SINTAKOTE Steel PiPeline Sy StemS Handling and …

1 SINTAKOTE Steel PiPeline SyStemSHandling and inStallation8TH EDITIONSINTAKOTE Steel PiPeline SyStemSHandling and inStallationRefeRence manual8TH EDITIONSINTAKOTE Steel PiPeline SYSTEMS4diSclaimeRThis manual has been prepared by Pentair Water Solutions to assist qualified Engineers and Contractors in the use of the Company s product, and is not intended to be an exhaustive statement on PiPeline design, installation or technical matters. Any conclusions, formulae and the like contained in the manual represent best estimates only and may be based on assumptions which, while reasonable, may not necessarily be correct for every installation depends on numerous factors outside the Company s control, including site preparation and installation workmanship.

2 Users of this manual must check technical developments from research and field experience, and rely on their knowledge, skill and judgement, particularly with reference to the quality and suitability of the products and conditions surrounding each specific PiPeline construction is being carried out for any water authority, as Principal, that water authority s standards, specifications or drawings, if at variance to any recommendation made in this manual, override the recommendations made in the Company disclaims all liability to any person who relies on the whole or any part of this manual and excludes all liability imposed by any statute or by the general law in respect of this manual whether statements and representations in this manual are made negligently or otherwise except to the extent it is prevented by law from so manual is not an offer to trade and shall not form any part of the trading terms in any transaction.

3 Pentair Water Solutions trading terms contain specific provisions which limit the liability of Pentair Water Solutions to the cost of replacing or repairing any defective product. Trading terms are readily available on request. Pentair LtdThis manual is a publication of Pentair Water Solutions Pty Ltd, and must not be copied or reproduced in whole or part without the Company s prior written consent. This manual is and shall remain the Company s property and its request. The Company reserves the right to make changes to any matter at any time without notice. Eighth Edition published Steel PiPeline SYSTEMS5contentSSEcTION PAgE1. Transportation 122. Site Preparation 133. Unloading and Handling 144. Stacking and Storage 165. Stringing 196.

4 Trenching 317. Bedding 238. Laying and Jointing 249. Backfilling 4510. Fittings 4911. Anchorage of Pipelines 5012. Hydrostatic Field Test 5213. Commissioning Water Pipelines 54 APPENDICESAPPENDIX A 53 Field Repair and Joint Reinstatement of SINTAKOTE APPENDIX B 65 Field Repair and Joint Reinstatement of Cement Mortar Linings and Guidelines for Pipe Hydration and Fitting End Caps APPENDIX C 72 Field Application of Electrical Cables to CP Lugs APPENDIX D 74 Safe Operating Procedure for Holiday Testing APPENDIX E 76 Field Application of Seal Coat to CML PipeAPPENDIX F 78 General DataAPPENDIX G 85 SINTAKOTE Repair KitAPPENDIX H 86 ReferencesSINTAKOTE Steel PiPeline SYSTEMS6contentS (continued)LIST Of fIgurES & TAbLESF igure - Securing pipes for transport 12 Figure - Twin slings or spreader bar 15 Figure - Pipe support 16 Table - Minimum pipe support area 17 Figure - Pipe bearing area 17 Figure - Stacking pipes using timber bolsters 20 Figure - Single stringing of pipes 20 Figure - Multiple stringing of pipes 20 Table - Minimum trench widths 21 Figure - Trench excavation machinery 22 Figure - Bedding layer minimum depth 23 Figure - Spreading bedding 23 Figure - Jointing systems 24 Figure - Pulling SINTAJOINT pipes home to joint 25 Figure - Fitting rubber rings into sockets 27 Figure - Alignment of pipes during jointing 28 Table - Permissible misalignment and

5 Offsets during entry 29 Figure - Temporary construction and pipe permanent SINAJOINT operating deflection 30 Figure - Axial offset measurement created by joint deflection 31 Figure - External inspection of assembled SINTAJOINT 32 Figure - D Series Rubber Ring joint direction 32 Figure - Section view of a SINTALOCK welding joint 34 Figure - Welded ball and socket or spherical slip-in join t field assembly 34 Figure - Raised face type flanges 36 Figure - Matched o-ring type flanges 36 Figure - Star pattern tightening sequence 36 Table - Recommended gasket composition for transport of general domestic liquids including brine and sewage 34 Table - Recommended Class 16 bolt sizes, bolt types and gasket types 39 Table - Recommended Class 21 bolt sizes, bolt types and gasket types 40 Table - Recommended Class 35 bolt sizes, bolt types and gasket types 41 Table - Indicative k Values 42 Table - Required tension and torque values 43 SINTAKOTE Steel PiPeline SYSTEMS7contentS (continued)LIST Of fIgurES & TAbLES ( cONTINuED)

6 Figure - Zones of backfill and compaction 45 Figure - Ring deflection limits 47 Table - Maximum allowable vertical deflection for inspection of SKCL buried pipe 48 Figure - Common fittings - welded pipe lines 49 Figure - Common fittings - SINTAJOINT pipe lines 49 Figure - Anchor blocks for horizontal thrust restraint 50 Figure - Anchor blocks for vertical thrust restraint 51 Figure - Pier support for above ground SINTAJOINT pipelines 51 Figure - Static head allowance for hydrostatic test with alternative pressure gauge locations 52 Figure - Flow chart for determining appropriate SINTAKOTE repair method 56 Figure - Joint region for Drader welding repair. 60 Figure - Drader gun assembly 61 Figure - Drader gun tip selection 62 Figure - Build up of material on cut end 63 Figure - Care required when trimming 63 Figure - Typical cement mortar lining crack greater than 2mm 68 Figure - Enlarge crack to 4 - 6mm 68 Figure - Completed repair 68 Figure - Field Application of Electrical Cables to CP Lugs - Align lugs 72 Figure - Field Application of Electrical Cables to CP Lugs - Strip SINTAKOTE 72 Figure - Field Application of Electrical Cables to CP Lugs - Bare cable ends 72 Figure - Field Application of Electrical Cables to CP Lugs - Crimp cable 73 Figure - Field Application of Electrical Cables to CP Lugs - Heat crimp joint 73 Figure - Field Application

7 Of Electrical Cables to CP Lugs - Apply sealant 73 Table - SINTAKOTE Thicknesses 78 Table - Cement Mortar Lining (CML) Thickness 78 Table - SINTAKOTE Steel Pipe Bores and Weights 78 Table - Manufacturing test pressure and rated pressure of MSCL pipe 82 Table - SINTALOCK Joint Rated Pressure 84 SINTAKOTE Steel PiPeline SYSTEMS8 SINTAKOTE tRaining PRogRamThe SINTAKOTE Quality PiPeline Installation Program was introduced by Pentair in 1989 and, to date, over 8,000 Water Industry personnel have participated. This program assesses individuals through competency-based training and assessment, the application of an adherence to Quality, Safety, Environmental and Risk line with Pentair Water Solutions commitment to continuous improvement, the program is accredited by the Australian Skills Quality (ASQA).

8 The program has been running for many years and is recognised as an Industry Leader. The Accreditation can be seen as a QA measure to ensure training for Steel PiPeline systems meets the most appropriate basis for the Program and the Accreditation is the Pentair Water Solutions Handling and Installation Manual and the PiPeline Installation Quality System, commonly known as the PIQS WATEr SOLuTIONS TrAININg & AuDITINg - rEgISTErED TrAININg OrgANISATIONSERVICES On-site auditing assessment Technical & systems support Pre qualification of installers On site and off site trainingbENEfITSTO CUSTOMER Confidence in installers Reduce unscheduled maintenance Traceability Confidence in asset performance Asset longevity Lower risk ratingTO INSTALLER Certification of workers Ability to tender for more work Lower risks Increase efficiencies Confidence in work Less re-work Lower injury ratesSINTAKOTE Steel PiPeline SYSTEMS9 RiSK & SafetyPentair Water Solutions is a strong advocate of Safety in the Workplace and believes that safety is paramount in all that

9 We contractors and installers should commit to providing a work environment where everyone in the workplace is safe at all times and recognise people as their greatest safe Handling and installation of the SINTAKOTE Steel PiPeline System in all applications relies on all personnel having a high level of safety awareness, reducing risk and improving site preparation and TO SAfETy1. RESPONSIBILITIES FOR WORKPLACE SAFETy- Be aware who has specific PLAN TO WORK SAFELy- Identify tasks and procedures, which control the risks arising from work INVOLVE EMPLOyEES- Display information in your workplace concerning health & safety. All employees should talk about ways to contribute to decisions that affect their safety in the DEVELOP PROCEDURES- Identify hazards in your workplace and assess any risks associated with them.

10 (Mitigate these hazards through developing processes to eliminate or control).5. INFORM AND TRAIN EMPLOyEES- Inform employees about hazards in their MONITOR AND REVIEW- Adjust, review and address any workplace or legislative changes. Processes change, staff change and so may the PLANT & EQUIPMENT- Regularly assess and inspect equipment and maintain Ensure appropriate Licences are held for Plant in above steps to safety may be undertaken throughout and continued through the On-Site Inductions, Toolbox Meetings, or Site you may have Principal Contractor s obligations whereby you may be responsible for:Injury or accidents to members of the public, employees and other on site contractors, at or near a construction site or Steel PiPeline SYSTEMS10 RiSK & SafetyENvIrONmENTALP entair Water Solutions embraces environmental protection and ensures its operations comply with relevant environmental , Pentair Water Solutions as well as SINTAKOTE PiPeline installers and contractors have a responsibility to ensure your work activities do not harm the are expected to take all reasonable and practical measures to ensure that: Waste (spoil, concrete, off-cuts, etc) is minimised and disposed of in the correct manner.