Water Transmission Lines

8/14/2019 Water Transmission Lines

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TABLE OF CONTENTS

PART III - MINIMUM DESIGN STANDARDS

Section 120

WATER TRANSMISSION LINES

120.1. GENERAL................................................................................................................................. 120.1

120.2. CATHODIC PROTECTION SYSTEM.......................................................................................120.1

120.3. PRE-MANUFACTURE OF STEEL AND CONCRETE CYLINDER TYPE

PIPE REQUIREMENTS ............................................................................................................ 120.2120.3.1. Design Calculations ........................................................................................ 120.2120.3.2. Shop Drawings................................................................................................ 120.2120.3.3. Material Lists and Delivery Schedule .............................................................. 120.2120.3.4. Pipe Laying Schedule and Marking Diagram .................................................. 120.2120.3.5. Submittal Revisions and Approvals................................................................. 120.2

TABLE 120-I ......................................................................................................................................... 120.4

120.4. MATERIAL FABRICATION, TESTING AND CERTIFICATION ..............................................120.5

120.4.1. Hydrostatic Testing ......................................................................................... 120.5120.4.2. Certification .....................................................................................................120.5120.4.3. Marking Pipe and Specials..............................................................................120.5120.4.4. Lining and Coating Protection .........................................................................120.5120.4.5. Standard Joints ............................................................................................... 120.5120.4.6. Harnessed Joints ............................................................................................120.6120.4.7. Flanges and Nozzles.......................................................................................120.6120.4.8. Mechanical Couplings .....................................................................................120.7120.4.9. Closures and Correction Pieces......................................................................120.8120.4.10. Specials and Fittings .......................................................................................120.8


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PART III - MINIMUM DESIGN STANDARDS

SECTION 120.

WATER TRANSMISSION LINES

120.1. GENERAL

Water transmission lines twenty-four (24") inch and smaller in diameter shall be polyvinylchloride (PVC), Glass Fiber Reinforced (FRP) or steel. Lines larger than twenty-four (24")inch diameter may be Steel (S), Concrete Cylinder (CCP) or Ductile Iron (DI). Steel andductile iron pipe shall be cement mortar lined and coated with an 80 mil. Polykin YG-3system. Concrete cylinder pipe exterior surface shall be primed and coated with a 30 mil.Polykin YG-3 wrap.

Except as herein modified, the pipe shall conform to the applicable AWWA Specification setforth in Section 30, Table 30-1. Metallic type pipe shall be designed, manufactured, tested,inspected and cathodically protected in accordance with these standard specifications.

Cylinder and metallic type pipe, harnesses and fittings shall be designed to withstand thesimultaneous application of external loading and 210 psi internal pressure in accordance withthe requirements set forth in Table 120-I, of this specification.

Unless modified in the special conditions all steel pipe, to be installed under a compactedbackfill cover of 4 1/2 foot shall be furnished with the following minimum steel cylinder wallthickness.

Pipe Diameter Minimum Wall Thickness Inches tw= Inches

18 - 36 = 3/16" = 0.1875

42 - 54 = 0.005 Cylinder I.D.

An approved corrosion protection and monitoring system shall be designed and included asa part of the contract documents, prior to bidding.

120.2. CATHODIC PROTECTION SYSTEM

The cathodic protection system shall be designed by a firm having no less than ten (10) yearsexperience, and proof of accreditation by the Nation Association of Corrosion Engineers(NACE), as a firm qualified in one or more areas of corrosion control. The on-the-jobsupervisor must be accredited by NACE as a Corrosive Specialist and all related work shallcomply with the recommended practice set forth in NACE RP-01-69, "Control of ExternalCorrosion on Underground or Submerged Metallic Systems."

The designing firm shall prepare and submit a design survey report, along with the cathodicprotection plans and specifications, for both an impressed current and a sacrificial anodesystem. The corrosion protection and monitoring system shall be designed so as to providean underground pipeline free of corrosion attack for a period of not less than thirty (30) years.The City reserves the right to select the system wherein its best interests will be served.

The submitted survey report and design calculations shall be based on field test data, takenat not less than 500 foot intervals along the centerline of the proposed pipe alignment,


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indicating soil resistivity and stray currents to be encountered at and below the pipe centerlineas well as the soil ph, chloride and sulfate content. Consideration shall also be given theprotection of structures, the dielectric insulation of the pipe and fittings to be installed, currentrequirements, DC outputs, foreign line crossings, pipeline casings, etc.

Plans and specifications shall clearly state the size, quantity, type and locations whereanodes, anode leads, ground beds, lead cables, test stations, terminal boxes, connectingdevices, rectifiers, reference cells, meters, insulated mechanical and/or flanged joints, etc.,are to be installed.

Specifications shall designate alternate types of materials to be installed. Specifyingproprietary materials will not be allowed unless approved by the City, ten (10) days prior tobid opening.

120.3. PRE-MANUFACTURE OF STEEL AND CONCRETE CYLINDER TYPE PIPE

REQUIREMENTS

Within twenty (20) calendar days following the "Notice of Award", the contractor shall obtainfrom the supplier and submit to the project engineer for approval four (4) complete sets of

the following:

120.3.1. Design Calculations - Design calculations shall comprise concise, yet complete, stressanalysis of each critical section of pipe wall, girth joints, harness system, specials, outlets andappurtenances, sufficient to ascertain conformance of the pipe and fittings with thesespecifications.

120.3.2. Shop Drawings - Shop drawings shall accurately indicate the Precise geometry; type, gauge,diameter, strength, manufacturing tolerance and thickness of the elements to be incorporatedin manufacture of the pipe, joints, fittings and appurtenances.

120.3.3. Material Lists and Delivery Schedule - Copies of purchase requisitions for all materials (pipe,valves, etc.) showing names of supplier, material specification or description, quantity

ordered and delivery schedule.

120.3.4. Pipe Laying Schedule and Marking Diagram - Laying schedule shall indicate by consecutivenumber the order and direction of installation of each pipe section, special fitting, valves,access manholes, nozzles, outlets, and other appurtenances. In addition, the laying scheduleshall include:

A. The invert station and elevation to which the bell end of each pipe shall be laid andall changes in gradient or horizontal alignment.

B. All elements of curves and bends, both in horizontal and vertical alignment.

C. The limits of each reach of welded joints, closures and concrete encasements.

120.3.5. Submittal Revisions and Approvals - The project engineer will inspect and return two (2)copies of design calculations, working drawings and other submittals to the contractorproperly executed and marked either "Approved as Corrected" or "Rejected" within twenty(20) calendar days after receipt thereof.


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The contractor shall review and back check indicated revisions deemed necessary by theproject engineer to correct defects. He shall revise submittals returned to him that have beenmarked "Approved as Corrected" or marked "Rejected", and shall resubmit in quadruplicatesaid revisions to the project engineer within fifteen (15) calendar days after the contractor'sreceipt thereof. Further revisions, if and when required, will be handled in accordance withthe above procedure.

Only upon the contractor's receipt of submittals marked or designated "Approved" or"Approved as Corrected" shall the manufacturer of pipe commence: Provided that saiddrawings designated "Approved as Corrected" are corrected and resubmitted to the projectengineer immediately. Upon receipt of duly executed "Approved" design calculations, layingdiagrams and shop drawings, the contractor shall immediately forward to the project engineereight (8) prints of each such approved submittals for use during construction.

Neither the inspection nor lack of inspection of any drawings, design calculation, material list,laying schedule, sample or piece of data (furnished to the project engineer for his approval)shall waive any of the requirements of these Specifications, Drawings and ContractDocuments or relieve the contractor of any obligations thereunder; and defectiveworkmanship, work, materials and finished product may be rejected notwithstandingconformance with Drawings and other submittals inspected by the Engineer.


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TABLE 120-I

STEEL PIPE CONCRETE CYLINDER PIPE

Pre-Stressed Pre-Tensioned

=< 42" Dia.

AWWA Standard Specifications C-200 C-301 C-303Cylinder Yield Strength f y- (max) = 42,000 psi* 42,000 psi* 36,000 p

Hoop Stress f s- (max) = 0.5 f y@ Ps Appendix "B" 16,500 pHoop Stress f s- (max) = 0.90 fy@ 1.5(Ps+Pwh) Appendix "B" 0.75 f y@Hoop Stress f s- (max) = Appendix "B"Dead Load WD= lbs/ft = 130 Cd(Bc

2+3Bc)) 130 Cd(Bc+3)

2130 Cd(B

Live Load WL= lbs/ft = AASHTO HS-20 AASHTO HS-20 AASHTODesign Load W = lbs/ft = (WD+ WL) (WD+ WL) (WD+ WDeflection x = in. max = 0.02D' ** 0 (D

2/4000

Cylinder Test Pressure P = psi 0.75 f y @ fs= 25,000 @ f s= 25

Line Pipe Joint Rubber gasket in Carnegie M 3516 rolled spigot and bspigot joints.

HS-20 LOADING * Carbon content of the steel shall WHERE: not exceed 0.24%

Height of Load Cover ** x=D e K(W/12) r

3 Bc= Outside pipe diameter in

ft lbs/ft2

(EI + 0.061 (E') r3) Cd= Load co-efficient

1 1800 D = Finished inside dia. of pip2 800 D' = Steel cylinder outside dia3 600 SOIL MODULUS E' De = Deflection lag factor - 1.24 400 E = Modulus of elasticity of st5 250 Pipe 0 Inches Kips/IN

2 30,000,000 lbs/in

2

6 200 24" 600 E' = Soil modulus7 175 30" 650 I = Moment of inertia of pipe w8 100 36" 700 in

4/in = t

3/12

42" 750 K = Bedding factor = 0.10 48" 800 Ps= Working pressure = 150 p

54" 850 Pwh= Water hammer = 60 psir = Mean radius of cylinder intw= Steel cylinder thickness in = .005D" (Min)


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120.4. MATERIAL FABRICATION, TESTING AND CERTIFICATION

The project engineer or his designated representative shall be permitted to make inspections

necessary during the manufacture of the pipe and appurtenances to determine compliance

with the specifications.

120.4.1. Hydrostatic Testing - Each length of steel pipe or cylinder with joints attached, shall be

hydrostatically tested to the hoop stress designated in Table 120-I. Those lengths that are

found defective shall be repaired by welding and then retested to the designated stress until

it is free from leakage.

120.4.2. Certification - The manufacturer, via the contractor, shall furnish the project engineer four (4)

copies of the following certifications as to compliance with the specifications:

Mill analysis and test of steel. Hydrostatic test reports. Compliance of materials and

application of linings and coating. Usage of Type V or modified Type II cement as required

in mortar coatings on pipe, specials and fittings. Compression test results of concrete from

cylinders made from concrete used in pipe core and/or wall.

120.4.3. Marking Pipe and Specials - The manufacturer shall legibly mark and number in sequence

all pipe sections and specials in accordance with the laying schedule and pipe installation

survey laying stations. All pipe specials shall be marked at each end with the top field

centerline stations.

120.4.4. Lining and Coating Protection - It shall be the responsibility of the manufacturer to provide

adequate strutting to prevent damage to the coating and lining caused by deflections beyond

the specified allowable limits for the type of pipe supplied during handling, loading,

transporting, unloading and storing. Any additional strutting or stulling required during

installation to prevent damage to the coating and/or lining caused by deflections beyond the

allowable limits shall be the responsibility of the contractor. The contractor shall be

responsible to be sure that all strutting remains in place until after the pipe section, special

or fitting has been properly backfilled.

The manufacturer shall provide a polyethylene or other suitable bulkhead on the ends of the

pipe section and on all special openings to prevent drying out of the linings. The contractor

shall be responsible to assure that the polyethylene or bulkheads remain intact on the pipe

ends until the section or fitting is being installed in the trench.

120.4.5. Standard Joints - Standard joints for transmission line pipe shall be either an expanded bell

and rolled spigot or the Carnegie bell and spigot end ring, each with rubber gasket.

Mechanically coupled, flanged or welded joints may be required where called for on thedrawings.

The joint construction shall be suitable for at least 250 psi water service and regardless of

type shall be designed to be self-centering. The bells and spigots shall have a smooth close


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sliding fit at the self-centering surface, and the joint shall be capable of either symmetrical

or asymmetrical joint closure and shall remain water-tight under all conditions of water

service.

The joint assemblies shall be so formed and accurately manufactured that when the pipes

are drawn together in the trench, they shall form a continuous watertight conduit with smooth

and uniform interior surface and shall provide for a slight movement of any pipe in the

pipeline due to contraction, settlement or lateral displacement.

The maximum tolerances permitted in the construction of the joint shall be that stated in the

pipe manufacturer's design as approved. Any fabrication performed prior to approval of

details shall be at the contractor's risk. Approval by the engineer shall not be held to relieve

the contractor of any part of the contractor's responsibility to meet all of the requirements of

these specifications or of the responsibility for the correctness of the joint details.

120.4.6. Harnessed Joints - Harness joint designs shall be submitted to the project engineer for

approval. On transmission lines twenty (20) inches and larger, the joint harness designs shall

include considerations of stresses induced not only in the attachments, but also in joint ringsand steel cylinder by thrust at bulkheads, bends, reducers, and valves resulting from the

internal working pressure including the transient pressures. Design stresses shall not exceed

fifty (50) percent of the specified minimum yield strength of the grade of steel utilized when

longitudinal thrust is uniformly distributed around the circumference of the joint.

The manufacturer shall supply a mechanical method of joint restraint suitable to the engineer

that will allow for expansion, contraction and deflection after assembly.

Proof-of-design tests need not be conducted specifically for a project. Certified reports

covering tests of harnessed joints constructed in the identical fashion as that proposed may

be found acceptable.

120.4.7. Flanges and Nozzles - Flanges in the line and for outlets of the size and at locations shown

on the drawings shall meet the requirements of AWWA Standard C-207, Class "D", 150 psi

working pressure. Flanges may be either ring type flanges or hub type flanges, but all

flanges supplied must be of the same type and class. Blind flanges shall be designed in

accordance with ASME Unfired Pressure Vessel Code, Section VIII. The design pressure

for blind flanges shall be 150 psi.

Bolt holes in all flanges shall straddle field vertical centerline. Bolt holes for insulating flanges

shall be 3/16" larger than the bolt diameter.

Gaskets for standard flanged outlets shall be 1/8" ring type Garlock #7021 compressedasbestos sheet packing or approved equal. Insulating flange gaskets shall be PSI - Pacific

Seal gaskets with sleeves and double insulating washers.


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Nozzles shall have 1/4" minimum wall thickness.

The machined faces of all flanges shall be shop coated with rust preventative compound,

Dearborn Chemical "No-Ox-Ld", Houghton "Rust-Veto 344" or Rust-Oleum "R-9". Edges

and back faces of attached flanges shall be shop coated with Koppers "Bitumastic Mill

Undercoat". All surfaces of blind flanges, except the machines surfaces, shall be shop

coated with Koppers "Bitumastic Mill Undercoat".

120.4.8. Mechanical Couplings - Where mechanical couplings are required, the ends of the pipe shall

be prepared for flexible steel couplings, Dresser or approved equal. Plain ends for use with

couplings shall be smooth and round for a distance of twelve (12) inches from the ends of

the pipe, with pipe diameter not more than 1/64" smaller than the nominal 0.D. of the pipe.

The middle ring of the coupling shall be truly round. After welding, all middle rings shall be

tested by cold-expanding a minimum of one (1) percent beyond the yield point to proof-test

the weld to the strength of the parent metal. The weld of the middle ring shall be subjected

to air test for porosity.

The followers shall be single-piece contoured mill section welded and cold-expanded asrequired for the middle rings. They shall be of sufficient strength, in the opinion of the

engineer, to accommodate the number of bolts necessary to obtain adequate gasket

pressures without excessive rolling. The shape of the follower shall be of such design as to

provide positive confinement of the gasket.

Gaskets shall be rubber-compounded material that will not deteriorate from age or exposure

to air under normal storage or use conditions. The rubber in the gasket shall meet the

following specifications:

Color - Jet Black Tensile Strength - 1000 psi Minimum

Surface - Non-blooming Elongation - 175% Minimum

Durometer Hardness - 74 + 5

The gaskets shall be immune to attack by impurities normally found in water. All gaskets

shall meet the requirements of ASTM designation D2000 AA 709Z meeting Suffix B13 except

as noted above.

In addition, where insulating couplings are required, both ends of the coupling shall have a

wedge-shaped gasket which assembles over a rubber sleeve of an insulating compound in

order to obtain insulation of all coupling metal parts from the pipe.

Each coupling shall pass a resistance test of 10,000 ohms after being assembled on the pipe

for 72 hours.

120.4.9. Closures and Correction Pieces - Closures and correction pieces shall be provided as

required so that closures may be made due to different headings in the pipe laying operation


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and that correction may be made to get the pipe laying on station. Closures and correction

pieces shall be provided as required by the contractor and shall be approved by the engineer.

Closures shall be so constructed as to have not less than a minimum of eighteen (18) inches

and maximum of two (2) times the pipe I.D. adjustment, which may be made in the field.

The correction piece shall be a nominal length of pipe with a length of bare pipe on the spigot

end for a field trim. Linings shall be held back six (6) inches from the required length on the

spigot end.

120.4.10. Specials and Fittings - Unless otherwise specified herein or on the plans, all specials and

fittings for transmission lines shall conform to the dimensions of the applicable AWWA or

ASTM Standards. Specials and fittings shall be designed and constructed to be of equal or

greater strength than the transmission line and shall have the same type of lining and coating

as the abutting pipe. Specials and fittings shall be made of segmentally welded sections from

hydrostatically tested Pipe cylinders, with ends to mate the type of joint or coupling specified.

The deflection angle between adjacent segmented bands shall not be greater than 22 1/2

degrees.

Specials and fittings that cannot be mechanically lined and coated shall be lined and coated

by hand, using the same materials as are used for the pipe and in accordance with the

applicable AWWA Standards. Coatings and linings applied in this manner shall provide

protection equal to that specified for the pipe. Fittings may be fabricated from pipe that has

been mechanically lined and/or coated. Areas of lining and coating that have been damaged

by such fabrication shall be repaired by hand applications in accordance with applicable

AWWA Standards. Areas of cement-mortar linings repaired in this manner need not be

reinforced with wire mesh.

Reinforcement for wyes, tees, and nozzles shall be designed in accordance with AWWA M-

11 "Steel Pipe Manual". Reinforcement shall be designed for the working pressures

indicated.

Access manholes with covers shall be 20" in diameter (0.D.) as detailed on the drawings.

All threaded outlets shall be forged steel suitable for 3000 pound service.

Moderate deflections and long radius curves may be made by means of beveled joint rings,

by deflecting a straight pipe, by using short lengths of pipe, or by a combination of any of

these methods.

Unless specifically approved by the engineer, all curves must begin with a pipe joint or

fabricated angle at the P.C. and end with a pipe joint or fabricated angle at the P.T. within

station locations shown on the Drawings. All deflection angles shall fall on the curve. Thelaying schedule P.I.'s must meet the P.I.'s as shown on the Drawings in the horizontal

direction. The laying schedule for vertical P.I.'s must meet the P.I.'s as shown on the

Drawings where interference is critical.


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