SH Edition Sedition ff Nome am industry Sawer Networks & Pump StationsFOREWORD BY THE CEO OF SPAN Gin intend fe wana niente Maas hve coed through the introduction of new systems in the industry. Sine then basic sanitation facilites as overhang latrines, pit and bucket systems and pour fush systems were slowly replaced by more modern systems like aerated lagoons, activated sludge system, package systems and variety of mechanical plant. However, sewage still remains as fone of the major polluants of our inland waterways. In the 1900s, the emergent of new treatment technologies were mainly driven by the basic need to treat the sewage 0 a8 {0 control waterborne diseases. Today, the environmental regulations including effluent discharge stardards are becoming mote stringent with inctexsing awareness foward sustainable environmental management, Public are also more educated and more alert on the need to preserve the water source and the environment. Hence the introduction of more iraovative design in municipal wastewater treatment technologies is needed in order to meet the slrieter regulatory requirements. Faster approvals of sewerage system provide better development potential within an area while standardization of system and equipment will lead to better ‘operational efficiencies, Thus th first edition ofthe guidelines for sewerage industry entitled "Design and Installation of Sewerage Systems” was introduced in 1995. The main purpose of these guidelines is to assist the developer and professionals to plan land design sewerage systems that comply with the regulatory requirements. Certainly those guidelines have successfully paved the road towards nurturing a more structured sewerage industry development. “The National Water Services Commission (SPAN) has completed the exercise initiated by the Sewerege Services Department to review and improve those guidelines, "The new revised documents were renamed as the “Malaysian Sewerage Industry Guidelines” which comprise of five (8) volumes. ‘These new revisions incorporated invaluable knowledge gained by various stakeholders in the sewerage sector over the past decade. SPAN would like to thank all parties involved ia the revision exercise. It is hoped that the publication of the third edition of this volume will further improve the sewage system development in this count. Chief Execu National Water forticer erviees Commission (SPAN)‘Tamue or Contents Section 1 ul 12 13 Section 2 2a Introduction Purpose of This Volume ‘Who Should Use This Volume Related Reference Material Planning, Material and Design Sewers LLL Pipe Mate 2.1.2. Pipe Materials and Fitings 21.3 Pipe Selections 1.4 Requirements and Limitations for Use of Cert Pipe Material 215 Vinitied Clay Pipe 21.6 Reinforced Concrete Pipe 21.7 Ductile hos Pipe 21.8 Stee Pipe 21.9. Solid Wall PE Pipe 2.1.10 Profiled Wall PE Pipe 21.11 Glass Reinforced Plastic Pipe 2.1.12 Acrylonit 2.1.13 Sewer Design - General Requirements 2.1.14 Flow Rate Estimations 2.115 Sewer Cleansing Velocities 2.1.16 Pipe Roughness 2.1.17 Design of Gravity Sewer 2.1.18 Design of Force Mains 2.1.19 Vacuum Sewerage System 2.1.20 Computerised Sewer Designs 2.1.21 Design of Inverted Siphon 2.1.22. Stmctural Design of Sewers le Butadiene Styrene Pipe22 23 24 Manbole 22.1 General 22.2 Manhole Location 22.3, Pipe Lengths from Manhole 2.24 Structural Design Considerations for Manhole Manhole Covers and Frames 23.1 General 232 Load Class 233. Mater 2.34 Dimensions, Marking and Surface Finish 23S Seating 236 Casting 23.7 Protective Coating 238 Watertighiness 239 Safety Features 2.3.10 Produet Certification Design of Network Pump Stations 24.1. Specifying of Network Purp Stations 242 General Requirements 243 Bulfer Requirements 244 Pipework Requizements 245 Wet-well Requitements 2.46. Dry-well Requirements 24.7 Structural Requirements 24.8 Ventilation Requirements 249 Odour Contr 2.4.10 Requitements for Lighting and Electrica Fitings 2.4.11 Acceptable Pump System (Fixed Speed Pumps only) 24.12 Valve Requirements 2.4.13 Requirements for Level Controls 24.14 Requirements for Alarms 2.4.15 Requirements of Hydraulic Design and Performance 244.16 Maintenance Considerations 24.17 Hazard and Operabilty 24,18 Other Requirements * ges 33 3 35 55 55 56 56 56 3T 3? 37 ss 58 38 39 6 61 e eeageees25 26 Section 3 31 32. 33 34 3s Interceptors 25.1. Oil Interceptors 252 Grease Taps Concrete and Reinforcement Requirements 26.1 Concrete 262. Cement 2.63. Steel Reinforcement and Falsework ‘Constrwetion and Installation Inteoduetion Pipes and Fitings Delivery and Handling 321 Pipes and Fittings Delivery 3.22 Pipe Handling at Site 323 Pipe Stonge 324 Pipe Damage “Trench Excavation 33.1 Protection of Affected Services, Pavements and Vegetation 3.32 Excavation Requirements 333. Bored Excavation Pipe Laying. 341 Pipe Bedding 342. Pipe and Fittings Placement 343. Pipe Jacking 344 Concrete Pipe Support 345 Pipe Cuting 346 Backiill of Tench 34.7 Other General Requirements Pipe Joining 35.1. Flexible Joins 352. Solvent Weld Joins 353 Flanged Joints 3.54. Steal Pipe Welded Joints (Field Welding) 3.555 Polyethylene Butt Welded Joins 8 80 80 80 8 82 83 BRESB 85 86 37 a7 8836 a7 38 Seetion 4 4a 42 43 44 45 46 47 48 49 4.10 Special Requirements For Sewer 3.6.1 Thrust Blocks fr Pressure Pipelines 3.62. Pipe Restraints and Bulkheacls on Steep Slopes 3.63 Pipe Embedment and Overlay 3.64. Sleoving of Ductile Iron Pipe 3.65 ‘Rocker’ Pipe Connections to Manholes Reinstatement Connections to Public Sewers 38.1 General 38.2 Junction Connections 38.3 Saddle Connections 384 Manhole Conaections Sewer Testing General ‘Testing of Gravity Sewers ‘Testing of Foree Mains Testing of Manhole and other ancillaries Low Pressure Ait Test, 45.1. General 45.2. Procedre for Testing 45:3, Procedures for Handling Air‘Test Failure Low Pressure Water Test 46.1 General 4.62. Procedure 463 Handling Water Test Failures High Pressure Water Test ATA General 412 Procedure High Pressure Leakage Test 48.1. General 48.2. Procedure ‘Test for Stsighiness, Obstruction and Gradient CCTV Inspection 4.10.1 Objectives of CCTV Inspection 88 88 9 89 9 91 2 2 7 98 100 100 rat 102 102 102 103 104 108 os 104 106 106 106 106 107 1074m 42 410.2 Technical Requirements and References 410.3 Equipment Specitications and Test Devices 4.10.4 CCTV Inspection Requirements 4.10.5 CCTV Inspection Implementation Procedure for [New Sever Network 4.10.6 Interpretation OF Results From CCTV Inspection 10,7 Follow-Up Action to Be Taken Inflation Test 4111 General 4.11.2 Procediare 4.113. Handling Test Fa ‘Watertightness Test 4121 General 4.122 Procedures 107 108 108, 110 m2 ua my ua ua ry 4 usLasr oF Tames ‘Table 2a Table 2.18, ‘Table 22 Table23 ‘Table 24 ‘Table25 Table 26 ‘Table 27 ‘Table 28 Tablet ‘Table 42 Appendix A. Figure AI Figure a2 Figure a3 Figure Ad Figure AS, Figure AS Figure AT Figure as Figure AD Figure A10 Figure Alt Figure 12 [Normal Pipe Roughness for Gravity Sewer ‘Normal Pipe Roughness for Force Mains for All Pipe Materials ‘Typical Roughness Coeticient, ks ‘Typical Manning Coefficient,» ‘Typical Hazen-Wiliams Coefficient, C Conditiontam ofthe station equipment Minimum Manhole Diameters inal inspection and testing Recommended Design Parameters for Pump Stations ‘Test Duration Defect Grades Descriptions ‘Typical Drawings Diagrams ‘Standard Manole Cover lan View of Typical Manhole ‘Typical Shallow Precast Concrete Manhole (Ground Level to Invert of Pipe 1.2m = Depth <2.5 m ‘Typical Shallow Precast Concrete Manlole with Backdrop (Ground Level o Invert of Pipe 1.2 m = Depth <2. m) ‘Typical Mesium Precast Concrete Manhole (Ground Level to Invert of Pipe 2.5 m = Depth <5 m) ‘Typical Medium Precast Conerete Manhole with backdrop (Ground Level to Invert of Pipe 2.5 m = Depth <5 m) ‘Typical Deep Precast Conerete Manhole (Ground Level to Invert of Pipe 5 m = Depth < 9m) ‘Typical Deep Precast Concrete Manhole with Backdrop (Ground Lese to Invert of Pipe 5 m= Depth = 9 m) ‘Typical Deals of Large Diameter Manhole (LDM) Type ‘Typical Inet Vent Detail Deiails of Household Connection to Main Sewer Reiiculation Pipe for V.C. Pipe ‘Typical Details of Concrete Thrust and Anchor Block Figure A13(@) Typical Deuils of Inverted Siphons or Depressed Sewer n 2 8 8 29 45 31 37 101 us 19 20 PI red 123 14 125 126 a 128 19 130 BLFigure A130) Figure ALM) Figure A140) Figure AIS Figure At6(a) Figure A160) Figure AI7 Figure A19(@) Figure A190) Figure A20(a) Figure A20(b) Figure A20(¢) Figure A21 Figure A2 Figure A23 Figure A24 Figure A2S Figure A26 Figure A27 Figue A28 Figue 29 Appendix B ‘Table BL Appendix © Appendix C1 Appendix C2 Appendix C3 Appendix C 4 Appendix C5 Appendix C6 “Typical Details of Inverted Siphons or Depressed Sewer “Typical Details for Ponce Main ~ Scour Valve and Receiving Manhole Sheet 1 t02) 1 ls of Force Main ~ Air Valve (Sheet 1 to 2) Typ of Force Main Crossing Standard Pipe Beddings (Sheet 1 102) ‘Standard Pipe Beddings (Sheet 1 02) ‘acim sewage collection system Example of vacuum station with housed collection vessel Example of vacuum station with housed collection vessel Collection chambers with interface valves vented through breather pipes Collection chamber with interface valve activated by float “Mut-valve collection chamber ‘Vactum sewer profiles (not to seal) ‘Example of vactum sewer priles for uphill and downhill ‘transport (not to seal) ‘Y-brnch for vacuum sewer “Method of joining crossover pipes and branch sewers to “Typical details of dry-well pump station “Typial detail of wet-well pump station ‘Butfer Zone for Pump Station wth Super Structure Bur Zone for Pump without Super Structare Standard Symbols and Abbreviations “Tables Cases of Right Pipe Requited for Various Depth CCTV Format and Codes Report format for CCTV Inspection Report format for CCTV Inspection Report frinat for CCTV Inspection efor format for CCL Inspection Rezo format for CCTV Inspection Modules 132 133 1 135 136 137 8 139 40 1 at 142 143 M3 as a 145 7 as 49 133 137 138 159 160 161 162Section 1 Introduction44 1.2 13 Purpose of This Volume ‘This volune 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 il and grease from garage workshops, hotels, restaurants, canteens or any premises that collect such matter. Who Should Use This Volume ‘This volume is primarily intended for owners, developers, consulting engineers, sewetage conteactors, manufacturers, planners, and Public ‘Authorities who have a direct interest in the planning, design and installation of sewer networks andlor network pump stations. Related Reference Material “This volume does not cover all aspects of design and construction of sewer networks and network pump stations. Where information is not covered inthis volume, the designer shall follow the requirements given in MS 1228, MS 1228 shall take precedence over other foreign standards in the eves when there are discrepancies on the requirements, ‘The following documents are also referred to in this volume, a) Malaysian Standards i) MS.28 Specification for test for water for making concrete i) MS 29 Specifiewtion for aggregates from natural sources for conerete iit) MS. 144 Specification for cold reduced mild steel wire tor reinforcement of concrete ‘Sewer Networs and Pup Staton Volume 3Introduction wy) » vi) vii) viii) in ” xi) sii) wii) xiv) x) wi) Ms 14s Ms 146 Ms 522 Ms 523 Ms 628 Ms 672 as 740 Ms 822 MS 881 Ns 922 MS 923 Ms 979 Ms 980 MS 981 Specification for stee! welded fabric for the forcement of concrete. Specification for hot rolled steel bars forthe Specification for Portland cement (ordinary and rapid hardening) Specification for concrete including ready mixed concrete Specification for unplasticised PVC (uPVC) pipes for water supply Part 1 : Pipes Part 2 : Joints and fittings for use with Lnplasticised PVC pipes Specification of eubber seals in water supply, drainage and sewerage pipelines Specification for hot-dip galvanized coatings fn iron and steel articles Specification for sawn timber foundation piles Specification for pre-cast concrete pipes and fillings for drainage and sewerage Part 1 : Specification for pipes and fittings with flexible joints and manholes Specification for concrete admixtures Part 1 : Accelerating admixtures, retarding admixtures and water-reducing admixtures Specification for joints and fittings for use with uPVC pressute pipes (delete) Part 3 : Mechanical joints and fittings, principally of uPVC [delete] Specification for uplasticizes sewerage pipes and fitings| Part 1 : Pipes of diameter 100mm and 135mm Part 2 : Pipes of diameter 200mm and above Specification for safety signs and colours Colorimetric and photometric properties of materials Specification for safety signs and colours : Cofour and design Wome Matsa Sewerage Tadty Goldlinesvi) MS 982 xviif) MS 1037 xix) MS 1058 sx) MS 1061 xxi) MS 1195 xxit) MS 1227 xii) MS 1228 xiv) MS 1347 sav) MS 1292 xxv) MS 1389 scwvil) MS EN xxviii) MS ISO b) British Standards Rss iy) Bs 915 iii) BS 3416, Sever Networks and Pomp Sains Introduction Specification for fire safety signs, notices and ‘graphic symbols. Specification for sulphate-resisting Portland ‘cement MS 1058 Specification for polyethylene (PE) pining systems for water supply Part 1 : General Pact 2: Pipes Vitrified clay pipes and fitings nd pipe joints for drains and sewers Code of practice for structural use of Specification for Por Code of Practice for Design and Installation ‘of Sewerage Systems Cathode Protection : Part 1 Code of practice for land applications Specification for rubber seals ~ water stop for sealing joints in conerete ~ Specification ‘of materials Specification for Portland blastfurnace ‘eement ‘Specification for general criteria fr certification bodies operating product certification General requirements for bodies operating product eertifieation systems nd pulverised fuel ash Specification for vitrified clay pipes, fittings tnd ducts, also flexible mechanical joints for use solely with surface water pipes and fittings ‘Specification for high alumina cement. Metric unit Specification for bitumen-based coatings for cold application, suitable for use in contact with potable water Volume s» » vi) vii) viii) ix) » x) xii) wii) xiv) ~) wi) wwii) 38 1692 bs 4147 BS 4164 BS 4248 BS 4515 Bs 5153 BS 5480 BS 5911 Bs 5975, BS 6076 Bs 7123 Bs 7874 Bs 8007 BS 8010- 21 BS 8666 ISO metric precision hexagon bolts, screws and nuts, Specification, Specification for bitumen based hot applied coating materials for protecting iron and steel including suitable primers where requited Specification for coal-ar-based hot-applied {coating materials for protecting iron and stee! including a suitable primer Specification for Supersulfated cement Specification for welding of steel pipelines fon land and offshore. Specifiation for east iron check valves for general purposes, Specification for Glass Reinforced Plastic (GRP) pipes, joints and fittings for use for water supply or sewerage Part I : Precast concrete pipes, fittings and ancillary products, Specification for lunreinforced and reinforced concrete pipes (including jacking pipes) and fittings with flexible joints (complementary to BS EN 1916) Code of practice for falsework. Specification for polymere film for use as a protective sleeving for buried iron pipes and fitings (for site and factory application) Specitication for metal are welding of steel or conerete reinforcement. Method of test for microbiological deterioration ‘of elastomeric seals for joints in pipework and pipelines Code of practice for design of concrete structures for retaining aqueous liquids Colle of practice for pipelines. Pipelines on land : design, constriction and installation, Ductile iron Specification for scheduling, dimensioning, bending and cutting of steel reinforcement for concrete. ome Malian Sewerage Indy Guldensvi) RS EN 24 xis) BSEN 205-1 sx) BSEN 295-7 xxi) BS EN 54s xxii) BS EN 598 xxiii) BS EN 68l xxiv) BS EN 682 xxv) BS EN 752 xavi) BS EN 1091 xxvil) BS EN 1361 xxviii) BS EN 1563, xxix) BS EN 1992, xxx) BS EN 002s xxi) BS EN 10220 xaxil) BS EN 10224 Sewer Newor Pap Stations | Insoction Gully tops and manhole tops for vehicular and pedestrian areas. Design requirements, type testing, marking, quality eontrot Vitrified clay pipes and ftings and pipe joints for drains and sewers. Requirements Vitefied clay pipes and fittings and pipe joints For drains and sewers. Requirements for vitiied clay pipes and joints for pipe jacking Ductile ion pipes fittings and accessories and their joint for water pipelines ~ requirements and test methods Ductile iron pipes fittings and accessories and their joint for sewerage applications ~ requirements and test methods. Elastomeric seals, Materials requirement for pipe joint seals used in water and drainage applications lastomerie seals. Materials requirement for pipe joint seals used in pipes and fitings farrying gas hydrocarbons Muids. Drain and sewer systems outside buildings Vacuum sewerage systems outside buildings Specification for sake graphite east ira ‘Specification for spheroidal graphite or nodular ‘graphite cast iron Copper and copper alloys. Ingots and castings. Hot rolled products of non-alloy structural steels ‘Seamless and welded steel tubes, Dimensions land masses per unit length Non-alloy steel tubes and fittings for the conveyance of aqueous liquids including water or human consumption. Technical delivery conditions. Voune 3 7Invovetion sci) xxiv) a) soxvi) sass) BS EN 10277 BS EN 10278 3S EN Ins BS EN 180 3766 BS EN 180 3506 Bright steel products, Technical delivery conditions Part 1: General Part 2: Steels for generat engineering purposes Part 3 : Free cutting steels Part 4 : Case-hardening steels Part $: Steels for quenching and tempering Dimensions and tolerances of bright steel Products, Air quality ~ Determination of odour concentration by dynamic olfactomety. CConstretion drawings. Simplified representation ‘of eonerete reinforcement. Mechanical properties of corrasion-rsistant stainless-steel fasteners Part 1: Bolts, serews and studs Part 2-: Nuts, ©) Australian / Now Zealand and Australian Standards, a ip ii iy) » w vii) ASINZS 160 ASINZS un ASINZS 2566 ASINZS 3518 ASINZS 3582 ASINZS 423 AS 3725 PVC-u pipes and fittings for drain, waste and vent application (refer to uPVC profiled wall pipe only) PVC pipes and fittings for pressure applications Buried flexible pipelines Part 1 : Structural design Acrylonitrile Butadiene Styrene (ABS) compounds, pipes and fittings for pressure applications. Supplementary cementitious materials For use with porttand and blended cement Part 3 : Amorphous silica, Stationay source emissions Part 3: Determination of odour concentration by dynamic olfactometry. Loads on buried concrete pipes Votes aap Senerage Indy Goll:witty AS 3750.2 Paint for steel structure ~ Ultra high-build piant AS Paint for steel structure ~ Alkydimicaccous 3750.12 ikon oxide ix) AS 3751 Underground mining ~ Slope haulage ~ couplings, drawbars and safety chains. x) AS 3996 Metal access covers, road grates and frames xi) AS 4060. Loads on buried vitrified clay pipes d) German Standards i) DIN 16961. Thermoplastic pipes and fitings with profiled cuter and smooth inner surfaces Part 1: Dimensions Part 2: Technical delivery conditions @) Intemational Standards i) 180.1083 Spheroidal graphite cast irons Classification ii) 180.3506 Mechanical properties of corrosion-resistant sainless-stel fasteners iii) ISO-TR Underground instalation of flexible lass: 10465 reinforced thermosetting resin (GRP) pipes Part 1+ Installation procedures Port 3 : Installation parameters and pplication limits 4) Water Industry Specifications (U.K) i) WIS 04 Specification for PE 80 and PE 100 spigot 32-15 fittings and drawn bends for nominal sizes up to and including 1000 ii) WIS 04 Specification for mechanical fittings and joints 24.01 for polyethylene pipes for nominal sizes 90 to 1000 iit) WIS 04+ Specification for PE 80 and PE 100 electrofusion 3214 ftings for nominal sizes up to and incl 630 “Sever Networks and Pap Staton Votoms 3lotaduction 9) American Society for Testing and Material i) ASTM D_ Specifications for “Piberglass” Glass-Fibre- 2262 Reinforced Thermosetting- Resin Sewer Pipe ii) ASTM D Practice for Underground Installation of Flexible 2521 ‘Thermo Plastic Sewer Pipe iii) ASTM F Specification for Polyethylene (PE) Large $94 Diameter Profile Wall Sewer and Drain Pipe iv) ASTM D__ Standard Specification for Polyethylene Plasties 3350 Pipe and Fitting Materials ¥) ASTM D__ Standard Specification for Joints for Drain and 3212 Sewer Plastic Pipes Using Flexible Flastomerie Seals h) Other Reference Materials ') _Simpltied Tables of External Loads on Buried Pipelines ~ UK Transport Research Laboratory The Commission will, fron time to time, specify additional standards to be used in the design and construction of sewerage works. These standards shall be referred {0 as appropriate for the design and construction of sewer networks and network ump stations Al standards used in the design and construction of sewerage works shall be the latest of the most updated. When any one of the above mentioned standards ts withdravyn or superseded, the latest or updated standards shall be referred to a ‘ppropriate. This shall be the same for any applicable act, guideline, by-law, ete related to sewerage works endorsed by the government, Other Guidelines in This Set ‘The Malaysian Sewerage Industry Guidelines comprise of 5 volumes: 4) Volume 1 Sewerage Policy for New Development b) Volume It Sewerage Works Procedures ©) Volume Il Sewer Networks and Pump Stations 4) Volume IV. Sewage Treatment Plants ©) Volume V Septic Tanks 0 Note Matin SeesSection 2 Planning, Material and Design24 244 Panning, Materia and Design Sewers Pipe Material Selection Factors ‘The following considerations are the important factors to be considered before selzcting oF approving any pipe material and pipeline system for sewer networks: 4). Resistance to acide condition of which is prevalent in sewer networks in woyical climates. 'b)_ Resistance to sulphate attack from aggressive soils and groundwater ©) Resistanee to corrosion in contaminated sols {d)_ Resislance to severe abrasion from sewage flow and usual clean metheds. €) Resisiance to groundwater entry (infiltration) and sewage escape {exfitiation) through joints. 1) Resistance of the joint material (0 corrosion and microbiological degradation, 2) Struciural damages and other damages that may oceur during hanl ng hy Handling, laying and jointing care and difficulties. ’) Methods of pipe embedment to ensure good structural performance J) Maintenance of structural strength and performance in service. ) Methods of maintenance and repait 1) Cost af supply, transportation and installation ‘m) Range and suitability of fittings for smaller diameter sewers, 1) Previous local experience. 9) Local availability P). Pipe pressure ratings 4) The design life of a pipe shall be at least 50 years. 1) All bolts and nts shall be siaintess steel (SS) 304, 5) Where necessary, special tools and tained personal shall be made available ducing the handling and installation of pipes. [Additionally, the following factors should be considered before selecting ‘approving any pipe manufacturer and supplier. 4) Comyliance of products to standards +b) Comiance to adlitional material and produet requirements specified by the Commission, ©) Quality contol id assuiace practised by the manufacturer and supplier fo ensure good pipe product quality from manufacturing to delivery ‘Sever Networks and Pup Stations Volume 3Panning, Mateo and Design 242 Pipe Materials and Fittings There is an extensive range of pipe materials available in Malaysia to be used as gravity, pressure and vacuum sewers. The materials and the standards which the pipes are required to conform to are as follows a) Vitrified elay (VC) i) MS 67 ii) MS 1061 iil) BS EN 29 »)_ Reinforced concrete (RC) i) MS 881 ii) BS 5911 iit) BS 7874 iy) BS EN 681 ¥) BS EN 682, ’). BS EN 1002 i) BS EN 10224 ©) Stainless Stee! i) BS EN 10220 5) Polyethylene (PE) solid wall i) MS 1058 ii) WIS 08-32-15, iii) WIS 0432-14 iv) WIS 04.24.01 8) Unplasticised polyvinyl chloride (uPVC) solid wall i) MS 628 : Part 2 : Section 2 ii) MS 923 iil) MS 979 iv) ASINZS 1477 1h) Polyethytoxe profiled wall i) DIN te961 {i Unplasticised polyvinyl ehloride profiled wall i) ASINZS 1260 Volume Malaysian Sewerage Tasty Gide24.3 Sewer News and Pap Stains | Volume s Planing, Material and Design 4) Glass reinforced plastic (GRP) i) BS 5480 fi) AS 3571 ky Acty nitrile butadiene styrene (ABS) i) ASINZS 3518. Marking of all pipes shall comply with Malaysian or British Standards ‘where applicable, Additional requirements to those given in the above Standards may be specified from time to time by the Commission Pipe Selections Except where otherwise specifically approved by the Commission, the pipe materials to be used for @ specific type of sewer are listed below: 1) Gravity sewers 1) Rigid pipes by Flexible pipes pve i) GRP ii) RE ii) Ductile Iron iii) HDPE (Profile) 2) Force mains (Rising mains) it Ductile tron i) GRP ii) ABS is) HDPE (Solid) 4) Steel 3 i) ABS ~ for internal use ii) HDPE (Solid) ~ for external use “There ave specific requirements such as pipe class, joint type, linings ete. which the above approved pipe materials must meet in order 10 Suit the above applications. Also, there are certain limitations for use of teach pipe type. These requirements and limitations are specified in the Following sections. From time to time, the Commission will publish sewer selection guides whieh will provide more detailed direction on the selection and use of sewer materials For other pipe materials not listed above, their use will be giver cconsidetations in special circumstances. However, only pipes and fittingsPlnaing, Material and Design 244 from peri inufacturers and suppliers approved by the Commission are to be used for sewerage applications, Requirements and Limitations for Use of Certain Pipe Material Unless the exemption is granted by the Commission, the following limitations or requirements shall be followed when selecting the pipe materials 1) Gravity Sewer a) ve i). Only size 150 mm of above shall be used, ii) The minimum size for public sewer shall be at least 225 mm. ii) Pipe shall not be used in unstable ground, iv) Flexible joints are recommended, by RO i) Pipe protection linings are required ii) Orly sizes 600 mm or above are allowed in compliance to the poliey i) Flexible joints are recommended. ©) GRP ') Pipe shall not be used in ground contaminated with high concentration of chemicals Such as solvent that ean degrade the pipe. ii) Pipe shall not accept any industrial or other aggressive discharges that may affect the pipe integrity it) Pipe shall be used only when no fittings are required. iv) Ony sizes 600 mm or above are allowed 4) DI i) The use is only allowed for applications nceded high pipe sirength ii) Pip» protection linings and coatings are required. iti) Polyethylene sleeving is required for all buried applications. ©) HDPE ') Pipe shall not be used in ground contaminated with high concentration of chemicals Such as solvent that can degrade the pipe. Manian Sewerage Tn GuidlinesPlanning, Material and Design ii) Pipe shall not accept any industrial or other aggressive ‘discharges that may affect the pipe integety i) Only pipe with profile wall is permitted. MN) Eorce Mains a) bl i) Pipe shall not be used in unstable ground, ii) Pipe protection linings and coatings are required ii) Polyethylene sleeving is required for all buried 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 ean degrade the pipe. ii) Pipe shall not accept any industrial or other aggressive discharges that may affect the pipe integri ii) Fittings shall be made of ductile iron. in) Only sizes 600 mm oF above are allowed. ©) ABS i) Where VC or RC pipes are not suitable. for nominated projects or as permitted by the relevant hority d) HOPE i) Pipe shall not be used in ground contaminated with high ‘concentration of chemicals such as solvent that ean degrade the pipe. ii) Pipe shall not accept any industrial or other aggressive discharges that may alfect the pipe intesrty ©) Stoo! i) Pipe is allowed only for sizes 700 mm or above, ii) Pipe protection linings and coatings ate required 24.5 Vitrified Clay Pipe Vitrified slay (VC) pipe is manufactured in Malaysia in diameters of 100 mim 49 600 sam and lengths ranging from 0.91 m to 2.50 m. Larger Sewer Networks acl Pump Stains | wane ”Panning, Matsa and Design diameters of VC pipe are imported. VC pipes are classified according (o the pipe ring erushing strength which depend on the manufacturing process and quslity. VC pipes and fitings ean be produced either unglazed or glazed on the interior and/or exterior, When glazed they need not be slazed on the jointing surfaces of the spigot and socket. VC pipes which are availabe ir Malaysia are normally manufactured with spigot-socket exible joints. Most manufacturers offer rubber ring seals. However, polyurethane seals are sometimes offered by some manufacturers. Vitrified clay sipe 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 siz for public gravity sewer shall not be less than 225 mm ‘nd for service connection shall not be less than 150 mm, VC pipes and fittings shall conform to the requirements of MS1061 Pipe strength is classified by the crushing strength (FN) value tested in accordance with BS EN 205.3. The erushing strength for pipe with DN1O shall not be less than 22 kN/m. The crushing strength of the Pipe with size > DN 225 is classified by class number, All VC pipes and fitings shall be furnished with spigot-socket flexible joints and rubber Fing seals or polyurethane seals, Glazing of VC pipes and fittings a preferred. Reinforced Concrete Pipe Reinforced concrete (RC) pipe is manufuetured in Malaysia in diameters from 150 mm to 3600 mm. The standard pipe length is 3,05 m. RC pipe is classified neconting to pipe crushing test load or the three-edge bearing strength which varies with wall thickness and reinforcement. Common reinforced concrete pipes are not resistant to acidic corrosion which occurs in certain septic sewage conditions. The cement used t0 manufacture concrete pipe shall be factory produced by the cement ‘manufacturer. Pipes can be manufactured using Portland Cement, Povtland Blast Furnace Cement, Portland Pulverised Fuel Ash Cement and Sulphate Resisting Portland Cement, All these types of cements are corrosion resistance, except Ordinary Portail Cement itd Rapid Hardening Portnd Cement. To improve the earrosion resistance, high alumina cement mortar lining and sacrificial lining have been used. Low and super-silphated cements have also been found in some tests to Volume asin Sewerage ty GoidelnesPanning, Mates and Design {improve the corrosion resistance, The inclusion of ealeareous or limestone aggregate 18 another measure found 10 improve coxusion resistance. ‘To resist corrosion by neutral sulphates occurting, in aggressive soils and groundwater, RC pipes are sometimes manufactured using sulphate ble, Portland Pulverised Fuel ‘Ash Cemest or Portland Blast Furnace Cement shall be used with the approval from relevant authority IRC pipes are permitted for gravity sewers of diameter DN6DO and Target. Pipe shall be of Standard Strength or higher as determined from structural design. RC pipes linings shall consis of either [2mm thick high alumina cement ot 38 mm thick (as appropriate) sacrificial concrete Tining. Other linings may be used if approval from the Commission is joblained. Concrete pipe junctions shall be fixed to the main pipe by the pipe manufacturer and fabricated to clay pipe dimensions. Flexible joints ‘which use a rubber ring to join a rebated joint and a spigot toa socket fare commonly used and are recommended. Ogee joint (fixed joint) shall be used in conjunction with eonerete bedding haunching only. RC pipe ‘when usec for pipe jacking purpose, shall comply with BS 5911. The RC pipes also incorporate rebated joints with joint clastomere ring seals either integrated in the unit or supplied separately. Ductile Iron Pipe Ductile Iron (DI) pipe manufactured in Malaysia for diameters from 80mm to 1200 mm, The diameter imported pipe can be up to 2000 nm. Standard lengths are 6.0 m, DI pipe is classified according to wall thickness. The pressure rating of the pipe increases with an increase in wall thickness. Commonly used pipe strength is class K9 and shall comply with BS EN 598 for working pressure exceeding 6 bars. DI pipe is permitted for force mains and internal pipings of pump stations. DI pipe shall be used for gravity sewers only where it is needed to take the advantages of the high strength of ductile iron, eg. shallow cover sewers subjected to high live load or sewers of above ground applications Pipes shal have flexible joints, Le. spigot-socket rubber seal joints or ‘mechanieel joints except for pump station pipeworks and valve connections ‘where Mange joints shall be used Ductile iron will corrode when exposed to certain aggressive groundwaters and conveying certain aggressive water. Therefore, intemal lining. a extemal coating protection are required to protect against corrosion. Unless otherwise approved by the Commission, all ductile iron pipes shall ‘Sewer Nework and Pan Stations Vatune3 »Planning, Matera and Desipy hhave an external coating t0 be determined by a Qualified Person based fm actual soil condition, For internal lining of a constant full Mowing Pipe, ordinary Portland cement shall be used, while high alumina cement ‘mortar or plastic adhesive lining is required for party full flowing pipes Buried pipe shall have zine with bitumen external couting and Tttings shall have bitamen external coating. The end surfaces shall include the internal surface of the socket and external surface of the spigot for Aexible connection, The finishing layer, which is normally bituminous product, shall cover the whole surface of the applied coating and shall prevent defects such as the loss of adhesion. In addition, the material of the finishing layer shall be compatible with the coating, Unless otherwise approved by the Commission, a fittings and accessories shall be provided with external and internal epoxy coating Polyethy ne sleeving shall be used for all the buried pipe and Stool Pipe Steel pipe is manufactured in Malaysia in a wide range of di {© 3000 mm and tengths up to 10'm, Pipe joints are normally welded Utilising either spigot-socket ends, plain ends or a collar, Flanged and mechanical joirts are also avaiable, Steel pipes will undergo corrosion when in contact with aggressive soil and sewage and, thus, require aa internal lining and an external coating. Pipe internal linings normally include high alumina cement mortar, coal {ar enamel, con tar epoxy, sulphate resistant cement lining, or bitum Pipe external coatings often include coal tar enamel, bitumen enamel oF asphalt enamel and lass fibre, Steel pipes are permitted only for inverted siphons (depressed sewers) and internal pump station pipework. For force main larger than 700 nm, steel pipe may be used if the approval fiom the Commission is “obiained ‘The internal and external surfaces of the pipes and fittings shall be coated with thermosetting (epoxy paint or powder or epoxy tar resin) for thermoplastic (polyethylene or polyurethane) material. The type of external protection shall be determined by the Qualified Person based ‘soil condition. Following the completion of pipe jointing, exposed steel a the joints shall be protected from cortasion by manually applied external tape wmp and internal cement mortar lining ohne Manji Sonerage Inst Galles24.40 Phnning, Material and Design 'A spigot snd socket joint welded both externally and internally shall be used for pipe joints except for pump station pipeworks wd valve connections where flange joints shall be used, Mechanical joints are fnly perm ted for eut pipe lengths, where internal cement mortar ining fat joints is not possible and where movement of the pipeline is to be allowed fee, Solid Wall PE Pipe Polyethylene (PE) pipe is resistant to sulphuric acid of concentrations that might be found in septic sewage under the worst conditions. PE solid wall pipe is available locally in diameters up to 1000 mm and in standard lengths of 6 m and 12 m. This pipe is normally butt fusion jointed. Pipe size of 160 mm or less may be flange jointed or clectrofusion jointed. PE pipe is classified by pressure rating with static Working pressures up to 1,6 MPa, High density PE (HDPE) is used for sewerage applications. Since PE pipes are flexible, the design of the pipe/trench system is ‘move critical than for rigid pipe materials. Compared to rigid pipes, the Sability of Mlexible pipes relies more on the side support of the earth ‘backfill around the pipe. Consequently, in an urban environment, where the side support may be removed during. future adjacent construction ‘of underground services, pipe flutes could be more frequent. Ground “conditions which provide poor pipe side support are unsuitable for flexible PE pipe Solid wall HDPE pipes ate suitable for buried pressure sewer and buried ‘vacuum sewer installations, Butt fusion joins shall be used for PE pipe. UPVC fitings are not petmitted for force mains. Solid wall pipe for pressure nain application shall be of minimum PESO-PN10, The use bf 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 PESO-PN8 and at least PN1O for heavy vehicle Toading Profiled Wall PE Pipe [A profited wall pipe is a pipe with a plain inside surface and with a fibbed or corrugated outside surface, The nibs or corrugations are normally tither aligned circumferentially or helically. These corrugated or ribbed profiles cptimise the pipe ring sifiness to weight ratio. The pipe ean be esigned with double-wall profile or triple-wall profile. SowerNewors and Pop Stains ‘lune 3 aPlanning, Mate and Design 24M Corrugated hizh density PE pipe is available in Malaysia in « range of size from 100 mm to 3000 mm nominal diameter and in standard 6 lengths, The standard joint is a flexible spigot-socket joint with rubber sea Pipes from specific manufacturers in this eategory may be permitted by the Commissicn to be used for gravity sewers where special ireumstances require the benefits of such pipes Glass Reinforced Plastic Pipe Giloss reinforced plastic (GRP) pipe is imo Malaysia rently required to be imported There are two principal manufacturing methods for GRP pipes, centrifugal «casting and filament winding. The cenuifugal eating GRP pipe incorporates silica sand in the wall sicucture in addition to resin and chopped strand mat glass fibres. The silica sand shall have maximum pavicles size Of 10-mm. The centrifugal casting GRP pipe shall be according, to AS a7 The filament winding GRP pipe does not normally incorporate sand, which Permits centrifugal casting GRP pipe to have # much thicker wall, and thus much higher ring stiffness than the filament winding GRP pipe. The filament windirg GRP pipe uses continuous glass fibres wound helically bout the pipe. The design of filament winding GRP pipe shall be in accordance with BS 5480, Centrifugal casting GRP pipe is classified by internal pressure resistance for pressure arplications and by pipe ting stiffness for non-pressure applications. Centrifugal casting GRP is available up to 10000 Nim! sfiffaess and up to 2.5 MPa static working pressure. Filament winding GRP is availabe up to 5000 Nin? stiffness and up to 1.6 MPa static working pressure Centrifugal eastrg GRP pipes available in sizes from 200 mon to 2400 mm and Standard length of 6 m. The inner sueface of the pipe is usually finished With «resin ric lining which is resistance to attack by sulphuric acid ‘that may result from septic sewage. Centrifugal casting GRP pipe has a rubber sealing seve joint which is supplied fitted to one end. So jointing is similar to a spigotsocket joint, These pipes can also be supplied with flange juints,sleeve-locking joints and sleeve recessed joints Tor spec applications suc1 as pipe jacking and pipeline towing, Filament winding GRP pipe is available in sizes up to 3700 mm and standard lengths of 6 m and 12 m (size dependent. It also has a resin Volume Malai Senerage Indust Gaietoes2442 Sewer Networks and Pay Stations | etune 2 Phnning, Material and Design rich inner surface although the thickness of this resin surface layer is often Timited by the manufacturing method. Some Iulament winding GRP pipe manufacturers incorporate corrosion resistant glass fibres. This feature can be essential with this GRP pipe because its resin rich surface (geleoat) is thinner of, sometimes, removed for fabrication purposes. Filament ‘winding GRP pine currently being offered ean be jointed using a sleeve tnd two rubber © rings. Filament winding GRP pipe does not have a smooth ourer surface like centetgal casting GRP pipe, Machining may be required for the outer surface where rubber sealing rings are used. Flange joints and mechanical couplings ate also available for special applications GRP pipe is classified as a flexible pipe. It requires sufficient side ‘support to retain its structural integrity in cross-section in the same way ‘as uPVC amd PE pips. GRP pipe has lower strain imits than uPVC and PE pipes since itis made of thermoset resin, wich is brittle compared to thermoplastic material, Due to its inherent structure, GRP pipe has a much higher modulus of elasticity than uPVC and PE pipe. Thus, it may have a much thinner wall than uPVC and PE pipes to achieve equivatent ring stiffness. GRP pipe is generally available in higher stifpess than UPVC and PE pipe. Approval forthe 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 pproptiat2 stiffness determined in accordance with structural design to AS 2566, For pressure sewers, fitings must only be of ductile iron meeting tte coating, lining and other requirements Acrylonitrile Butadiene Styrene Pipe Acrylonitile butadiene styrene (ABS) pipe is a thermoplastic pipe. It is ‘manufactored in Malaysia in diameters up to 630 mm, ABS pipe is classified by internal pressure resistance. It comes in various Satie worcing pressure ratings up 10 1.5 MPa, “The most common jointing method is by solvent cementing. The cementing, jointing process is more complex than the jointing provess of uPYC pipe ‘A spigot/socket rubber ring joint is generally not available, Because of the care required to make a solvent cement joint, particularly in larger diameters, the jointing of ABS pipe requires spectal trainings.Planning Material and Design 24.43 u 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 {o abrasion and UV degradation, ABS has found use in industrial and ‘mining applications and also in treatment plants for sewage and wate. ABS pipes mey be permitted for foree mains under special circumstances ‘which require the benefits of sueh pipes. If used, the approval of the Commission is required. ABS pipes may be permitted for use in buried foreed mains and buried interconnecting pipe-works within pump stations. ‘Sewer Design - General Requirements, ‘The design of a sewerage system shall generally be in accordance with the principles set out in this Guidelines. Additional requirements in the Malaysian Stndard MS 1228:1991 Code of Practice for Design and Installation of Sewerage System shall also be referred to in design, ‘The sewerage system shall be suitably designed to carry all sewage flows includirg sullage (0 the approved disposal point. Unauthorised connections of surface waters or excessive infiltration to the sewerage system are not permited Unless otherwise agreed by the Commission, all sewers shall be sited in public roac reserve 50 that access can be gained for maintenance Purposes. Under special circumstances where the sewer cannot be sited in public road reserve then vehicular access for the sewerline of atleast 3 m in width and road bearing capacity of not less than $ tonne shall be provided. Sewer pipes should not be constructed on slope oF within stope failure envelope. In the event where itis unavoidable, the said structures must he designed not to encounter settlement or the sorts and at any time at risk of collapse during its operating lifespan, ‘An overflow pipe shall be provided at the last manhole before network ump station and/or sewage treatment plant, Otherwise it should be Tocated at the manhole sited at the lowest ground level, A checklist for sewer reticulation design is given in the MSIG Volume 2 Flow Rate Estimations Few principal considerations when selecting the diameter and gradient of a sewer a Votoms 3 Malian Sewerage Indy Guidlines24.48 Planing, Material and Design 1a) to eater for peak Flow. 1) to ensure that there will be sufficient velocity during each day 10 sufficiently cleanse the sewer of slime and sediment. ©) to limit the velocity to avoid scouring of sewer 1) Average Flow “The volume of sewage that needs t0 be treated per day is based ‘on an assumed contribution per population equivalent of 225 lites from various types of premises where the contribution from each premie type is defined in terms of a population equivalent. The Fecommended minimum population equivalent values are given in Table BI 1M) Peak 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 ‘onan day when considering daily flow fluctuations and infiltrations. ‘The peak flow is derived from the average flow by applying 2 peak factor for daily flow fluctuations. The peak factor shall be estimated from the following formal Peak Factor = 4.7 (PE/1000)** ‘Where PE ~ assumed population equivalent Ut Infittration Infiltration is the amount of groundwater that enters sewers through damage in the network such as cracked pipes, leaked joint seals and manhole walls, etc. Thete are many variables affecting infiltration Such as quality of workmanship, joint types, pipe materials, height ff water table above pipeline, soil type, ete. The peak factor above has included the contribution of infiltrations. The maximum allowable infiltration rate shall be $0 litre / (mm diameter.km of sewer length day), ‘The principal accumulants in sewers are slimes and sediments. The hydraulic requirements for cleansing the sediments of sewer differ from those required for cleansing the slimes of sewe. 1) Sediment Cleansing For the removal of sediments, the traditional design approach has ‘been to set a minimum velocity to be achieved at least once daily. ‘Sewer Networks and Pay Stns une ssPlaming, Material and Design 24.16 26 Minimu velocity values at full bore of 0.8 mvs are commonly specified. However, it as been found that larger pipe diameters require higher velocity fo cleanse the sediment, This is mainly due to higher sediment depths in large diameter pipes ‘The movement of sediment is mainly a funetion of shearing stress needed to dislodge sediment off the pipe wall. Similarly, shear stress is a function of pipe diameter. The type of sediment (ie. grain size, specific gravity, cohesiveness) also influences the movement of sediment and, thus, the amount of required shear stress. For Aesign purposes however, only a single sediment type needs to be assumed Ml) Slime Cleansing The removal of slime depends on the stress needed to shear sections ‘of slime from each other or from the pipe wall, However, the shear stress required to remove slimes is not a funetion of pipe diameter, ‘The necessary shear stress depends on the thickness of slime to be Femoved and the pipe material. The degree of removal of slimes in ‘any pipe material varies with the sewage velocity. Removal of large portion of slimes requires high sewage velocities. thas been found that 85% or more of the sulphide producing slimes are removed when the grade of the sewer is 2.5 times of that for sediment cleansing. In many instances, i may not be practical (0 design a sewer to achieve such velocities due to the excessive cost of constructing such a deep and steep sewer. Although increasing the velocity up to the critical velocity will inrease the amount of slime being sloughed off, the rate of sulphide production remains Substantaly unaffected by the thinner slime layer, Therefore, the selection of steep gradient to achieve velocities for full slime stipping is not a design requirement Pipe Roughness 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 incremensal changes in velocity. In addition, the velocity of the wage flow varies due (othe Factors such as daily fivetuations, differen type of catchment, different stage of catchment maturity, ete. Therefore, itis not possible fo select the pipe roughness with great accuracy. Conservative roughness values a8 given in Table 2.1 shall be referred to ‘when determining sewer discharge capacity. Vata Malysan Sewerage Tact Gait2AAT Table 2.1 Normal Pipe Roughness for Gravity Sewer Cian old ree ‘Old and sew roughness values shall be used to determine the sewer cleansing end maximum design velocities respectively. Table 2416 Normal Pipe Roughness for Force Mains for All Design of Gravity Sewer Unless special arrangements have been agreed forthe 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 mininum size of public gravity sewers shall be 225 mm in diameter ‘The minimum size of domestic connections to the public sewer shall be 150 mm in diameter. The maximum design velocity at peak flow shall not be mote than 4.0 m/s ‘The desigy 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 1. Colebrook - White Equation V = -2 Y@EDS) toe 2sWv 37D * Dd yaebs ere 5 dai pation cn) . neatievicoiy of water (5) > ater ante) t ‘ounce Ser Networks and Pan Stations Volume 3 ”losing, Material and Desig Typical k, values for various types of sewer pipes are presented in Table 223 below! Table 2.2 Typical Roughness Coefficient, k, Ein Conere o3103 Gaston 026 ~_Asphalted east iron 0.12 [ Dei ron 046 2. Manning Equations 219g 12 = velocity (ise) hyde gradient hyde avs Manning coeticint Typical n values for various types of sew Pipes are presented in Table 2.3 below Table 2.3 Typical Manning Coefficient, n Uncoated cast-iron oor 015 Coated east iron oon 0.013 Dust iron 0012 01s Vivitod clay pine 2.010 0017 ‘Conerote 0012 0016 2s Vote 3 Manysin Sewerage Tasty Goldline24.48 Plowing, Materials Design 3. Hazen - Williams Equations v0.84. CR™S% here locity (see) = ya graiont hye radius Hazon - Williams oetisint ‘Typical C values for various types of sewer pipes are presented in Table 2.4 below: Table 2.4 Typical Hazen-Williams Coefficient, © Top quliy pipes, straight and smooth 13010 140 Smooth masonry 120) Vite clay m7 Old east iron 10 ‘Old sation in bad condition 01080 Colebrook-White Equation has been deemed to give the most accu results, However, the other equations, such as Hazen-Williams Equation fand Manning Equation are easier 10 use and may be used too. Various design charts and tables have been developed elsewhere to aid the manual computations. Design of Force Mains “The minimum diameter oF force mains (also known a rising mains) shall be 100 mm diameter. There shall be no reduction in force main fiameter with distance downstream All bends on force mains shall be securely anchored to resist lateral thrusts ard subsequent joint movements Air release valves along the longi d jashouts shall be provided at appropriate locations profile For long and undulating force mains, hydraulic pressure transient analyses may be required to ensute that the force main can cope with water hhammer pressures. Sener Networks ad Pump Stns ‘Volume 3 ~Panning, Mattia and Design Retention times in force mains must not exceed 2 hours without speci precautions to mitigate septic. 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 isto be designed to withstand pressure less than the pressure stated above. Where retentcn times in the force mains exceed two hours and where conerete pipe are laid downstream of the foree mains, an induet vent shall be provided at manholes receiving pumping discharges. Friction losses are normally calculated using either Darey-Weisbach (Colebrook-White) Equation or Hazen-Williams Equations. The forms Of the equatiors are different from the equations used to design gravity sewers, The equations are listed below: 1. Darcy-Weisbach Equation = Equivalent diameter ofthe pipe = Length ot pipe Ay ae 29D ere ‘ Fiton oe f = Coeticieto iction v Vel n th pipe s Aetleton df gravity t ‘The value of fis known to depend on the Reynolds number, Re, pipe roughness, and pipe diameter, D, through the Colebrook-White equation as follows: = Alef as ww 30 RET ‘The Reynolds number is defi Re vp Where » is the kinematic viscosity of the fluid, typically equal to 1 x 10 mis for sewage. ‘The above équitions together with the Moody Diagram are used to determine the coefficient of friction, f » Volume Matyi Sewenge Tasty Guidelines24.19 19.4 Panning, Material and Design 2. Hazen-Williams Equation vee c pw = Friction oss Haven-William Coeticint refer to Table 24) Velocity inthe pipe = Length ot pipe = Equivalent damster ofthe pipe Force mains shall be designed to handle the full range of flows from present mrinimum to future peak “The design velocity shall fall within the range of 0.8 to 3.0m/see over the full ange of design flows. “The hydraulie resistance of force main fitings and bends shall be included in the hydraulic design Vacuum Sewerage System “The design requirements of this Guidelines ate the minimum requirements, and do not constitute in themselves comprehensive design guide SifTiient to ensure a correctly functioning system. Every system must he individually designed, based on the design parameters of the system ‘employed; where proprietary systems are employed, it shall be designed in compliance with the requirements of system manufacturers General Specificstion of @ vacuum sewage collection system shall only be considered where the life-cycle costs of a conventional gravity sewage collection system are clearly shown to be higher: ‘This Gucdetines assumes that all sewage transportation modes have been identified, their respective feasibilities evaluated against technical, cnvirontrental, financial, economic and other relevant criteria aver the design life of the asset and that vacuum sewage collection system his been corfirmed as the bes! option. The Commission may request for net present value (NPV) calculations for all options prior to approving construction of a vacuum sewage collection system. Sewer Networks al Pap Stations | ‘Volume aPlanning, Maeil and Desige }) Application of Vacuum Sewerage Collection System Consideration shall be given to the use of the vacuum system in ‘one or moze of the following eircumstances: 8) Flat or undulating terrain, b) Obstacles to the sewer route eg ulilty services, waterways ©) Poor ground subsurfce eg high ground water table, rocky terrains Isolated, low density communities. ©) Where itis necessary to minimise the impact of construction worl. 1) Where it is necessary to minimise the environmental impact. II) Unit Processes ‘Typical unit processes for a vacuum sewerage collection system is shown in (pical drawing in Appendix A. The unit processes shall ‘comprise of, but not limited to, the followings: 8) Collection chamber for housing vacuum interface valve and also forming sump from which collected sewage is evacuated. b) A vacuum sewer network for the tansport of sewage collected inthe collection chambers to a central vacuum station. ©) Acentul vacuum station where the vacuum pressure is generated Which allows the sewage to be collected and forwarded to & receiving gravity sewer manhole or a sewage treatment plant. lil) Description of System ) Collection Chamber and Vacuum Pipeline When the volume of sewage draining into a collection chamber reaches predetermined level in the sump, the normally closed interface valve opens. The differential pressure between the vactusm sewer and aimosphere forces the sewage from the eallection chamber into the vacuum sewer via a crossover pipe. Typical crossover pipe connection 's shown in typical drawings in Appendix A. After the sump is emplied, the valve loses. Airis admitted simultaneously with, for after, the admittance of the sewage. The sewage is driven along the sewer unl! fritional and gravitational forces eventually bring it {o rest in the lower section of the pipe profiles. The characteristics of the vacuum sewerage system ensure that peak discharges into the sewer are rapidly tenuate ‘The vacuum sewer discharges into the vacuum vessel atthe vacuum station, The vacuum is maintained by vacuum pumps ata predetermined level. The sewage is generally pumped from the vacuum station by sewage discharge pumps. 2 Volume Malian Sewerage Tad GuidtnesPaoning, Materiat and Design b) Vacuum Station “The yacuum station is similar to a conventional pump station with the addition of vacuum pumps and a closed vacuum vessel. Typical vacuum station is shown in typical drawings in Appendix A. The levele of the sewage in the vacuum vessel are monitored by a set level detection probes which activate the sewage discharge pumps. If the sewage rises too high in the vessel then a high level detection probe stops and locks out the vacuum pamps to prevent the flow of Sewage into the vacuum vessels, The vacuum in the vacuum vessel is maintained within the operational range by pressure switches, c) Warranty of System Performance ‘Since the vacuum system involves proprietary design and equipment, specislised system designers shall be accountable tothe performance fof the entre vacium system including both design and construction aspects. The specialised system designers shall also specify clearly the specific maintenance and operational requirements of the system. 2.4.19.2 Collection Chamber General Design Requirements Collection chambers shall have sufficient capacity to store sewage disehged from all connected properties for atleast 6 hours in the fevent ofa valve failure or similar emergency, which is sufficient to ‘cover the Services Licensee emengency response time, ‘The overflow storage time shall be based on the ultimate sewage design flow that will enter the collection chamber. The volume that can be used for emergency storage shall be the volume contained in the collection chamber from the base of the collection chamber up to the lowest ground level at any point served by the chamber as nvell as the volume contained in the gravity lateral sewers entering the ealleetion chamber. Separate chambers shall be provided to serve properties at different clevations where there is Tikelihood of sewage from one property Flooding another property. ‘The chamber shall resist external forces and internal water pressure. ‘The preferred material of construction for collection chambers is pre-east concrete, The two sections (the valve compartment and the Sewer Networks and Pop Stains Volume 3 =Panning, Materia and Desigr » Mm ™ collection sump) may be mounted vertically one on top of the other f5 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, ‘The collection sump requires a benching section that allows a scouting ation from the sewage as it enters the suction pipe, thereby rendering the sump sef-cleansing. The internal surfaces of the sump shall be both strong as well as resistant to corrosive attacks from the collected sewage, Where the interface valve is situated over the collection sump, 4 working platform shall be provided for allowing maintenance Personnel to stand on when carrying out scheduled maintenance to the interface valve ‘The sump shall be sufficienly vented to allow the intake of air without catsing a noise nuisance and to ensure thatthe operation of the vacuur system does not unseal the water traps on the gravity drainage system, Number ef Properties Connected The location of each collection chamber and the number of properties connected t> each collection chamber shal be specified inthe design drawings / calculations. flow from the maximum numberof existing or future properties © preposed to be connected to a collection chamber shall be ‘quantified, and the retention time of the collection chamber can be then established. The retention time shall exesed 6 hours. Maximum Flows to Collection Chambers ‘The maximum sewer design flow to a single vacuum interface valve collection chamber shall not exceed 0.25 Us. Where single poi Flows in excess of 0.25 Vs occur, multiple vacuum interface valves shall be insalled, Typical multi-valve collection chamber is shown, in typical drawings in Appendix A. Breather Pipes Some vacuum interface valves inhale and exhale air during their ‘operation. This is accomplished through a sereened air pipe known as a “breather” Volume Malaysian Senerape Tnty Guidlesy Planing, Material and Design While breather bells are generally mounted inside the collection hauls it may be necessary to mount them externally Each breather pipe shall be fitted inside the “breather bell” located atthe top of the collection chamber in an aceessible location to allow their removal for maintenance purposes. Covers and fram Collection chamber covers shall provide an access opening of at least 6600 mm diameter. Covers and frames shall be installed in accordance withthe requirements stipulated in Clause 2.3. 2.4.49.3 Vacuum Interface Valves » 0) um) General ‘The interface valve shall failsafe in the closed position and shall prevent backMlows 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 cach time per cyele, Valves installed in the sump shall be capable fof operating when submerged provided thatthe breather pipe is not submerged, The velve shall be installed in the collection chamber using demountable, re-useable No Hub” couplings suitable for vacuum service. Level Sensor ‘The valve shall be equipped with a sensor to determine the level of sewage in the collection sump; this sensor shall be designed to be fouling resistant, Level sensor pipes shall not be less than DNIID 45, Interface Valve Controller ‘The eonteoller 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 atleast the batch volume has been evacuated If the design provides for the inteoduetion of ait after the sewage has been evacuated, the controller shall maintain the valve open for «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. Sever Networks and Pump Stations | Volume sPanning, Matsa and Desigs IV) Explosion Proof The valve mechanism and controller shall be explosion proof if ‘exposed to potentially explosive atmosphere V) Life of Valves and Membranes Every interface unit, comprising the interface valve, controller and sensor shall be expected 10 last in excess of 25 years, Manufacturers shall clearly specify scheduled maintenance, this allowing the operators to keep the interface units in tip-top conditions at all times, 24.49.4 Vacuum Sewer Design %6 1) General For # completely flat area, the length of a single sewer branch shall not be more than 3 kin. However, the maxinnum limit of the Pipe length would vary according to the gradient achievable in that line. Specialised system designer shall provide a detailed hydraulic ealeulatior for the vacuum sewer network ‘Vacuum main routes shall be selected to: a b) Minimise length ©) Equalse flows on each vacuum main, 4) Provide adequate access for operation and maintenance, MN) Sewer Depth Vacuum sewers, branch sewers and erossover pipe connections from the collection chambers, shall have a minimum eover of 0.9 m ta withstand the stresses arising from traffic loads, ‘When sewers are not buried, they shall be protected from extremes of temperature, ultra-violet radiation and possibility of vandalism When sewers are suspended underside walkways or bridges, they shall be rigidly supported so there is no visible sagging between ‘supports. Supports shall withstand all state and specified dynamic conditions of loading to which the piping and associated equipment may be subjected. As a minimum, consideration shall be given to the following conditions: ue 3 Malaysian Sewerae Toasty eldeiesPhoning, Material and Design 4) Weights of pipe, valves, fittings, pipe protection materials, and median in the pipe. b) Reaction forces due to the operation of isolation valves. {9} Wind loadings on outdoor piping, ul) Sower Profiles Pipeline profiles shall be self cleansing and prevent the accumulation of solids. Typical pipeline profiles are shown in typical drawings in Appendix A. For crossover pipes, the minimum distance between Tif shall be 1-5 m. Vacuum sewers shall have a minimum gradient of 1 in $00. Where the ground has a gradient of 1 in 500 or more in the direction of flow, the vacuum sewer may be laid parallel to the surface as shovin in typical drawings in Appendix A. a) Design Tolerances “The chainage and invert levels ofthe pipeline(s) shall be determined to the following levels of design accuracy and specified in the Design Drawings: i), Sewer chainage to the nearest 0.5 m. ii) Sewer invert levels to the nearest 0.01 m, b) Lit Design “To provide for efficient vacuum transport to sewer extremities, the size cf individual Lifts shall be kept as small as possible, Many small lifts are preferable to one large lift. The change im invert at ‘each lift shall not exceed 1.$ m. For vacuum sewers, the minimum distances between lifts shall be 6 m. €) Crossover Pipe Connection Crossover pipe shall initially fall away from the interface valve and shall eonnest into the top sector of the vactum sewer contained within the angle of + 60° about the vertical axis as shown in “Appendix A. 4d) Branch Connections All banish connections to vacuum sewers shall be by a ¥ junction connected {0 the sewer above the horizontal axis as shown in ‘Appendix A. In plan, the angle of the Y-junction shall ensure that flow tawards the vacuum station is generated and backilows are minimised. No connection shall be made within 3m of a lift ‘Sever Networks and Pang Stations Vote ”Panning, Material and sign IV) Pipework and Fi vy ©) Waterlogging The profil shall ameliorate water-logging at any change in gradient even when a prolonged power failure occurs (both TNB supply and standby genset ful), and the vacuum interface valves continue t0 ‘operate and admit sewage until the vacuum level reduced tothe point when they will no longer open. When the power is again available, the system shal be capable of recovering to normal operation without intervention by an operator. ings for Vacuum Sewers ‘The recommended material from which to construct vacuum sewers is minimum PE 80-PN 8 rated solid wall polyethylene pipe. Pipe fitings shall be PE 100-PN 8. Pipes shall be UV stabilised with ‘carbon black which shall give the pipe a black colour throughout. ‘The polyethylene pipe is selected because it is both structurally strong and compatible with potentially chemically aggressive and abrasive flows in the sewage, a) Pipe Size ‘The suction pipe DN/ID shall not be greater than the DN/ID of the interface valve. The minimum diameter of erossover 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/D 80. b) Jointing of PE Pipes and Fittings PE pipes and fittings less than DN_ 160 shall be jointed using clectrofusion fitings. Pipes and fittings DN 160 and larger shall be jointed wity electrofusion fittings or butt fusion welding ©) Warnirg System ‘To act as a warning to an excavation possibly catried out ata later date, the use of a marker tape laid 300 mm on top of the pipe is recommended. This shall be a 150 mm wide polyethylene and printed with a descriptive warning of the pipeworks below. Isolation Valve The isolation valve clear opening shall be not tess than the DN/ID ofthe pipe, and be capable of sustaining a vacuum pressure of -0.8 bars) Volume “Masi Sewenge Tndstey GailePooning, Materia sn Design Isolation valves shall be resilient seated gate valves with the body, bone, yate an! bridge fabsiewted fiom ductile or cast iton. 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. a) Isolation Valve Installation ach isolation valve shall be located in a chamber, which shall contain a dismantling arrangement for replacement of the isolation valve if needed. When isolation valves are buried, they shall have extension spindles and surface boxes. b) Isolation Valve Location ‘Means of isolating lengths of vacuum sewer (© permit repairs or to locate faults shall be provided at distances of not more than 00 m and on branch sewers longer than 200 m, 2449.5 Vacuum Station Design 1) General 1 is desirable to have the vacuum station located as centrally as possible within the sewer network. This lends itself toa system with ‘mult-beanches hence giving added operating and design flexibility Ideally, the design capacity of a single-vessel vacuum station shall hat exceed population equivalent of 8000 persons. ‘A dusl-vessel station, oF more than a single-vessel station that is completely isolated, shall be provided when the population equivalent exceeds 8000 person 1) Vacuum Station Layout ‘A typical vacuum station layout is shown in typical drawings in AApperdix A. The vacuum station shall be divided into two main areas, an above ground plant room and a below ground dry well ‘The oor level of the dry well shall be designed to suit the inver levels of the incoming sewers, the vacuum vessel diameter and the «imensions of the selected sewage discharge pumps. Sewer Networks an Pp Sains Vote | Py© m ‘The vacuum vessel, the sewage discharge pumps, valves and pipework associated wilh he sewage discharge pumps ad a small simp 10 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. Vacuum Vessel actu vessels shall be designed to meet the requirements of ASME Section Vill Division | — 2004 Edition. The vessel shell shall be constructed from mild steel or any other approved material Sewer inlets shall be provided with short radius elbows inside the vessel (0 cireet the sewage inflow away from the sewage discharge Pump suetion connections and the vessel walls, ‘A vacuum vessel may have up to five (5) incoming vacuum sewers connected directly to the vessel. No inlet pipes shall be connected below the system emergency stop level. Sewage discharge pump suction comections shall be provided at the invert of the vacuuin vessel. The vacuum vessel shall be fited with an externally mounted sight glass which is suitable for operation in a vacuum and is easily removed for cleaning without decommissioning the vessel. ‘The vacuum vessel shall be provided with a DN 600 access opening, and the cover shall be provided witha lifting eye. Wherever possible, the opening is preferably positioned on the top of the vessel in order to minimise the size of the structure necessary to house the vessel, this conserves valuable resource, reduces the footprint ofthe building, and thus allows adjacent residences to enjoy more buffer spaces. During the inspection or maintenance works, safe entry procedures shall be achered to, according to the Department of Occupational Safety and Health (DOSH) codes of laws, by trained certificated ‘operator, and that the vessel is decommissioned, with the access opening removed and discharge pipeworks at the two (2) draw-off Points dismantled, and forced air ventilation is applied is importa 1 ensure dha the system would operate continiously inthe face of having the vacuum vessel temporarily out of service during an interval inspection. The incoming sewage shall manually bee bypassed to a mobile vacuum tanker via a flexible ribbed pipe The pipe is of an adequate length to reach the bypass valves safely, Vohume 3 Malnysin SeveranePlaning, Mate and Design ‘Typical bypass valve arrangement is shown in typical drawings in Appendix A. Vi) Moisture Trap When mechanical vane vacuum pumps are selected, moisture shall be provided for the vacuum pumps. Baffles o¢ moisture removing material shall be Fitted inside each vessel to assist with moisture removal V) Vacuum Pumps Vacuum pump capacity (Qvp) shall be rated. The selection of approptiate size of vacuum pump is determined by the following four fators:= 4) ‘The peak low of the sewage to be collected b) The length of the longest single sewer within the sewer rework, ©) The total volume of the sewer pipework within the network 44) Air to liquid ratio employed (ratio not less than 3), a) Evacuation Time When the vacuum pumps, collection chamber and vacuum vessel have been sized, system evacuation time for an operating range of ~ 0,55 bar(g) o'-0.65 bar(g) shall be calculated using: [Fyne vo)evmi fon Op ume of vacuum sewers, fof var vessel, Sever Networks and Pun Stations ‘alone 3 aPlaning, Material and Desa 2 NOTE: In normal operation it is assumed that the vacuum sewers will be approximately 1/3 liguid fille. The system evacuation time, which is defined asthe time period between the vacuum pump start and stop, shall be between 2 and 5 minutes, ) Selection of Vacuum Pumps ‘Vacuum pumps shall have sufficient capacity to serve the system, A minimum of two vacuum pumps of equal capacity shall be installed such that ene pump can be removed for maintenance without the loss ‘of system sapacity. Vacuum pumps, where used, shall be suitable for both contiauous operation and for a minimum of 6 starts per hour ©) Vacuum Pipework ABS pipes and fittings shall be used for interconnecting pipework between the vacuum pumps and the vacuum vessel within vacuum Pipework shall be fully supported. Vil) Sowage Discharge Pumps Two sewage discharge pumps of equal capacity are recommended for use in 4 vacuum station. Each pump shall be sized to discharge sewage at a rate at least equal to the calculated design peak flow forthe vacium system. Sewage discharge pumps shall be capable of pumping wisereened sewage and suitable for immersed operation in the event ofthe vacuum station dry-well flooded. In normal operation the dry-well will not contain water, Pumps may have a vertical or horizontal configuration Sewage discharge pumps shall be suitable for a minimum of 6 Sarts per hour. Equalising lines connecting the discharge side of the centefigal sewage discharge pumps ta the vacuum vessel shall bee installed if required to prevent cavitation or to ensure that the Dump inlet is always flooded, Sewage di removal of the pump without disrupting the charge pumps shall be ited with isolation valves to allow system operation. Discharge pipework for each pup shall be fitted with a non-return valve and a resilient seated gate valve on the discharge side. Where ume Malian Sewenge Tad GaidenPlanning, Material and Design the discharge pipework is manifold, the final discharge pipe shall also be fitted with a non return valve. The valves shall be able 10 be operated from the vacuum station floor, Vill Vacuum Gauges 30mm vacuum gauges calibrated to read 010-1 bar to an aceuraey ‘of 42% shall be fitted to the vacuum vessel and each incoming. ‘vacuum sewer. Vacuum gauges shall also have bottom outlets fited With Teveroperated ball valves. All gauge diaphragms shall be suitable for use with sewage gases. The gauges indicate the vacuum pressure within each sewer and enable pressures within the sewer network t0 be monitored Ix) Fire-fighting System Fite-ighting system using carbon dioxide atthe genset / fuel room shall be provided at every vacuum station in accordance with Boomba's requirements X) Odour Control Effective odour control system shall be provided to treat air vents froma vacuum station to prevent malodour impacts being imposed ‘on davnsteeam residential areas, Biofiters is one of the systems used ta remove the odours from the vacuum pump exhaust gases containing toxie and odorou ‘compounds by passing the gases through a natural biologically active filter medium. XI) Noise Control ‘Vacuum station shall be acoustically designed and fitted with noise contol measures, a8 required to control noise to levels that comply with local council's regulations. XII) Controls and Telemetry a) Vacuum Level Control YYacium levels In the vacuum vessel shall be controlled by vacuum switches with operating range of O to -1 bay(a). Their purpose is {to cantral the operation of the vacuum pumps and to maintain the ‘vacuum within the vessel inside the operating range, A minimam of four vacuum switches shall be provided to operate the duty and ‘assis: pumps, and to provide a high and a low vacuum alarms Sever Networks and Pap Stains Vote %Planning Matera snd Design b) Level Controt ‘The level detection probes shall be mounted on the vacuum vessel. ‘The purpeses are to contol the operation of the sewage discharge pumps and to maintain the sewage within the vestel*inside the ‘operating range. Probes shall be manufactured in one length without any serew joints along thei length. Any form of float switeh, including magnetic and ultrasonic types shall not be permitted. “The level control system shall respond to the following sewage levels in the vacuum vessel: Emergeney stop level stops vacuum generation; sewage discharge pump operates; Start evel = starts sewage discharge pump; Stop kvel - stops sewage discharge pump: ©) Vacuum | Sewage Discharge Pump Control ‘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 intraduetion of the standby units in the eveat of failure The electical controls shall allow sequential operation of all pumps so shat running times are equalised. The standby pump shal ‘automatically cut-in should the duty pump fail d) Valve Monitoring System / Station Telemetry ‘Valve moritoring and station telemetty systems are optional, but, shall be implemented for larger schemes comprising more than 50 interface valves The open and closed status of interface valves shall easily be detected by the use of a remote control via infrarediradio signals, Alternatively, system suppliers may install @ signal cable to relay this information to a display panel within the vacuum station. All monitoring components installed atthe collection chambers shall be robust and suitable for use in sewerage application, Large schemes shall also include a telemetry section with valt-free contacts for each condition/alarm ofthe station equipment as shown, in Table 25 “ Volume 3 Matin Sewerage Tasty Guidlines2.4.20 24.24 Planning, Materia and Design Table 2.6 Conditionfalarm of the Station Equipment Staion pover net OK ‘Vacuum pump power “Isolated / OK ‘Sewage discharge pump power Isolated /OK em —itopei70 Sewage discharge pump overload Tripped /OK ‘Vacuum level | Low / OK Vesa Heh /OK ‘Sewage level 7 High /OK Tidal atta ox | Fire alam Xill) Emergency Power Generation [A back-up diesel generator shall be provided to adequately run the station inthe event of an electric power disruption. The generator shall be capable of providing 120% of power for at least one ‘vacuum punip and one sewage discharge pump and other necessary equipment Computerised Sewer Designs Manual computations for the hydraulic design of a sewer network can be avoided for many aspects using proprietary computer software o house computer programs, However, there are many variations possible for the different aspects of hydraulic design, Le. flow contributions from different sources, quantity of infiltration, quantity of inflow, sediment cleansing requirements, pipeline roughness coefficients, et, Itis therefore necessary that the computer software or programs adopt the hydraulic design requirements as detailed in this guideline. Some proprietary Softwares may not permit certain adaptations required to conform to the hydraulic design requirements given in this guideline. As such, these software would be unsuitable. Design of Inverted Siphon Inverted siphons are introduced along a gravity sewer line in order to pass under an obstacle (e.g. railway line, stream, culver, etc). An alternative Sewer Networks al Pap Stains ‘Volume 3 sPlannin, Material snd sigs 24.22 « to an inverted siphon for bypassing obstacles is a pump station. But such fn option may be economically not viable. The profile of an inverted siphon encourages solids settlement and accumulation and therefore they require more frequent cleaning, They must be avoided as much as practicable, Inverted siphon shall consist of at least two of more parallel pipelines (or barrels). The minimum pipe size of a barrel shall be 225 mm, and shall be provided with necessary appurtenances for convenient Mushing and maintenance. There will be an inlet chamber designed to divide the flow among the pipes by allowing each pipe t come into operation im succession and an outlet chamber designed to prevent eddies from carrying solids and sediments back into the siphons. Longer siphons shall be provided with hatch box with access for maintenance ard cleaning, These siphons shall have independent washout Facilities. ‘The manholes shall have adequate clearance for rodding. In general sulficient head shall be provided and pipe sizes selected to secure flow velocities of a: least 0.9 mvsee for average flow. The inlet and outlet shall be arranged so thatthe normal flow is diverted to one barrel, and so that either may out of service for cleaning. Its choice should be taken into consideration the operational and maintenance aspect of siphons, The siphons shall not have sharp bends, either vertical oF horizontal, ‘The horizontal leg of the siphon shall have a negative gradient of 8° to 10°, whilst the rising leg shall be limited to 30° 10 48° should space permitting. Thete shall be no change in pipe diameter along the length of the barrel. Pipes and pipe joints used for siphons shall be designed at the appropriate pressure rating Structural Design of Sewers ‘The structural design ofa buried sewer can be divided into the following two categories: a) Rigid pipe. ») Flexible pipe, Al1wostsuctural designs shall take account of how the sewer is supported 'w determine the loading which the sewer can sately withstand, ‘The structural design of @ buried sewer normally considers only the siructural integrity of the pipe cross seetion, Although not as etitcal as the structural integrity of the pipe eross section, the considerations for ane 3 Mats Sewerage Tadtry GuidelinesPinning, Materia and Design the ground conditions and sewer installation practices that will affect the longitudinal strcturalinvegrty shill wot be onsite. “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 {uideline will prevent the selection of a particular design approach purely tw favour ene material aver another. Als, 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 of any other standards deemed appropriate by the Commission, a) Rigid ipe Structural Design Pipes which ate classified as rigid are: ')Vitsfied clay (VC) pipe. li) Reinforced conerete (RC) pipe ‘The failure of a rigid pipe normally occurs by pipe fracture. Thus, {or stesctural performance, the determination ofthe pipe ring crushing strength / load is required, This strength is determined using three points loading test as described in the respective Malaysian Standards for the above pipes. Both VC pipe and RC pipe can be made (0 fchieve different ring strengths a defined in the Standards |When a buried rigid pipe is supported, the load which the pipe ean safely withstand is higher than the load which eaused failure in the thee point loading tes. ‘The improvement in load resistance provided by different pipe support designs is defined by the bedding factor. Where the sewer is supoorted on granular material, such a8 erushed rock, the bedding factor becomes a function of the deasity of the granvlar material and the height to which the granular material is placed above the By varying the pipe ring strength and the pipe support, different load resistance ean be achieved. ‘The pipe support designs permitted by this Volume are limited to those in typical beddings in Appendix A. They include the following: ‘Sever Networks and Pap Stations Wome | 7Planing, Mate and Design 1) Granalar bedding/ Crusher rock, i) Conaete eral i) Conerete arch (with granular bedding) iy) Concrete surround, Granular bedding design shall be adopted wherever possible. Conerete support or arch designs should be avoided. This is due to the diffculty in achieving full contact of the conerete support with the pipe ring. AA higher sitength pipe in combination with erushed rock support is preferred over a lower strength pipe in combination with concrete support or arch designs. It is important thatthe pipe bedding should be properly constructed to allow for the flexibility at the pipe joints and t0 ensure uniform pipe supports. Point supports or loads which may lead to pipe failure ‘must be avoided. ‘The soil loud to which a rigid pipe can be subjected to shall be determined from Martson Load Theory. According to the theory, the soil load on a rigid pipe differs from that on a flexible or semi flexible pipe. The load on a rigid pipe is «function of trench width, ‘backfill soil type and trench depth. In a nareow trench, trench wall friction reduces the load applied by the soil backfill. Therefore, Wide trench gives @ more conservative loading and shall be used to determine the load on rigid pipe. Where vehicles will pass over the sewer and the sewer is Isid with 4 cover depth of less than 2.5 m, the sewer will be subjected to ‘ditional loads from such vehicles. The Boussinesq Theory should bbe used to determine the loads from vehicles in the design. ‘The ultimste vehicle load to which the sewer will be subjected to shall be used for structural design. Where the sewer may be subjected to construction traffic or may have tempos Ww cover daring installation, structural design must examine such loading conditions to ensure the sewer can withstand such temporary vehicle loadings, Determination of vehicle loading shall be in accordance with AS 3725 (Loads on buried concrete pipes) and AS 4060 (Loads on buried vitrfied clay pipes.) Loads on buried rigid pipe for field conditions and for main roads can be found in Simplified Tables of External Loads om Buried Pipelines published by the UK Transport Research Laboratory. * ‘Volume 3 Malian Sewerage Indy GuidesPinning, Materia and Design b) Flexible Pipe Structural Design Pipes which are classified as flexible are: ’) PS pipe ii) GRP pipe iil) ABS pipe iv) Steel pipe ‘The mode of failure of flexible pipe is usually by excessive pipe ring deformation, except for GRP pipe which may be by excessive pipe ting strain. The occurrence of such a GRP pipe failure depends fn the wall thickness. [Nommly a standard Jong term allowable ring deflection is applied for all flexible pipe. A 5% long term deffection limit has been the ‘most commonly adopted limit and shall be used except for steel pipe With cement mortar lining, For steel pipe with cement lining, a 2% deflection limit shall be used, Where surface settlement is critical, 4 lower allowable deflection limit may be adopted “The resistance of a flexible pipe to ring deformation is classified by pipe rng stiffness, The stiffness classification is derived from a two Point short term loading test. It is a function of the loading force divided by the specified test deflection. Flexible pipe can be made to achieve different ring stiffness by varying the wall thickness. For PE pipes, the ring stiffness can also be varied by varying the wall structure, Simile to rigid pipe, the loading which a flexible pipe can withstand ‘an be increased wien the pipe is supported. For flexible pipes, this fexteral 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 By varying the pipe ring stiffness and surrounding soil stiffness, different load resistance ean he achieved for flexible pipe. Flexible pipe must be completely embedded in crushed rock, with the rock to be finished at 150 mm over the top of the pipe. Crushed rock will give a uniform support around the pip. ‘The soil load used for structural design for flexible pipe support shall be the prism Joad or the weight of the column of soil directly above the pipe. Marston Load Theory mentions that this column of soil is parly supported by friction provided by adjacent soil. Therefore, Sewer Networks and Pam Stations | Volume 3 °Panning, Material and Design 22 224 this frictional support of soil column causes the load on the flexible pipe to be less than the weight of soil directly above the pipe. This fictional support may be lost with time and the design using prism Toad represents a conservative design. Where vehicles will pass over the sewer and the sewer is laid with 4 cover depth of less than 2.5 m, the pipe will be subjected to aulditional loads from such vehicles, The Boussinesq Theory should bbe used to determine the loads from vehicles in the design approach in this guideline ‘The ultimate vehicle foad t© which the pipe will be subjected to shall be used for structural design. Where the pipeline may be subjected ‘0 construction traffic oF have a temporary shallow cover luring installations, structural design must examine such loading conditions to ensure the pipeline ean withstand such temporary vehicle losdings Granular bedding design shall be adopted wherever possible. Typical details of granular bedding for flexible pipe is given in Appendix A. ‘The structural design of flexible pipe support must be in accordance With Australian Standard AS/NZS 2566, which uses a modified form ‘of Spangler’s equation forthe determination of pipe deflection. This, ‘Spangler equation incorporates Leonhardt’ factor to account for the change in support provided by surrounding soil stiffness when the trench widih is varied For force mains with shallow cover, structural design of flexible pipe may rot be necessary. However, when the structural design of exible pipe for such a force main is undertaken, the re-rounding elfect of internal pressure should be ignored to allow for the worst cease desigr, which eceurs when the line is out of service Manhole General Pre-cast concrete manholes shall conform to MS 881 and BS S911 “Manholes shall 2e constructed with pre-cast concrete sections surrounded by an in-situ eonerete surround. Protecting lining / coating. shall be provided fo prevent corrosion of the conerete due to sulphide attack. Walls shall be cither rendered with sulphate resistant cement mortar at feast 20 mm thick or lined with PVC, HDPE or epoxy coating. PVC ‘or HDPE fining shall be at least $ mm thick, Continuity of the lining Volume Maayan Sewerge nat GuilesPlaning, Material and Design shall be provided by means of welding or fusing each individual sheet te the nex: prior fo the concrete curing, The epoxy coating shall either be high build tar epoxy system complying with AS 3750.2 and applied two or nore coats to give a total dry film thickness of not less than 500 jm er high build micaceous iron oxide pigmented epoxy system complying with AS 3750.12 and applied in two or more coats f0 give a total dry flm thickness of not less than 280 um. The benching shall be protected with epoxy coating, high alumina cement mortar, or equivalent, Only materials and application processes approved by the Commission may be used. Brick manholes shall not be used, duc to the high risk of excessive infiltration. Details of manhole types and construction are shown in Appendix A. Straight beck type taper {op shall be used while reducing slabs type are acceptable as alternative. Any other type of pre-fabricated manhole will requite prior approval of the Commission, ‘The mininwum diameter of manhole chambers consteucted from pre-cast conerete rings shall be as given in Table 2.6 below: Table 2.6 Minimum Manhole Diameters EPROM eaeetat eel Means oa Core <150) 1000 225 10.300, 375 10450, 52510 710, «Ls = $2010 900, 1800) > 900 Subject to designer's requirements based on ieconcltion 3750450 52510710. 1500) 21s $320 10 900 1800 > 900 Subject to designer's equirements based on site condition ‘Sewer Networks and Pump Stans ‘ohne FyPanning, Matra and Design 222 Note: 8) These sizes apply to straight-through pipesy larger siees may be Fequited for turing chambers or chambers with several side branches or Where specific maintenance requirements are necessary, e.g disconnecting traps, induct vent shall be provided at manholes eeeiving pumping discharges Where retention times in the force mains exceed two hours and where ‘concrete pipe are laid downstream of the force mains. The induct vent shall have a diameter of approximately one half af the force mains but shall not exceed 300 mm in diameter. The top of the concrete support of| the vent shall be built up above flood level. Details of the induct vent are shown in Appendix A. Provision of back-drop mi jole shall be based on the following 8) For pipe size equal o 225 mm or less, back-drop manhole shall be provided vhen the difference in invert level is equal 1o 900 mm or b) For pipe size more than 225 mm, back-drop manhole shall be provided when the difference in invert level is equal to 1000 mm or more Manhole Location Unless otherwise agreed by the Commission, all manholes shall be sited in public road reserve so that access can be gained for maintenance purposes. Mantole shall be provided for the following locations: 4) The starting end of all gravity sewers, this may be replaced by @ terminal layout b) Every charge in direction or alignment for sewers less than 600 mm in diameter ©) Every charge in gradient 4) Every junetion of two oF more sewers ©) Every charge in size of sewer Unless adequate modern cleaning equipment is used for the maintenance of the sewer, tke spacing between manholes shall not be more than 100 1m for sewers less than 1.0 m in diameter. For sewers with diameter larger than 1.0 m, the spacing between manholes shall not be more than 150 m. tions preyent manhole construction on the existing public manele shall be provided on the connection pipe as near to ublic sewer as possible osu Malye Sewenge Tndaty Geet22.3 224 Planing, Material and Design ‘The connections, details, and methods of manhole construction not covered n this Guldelines shall be in accordance with MS 1228. In addition, the current policies of the Commission with respect to safety and operation shall be stctly followed, Pipe Lengths from Manhole To prevent the differential settling of the manhole and the connecting sewer from breaking the sewer pipe, rotational flexibility in the sewer close o the manhole is required. A single flexible joint placed immediately outside the entry to the manhole is not sufficient to solve the differential settlement problem, unless graded (governed by gradient petmissible range) to connect directly to match invert level of manhole channel, if tunable to match invert level, A short length of “rocker pipe” having a Aexible joint at both ends shall be provided. A 600 min length short “rocker pipe” is sufficient to provide the rotational flexibility required for most circumstances in small diameter pipelines (<300 mm). For larger pipe, a 900 mm length short “rocker pipe” shall be provided. Refer to ravings in Appendix A. Structural Design Considerations for Manhole 8) Concrete used in situ shall be 25MPa Portland cement unless shown, otherwise by the qualified person, b) A coment blinding with a minimum of $0 mm thickness shall be placed before pouring the concrete manhole base, ©) The base of the manhole shall not be less than 300 mm thickness, which is measured from the channel invert, 44) Chansel inverts shall be laid accurately to meet entry and exit pipe ©) The channel invert shall be graded evenly between the entry an exit pipes. 4. Flexible joints shall be provided at the exit and entry of the manholes and shal be placed immediately outside any poured-in-situ concrete surround, £8) Jointsbetween the pre-cast chamber rings shall be sealed with suitable ‘morta, which can be high alumina cement mortar or equivalent 4h) The top of the benching shall be sloped at 1 in 12 towards the channel i) The finish surfaces of cast in-sit concrete structures shall be troweled smooth without poke holes or exposed aggregate, Sewer Newors al Pump Sons Wume 3 =Plooning, Mate snd Design 1) A minimum of 150 mm thick Grade 25 conerete in-situ shall be fencased to the precast concrete section. Brick manholes shall not be used. 1) Box outs sealed with bricks or equivalent shall be made for any proposed connections. 1) Drop connection pipes and fittings in the manhole shall be of the same dameter and material as the connesting sewer. 1m) A factory pre-cast intermediate slab shall be provided at every 3 meters depth and placed at half of the manhole depths. The slabs rust have holes for ventilation, 1) Pre-cast reinforced concrete landing, cover slap and fat top's lundersides shall be painted with 2 layers of coal tar epoxy. ‘9) Manhole covers in roads shall be set to the road profile and shall be flashed with the road surface. P) Manbole covers in unimproved areas shall be set at an elevation to prevent entry of surface water, 4) Manhok frame surrounds shall be Filled with non-shrink eementitions| ‘material or premix. 1). Field coatings to manhole covers and frames shall be applied to surfaces that are clean, dry and free from rust. 5) Boltedin steps ate not permissible in all manholes, Provision shall be provided for portable ladder for acess. The lightweight removable ladders shall be used in manholes where they can easily be inserted and secured from the surface, in order to deter unauthorized access to sewers 1). Mano structures shall not be constructed on slope or within slope failure envelope. In the event where it is unavoidable, the said structures must be designed not to encounter settlement of the sorts and at any time al risk of collapse during its operating Tife span, 18) Maximam depth shal be equal or less than 9 meter and all manholes deeper than 6 meter are subjected t0 the Commission's prior approval. Depending on the catchment area and size of sewer pipe, manholes deeper than 9 meter may be considered for the ‘Commission approval v) Precast or cast in-situ concrete base of minimum Grade 25 with t layer of AG BRC, 400 mm thick or to qualified person’s design shall be provided under poor soil condition including piling, if necessary. ‘Volumes Matsa Sewerage Indy Guidlines2.3 234 232 233 234 238 Plannin, Mate and Design Manhole Covers and Frames 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 ENI24, the specifications in this Guidlines shall take precedence. Load Cless Manhole covers and frames shall be capable of bearing wheel loads of up (0 400 kN and, as such, shall meet the test load requirements for Class D400 manhole covers and frames given in BS EN124. Material The material for manhole covers and frames shall be of spheroidal or nodular graphite iron (otherwise known as ductile iron) complying with the requirements specified in BS EN1363 for Grade 5007, ‘The production, quality and testing of sphero comply with ISO 1083. sraphite east iron shall Dimensions, Marking and Surface Finish The manhole covers shall be free of defects which might impair their fitness for use ‘The dimensions, marking and surface finish of manhole covers and frames shall comply with the requirements given in Figure Al to Ad in Appendix 4, ‘Tolerance on dimensions shown in Figures Al to A2 shall be & 1 mm, The casting of markings shall be clearly legible. Seating When a random cover is placed in a random frame, the adjacent top surfaces 0° the cover and frame shall have flushness of level within = 1mm, ‘The manholes covers shall be compatible with their seatings. These seatings stall be manufactured in such a way to ensure stability and quietness in use ‘Sewer Networks an Pup ations Volume sPlaning, Material and Desige 236 237 23.8 2.3.9 Casting All ast units shall be cleanly cast and free from ait holes, sand holes, old shuts and chill. They shall be neatly dressed and carefully feted All castings svall be five from voids, whether due to shrinkage, gas inclusions or ether causes. Protective Coating Al surfaces of manhole covers and frames shall be supplied coated with cither {hot applied bituminous mater Grade C ii) cold applied bituminous material complying with BS 3416 Type IT complying with BS 4147 Type 1 Immediately prior to coating, surfaces shall be clean, dry and free of rust. The coating shall be free of bare patches or lack of adhesion. The mean thickness shall be no less than 70 jum and the local thickness shal be no less than $0 ym. Water-tightness No visible leatage shall occur between the manhole cover and its seating in the frame when tested in accordance with Appendix E of AS 3996, Safety Features Manhole covers shall be provided with locking device and hinge to prevent rocking due to traffic and to provide a theft proof desiga. a) Locking Devices Locking devices shall be either bolts and nuts or a mechanism with ‘special Key design, The mechanism shall be able to be integrated with the covers and can also be used as a lifting device. All the ‘mechanism for locking device shall be of stainless steel in accordance with BS EN ISO 3506. Bolts and nuts for locking devices shall be hhexagonally headed, complying with BS3692, b) Hinge All manhole covers shall be hinged. The hinge shall be designed ‘such that, when in the open position, they shall be secured by a ypositive inechanical retainer to prevent accidental closure of the overs, The opening angle of hinged covers shall be atleast 100" (0 the horizontal I hinge bolt is used for coupling separate sections of | covers and frames, it shall be of stainless steel in accordance with BS EN ISO 3506, Volume 3 Malayan Severae Testy Gadel