated.
b) Exhume failed pipe lengths and replace.
c) Repeat test until the sewer pipeline passes the test.
4.7.1 General
High pressure water test is normally used for testing the pressure sewers
and pipeworks within the pump station. The main aims of the test are
to ensure the mechanical stability of the pipe and joints can withstand
the working pressure. Since the test is conducted under high pressure,
the anchorage of the sewer is more critical than the low pressure tests.
Preferably, the test should be conducted before backfill. During the test,
the test pumps should not be subjected to hydrostatic pressure.
4.7.2 Procedure
a) Seal the sewer pipeline ends using “test-end” units consisting of short
lengths of pipe permanently fitted with caps or valves. Connected the
l) Pass the pressure test if there is no reduction from the test pressure
in the next 10 minutes after the test pressure is conducted. Do not
reduce the pressure as the high pressure leakage test should be
conducted immediately after this.
4.8.1 General
High pressure leakage test normally follows the high pressure water test
immediately. This is to avoid any unnecessary pressurising and water
filling, which could take time and is costly. The purpose of this test
is to ensure the pipe and joint will remain intact under the pressure
environment.
4.8.2 Procedure
a) Conduct the test immediately after the high pressure water test.
Maintain the following test pressures (whichever is lower) for 24
hours by pumping in make-up water if necessary:
i) The maximum rated pressure of the pipes laid, or
ii) 1.5 times the design operating pressure of the pipeline (includes
surge allowance).
b) Measure the amount of make-up water pumped into the pipe to
maintain the test pressure.
c) Pass the test if the measured amount of make-up water does not
exceed 0.1 litre per millimetre of pipe diameter per kilometre of
pipe per day for each 3 bars of pressure applied.
d) Reset the test pressure and check all visible joints to locate leakage
when the test length fails the test.
a) Visual inspection
b) Insertion of mandrel
c) CCTV inspection
The first three methods will provide a more exact assurance for both
the gradient and straightness of sewers, which shall be used whenever
possible. The latter two methods will provide a rough idea on whether
the sewers are laid in certain gradient or straight, which should be used
only for a quick check.
a) Solid state colour CCTV camera with pan & rotate features, together
with a lighting unit, automatic date/ metre age.
b) A self powered tractor or crawler on which the camera is conveyed
along a pipeline under inspection in a stable manner.
c) Calibration chart for various sizes of sewer for the camera used.
d) Test device for the CCTV camera using ‘Marconi Resolution Chart
No.1’ or its derivative to demonstrate satisfactory performance of
the camera.
e) Test device for the monitor and video recorder to establish the
effectiveness and accuracy of the ‘on-site’ monitor and video
recorder.
f) The control unit comprises the camera unit, crawler control and
screenwriter. This console can be mounted permanently in a vehicle
or use as portable system.
g) A video recorder for recording high quality video images.
h) A mean of producing still images from the monitor screen.
i) A PC-based site reporting system capable of producing reports
customised to the Contractor’s needs and to include photographs
captured directly from video.
For the diameter pipe greater than 600 mm, it shall have zooming
capabilities.
The following areas are identified as the minimum coverage for CCTV
inspection.
A 100% CCTV inspection shall be conducted for sewers laid in the ground
with high risk of failure and having the following characteristics:
a) The list of sewer segments and house connections selected for CCTV
inspection shall be recorded and the parties witnessing the selection
process shall duly sign the record.
b) Names and designations of all persons involved in the random selection
process as well as the time, date and place where the selection were
carried out shall be recorded in the report on the random selection
process. Record of the sewer segments randomly selected for CCTV
inspection shall be included as appendix in the report.
c) The random selection process shall be completed in a single
session.
a) The CCTV inspection shall be carried out 7 days after notice issued
by the Commission.
b) Inspection shall be carried out within 24 hours after random selection
has been completed.
c) Once started, CCTV inspection for a project shall be carried out
without any break. Should for any reason a break/delay of more than
24 hours become necessary, the random selection process shall be
repeated to select the remaining sewer segments for the inspection.
Reasons for the break/delay shall be recorded.
a) For Grade 1 and Grade 2, the developer shall rectify and make
good to all the defects in 30 days. These rectification works shall
be witnessed by the parties concerned and agreed together that the
works had been completed. The Commission or the authorised person
may instruct CCTV inspection to be carried out again. Under these
grade classifications, the letter of recommendation for CFO will be
released by the Commission or the authorised agency.
b) For Grade 3, 4 or 5 classifications, the developer shall change, replace,
relay or reconstruct the rejected works. Further CCTV inspection
shall be carried out before acceptance. The letter of support for CFO
will be released upon acceptance.
c) In the events of any blockages, damages, seepages and etc to the
sewer networks during the defects liability period, the Commission
may require the developer to carry out further CCTV inspection to
determine the cause and extent of the problems that arises. CCTV
inspection shall be carried out immediately within 24 hours.
Grade 1
Occurances without damage and no cracks of pipe but only acceptable displacement on
joint where no visual infiltration can be observe
Grade 2
Examples: Joint displaced large; badly torched intakes; minor deformation of plastic
pipes (<5%); minor erosions; infiltration seeping; Cracks – joint, circumference,
longitudinal; Debris, silt – 15%; Encrustation light.
Grade 3
Examples: Infiltration dripping. (OMD); Open joint; untorched intakes; cracks; minor
drainage obstructions such as calcide build ups; protruding laterals; minor damages to
pipe wall; individual root penetrations; corroded pipe wall; flexible pipe deformation
(>5%); Lining defect.
Grade 4
Grade 5
Examples: collapsed or collapsed eminent; major deformation; deeply rooted pipe; any
drainage obstructions; pipe loses water or danger of backwater in basements etc.
4.11.1 General
4.11.2 Procedure
a) Plug the inlets at all upstream open ends, after the groundwater level
has stabilised following backfilling.
b) Measure any infiltration from the sewer to the manhole or within
manhole itself.
c) Conduct the measurement of infiltration for at least 24 hours.
d) Pass the infiltration test if the infiltration does not exceed 1 litre
per hour per metre diameter per meter of pipe run.
4.12.1 General
The test should be carried out only after the structures have achieved
sufficient strength to withstand the test pressure. Where possible, the
test shall be carried out before backfilled or concrete surrounded.
For manhole less than 1.5 m in depth, the manhole shall be filled with
clean water to the bottom of cover. For manhole more than 1.5 m in
depth, the water head for the test shall not be less than 1.5 m or the
mean groundwater level, whichever is larger. For any other ancillary
structure, the water shall be filled to the top of the structure unless
otherwise specified by the authorised inspection person.
The procedures for testing the manhole are listed below. For other
ancillary structures, the procedures can still be adopted. However, the
height which the water level should be tested shall follow the instruction
from the authorised inspection person.
4.12.2 Procedures
HINGE DEVICE
Y
C 16mm Ø BOLT
HOLE
STAINLESS STEEL
BOLT AND NUT
Y
10mm Ø, 100mm BAHAYA
LONG RUANG TERKURUNG
SEE DETAIL '2' DILARANG MASUK
B B C
SEE DETAIL '1'
A A
MODEL NO.
AND THE MANUFACTURER'S NAME AND
MARKING " EN 124 PLACE OF MANUFACTURE
CLASS D400 "
DANGER
CONFINED SPACE
SEE DETAIL '3' EMBOSSED LOGO(SEE DETAIL '4') DO NOT ENTER
SERIAL NO.
PLAN
Z
SECTION A - A
TYPICAL SECTION OF HEAVY DUTY 3mm ± 0.5
SECTION Z - Z
DETAIL '1'
( TYPICAL SURFACE DETAIL )
10mm Ø STAINLESS
PRECAST R.C. MANHOLE STEEL BOLT
SECTION C - C SECTION Y - Y : COVER HINGE OPEN AT 90° SECTION Y - Y : COVER HINGE OPEN AT MIN. 100°
Figure A
Figure A44 :Typical
TypicalShallow
ShallowPrecast
PrecastConcrete
Concrete Manhole
Manhole with
with Backdrop
Backdrop
(Ground Level to Invert of Pipe 1.2m ≤ Depth < 2.5m)
(Ground Level to Invert of Pipe 1.2 m ≤ Depth < 2.5 m)
>
≥
Figure
Figure A
A 55 :Typical
TypicalMedium
MediumPrecast
PrecastConcrete
ConcreteManhole
Manhole
(Ground Level to Invert of Pipe 2.5 m ≤ Depth << 55m)
(Ground Level to Invert of Pipe 2.5m ≤ Depth m)
FigureAA66 Typical
Figure : TypicalMedium
MediumPrecast
PrecastConcrete
Concrete Manhole
Manhole with Backdrop
backdrop
(Ground Level to Invert of Pipe 2.5m ≤ Depth < 5m)
(Ground Level to Invert of Pipe 2.5 m ≤ Depth < 5 m)
>
≥
FigureAA77Typical
Figure : Typical Deep
Deep Precast
Precast ConcreteManhole
Concrete Manhole
(Ground Level to Invert of Pipe 5 m ≤ Depth ≤≤99m)
(Ground Level to Invert of Pipe 5m ≤ Depth m)
Figure A8
Figure A 8Typical
: TypicalDeep
DeepPrecast
PrecastConcrete
ConcreteManhole
Manhole with
with Backdrop
Backdrop
(Ground Level to Invert of Pipe 5m ≤ Depth ≤ 9m)
(Ground Level to Invert of Pipe 5 m ≤ Depth ≤ 9 m)
>
≥
Induct Vent
Centreline of manhole
150 Min.
Column Support
Notes :
1. All dimmensions are in millimetres.
2. Diameter of induct vent shall be approximately 1/2
of the forcemain but shall not exceed 300mm.
VARIES
¼°
½°
°
°
°
°
½°
¼°
Figure A 14a
14(a): Typical
: TypicalDetails
Detailsforfor Force
Force Main
Main – Scour
– Scour Valve
Valve and
and Receiving
Receiving
Manhole
Manhole
vacuum station
vacuum sewer
collection chamber
washdown sump
discharge
pumps
fire-fighting system
fuel tank
Vessel
Volume 3
service platform
sight glass
AMF board
handrail
standby diesel
vacuum gauges generator
chart recorder
up
control panel /
telemetry system
Figure A 19 (a) : Example Of Vacuum Station With Housed Collection
PLAN
139
Appendix A
140
Appendix A
ABS pipework to
vacuum pumps
vacuum take-off pipe
to vacuum pumps
vacuum pump
ABS vacuum exhaust
pipework to biofilter
Vessel
Volume 3
moisture trap
cast in-situ biofilter media
drainage pipe
plinth
vacuum vessel
discharge
pumps
ELEVATION
Figure A 19 (b) : Example Of Vacuum Station With Housed Collection
Industry Guidelines
Malaysian Sewerage
Appendix A
valve controller
to vacuum sewer to vacuum sewer
sensor pipe
chamber ring
to vacuum sewer
interface valve
landing slab
float
chamber ring
A A
landing slab
150mm thick
concrete surround
Plan
breather pipe
150mm thick
concrete surround
Section A - A
flow
150m 150m
100-200mm
flow
flow
0.2% min.
slope
flow
6m min.
flow
0 .2
%m
in . s
lo p e
Figure
Figure AA2323 : Y-Branch
: Y-Branch for
for Vacuum
Vacuum Sewer
Sewer
Direction
Direction of flow
of flow
branch
branch °
60° 60 vertical angle
vertical angle
Figure
Figure AA2424 : Method
: Method ofof Joining
Joining Crossover
Crossover Pipes
Pipes and
and Branch
Branch Sewers
Sewers toto
Vacuum
Vacuum Mains
Mains
flow
flow
45° elbow
45° elbow
45° elbow
45° elbow 45° elbow
45° elbow
vacuum
vacuum mainmain
Plan
Plan
crossover
crossover pipe pipe
/ /
branch
branch sewersewer
flow flow
vacuum
vacuum mainmain 45fitting
45 `Y' `Y' fitting
(may(may be fabricated)
be fabricated)
Elevation
Elevation
ground
ground levellevel
min. cover
min. cover
900mm
900mm
End
End View
View
OVERFLOW CHAMBER
PLAN VIEW
DOOR
SCREENINGS COLLECTION BIN
PENSTOCK BRICKWALL C/W
CEMENT PLASTER ON BOTH SIDES
WINDOW
HANDRAIL CHEQUER PLATE
3 LAYER CONC. VENTILATION
BLOCK
HANDRAIL
WET WELL
DRY WELL
PERFORATED SLAB
CAT LADDER
OPENINGS
ALARM
CHECK VALVE 2nd. STANDBY PUMP START
1st. STANDBY PUMP START
INCOMING SEWER 2nd. DUTY PUMP START
(FLOAT SWITCH) GATE VALVE 1st.. DUTY PUMP START
ALL PUMP STOP
STOP LOG
SUMP BWL
SECTION VIEW
BUILDING (WOODEN OR
DN 375 R.C.P DN 375 R.C.P
PROPOSED MANHOLE AND
SEWER IN PLAN
1:80 1:72
DIRECTION OF
BUILDING
SEW ER
(MASONRY)
GATE
POND
P ON
PAVED
RAIL
ROAD
CULVER EXIST ING MANHOLE AND SEWER IN
PLAN
BRIDGE
T ELEPHONE
POLE
LIGHT SIDE
T ELEPHONE CONDUIT
P OLE SIDE
T (GENERALLY 1.5m DEEP)
PROPERT Y, LOT OR RESERVE
PROVISION FOR BACKDROP FOR
SEWER CONNECT ION
SEPT IC PROVISION FOR T -JOINT FOR
T ANK SEWER CONNECT ION
ST BOREHOL
Abbreviations
A.C.P. ASBESTOS CEMENT N.T.S. NOT TO
C.I. CAST O.D. OUTSIDE
CH. CHAINAG R.C. REINFORCED
CL. CLASS R.C.P REINFORCED CONCRETE
CONC. CONCRET RET. RETICULATION
CRS CENTRE RT RIGHT
D.I. DUCTILE S SLOPE
DIA.(ø) DIAMETE STREAM OR
SG.
D.M.H. DROP SHT. SHEET
DN. NOMINAL SPEC SPECIFICATIO
DRG. DRAWIN STD. STANDAR
EXIST. EXISTIN SCW. STANDARD CUT-OUT
GD. GROUND STEEL
STL.
GR. GRADE STA. STATIO
H.A. HIGH
HORIZONTA TYP. TYPICA
HORZ VARIE
INSIDE VAR.
I.D. VERTICA
INVER VERT.
INV. V.C.P VITRIFIED CLAY
JLN. JALAN HDPE HIGH DENSITY
KG. KAMPUN
LRG. LORON
LT LEFT
MAX. MAXIMU
M.H. MANHOL
MIN. MINIMU
MOD. MODIFIE
NO. NUMBE
Appendix B
Project-Information
Project Name : Project Number : Contact : Date :
Client :
Contact :
Position :
Road :
Town :
State :
Telephone :
Fax :
Mobile :
E- Mail :
Site :
Contact :
Position :
Road :
Town :
State :
Telephone :
Fax :
Mobile :
E-Mail :
Contractor :
Contact :
Position :
Road :
Town :
State :
Telephone :
Fax :
Mobile :
E-Mail :
Contractor :
Inspection Report
Date: Job nr: Weather Operator Section Number PLR:
Purpose: Size/Shape:
Use: Material:
Catchment: Lining:
Category:
Comment:
Location details:
Slope Position Code Observation Counter Photo Grade
MH
No.
130
158 Volume33
Volume Malaysian Sewerage
Industry
Industry Guidelines
Guidelines
Appendix C
Appendix C
Inspection Photos
Town : Road : Date : Section Nmber : PLR :
160132
From MH : To MH :
Appendix C
Volume
Volume
3 3
N.B : When more than one defect is recorded at the same chainage, the most severe defect is counted.
( Name : Qualified Person & Company) ( Name : Qualified Person & Company)
Industry
Malaysian
Industry
Malaysian
Date Of Report : Date Of Report : Date :
Guidelines
Sewerage
Appendix C
Guidelines
Sewerage
Appendix C
Appendix C
From MH : To MH :
Item Position
Start MH Finish MH Code Description Grade
No. (M)
Appendix C 6 Modules
Section 5 - Structural Defect Coding (Module 6A)
C CRACK 5.1 F FRACTURE 5.7 B BROKEN 5.14 H HOLE 5.16 D DEFORMED 5.18 X COLLAPSE 5.22 J JOINT 5.25
CL Longitudinal 5.2 FL Longitudinal 5.7 BSV Soil Visible Beyond 5.14 HSV Soil Visible Beyond 5.16 DV Deformed Vertically 5.18 JO Joint Offset (Displaced) 5.25
CC Circumferential 5.2 FC Circumferential 5.7 Defect Defect (brick) XP Pipe Collapse 5.22 JS Joint Separated (Open) 5.25
CM Multiple 5.2 FM Multiple 5.7 BVV Vold Visible Beyond 5.14 HSV Vold Visible Beyond 5.16 DH Deformed 5.18 XB Brick Collapse 5.22 JA Joint Angular 5.25
CS Spiral 5.2 FS Spiral 5.7 Defect Defect Horizontally (brick)
S SURFACE 5.30 S SURFACE 5.30 S SURFACE 5.30 S SURFACE 5.30 S SURFACE 5.30 S SURFACE 5.30 S SURFACE DAMAGE 5.30
DAMAGE DAMAGE DAMAGE DAMAGE DAMAGE DAMAGE
SRI Roughness 5.30 SAV Aggregate Visible 5.30 SAP Aggregate 5.30 SAM Aggregate 5.30 SRV Reinforcement 5.30 SRP Reinforcement 5.30 SAP Aggregate Projecting 5.30
Increased SAVM Mechanical 5.31 Projecting Missing Visible Projecting
SRIM Mechanical 5.31 SAVC Chemical Attack 5.31 SAPM Mechanical 5.31 SAMM Mechanical 5.31 SRVM Mechanical 5.31 SRPM Mechanical 5.31 SAPM Mechanical 5.31
SRIC Chemical Attack 5.31 SAVZ Not Evident 5.32 SAPC Chemical Attack 5.31 SAMC Chemical Attack 5.31 SRVC Chemical Attack 5.31 SRPC Chemical Attack 5.31 SAPC Chemical Attack 5.31
SRIZ Not Evident 5.32 SAPZ Not Evident 5.32 SAMZ Not Evident 5.32 SRVZ Not Evident 5.32 SRPZ Not Evident 5.32 SAPZ Not Evident 5.32
S SURFACE 5.30 S SURFACE 5.30 S SURFACE 5.30 S SURFACE 5.30 LF LINING FAILURE 5.44 LF LINING FAILURE 5.44 WF WELD FAILURE 5.56
Volume 3
DAMAGE DAMAGE DAMAGE DAMAGE (continue)
SMV Missing Wall 5.31 SSS Surface Spalling 5.31 SZ Other 5.31 LFD Detached Lining 5.44 LFOC Overcut Service 5.44 WFL Longitudinal 5.56
SMWM Mechanical 5.31 SSSM Mechanical 5.31 SZM Mechanical 5.31 SCP Corrosion 5.31 LFDE Defective End 5.44 LFUC Undercut Service 5.44 WFG Circumferental 5.56
SMWC Chemical Attack 5.31 SSSC Chemical Attack 5.31 SZC Chemical Attack 5.31 (metal pipe) 5.31 LFB Blistered Lining 5.44 LFBK Buokled Lining 5.44 WFM Multiple 5.56
SMWZ Not Evident 5.32 SSSZ Not Evident 5.32 SZZ Not Evident 5.32 LFCS Service Cut Shifted 5.44 LFW Wrinkled Lining 5.44 WFS Spiral 5.56
LFAC Abandoned 5.44
Connection LFZ Other 5.44 WFZ Unidentified 5.56
Industry Guidelines
Malaysian Sewerage
134 Volume 3 Malaysian Sewerage
Appendix C
D DEPOSIT 6.1 D DEPOSIT (continue) D DEPOSIT (continue) 6.1 R ROOTS 6.7 R ROOTS (continue) 6.7 R ROOTS (continue) 6.7 R ROOTS (continue)
DA Attached 6.1 DS Settled 6.1 DN Ingress 6.1 RF Fine 6.7 RT Tap 6.7 RM Medium 6.7 RB Ball
DAE Encrustation 6.2 DSF Fine 6.2 DNF Fine Material 6.3 RFB Barrel 6.7 RTB Barrel 6.7 RMB Barrel 6.7 RBB Barrel
DAGS Grease 6.2 DSG Gravel 6.2 (silt & sand) RFL Lateral 6.7 RTL Lateral 6.7 RML Lateral 6.7 RBL Lateral
DAR Ragging 6.2 DSC Hard/Compacted 6.2 DNGV Gravel 6.3 RFC Connection 6.7 RTC Connection 6.7 RMC Connection 6.7 RBC Connection
DAZ Other 6.2 DSZ Other 6.2 DNZ Other 6.3
T TAP 7.1 T TAP (continue) 7.1 T TAP (continue) 7.10 IS INTRUDING 7.8 IS INTRUDING 7.8 L LINE 7.11 L LINE
TF Factory Made 7.1 TB Break in/Hammer 7.2 TS Saddle 7.2 SEAL MATERIAL SEAL MATERIAL (of sewer) (of sewer)
(junction) (connection) 7.2 (connection) 7.2 ISSR Sealing Ring 7.8 ISGT Grout 7.8 (continue)
TFA Active 7.2 TBI Intruding 7.2 TSI Intruding 7.2 ISSRH Hanging 7.8 ISZ Other 7.8 LL Left 7.11 LRU Right & Up
TFC Capped 7.2 TBA Active 7.2 TSA Active 7.2 ISSRB Broken 7.8 LLLU Left & Up 7.11 LRD Right & Down
Volume 3
TFD Defective 7.2 TBC Capped 7.2 TSC Capped 7.2 LLD Left & Down 7.11 LU Up
TFL Leaking 7.2 TBD Defective 7.2 TSD Defective 7.2 LR Left & Right 7.11 LD Down
TFL Leaking 7.2 TSL Leaking 7.2
163
Appendix C