Gravity Fed Main Industrial Training Report

Industrial Training Report on Gravity Feeder Main Kolar
Water Supply Project, Bhopal

Koushik Sarkar
G.F.M Kolar Water Supply Project Page 1

Abstract
Water treatment systems and Water supply systems are necessary to ensure that the quality of living of the
residents of any particular area is maintained at the necessary standards, thus the systems are not themselves
new as the origins of them date-back to aqueducts built in ancient Rome, although todays Systems are far
more sophisticated, and precisely engineered to meet the ever-changing demand of exceeding population.
This systems have their capacity determined keeping in mind the demographic situation and rate of the area
they are intended to service, and service factor that has to be properly estimated bearing in mind their less
than ideal operating conditions of urban surrounding and the resulting damages that can be endured by the
distribution system due to any unpredictable construction regarding activity. The training report attached in
the succeeding pages depict my learning as an Undergraduate student of Mechanical Engineer during my
industrial training at G.F.M(Gravity Fed Main) Water supply project, Tata Projects Ltd. ,Bhopal site. The
report tries to briefly summarize the underlying theoretical and executional aspect of the project. For any
Water Supply Project there are three aspects involved, the first being the source of the water, the second the
treatment system and the third being the distribution system.

ACKNOWLEDGEMENT
It gives me a great pleasure to have an opportunity to acknowledge and to express gratitude to those who
were associated with me during my training at G.F.M Kolar Water Supply Project, TPL, Bhopal.
Special thanks to Mr. Shailendra Prakash Gupta, for providing me with an opportunity to undergo training
under his able guidance and offering me a very deep knowledge of practical aspects of industrial work
culture.
I express my sincere thanks and gratitude to Tata Projects Limited authorities for allowing me to undergo
the training in this prestigious organization. I will always remain indebted to them for their constant interest
and excellent guidance in my training work, moreover for providing me with an opportunity to work and
gain experience.

Index
1. Planning and Design Factors

1.1 Water Resources Planning
1.2 Design Period Factors
1.3 Population growth
1.4 Water Demand
1.4.1 Average Water Daily Demand
1.4.2 Peak Water Demand
2. Water Treatment System
2.1 Brief Introduction
2.2 Cascade Aeration
2.3 Chican Room
2.4 Coagulation and Flocculation
2.5 Sedimentation Tank
2.6 Filtration using Sand Beds
2.7 Chlorination
2.8 Pumping Station
2.9 Venturi Section
2.10 Surge Absorber
3. Distribution System
3.1. Break Pressure Tank
3.2 The Selection of Pipe Type
3.2.A. Pressure Requirement
3.2.B. Service Period of Line and Corrosion Factor
3.2.C. Coatings
3.3 Ductile Iron Pipes
3.4 Spiral Welded Pipes
3.5 Line Accessories
3.5.1. Gate Valve
3.5.2 Butterfly Valve
3.5.3 Air Relief Valve
3.6 Mechanical Joints
3.6.1 Dismantling Joint
3.6.2 Expansion Joints
3.6.2.1. Rubber Expansion Joint
3.7 Thrust Blocks
3.8. Miter Bends
3.9. Girder Supported Span and Non Girder Supported Span
3.9.1. Girder-less Span
3.9.2 Girder Supported Span
3.10. Construction Activities
3.10.1 Excavation & Bedding
3.10.1.1 Alignment
3.10.1.2. Excavation
3.10.1.3. Bedding
3.10.2. Pipe Laying
3.10.3. Back-Filling
3.11 Non Destructive Testing Procedure
3.11.1 Die Penetrant Test
3.11.2 Hydro Test
3.12 Brief Project History and Current Status of project
3.12.1 Project History
3.12.2 Current Status

1. Planning and Design Factors
There are several factors involved in designing the water system for a community and the underlying section
explores the most significant of them.
1.1 Water Resources Planning
There are many questions to answer before the designing and hence construction of a water system can start
such as, identifying a water source and determining the average quantity of water that needs to be supplied,
Checking the quality of water and determining the necessary water treatment to employ. It is usually
advisable to avoid a water source that requires heavy treatment; if there is an alternative source meeting the
demand criterion is available. This is done to minimize the running costs of the project. The Bhopal
Municipality‟s water supply is sourced from tributary of River Narmada in the Kolar region of Madhya
Pradesh by utilizing a gravity dam‟s reservoir initially built for serving the purposes of irrigation demand in
the neighboring districts of Kolar. The water sourced from rivers is the most susceptible to water quality
issues because of runoff from agricultural fields and other untreated discharges from any concerned industry
and turbidity caused from periodic flooding following rainstorms. The water collected from such source also
tend to have higher than usual mineral content in them, owing to the minerals collected from river bed, this
affects the taste of water and can damage the water system. It is unfeasible to control the water quality over
the entire watershed region that is served by the river to prevent contamination. But the lack of any other
alternative source has led to utilization of the dam water.
Fig 1.1.1:Water Intake at the Kolar Dam
The water sourced from the dam undergoes physical and chemical treatment in the Kolar Water treatment
plant which has a rated capacity of 41 Million Liters Per Day(MLD).
1.2 Design Period Factors

The design period itself is a template of how long the system is expected to serve the community before
needing major repairs or upgrades or outright replacements. Selecting a time period depends on the needs of
the community. This service period of the distribution system was set to 25 years by the client, i.e., Bhopal
Municipality Corporation. The current distribution system is intended to be commissioned as the
replacement of the existing 35 years aged Pre-Stressed Concrete (PSC) supply line.
1.3 Population growth
Population Growth The water system not only has to be designed for the current residents requiring it, but
also for the future population it will inevitably serve during the design period and an increased water use in
the future. This is the most difficult factor to account for since there are so many other factors and events
that can take place to effect the growth of a population. The larger the design period is, the more off the
prediction becomes. This factor determines the capacity of the system required to support the present and
future demands of the population.
1.4 Water Demand
The Water demand is an essential factor responsible for determining the discharge rates required for the
distribution and treatment system. The following governing factors determine the water demand:
1.4.1 Average Water Daily Demand
The average daily water demand is the amount of water utilized in liters per second to supply every member
of the community with the necessary daily amount of water over the design period. This takes into account
the population growth and the predicted increase in water use over the design period. The value is of pivotal
importance to determine the necessary pipe size to supply water at that flow rate.
1.4.2 Peak Water Demand
The water demand determined above is an average of the daily needs of a community and do not take into
account cultural or religious events, harvests or climatic changes that require more water than baseline or
average requirement for the time periods when these events occur. This is called a peak water demand factor
and usually 10–30% more water than the average. The other factor is an hourly one that occurs during a day,
which is more severe. This demand is what the water storage tank is typically designed to handle. This
peaking factor is not compensated by the main distribution system as the system intended here is not a round
the clock water supply system to consumer, but a periodically staged supply that is divided through the city
zones, at different time periods of the day so, that required rate doesn‟t skyrocket immediately.
Since the distribution system is continually expanded as the community grows during the design period, it is
better to be on the engineering safe side and design the system with proper heed paid to the peaking factors.
2. Water Treatment System
2.1 Brief Introduction
Water treatment systems are mandatory to render contaminated or unaesthetic water fit for domestic use.
The problem involved with water treatment technology is that they need regular supervision and
maintenance. If they fail from lack of care, then the community will probably keep using the water even
though its detiorated quality. This defeats the purpose of constructing the system to begin with. So, these

systems are kept under close observation and monitoring of the Water Commission and Municipality (or any
other concerned government agency).
There are three stages of water treatment processes usually disinfection, clarification and conditioning.
Disinfection treats water contaminated by disease-causing and pathogenic organisms. Clarification treats
turbidity in water removing suspended solids by means of filtering or settling. Conditioning is responsible to
treat water with high concentrations of minerals, salts and/or metals that give water bad taste, poor color or
odor. In some cases the metals present are harmful to human health if continuously consumed but mostly
this form of treatment is of secondary importance. The underlying section intends to describe the
methodology adapted at the Kolar Water Treatment plant of Bhopal Municipality Corporation.
The processes adapted by the Kolar Water Treatment plant are as follows:
● Cascade aeration
● Coagulation and flocculation
● Sedimentation
● Filtration and disinfection
● Storage of Treated Water
● Pumping system
● Pressure Surge Absorber
Fig 2.1: Kolar Water Treatment Plant

2.2 Cascade Aeration
Kolar Water Treatment Plant (KWTP) has the intake water flow in steps this is called cascade aeration.
KWTP also has valves control chamber that has valve to control the water flow and water meter to measure
the volume of the flow of water.
This system of cascade aeration system has the objective to treat water by removing dissolved gas content
by increasing oxygen content.

In summary the cascade aeration system has the following purpose:
● Increase content of oxygen (O2)
● Decrease carbon dioxide content (CO2)
● Decrease hydrogen sulfide content (HS)
● Volatile organic compounds
● To remove bad odor contained in raw water
Fig 2.2.1:Cascade Aerator
2.3 Shican Room

Before the treatment of raw water, the turbidity must be tested to check amount of suspended particles in
water. After turbidity measuring, jar test take place in order to determine optimum required of coagulate and
PH required for treating water. All chemicals are prepared and injected in water by using shican room. After
jar test, the optimum required coagulate is calibrated and inject in water to form floc in water treatment .The
most coagulate usually used is aluminum sulfate (Al2 (SO4)3) called alum for flocculation. Then, polymer
is also used to increase speed of flocculation. As usually, the flocculation depends on PH its regulation
require the addition of lime.
Fig 2.3: Lime and Alum Mixing Area at the Kolar Treatment Facility
2.4 Coagulation and Flocculation
Flocculation tank is a way water passed from shican mixed with coagulant and lime goes for mechanical
agitation and stirring to favor the formation of flocs. The Kolar Water treatment plant is equipped with two
massive Flocculation tanks. The figure given below is a photograph of the Flocculation tank utilized.
Fig 2.4.1: Flocculation Tank
2.5 Sedimentation Tank
The Sedimentation tanks are settling chambers where the water treated in the flocculation tank is send to
settle down without any mechanical stirring and agitation, in this process the coagulants or floc coheres
together to form larger flocs or chunks and they being less dense than the water float on the surface, after a
particular interval of time the water is slowly drained from the sedimentation tank to be transferred to the
filter bed for further treatment and the sediment i.e., the coagulate formed earlier is removed partially.
2.6 Filtration using Sand Beds
The small amount of coagulate or floc left after the sedimentation process is needed to be filtered out, this is
done in the filtration tank where, the filtration of water is achieved using sand and charcoal beds, the density
of coagulants being greater than the density of water, the floc or coagulant floats on water surface and this
eases the separation. The rate of sedimentation depends on the flow velocity, surface area and the head of
the water available over the filter bed therefore the filtration tank is required to be kept at a constant head
for achieving uniform rate of filtration via the sand beds.

2.7 Chlorination
Chlorination is the process of disinfection of the water by using chlorine gas, the chlorine gas is mixed with
the water in the chlorination tank and the amount of chlorine required to be mixed is regulated by the onsite
chemist present at the plant, who also samples water for testing and data acquisition after treatment at
various stages to determine the quality of treatment is satisfactory or not. The chlorination process is
followed by a rapid charcoal filter bed to ensure the odor of chlorine is removed or minimized to an
aesthetically pleasant level. The next stage of the process being storage and later on pumped to the break
pressure water tank.
2.8 Pumping Station
The pumping is achieved using a multistage centrifugal pumps fit in parallel to each other to achieve higher
discharge rates the delivery sides of each pump merge into to a common header and the delivery side also
houses a Non Return Valve followed by a dismelting joint before being connected to the main header. There
are total of six pump sets housed in the Kolar Water treatment plant that serves the Break Pressure Tank.
The individual pump properties are described below:
Motor Horse Power(Hp) 985

Motor Kilowatt(Kw) 735
Motor Revolution per minute(RPM) 988
Motor Voltage (volts) 6600
Pump Rated Discharge in (cubic meter/hour) 2247
Manometric Head (pump head in meter) 90
Motor Make BHEL
Fig 2.8.1: Centrifugal Pumps Fitted in Parallel at pumping station for high discharge.
The common header is then passed through a venturi head to obtain the measurements of flow and the also
connected to the pressure surge absorber.

Fig 2.8.2: A common header connecting the pumps.
2.9 Venturi Section

This is a venturi section simply used to measure flow rate the, principle of which is discussed below,
Consider the venturi section shown below, the sections 1 and 2 are considered respectively, the difference in
level of the manometric fluid be, say h m , the density of the manometric fluid being higher than the pumped
fluid (i.e., water), the following analysis can be arrived at considering the Bernoulli‟s equation and the
continuity equation applied at the sections.
Fig 2.9.1: Venturi section
On application of Bernoulli‟s equation we can say that,
2 2
P1 V P2 V

1
 z1  
2
 z2 …………………Eqn. 2.9.1
g 2g g 2g
as z1  z 2 ,
We can write the equation as,
2 2
P1 P2 V V
h   
2

1
………………………………………Eqn. 2.9.2
g g 2g 2g

Now ,
 2  2
d V2  D V1 ,
4 4
2 2
d V 2  D V1 ,
2
D
V2  V 1 ………………………………………………………Eqn. 2.9.3
2
d
Using, Eqn. 2.9.2 and Eqn. 2.9.3 we obtain,
1  D  d  2
4 4
 V  h , this can be written as,
2g  4  1
 d 
4
2 ghd
V1  ………………………………………..Eqn. 2.9.4
4 4
(D  d )
The above equation 2.9.4 gives us the flow velocity in the main discharge pipe, and the discharge rate Q can
be written as,
4
 2 ghd
Q  D
2
………………………………..Eqn. 2.9.5,
4 4
4 (D  d )
Fig 2.9.1: A venture section used at the treatment facility.
The above is the equation for discharge rate through the main header, and the difference between the
pressure heads at the throat and the main header are made and noted as h, and the diameters are known so
we can calculate the actual discharge rate at which the main break pressure tank is supplied (i.e., the inflow
rate of the BPT(Break Pressure Tank).
2.10 Surge Absorber

The purpose of surge absorber is to absorb any sudden pressure rise in the delivery end of the pump that
lasts from the main header of the pump house at the treatment facility to the break pressure tank. The
pressure surge can be a resultant of any unwanted obstruction due to admission of debris in the delivery
pipe, due to failure of any air relief valve that might let rise to formation of a gas pocket in the delivery pipe,
or an unprecedented closing of any isolation valve in the stretch of delivery pipe.
The procedure adopted to absorb the pressure surge is as follows, There is an air-compressor that pressurizes
and stores the air at a pressure equivalent to the piezometric head of the water flowing through the main
header, so that there is no flow from the absorber tank to main delivery. There in an accumulator tank, this
tank is connected in turn directly to a surge absorber tank which is far much bigger in size and is partially
filled with water and pressurized air at the described pressure earlier. When a surge occurs the high pressure
rise gets transmitted towards the surge absorber, and flow occurs from the delivery pipe to the absorber tank
momentarily, this tries to compress the air stored over the free surface if the fluid in the tank and therefore
results in an immediate pressure rise of the air in absorber that gets vented by a pressure relief valve at the
top of absorber tank.
Now the air pressure on top of the liquid in absorber tank drops and to maintain the required pressure and
prevent inflow from deliver pipe the accumulator tank delivers pressurized air into the absorber and the
compressor gets switched back on to charge the accumulator tank.
Fig 2.10.1: Surge Abrorber Tank along with the Air Reservoir
Note: The absorber tank is fitted usually with a gate valve to isolate the absorber form delivery during
charging to the required pressure and maintenance operation. The pressure rise in the pipe due to sudden
obstruction of the flow can be taken as, considering the delivery pipe to be completely rigid.
Rise in volumetric strain energy=Loss of Kinetic energy of the flow,
Let ,
Rise in pressure= P,
Bulk‟s Modulus =K,
Velocity of flow in the pipe=V,
Cross Sectional Area of the pipe=A,
Length of the pipe=L,
Density=  ,

The volumetric strain energy = Volumetric Resilience x Total Volume.
2
1 P
Volumetric Strain Energy= AL …………………..Eqn. 2.10.1
2 K
1
The kinetic energy lost=  ALV
2
…………………….Eqn. 2.10.2
2
Equating the two we obtain, i.e., Eqn.2.10.1 and Eqn. .10.2 ,
2
1 P 1 2
AL   ALV ,
2 K 2
2 2
P  V K,
2 2
 V K K
P   V
 
P   VC ………………………………….Eqn.2.10.3,
Where C= Speed of propagation of pressure wave in the fluid (here water).
3. Distribution System
Now as mentioned earlier the water after being treated at the Kolar Water Treatment facility is pumped to
the the Break Water Pressure Tank and then distributed to the secondary storage overhead tanks that supply
the tertiary lines supplying house hold to house hold. Our concern is the primary distribution system and not
the tertiary distribution system, the secondary system already exists and is supplied by the overhead storage
tanks maintained by the supply from the main distribution system.
The Concerned System is a Gravity Fed System, this system are dependent solely on the difference in
elevation of the delivery area and the tank(i.e., source for delivery of water or any fluid. These systems are
passive in operation and do not need any active expenditure of external power to operate. This renders us
with the following advantages and disadvantages of the gravity fed system.
Gravity Fed System‟s Advantages:
 There is no active power expenditure for operation.

 Requires Less Maintenance during the service period.
 The Most Economical Way of Water Distribution.
Disadvantages of Gravity Fed Systems:
 The Survey to be done before design needs to be very explicit as the HGL levels must be properly
determined.
 The future load increase must be compensated in the design for the operation period.
 Not applicable in regions of sudden geographical contour variation.
 Discharge Rate cannot be exceeded beyond the existing design limits unlike exceeding the pump
capacity in case of pump distribution system.

The report will consider the construction procedure and briefly the theoretical validation required for the
hydraulic network of the main distribution system, the remaining part of the report has been discussed in
the following sections.
Fig 3: Network Diagram for Kolar Water Supply Scheme, Bhopal
3.1. Break Pressure Tank
The Break pressure tank is the most reliable method of breaking pressure in bulk and reticulation water
supply networks. They are generally used in rural areas where little or no maintenance is carried out. Simply
put the break pressure tank is a buffer storage between water treatment facility and the main distribution
system .There is not any specific need of capacity of the Break Pressure Tank as long as the net Inflow rate
(supply from the treatment facility) is equivalent to the net outflow rate (i.e., the demand of the distribution
system).But for a distribution system as large as the Kolar Water Supply project cannot afford the above said
condition, because of the enormous base demand and the limited supply rate of the treatment facility.
Therefore a buffer capacity of the Break Pressure Tank (BPT) of the Kolar Water Supply System is kept as
16.50 Lac liters.
Reasons to consider using a break pressure tank rather than a pressure reducing valve include:
 Less maintenance
 Break pressure tanks, operating in the same system, won‟t “hunt” against each other like pressure
reducing valves do.
 Break pressure tanks have a higher turn down ratio than pressure reducing valves.
 Even if the break pressure tank fails, the downstream pipeline will never be exposed to excessive
pressures.
 A break pressure tank has fewer components than a conventional pressure reducing installation.
3.2 The Selection of Pipe Type
The Selection of Pipe Type Depends on the Consideration of the following criterion:
 Pressure Requirement.

 Service Period of the Line and the corrosion factor.
 Hydraulic Friction Loss Factor.
3.2.A Pressure Requirement
The Pressure Requirement of the pipe is dictated by the maximum piezometric head at any junction of the
pipe ,the piezometric head is the summation of the pressure head and the static head of the system at any
junction. Therefore, the piezometric head can be defined by the Hydraulic Gradient Line Itself.
3.2.A.1 Total Energy Line (T.E.L): The total energy line is the graphical representation of the net energy
available per unit weight of water that is in terms of net head of work available at any point throughout the
distribution line per unit weight of water.
3.2.A.2 Hydraullic Gradient Line (H.G.L): The Hydraullic Gradient line is obtained from subtracting the
velocity head of the fluid at any point the value of Total Energy Line, in other words this will give you the
piezometric head at any junction of the flow network. The HGL and TEL are discussed in further detail with
the diagram given below.
Fig 3.2.1: Hydraullic Gradient Line and Total Energy Line
TEL at the junction 2 is given as T.E.L=h = H  hf ,
Where,
H= Z a  Z b =Difference in elevation in the between the two junction.

h f = frictional loss in the pipe between the junction 1 and Junction 2 of the network.
The energy available at that point is given as,

 gQh
P  (In Kilo Watt),
1000
Where h is the Total Energy Line height at the point, and similarly the Hydraullic Gradient Line is given as,
H.G.L= T.E.L – Velocity Head,

Pa
Hydraullic Gradient Line (H.G.L) =  Zb =Piezometric Head.
g
Therefore the Absolute pressure given by the H.G.L. Line gives us the pressure rating of the pipe to be used.
The pipe type selected for the calculated pressure for our application is of the following type:

 Mild Steel Pipe For diameters 1600 Dia to 800 Dia,(Internal Diameters).
 Ductile Iron Pipes for Internal Diameters for pipes having ID less than the 800 Dia.
3.2.B Service Period of the Line and the corrosion factor

As discussed earlier the service period of the system has been decided to be 25 years and the first five years
the System has to be maintained without any additional cost by the Contractor, Tata Projects Ltd, for Bhopal
Municipality Corporation, so it is increasingly important that the corrosion is paid heed to.
In a piping system there are a number of factors working alone or in combination that can effect the rate of
corrosion occurring in pipe. Depending on the degree of these factors a new piping system can show signs of
corrosive wear in as little as two years after installation.
The corrosive effect the source water can have on the piping system does not mean poor water quality is
being delivered. The rate of corrosion on a piping system is related to basically these factors:
 The pH of the water

 The amount of oxygen in the water.
 The chemical make-up of the water.
 The amount of galvanic corrosion from the use of dissimilar metals contained in or in contact with
the piping system.
 The temperature of the water
 The velocity/pressure of the water in the pipe
To prevent corrosion to occur in the pipes of the distribution system the internal and the external surfaces of
the pipes are coated, in the ongoing part of the report we will talk about the type of coating adopted and the
advantages and tradeoff concerned with it.
3.2.C. Coatings
The type of coatings utilized in the concerned system‟s Pipeline is as follows:

1. Liquid Epoxy Coating for internal surface.
2. Bituminous Layer Coating for External Surface.
3. Guniting Process for Bore of Mild Steel of Pipes.
3.2.C.1.Internal Coating:
Internal coating is applied for anticorrosive properties or flow improvement properties of coatings for gas
flow or for abrasion resistance in mineral ore slurry pipelines or for chemical resistance of transported fluid.
A typical water pipe lines are coated with liquid epoxies or with powdered epoxies. Due to the nature of
ease in application, low cost and better performance, the liquid epoxies are preferred. There are following
advantages of the internal liquid epoxies over concrete mortar linings:
1. Thin coatings (0.4-1 mm) compared to CML (15-25 mm) i.e. better throughput of pipeline.
2. Lesser friction due to smooth nature (Coating Rz<5 microns) or C value >150.
3. Lesser commissioning time as no flushing is required to wash pipelines for cement particles
4. Higher flexibility, reduced weight, reduced chances of damages or cracks
5. Higher chemical, fungi, slime, bacterial resistance
6. Reduced cost of transportation
7. No leaching out of coating material resulting unchanged water properties
8. Food grade epoxies are certified from NSF or WRAS organizations for drinking water.

3.2.C.1.1 Internal Liquid Epoxy Coatings: It is applied in shops in controlled conditions of proper surface
preparations and careful coating application.
3.2.C.1.1.1 Surface Preparation: For a long lasting and quality coating a proper and adequate surface
preparation is compulsory. This is achieved with series of following operations:
 Pipe surface cleaning: Solvent cleaning in case of any presence of oil or grease which are
detrimental to any coating.
 Pipe preheating: To remove moisture from pipe surface and also to carbonize any detrimental
hydrocarbon contamination of bare pipes.
 Abrasive blast cleaning: Normally 2 stages of abrasive blast cleaning are performed with 2 separate
blasting machines. Each blasting machines is fitted with two high speed, high powered blowers
which throws abrasive at very speed due to centrifugal force.
3.2.C.1.2 Internal Surface Guniting
The Gunite process is a time tested method adopted by Municipalities millions by its use in lining existing
sewer mains. These lines, whether originally constructed of masonry or concrete, can be sealed and restored
to full efficiency by installing a Gunite liner. While the liner will reduce the interior diameter, proper finish
of the Gunite may increase flow coefficients to such a degree as to counter the reduction in size.
The cement lining of steel pipes by the spun lining or spinning method is used for the particular application,
as it is a necessity for the protection of steel against corrosion and abrasion. The Spin-Lining process is also
a speedy and inexpensive way of installing the lining to steel pipes whether at the point of fabrication or in-
situ. There is a dis-advantage where fittings and bends are not practical for spun lining.
Fig 3.2.C.1.2:Internal Lining completed

Gunite construction and Cement lining method have always stood the test of time, lined subterranean pipes
and reservoirs can produce a lower per liter cost to convey and store water. Cement lining to steel pipes that
convey water provides the ideal solution to corrosion of steel this in turn provides long term protection and
reduces maintenance cost to a minimum; pipes with a wide range of diameter from 800 mm to 2000 mm can
be successfully lined using the spun lining method.
And in our case the spun lining method has been adopted in case for gunite lining for pipes of internal
diameter 1600mm, 1200mm and 800mm, the spun lining is done in-situ for the spiral welded pipes at the
main yard. And later on the pipes are transported to the sites of installation.
3.2.C.2 External Coatings

The coating procedure adopted for corrosion prevention of external surfaces is as follows:
Concrete Lining or Short-Crete for spiral Welded Mild Steel Pipe:
The process of lining the pipe can be broken down into:
3.2.C.2.1 Surface Preparation

3.2.C.2.2 Wire Mesh Laying
3.2.C.2.3 Concrete Coating
3.2.C.2.1 Surface Preparation
 Pipe surface cleaning: Solvent cleaning in case of any presence of oil or grease which are
detrimental to any coating.
 Abrasive blast cleaning: Normally 2 stages of abrasive blast cleaning are performed with 2 separate
blasting machines. Each blasting machines is fitted with two high speed, high powered blowers
which throws abrasive at very speed due to centrifugal force.
3.2.C.2.2 Wire Mesh Laying
 Prefabricated grid of 35 mm x 35 mm mesh made of 3 mm steel wire is layed around the pipe.
 The laying of the grid on the pipe is done and the spacer blocks of thickness 16mm  3mm is used to
maintain the proper spacing.
3.2.C.2.3 Concrete coating
A M25 mixture of concrete is prepared using 5/8th of inch of fine aggregate, and Portland slag cement (PSC)
is blasted using a blower on the surface of the pipe and surface is leveled of using masonry instruments and
the coated layer is left for curing.
3.3 Ductile Iron Pipes
For all main distribution system whose internal diameter is less than 800 mm,Ductile Iron Pipe is used , for
their ease of application ,ease of pipe laying and their corrosion resistant properties. For the application in
this project European Standards for Ductile Iron Pipes,EN 545( Potable Water) K9 Wall Thickness is
used.Ductile iron pipe is a pipe made of ductile cast iron commonly used for potable water transmission and
distribution. This type of pipe is a direct development of earlier cast iron pipe, which it has superseded. The
ductile iron used to manufacture the pipe is characterized by the spheroidal or nodular nature of the graphite
within the iron. Typically, the pipe is manufactured using centrifugal casting in metal or resin lined
moulds. Protective internal linings and external coatings are often applied to ductile iron pipes to inhibit

corrosion: the standard internal lining is cement mortar and standard external coatings include bonded
zinc, asphalt or water-based paint, or liquid epoxy coat. The liquid epoxy coating for the internal surface has
been adopted. Life expectancy of unprotected ductile iron pipes depends on the corrosiveness of soil present
and tends to be shorter where soil is highly corrosive.
Table 3.3.1 EN 545 Ductile and Iron Wall Thicknesses

Outside Diameter Wall Thickness
DN
mm(In) K9 K10
40 56 (2.205) 6.0 (0.236) 6.0 (0.236)
50 66 (2.598) 6.0 (0.236) 6.0 (0.236)
60 77 (3.031) 6.0 (0.236) 6.0 (0.236)
65 82 (3.228) 6.0 (0.236) 6.0 (0.236)
80 98 (3.858) 6.0 (0.236) 6.0 (0.236)
100 118 (4.646) 6.0 (0.236) 6.0 (0.236)
125 144 (5.669) 6.0 (0.236) 6.0 (0.236)
150 170 (6.693) 6.0 (0.236) 6.5 (0.256)
200 222 (8.740) 6.3 (0.248) 7.0 (0.276)
250 274 (10.787) 6.8 (0.268) 7.5 (0.295)
300 326 (12.835) 7.2 (0.283) 8.0 (0.315)
350 378 (14.882) 7.7 (0.303) 8.5 (0.335)
400 429 (16.890) 8.1 (0.319) 9.0 (0.354)
450 480 (18.898) 8.6 (0.339) 9.5 (0.374)
500 532 (20.945) 9.0 (0.354) 10.0 (0.394)
600 635 (25.000) 9.9 (0.390) 11.1 (0.437)
700 738 (29.055) 10.9 (0.429) 12.0 (0.472)
3.4 Spiral Welded Mild Steel Pipes
The current distribution system of Kolar Water supply project utilizes Spiral Welded Pipes with internal
surface coated with cement lining using spun lining process in other words guniting process and the external
coating being 25.4 mm M25 concrete.
Spiral pipes are commonly used for large diameter (24”- 140” OD) projects where hot rolled coils are easily
available. The spiral pipe mills have modern machinery with automation to deliver pipes of higher quality at
competitive price due to flexible process of accommodating wide range of coil width for a similar diameter.
Hot rolled coil are formed by 3-roll forming technique to a specific helix angle and submerged arc welding
carried out in 1 step or in 2 steps depending on wall thickness (Figure 4.4.1). The quality assurance process
is similar to ERW (Electric Resistance Welding) pipes. Spiral welded pipes are superior to ERW in terms of
strength and other pipeline design requirements.

Fig.3.4.1: Spiral Pipe Manufacturing Process
3.5 Line Accessories

The next section will list the Line accessories that are used in the Main Distribution system of G.F.M. Kolar
Water Supply system, this includes the valves, mechanical joints, and thrust blocking etc. the section will
discuss each topic one by one.
3.5.1. Gate Valve
A gate valve can be defined as a type of valve that used a gate or wedge type disk and the disk moves
perpendicular to flow to start or stop the fluid flow in piping. This gate valves are used for isolation purposes
only.
A gate valve is the most common type of valve that used in any process plant. It is a linear motion valve
used to start or stop fluid flow. In service, these valves are either in fully open or fully closed position. When
the gate valve is fully open, the disk of a gate valve is completely removed from the flow. Therefore
virtually no resistance to flow. Due to this very little pressure drops when fluid passes through a gate valve.
To achieve proper sealing, when the valve is fully closed, 360° surface contact is required between disk and
seats.
Gate valves should not be used for regulation or throttling of flow because accurate control is not possible.
The high velocity of the flow in the partially open valve may cause erosion of the disc and seating surfaces
and also creates vibration and noise.
Fig 3.5.1.1: Gate Valve Used Commonly (Rising Stem Type)

For the application in confined spaces the non-rising stem Gate Valves are used in the main distribution line.
As shown below the in the Fig 4.5.2.
Fig 3.5.1.2: Gate Valve with Non-Rising Stem
Advantages of Gate Valve
 Gate valve provides good

 Pressure drop during operation is very less.
 Most of the gate valve can be used as bi-directional.
 They are suitable for high pressure and temperature application and required less maintenance.
Disadvantage of Gate Valve
 It cannot be used to control the flow.
 A gate valve is slow in operation. Opening and closing take times which is good also as it reduces
the chance of hammering.
 When partially open it creates vibration and noise.
 Repairs, such as lapping and grinding of seats are more difficult due to limited access.
3.5.2 Butterfly Valve

Butterfly valves find application in the main distribution line where throttling is required instead of isolation
process. A Butterfly valve is a quarter-turn rotary motion valve, that is used to stop, regulate, and start the
flow. Butterfly valves are a quick open type. A 90° rotation of the handle can completely close or open the
valve. Normally, they are used in systems where positive shut-off is not required.
Large Butterfly valves are usually equipped with gearbox type actuator, where the hand-wheel is connected
to the stem via a gearbox. This will reduce the force but at the same time reduce the speed of the operation.
This type of valve should be installed in the open position. If the valve is closed during installation, the
rubber seat will wedge against the valve disc and make it difficult to open.

Fig 3.5.2.1: Ductile Iron Butterfly Valve
Butterfly Valve’s Advantages
 Butterfly Valve is suitable for large valve applications due to Compact, lightweight design that
requires considerably less space, as compared to other valves
 Due to a quick operation, it needs less time to open or close
 The maintenance costs are usually low compared to other valve types
 A pressure drop across a butterfly valve is small
 Valve with Non-metallic seating can be used in chemical or corrosive media.
Butterfly Valve’s Disadvantages
 Throttling is limited to low differential pressure services and that too with a 30- to 80-degree disc
opening.
 There is a chance for cavitation and choke as the disk is always in the flow Turbulence flow can
affect the disc movement.
3.5.3 Air Relief Valve
Air Release Valves or Air Relief Valve function‟s is to release air pockets that collect at each high point of a
full pressured pipeline. An air release valve can open against internal pressure, because the internal lever
mechanism multiplies the float force to be greater than the internal pressure. This greater force opens the
orifice whenever air pockets collect in the valve. Air Release Valves are essential for pipeline efficiency and
water hammer protection. They are provided at every 500 m traversal length of the pipe and at high spots of
the pipe line. The basic construction of air relief valve is shown in Fig 4.5.3.1 and the Fig. 4.5.3.2 shows the
usual application points of the Air Bleed Valve, points B and D are ideal location for Air Relief Valve.

Fig 3.5.3.1: Cast Iron Air Relief Valve
Fig 3.5.3.2: Ideal Location for Air Relief Valve
3.6 Mechanical Joints
3.6.1 Dismantling Joint

Dismantling joints play a decisive role in the design and layout of pipelines and valves. They are an essential
aid during the installation and removal of pipe sections and valves. Without a dismantling joint offering
longitudinal adjustment, it is almost impossible to insert a valve exactly into a pipe section. Thanks to this
adjustability of the dismantling joint, the valve can be fitted next to the dismantling joint, and the
dismantling joint can be to set to the exact length required prior to being securely connected to flanges.
Fig 3.6.1.1: Sectional View of a Dismantling Joint

Fig.3.6.1.2:A typical Dismantling Joint
The reverse sequence is used for dismantling, where readjustment of the length of the dismantling joint
creates enough space to loosen and remove the valve. In both cases, the dismantling joint guarantees fast
installation and removal, thus contributing to increased efficiency and reducing site operations and down
time. The procedure is similar where pipe sections have to be fitted together. Certain types of dismantling
joints are also suitable for use without restraint in flexible pipelines. Finally, dismantling joints can be used
to fill gaps e.g. where a pump installed in a fixed position has to be connected to a pipe protruding from a
wall. This joint find applications at location where a certain valve, or any accessories such as a pump, or
flow measurement devices such as a Flow-meter or Venturi-Head needs to be coupled with the pipeline, and
exact clearances are impossible to achieve in the extensive construction site of the project.
3.6.2 Expansion Joints
Expansion Joints are necessary to prevent thermal stresses from occurring in the pipeline, for small diameter
lines and low pressure lines expansion loops can be allowed, but for the application in the water supply
system expansion loops are impractical due to large diameter of the pipe and the required flow, so
Expansion joints are provided in the straight stretches of the pipeline. Rubber type expansion joint is used in
the distribution system, and is briefly discussed below.
Fig 3.6.2.1: An 800 mm Rubber Expansion Joint.

3.6.2.1 Rubber Expansion Joint
Rubber Expansion Joints are a flexible connector fabricated from natural or synthetic elastomers and fabrics
with metallic reinforcements designed to provide stress relief in piping systems due to thermal changes.
When flexibility for this movement cannot be designed into the piping system itself, an expansion joint is
the ideal solution. Rubber expansion joints compensate for lateral, torsional and angular movements
preventing damage and undue downtime of distribution system‟s operation. See Fig.3.6.2.1.
The application of a Rubber Expansion Joint can eliminate the problems as:
 Vibration, Noise, Shock, Corrosion, Abrasion.

 Stresses, i.e., Thermal Stress.
 Vibration, Pressure Pulsation and Movement in a Piping System.
3.7 Thrust Blocks
Whenever the pipeline encounters bend there is a change of momentum of the fluid flowing inside, there is
a forced required to cause this change of momentum of the fluid, this force is applied by the pipeline on the
fluid and therefore an equal and opposite reaction force acts on the pipe, this force can cause severe damage
to the system and even cause to rupture of the pipeline if not properly supported, therefore for providing
proper support and anchorage to the pipeline with the ground Thrust Blocks are used. The magnitude and
direction of thrust can be calculated from the momentum equation as following.
Let,
P1  Pressure at section 1,
A 1  Cross-sectional Area at section 1,
V1  Velocity of flow at section 1,

P 2  Pressure at section 2,
A 2  Cross-sectional Area at section 2,
V 2  Velocity of flow at section 2,
  Density of the fluid,
  Angle of Bend in degrees.
F x  Force exerted on the fluid in x-direction.
F y  Force exerted on the fluid in y-direction.
The Net force acting on the fluid in the x-direction can be written as,
F x  P1 A 1  P 2 A 2 cos    Q (V 2 cos   V 1 )
,
Where the right hand side of the equation is the change in momentum due to application of the force,
F x   Q (V 2 cos   V 1 )  P1 A 1  P 2 A 2 cos 
,
The force exerted on the pipe will be equivalent to - F x given as,
 F x  P1 A1  P 2 A 2 cos    Q (V 2 cos   V 1 ) .........................Eqn.3.7.1

(  F x )  ( P1 A 1  P 2 A 2 cos    QV 2 cos    QV 1 )

Similarly for the y-direction can be written as,
F y  P2 A 2 sin    Q (V 2 sin  )
The above equation can be re-written as,
F y   QV 2 sin   P2 A 2 Sin  ,
The force acting on the pipe in the y-direction can be written as,
F y   (  QV 2 sin   P2 A 2 Sin  ) ……………………………………..Eqn. 3.7.2
Using equation 4.7.1 and 4.7.2,the net resultant force can be achieved as,
2 2
Fr  Fx  Fy ……………………………………………….Eqn.3.7.3
And the direction of the force acting on the pipe bend can be written as,
 Fy P1 A 1  P 2 A 2 cos    Q (V 2 cos   V 1 )
tan    ,
 Fx  (  QV 2 sin   P 2 A 2 Sin  )
 1  P1 A 1  P 2 A 2 cos    Q (V 2 cos   V 1 ) 
  tan 



……………………………..Eqn.3.7.4,
  (  QV 2 sin   P 2 A 2 Sin  ) 
So, using the equations 3.7.1, 3.7.2, 3.7.3, 3.7.4., we can obtain the force or thrust acting on the pipe ,its
magnitude and its direction, the pressure head drop for pipe bends with uniform cross sectional area on both
sides is given as minor head loss,
2
kV
hl  ,
2g
Where, k= constant of proportionality depending on the bends,k depends on:

 Radius of curvature of bend.
 Degree of bend.
 Velocity of flow through the pipe.
Fig.3.7.1: A Thrust Block Under Construction on site.

For the bends used in the Kolar Water Supply project the Client i.e., Bhopal Municipality Mandates the use

of appropriately sized thrust block for all pipe diameters for any bend angle exceeding 11 .The figure given
below shows the thrust block under construction for the project.
3.8. Miter Bends
Many times in a construction environment as dynamic as this one is concerned there will be a major
difference between the intended drawings route for the pipeline and the feasible route, in such cases exact
bend angle can-not be pre-anticipated before construction actually reaches the point of bend, therefore a
readymade bend for the pipe section of the required diameter cannot be procured, and also for pipe of large
diameters (ID>1000 mm) bends for varying bend angles encountered it is more suitable to manufacture the
required bends by Mitering Process from section of pipe available at the yard. Miter bends. Another type of
bend is a Miter bend. A Miter bend is a bend which is made by cutting pipe ends at an angle and joining the
pipe ends.
The calculation for the miter bends can be calculated as,

In the figure given below Fig.4.8.1, dotted lines are where the pipe should be cut. Each dotted cut line has a
vertical reference line marked at following distances from pipe end.
 L2 : Distance of first and last reference line from pipe ends.

 L1 : Distance between reference lines.
 Cut Back : Offset distance of cut lines from reference lines at the top and bottom of pipe.
Fig 3.8.1: Diagram for calculation of cut-lines for the miter bends.
The length L1 is given as,
 D 
L 1  tan   E  2 …………………….Eqn. 3.8.1
 N  2
L1
L2  ……………………………………..Eqn. 3.8.2
2

 D 
tan    POD
 N  2
Cutback = ……………..Eqn. 3.8.3,
2
Where,
D =required elbow degrees.

N =Numer of cuts.
E =Elbow center radius required.
POD =Pipe Outside Diameter.
Fig 3.8.2: The Pipe Section Cut For Mitered Bend.
3.9. Girder Supported Span and Non Girder Supported Span
For certain Over-ground Segments of the pipe, the pipe encounters sudden river crossings or low land that
has to be crossed by the pipe, in such cases the pipe has to be carried over the pier to pier, built out
reinforced concrete covering the span of the segment in either of two ways:
3.9.1: Girder-less Span or Unsupported Span.

3.9.2: Girder Supported Span,
These two methods are discussed below, in the underlying section.
3.9.1. Girder-less Span
Girder-less Span is also called a self-supported span, in other words the pipe itself behaves as a beam in such
case. In such cases the total span of the segment is broken down into several spans of equivalent length say
L, the weight of the water can be assumed to be a UDL load acting on the pipe behaving as a beam, we here
calculate the maximum bending stress induced in the span of the pipe, if the stresses in the beam exceeds the
permissible value of the design standard the Pipe segment has to be supported by external Prefabricated steel
Girders, or Precast / In-Situ cast Concrete Beams. The shear stress consideration is neglected here for the
beam as calculation are made at the middle point of the span (i.e., where bending moment is maximum and
the shear force is zero, i.e., the point of symmetry in the loading case).The loading being UDL the spans are
considered as simply supported beams that closely resembles the actual case and also to simplify the
problem and make the beam(i.e., pipe) statically determinate.
Let,
d=inner diameter of the pipe (in mm)

D=outer diameter of the pipe (in mm),
 =density of the fluid flowing through the pipe,

g=acceleration due to gravity,
w= Load Applied per unit length in KN/m,
I=Second Moment of area about the Neutral Axis of the section of the beam.
Z=sectional Modulus of the section.
 max = Maximum Bending Stess.
M=moment in Kn.m,
l=length of the span(pier to pier distance) (in Meters).
Maximum bending moment occurs at the center of span given as M,

2
1 wl l wl
M   …………………………...Eqn.3.9.1.1,
2 2 2 8
w is calculated as ,
 2 6
w  g d  10
4 (in N/m),
This can be expressed in KN/m
2
 gd 6
w   10
4000 (in KN/m)…………………………………………Eqn.3.9.1.2,
4 4
 (D  d )
I  4
64 (in mm )………………………..........Eqn.3.9.1.3,
4 4
I  (D  d )
Z  
D 2 32 D 3
(in mm )……………………………….Eqn 3.9.1.4,
We know that,
M  Z  max
,
Using Eqn. 3.9.1.1, 3.9.1.2 and 3.9.1.4, we get,
2 4 4
wl 3  (D  d )
 10   max
8 32 D
2 2 2 2
 gd l 32 D 6  gd l D 6
 max    1000   10   10 ,
4 4 4 4
4000 8  (D  d ) (D  d )
2 2
 gd l D 3
 max   10
4 4 2
(D  d ) N mm
(in )…………………….Eqn. 3.9.1.5
 e
permisssib le 
F .O . S ……………………………………………..Eqn. 3.9.1.6,
If the value of bending stress calculated from the Eqn. 3.9.1.5 exceeds the value of permissible stress as
calculated using the Eqn. 3.9.1.6,then the segment has to be supported externally using girders and is not
self-supported.
Often the deciding factor in this case becomes the maximum allowable deflection instead of the bending
stress due to the high sectional Modulus of the pipes. As high deflection can result in damage caused to the
outer and the inner coating of the structure.

Fig 3.9.1:Girderless Span
3.9.2 Girder Supported Span
As discussed earlier if the bending stresses exceed the permissible stress level then the span is supported
using prefabricated, girders usually I-Beams laid parallel to each other with cross-bracing is used, in the
current project concerned the girders are made of precast concrete. This is a fairly simple structure and it is
illustrated below in the figure 3.10.1.
Fig 3.9.2: A typical Pipe Crossing
3.10. Construction Activities
Type of Construction Activities :

A) Piping related activities:
• Inlining
• Guniting
• Pipe shifting
• Excavation & bedding
• Pipe Laying
• Jointing (Welding/Jointing)
• DP Testing/joint coating
• Back filling
B) Bridge/Pedestal work (Civil Engineering Works):
• Pile/Pier/Abutment/Girder casting
• Girder erection
• Slab casting
• Pedestal casting
The construction activities regarding Inlining, Guniting has already been discussed earlier, pipe shifting
being a logistics task doesn‟t need to be further elaborated, the procedure for DP testing, and hydro test will
be destruct in Non-Destructive testing methods in later section 3.11 of the report, the current part will be
concerned on discussing about Excavation & Bedding, Pipe Laying, Jointing and Back Filling part.
The Part B of construction activities are civil engineering works ,although deeply rooted with the
construction aspect of the project in parallel to the Mechanical Engineering works, but doesn‟t concern my
scope of industrial training as a Mechanical Engineering Student, So these works are not detailed in the
report and just being dully listed.
3.10.1 Excavation & Bedding
3.10.1.1 Alignment
The trench or pipe centre line shall follow the line and grades staked out by the Engineer.
This position is traced out using GPS configured All stations. The trench or tunnel centre line shall not
deviate from the required alignment by more than 100 mm. Where a profile of the proposed pipeline is
provided, and where elevations are given on the stakes, as in our case, the pipe shall is required to be
installed within 25 mm of the required elevations In cases where no profile of the proposed pipe is provided,
the plans or specifications shall specify a minimum depth of cover for the pipe.
In cases where the pipe crosses a road or driveway, the pipe shall be laid at a uniform gradient between the
elevations of the pipe on either side of the road or driveway.
Fig 3.10.1.1: A bedded Trench Section in Forest Area Section of the System

3.10.1.2. Excavation
The excavation of trenches shall be carried out in accordance with the plans and specifications and as staked
out on the ground by the Engineer. Where in the opinion of the Engineer, the subgrade is found to be
unstable, unsuitable material shall be removed and replaced with approved materials. Trench walls shall be
kept vertical from the bottom to 300 mm above the top of the pipe. The trench width in this section shall be
not less than twice the outside diameter of the pipe. The minimum clear width shall be available between
any shoring or bracing that is required.
In our case the most areas where trench is to be excavated belongs to a rocky region, which makes the trench
excavation far more difficult than usual, the job was handed over to specialized contractors who are
experienced in the use of high energy explosives, at certain situation where use of explosives was prohibited,
hydraulic hammers fitted on excavators are used (in case of excavation performed in populated areas ).
3.10.1.3. Bedding
The pipe bedding , shall be smooth and even to provide full support for the pipe invert, with cavities
provided for flanges, couplings, dismantling joints, sleeves and weld pockets.
The pipe bedding is classified into 4 categories briefly discussed below,

1. CLASS “A” Concrete shall be placed in the trench such that the pipe is supported along its
entire length by a layer of concrete. Concrete shall be placed as shown on the plans and as
directed by the Engineer. The concrete shall be allowed to cure for no less than three hours
prior to backfilling. The pipe shall be backfilled with bedding material approved by the
Engineer to a depth not less than 200 mm above the top of the pipe.
2. CLASS “B” Bedding sand shall be placed and thoroughly compacted in the trench such that
the pipe is supported along its entire length (and under bells and flanges) by a layer of sand,
the thickness of which shall be no less than 100 mm.
3. CLASS “C” Excavated bedding material shall be placed and thoroughly compacted the entire
width of the trench such that the pipe is supported along its entire length (and under bells and
flanges) by a layer of compacted excavated bedding material the thickness of which shall be
no less than 100 mm. Excavated bedding material shall be placed and compacted around the
pipe and to 200 mm above the top of the pipe for the entire width of the trench.
4. CLASS “D” The bottom of the trench shall be smooth, such that the pipe is supported along
its entire length with cavities provided for flanges, couplings, sleeves or bells of the pipe.
In The case of the Kolar Water Supply Project the Class „C‟ and Class „D‟ Pipe bedding is
utilized, due to the constructional and economic feasibility of the procedure at the job site.
3.10.2. Pipe Laying
After the bedding is completed the pipes are aligned up in the trenches using Extendable boom cranes and
hydras under the careful supervision of a site engineer and safety engineer, the alignment is the final
criterion in the pipe laying procedure, and it is necessary to maintain proper adherence to the intended center
line path and the gradient and avoid any sudden elevation which might lead to air pockets in the line when
charged. As it is quite unfeasible to provide unplanned vents at section of underground ( sub terrain)
segments of the distribution system. Fig 3.10.2.1 depicts a procedure of the pipe laying procedure under-
process.

Fig 3.10.2: Pipe Laying in Progress
3.10.3. Back-Filling
The trench is backfilled with common backfill material to the top of the trench. The backfill material shall
be consolidated with the wheels or tracks of excavating or grading equipment. The backfilled trench shall be
left in a slightly mounded condition to minimize the effects of settlement. The backfill material is to be
uniform and not composed with boulders, this possesses a problem in the particular location of Kolar as
backfill soil has to be brought from other places other than the excavated trench material to be used again in
backfilling. This adds to delays in the project as backfill soil is not easy to come-by and alternatives method
of using fly ash for partially backfilling is being proposed to the client.
3.11 Non Destructive Testing Procedure
The following Two methods of Non-Destructive Procedure adopted in the present construction site are:

3.11.2 Hydro Test

The die penetrant test is performed over the root pass and the final hot pass of the welded joints in the pipe
section of distribution system to ensure that the there are no surface flaws present in the welds made, this is
done in parallel to the Hydro-Test to ensure earlier flaw detection before the Hydro-Test which saves time as
well as resources of the concerned parties.
Liquid penetrant examination is one of the most popular Nondestructive Examination (NDE) methods in the
industry. It is economical, versatile, and requires minimal training when compared to other NDE methods.
Liquid penetrant exams check for material flaws open to the surface by flowing very thin liquid into the flaw
and then drawing the liquid out with a chalk-like developer. Welds are the most common item inspected, but
plate, bars, pipes, castings, and forgings are also commonly inspected using liquid penetrant examination.

Advantages of Die Penetrant Test:
 Sensitivity to small surface discontinuities

 Easy inspection of parts with complex shapes
 Quick and inexpensive inspection of large areas and large volumes of parts/materials
 Few material limitations (metallic and nonmetallic, magnetic and nonmagnetic, and conductive and
nonconductive can all be inspected)
 A visual representation of the flaw are indicated directly on the part surface
 Aerosol spray cans make the process portable, convenient, and inexpensive
 Indications can reveal relative size, shape, and depth of the flaw
 It is easy and requires minimal amount of training
Disadvantages of Die Penetrant Test:
 Detects flaws only open to the surface

 Materials with porous surfaces cannot be examined using this process
 Only clean, smooth surfaces can be inspected. (Rust, dirt, paint, oil and grease must be removed.)
 Metal smearing from power wire brushing, shot blasting, or grit blasting must be removed prior to
liquid penetrant examination
 Examiner must have direct access to surface being examined
 Surface finish and roughness can affect examination sensitivity. (It may be necessary to grind
surfaces before PT.)
 Multiple process steps must be performed and controlled
 Post cleaning of parts and material is required, especially if welding is to be performed
 Proper handling and disposal of chemicals is required
 Fumes can be hazardous and flammable without proper ventilation
Fig 3.11.1: Die Penetrant Test Being Performed
Note: It is important to remember penetrant is a very thin liquid designed to seep into the smallest crack.
Consequently, if an assembly has stitch welds or material not sealed by a weld, the penetrant will travel
behind the welds and between layers of unfused material. Penetrant can be nearly impossible to remove
from these areas. Trapped penetrant will cause defects in welds if further welding is done or will bleed out
over time and contaminate paint and process fluids.

3.11.2 Hydro Test
Hydro-test or Hydrostatic test is a process where components such as piping systems, gas cylinders, boilers,
and pressure vessels are tested for strength and leaks. Hydro tests are often required after shutdowns and
repairs in order to validate that equipment will operate under desired conditions once returned to service.
Furthermore, hydrostatic testing cannot be performed during normal operations and cannot monitor
equipment for leaks after the test has been performed.
Although hydrostatic testing is considered to be a nondestructive testing method, equipment can rupture and
fail if the inspection exceeds a specified test pressure or if a small crack propagates rapidly.
Procedure for Hydro-Test :
Hydrostatic testing is a type of pressure test that works by completely filling the component with water,
removing the air contained within the unit, and pressurizing the system up to 1.5 times the design pressure
limit the of the unit. The pressure is then held for a specific amount of time to visually inspect the system for
leaks. Visual inspection can be enhanced by applying either tracer or fluorescent dyes to the liquid to
determine where cracks and leaks are originating.
The main disadvantage of hydro-Test is that it is a very clumsy method of testing and requires the filling of
the entire section to be tested to be filled with water and then pressurized, this mandates the need of huge
quantities of water for large bore pipes, and this is posse a problem in areas such as Bhopal due to periodic
unavailability of excess water during summer seasons, so these tests are scheduled for the monsoon seasons
usually. Although of having this disadvantage the following procedure is adopted as it is far more
economically feasible than radiography test of the entire distribution system.
3.12 Brief Project History and Current Status of project
3.12.1 Project History
Survey, Investigation, Design including providing, Laying, Jointing and commissioning of

Gravity/Feeder main for Kolar water supply scheme comprising of 1600 mm diameter MS Pipe
having thickness of 10mm – 14mm as per IS 3589: 2004 including inner and outer lining of the MS
pipe. The work shall also include all necessary civil structures including Bridge/Support structures
for crossing of Rivers including Kerwa & Kaliyasot River and nallas with access road for
maintenance.
3.12.2 Current Status
 Design – 100% design is completed.

 Procurement – 96% procurement has been completed, balance is under process.
 Inlining & Guniting – 93.3% inlining & guniting has been done.
 Laying ( MS & DI) –
 MS Pipe (Scope: 34333 RM, Completed: 22528 RM “65.62%”)
 DI Pipe (Scope: 23833 RM, Completed: 17249 RM “72.38%”)
 Bridge – Kerwa: 50% work completed. Kaliyasot: 30% work completed.

3.13. References
[1] Tesson, P.A., GURTLER HEBERT AND CO Inc, 1968. Method of laying pipe line.
[2] Battle, B.J. and Jones, L.S., United States Pipe and Foundry Co LLC, 1985. Guides for gate valves. U.S.
Patent 4,532,957.
[3] Khan, Z., Zayed, T. and Moselhi, O., 2009. Structural condition assessment of sewer pipelines. Journal of
performance of constructed facilities, 24(2), pp.170-179.
[4] Balkaya, M., Moore, I.D. and Sağlamer, A., 2013. Study of non-uniform bedding support under continuous
PVC water distribution pipes. Tunnelling and Underground Space Technology, 35, pp.99-108.
[5] Mishra, Manoj Kumar, and UM Rao Karanam. "Geotechnical characterization of fly ash composites for
backfilling mine voids." Geotechnical & Geological Engineering 24, no. 6 (2006): 1749-1765.
[6] Ducoste, Joel J., and Mark M. Clark. "The influence of tank size and impeller geometry on turbulent
flocculation: I. Experimental." Environmental Engineering Science 15, no. 3 (1998): 215-224.
[7] Bhave, Pramod R. "Optimization of gravity-fed water distribution systems: Theory." Journal of Environmental
Engineering 109, no. 1 (1983): 189-205.

Gravity Fed Main Industrial Training Report

Uploaded by

Copyright:

Available Formats

Gravity Fed Main Industrial Training Report

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Gravity Fed Main Industrial Training Report

Uploaded by

Copyright:

Available Formats

Industrial Training Report on Gravity Feeder Main Kolar

Water Supply Project, Bhopal

G.F.M Kolar Water Supply Project Page 1

G.F.M Kolar Water Supply Project Page 2

G.F.M Kolar Water Supply Project Page 3

1. Planning and Design Factors

G.F.M Kolar Water Supply Project Page 4

1.1 Water Resources Planning

Fig 1.1.1:Water Intake at the Kolar Dam

1.2 Design Period Factors

G.F.M Kolar Water Supply Project Page 5

1.3 Population growth

1.4 Water Demand

1.4.1 Average Water Daily Demand

1.4.2 Peak Water Demand

2. Water Treatment System

2.1 Brief Introduction

G.F.M Kolar Water Supply Project Page 6

Fig 2.1: Kolar Water Treatment Plant

G.F.M Kolar Water Supply Project Page 7

Fig 2.2.1:Cascade Aerator

2.3 Shican Room

2.4 Coagulation and Flocculation

2.5 Sedimentation Tank

2.6 Filtration using Sand Beds

G.F.M Kolar Water Supply Project Page 9

2.8 Pumping Station

Motor Horse Power(Hp) 985

G.F.M Kolar Water Supply Project Page 10

2.9 Venturi Section

Fig 2.9.1: Venturi section

On application of Bernoulli‟s equation we can say that,

We can write the equation as,

G.F.M Kolar Water Supply Project Page 11

Using, Eqn. 2.9.2 and Eqn. 2.9.3 we obtain,

Fig 2.9.1: A venture section used at the treatment facility.

2.10 Surge Absorber

G.F.M Kolar Water Supply Project Page 12

Rise in volumetric strain energy=Loss of Kinetic energy of the flow,

G.F.M Kolar Water Supply Project Page 13

Equating the two we obtain, i.e., Eqn.2.10.1 and Eqn. .10.2 ,

Where C= Speed of propagation of pressure wave in the fluid (here water).

Gravity Fed System‟s Advantages:

 There is no active power expenditure for operation.

Disadvantages of Gravity Fed Systems:

G.F.M Kolar Water Supply Project Page 14

Fig 3: Network Diagram for Kolar Water Supply Scheme, Bhopal

3.1. Break Pressure Tank

3.2 The Selection of Pipe Type

G.F.M Kolar Water Supply Project Page 15

3.2.A Pressure Requirement

Fig 3.2.1: Hydraullic Gradient Line and Total Energy Line

TEL at the junction 2 is given as T.E.L=h = H  hf ,

H= Z a  Z b =Difference in elevation in the between the two junction.

The energy available at that point is given as,

H.G.L= T.E.L – Velocity Head,

G.F.M Kolar Water Supply Project Page 16

3.2.B Service Period of the Line and the corrosion factor

 The pH of the water