THE FEDERAL DEMOCRATIC REPUBLIC OF ETHIOPIA

MINISTRY OF WATER, IRRIGATION AND ELECTRICITY

RURAL PIPED SYSETM WATER SUPPLY

OPERATION AND MAINTENANCE
MANAGEMENT

Module - C
A Trainer’s Manual for Technical Operation and
Maintenance Requirements For Rural Piped System

DEMEWOZ CONSULTANCY
P.O.BOX 20023 CODE 1000
ADDIS ABABA ETHIOPIA
TEL: +251-(0)118-60 80 12 / 0911-15861
E-mail: [email protected]
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

PART - A: TECHNICAL OPERATION & MAINTENANCE MANAGEMENT

MODULE NO. SESSION SESSION TITLE ESTIMATED

TIME (Hours)

Session – A Facilitator’s Guide for Rural Water Supply

4
Operation & Maintenance Management

Session – B Introduction to the training:

MODULE – A 2
objectives and expectations

Session – C Introduction of Rural Piped System and

2
Pastoral areas Water Supply Technologies

MODULE – B Session – A Description of Water Sources for Water

2
Supply

Session - A Introduction of Rural Piped System

2
Operation and Maintenance

Session - B O&M Requirements for Water Sources to 4

Water Supply

Session - C O&M Requirements for Intakes 4

MODULE – C Session - D O&M Requirements for Electro-Mechanical 32

Equipment

Session - E O&M Requirements for Pipelines 8

Session - F O&M Requirements for Storage 4

Tanks/Service Reservoir

Session - G O&M Requirements for Consumer Points 4

Sub Total for this Module 58

Session -A Spare Parts Supply and Management 36

MODULE – D Session - B Equipment and Tools Management 8

Session - C Asset Management 16

MODULE - E Session – A Water Audit and Leakage Detection 16

MODULE - F Session – A Water Quality Monitoring and Surveillance 24

Session – A O&M Requirements for Solar Energy 4

MODULE - G
Session –B O&M Requirements for Wind Energy 4

DEMEWOZ CONSULTANCY
i
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Session – A O&M Requirements for Sand Dam 6

Session – B O&M Requirements for Haffir & Berkads 6

MODULE - H
Session – C O&M Requirements for Rain Water 8
Harvesting

TOTAL 196

Total Training duration for Part – A is about 25 days.

DEMEWOZ CONSULTANCY
ii
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

MODULE - C: TECHNICAL O&M TRAINING MANUAL FOR

RURAL PIPED SYSTEM

Table of Contents
1 SESSION – A: INTRODUCTION TO RURAL PIPED SYSTEM OPERATION
& MAINTENANCE 1
1.1. Session Outline 1
1.2. Objective 1
1.3. Introduction 1
1.4. Special Features of RPS in Ethiopia 2
1.5. Configuration of Rural Piped System 2
1.6. Classification of Maintenance 2
1.6.1. Scheduled (Preventive Maintenance) 2
1.6.2. Un-scheduled (Breakdown) Maintenance 4
1.7. Maintenance Planning Process 6
1.8. Inputs, spares, tools and technical assistance 6
2 SESSION – B: TECHNICAL O&M REQUIREMENTS AT WATER SOURCES 1
2.1 Session – B1 1
2.2 Session Outline 1
2.3 Objectives of the Training 1
2.4 Introduction 1
2.5 Step 1: System Overview 2
2.6 Step 2: O & M tasks specific to Boreholes 3
2.7 Step 3: Trouble Shooting 3
2.8 Step - 4: Spares, Tools, & Technical Assistance 5
3 SESSION – C: TECHNICAL O&M REQUIREMENTS AT WATER SOURCES 9
3.1 Session – B2 9
3.2 Session Outline 9
3.3 Objectives 9
3.4 Introduction 10
3.5 Step –1: System Identification 10
3.6 Step – 2: Intake Specific O & M tasks 11
3.6.1 Spring Intake 11
3.6.2 River and Lake Intakes 14
3.6.3 Impounding Reservoirs 15
3.7 Preventive Maintenance Checklist 17
4 SESSION – D: O&M REQUIREMENT FOR ELECTRO – MECHANICAL
EQUIPMENT 25
4.1 Session Outline 25
4.2 Objective 25
4.3 Introduction 26
4.4 Component in Pumping Station 26

DEMEWOZ CONSULTANCY
iii
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

4.4.1 Pumping Equipment 26

4.4.2 Ancillary Equipment 26
4.4.3 Pumping Station 27
4.5 Definition 27
4.6 Types of Pump 28
4.6.1 Potential Problems 28
4.7 Brands of Pumps and Generators under operation in Ethiopia 28
4.7.1 Submersible Pumps 29
4.7.2 Surface Pumps 29
4.7.3 Engine and Alternators (generators) 29
4.8 Important Points in Pump Operation 29
4.8.1 Inspection before starting up of pumps 31
4.8.2 Inspection REQUIREMENTs during staring and Operation of
Pumps 32
4.8.3 Inspection Requirement during stopping of pumps 34
4.9 Preventive Maintenance of Pumping Equipment 35
4.9.1 General 35
4.9.2 Maintenance Schedule for Pumps 35
4.9.3 Maintenance Schedule for Motors 38
4.9.4 Maintenance Schedule for Valves at Pumping Station 41
4.9.5 Maintenance Schedule for L.T. Starters, Breakers and Panel 43
4.9.6 Maintenance Schedule for Lifting Equipment 43
4.9.7 Maintenance Schedule for Water Hammer Control Devices 44
4.9.8 Maintenance Schedule for Air Compressor 45
4.10 Maintenance of Pumping Station 46
4.10.1 Screens 46
4.10.2 Sluice Gate 46
4.10.3 Sump/Intake Well 46
4.10.4 Pump House 47
4.11 Driving Equipment 47
4.11.1 Diesel/Gasoline Engines/Alternators 47
4.11.2 Schedule of Preventative Maintenance for Diesel Engines 50
4.11.3 Troubleshooting for Generator 52
4.11.4 D.C Battery 54
4.12 Facilities for Maintenance and Repairs 55
4.12.1 Consumables and Lubricants 55
4.12.2 Spare parts 55
4.12.3 Tools and Testing Instruments 56
4.12.4 Safety Rule 56
5 SESSION – E: TRANSMISSION & DISTRIBUTION PIPELINES 64
5.1 Session Outline 64
5.2 Objective 64
5.3 Introduction 64
5.4 System Description 65

DEMEWOZ CONSULTANCY
iv
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

5.4.1 Option-1: Pumping System from Single Borehole 65

5.4.2 Option-2: Pumping -Gravity System from Multiple Boreholes 65
5.4.3 Option-3: Pumping-Pumping-Gravity System from Multiple
Boreholes 66
5.4.4 Option-4: Gravity system from River and Reservoir sources 66
5.4.5 Option-5: Pumping system from River and Reservoir sources 66
5.5 System Identification 66
5.5.1 Gravity or pumped system 66
5.5.2 Pipeline components 67
5.5.3 Valves 68
5.6 Specific Pipeline O&M Tasks 68
5.6.1 Preparation for Repairs 69
5.7 Troubleshooting 75
5.7.1 Troubleshooting for Pipeline 75
5.7.2 Troubleshooting for Water meter 76
5.8 Service Lines Repair 78
5.9 Step 4: Spares, Tools, & Technical Assistance 78
6 SESSION – F: O&M REQUIREMENTS FOR STORAGE TANKS 83
6.1 Session Outline 83
6.2 Objective 83
6.3 Introduction 83
6.4 Components of Service Reservoir 84
6.5 Operation of Service Reservoir 85
6.5.1 General Procedures 85
6.6 Specific Service Reservoir O and M Tasks 85
6.6.1 Concrete Reservoirs 85
6.6.2 Steel Tanks 85
6.6.3 Crack Maintenance 86
6.6.4 Cleaning of Service Reservoir 87
6.6.5 Maintenance of Reservoir Appurtenances 88
6.6.6 Records at Service Reservoir 89
6.7 Troubleshooting for Service Reservoir 90
6.8 Spares, Tools and Technical Assistance 90
7 SESSION – G: O&M REQUIREMENTS FOR CONSUMERS POINTS 92
7.1 Session Outline 92
7.2 Objective 92
7.3 Introduction 92
7.4 Identification of Components 92
7.4.1 Water-point components 92
7.5 Specific Water-Point O&M Tasks 93
7.6 Troubleshooting for Water Points 95
7.7 Scheduled Maintenance 96
7.7.1 PM Programs and Schedules 96
7.7.2 PM Checklist 96

DEMEWOZ CONSULTANCY
v
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

7.8 Record and Report 97

7.8.1 Record System 97
7.9 Spares, Tools, and Technical Assistance 99
Annexes 101

List of Tables
Table 1-1: Elements of Preventive O&M 2
Table 2-1: Typical Component of Borehole 2
Table 2-2: Borehole Troubleshooting 3
Table 3-1: Typical Intake Components 10
Table 3-2: Summary of O&M Tasks for Spring Protection 13
Table 3-3: Troubleshooting for Spring Intake 14
Table 3-4: Troubleshooting for River Intake with Weir or Sump 14
Table 3-5: Components of Impounding Reservoir 15
Table 3-6: Trouble Shooting for Impounding Reservoir 16
Table 3-7: Preventive Maintenance Checklist for Water Sources Facilities 17
Table 4-1: Maintenance of Valves at Pumping Stations 41
Table 4-2: Maintenance Activities of L.T Starter, Breaker and Panel 43
Table 4-3: Maintenance Activities of Lifting Equipment 43
Table 4-4: Maintenance Activities of Lifting Equipment 45
Table 4-5: Different parts of Generator Engine and its purposes 47
Table 4-6: Pre-Start Check and Service of Generator Engine 48
Table 4-7: Schedule of PM for Diesel Engines 50
Table 4-8: Troubleshooting for Diesel Engines 52
Table 4-9: Lists of Spare parts need to be stock for O&M of Pumps and Generators 55
Table 4-10: Lists of Tools and testing Instruments required for O&M 56
Table 5-1: Pipeline components and their functions 67
Table 5-2: Required Flushing Velocity for sand particles, d=0.2mm (Brandon, 1984) 73
Table 5-3: Troubleshooting for Pipelines 75
Table 5-4: Troubleshooting of Water Meter 76
Table 6-1: Components of Service Reservoir 84
Table 7-1: Function of components of public water point 93
Table 7-2: Troubleshooting of public water point 95
Table 7-3: Preventive Maintenance Checklist for Transmission and Distribution System 96

List of Figures
Figure 1-1: Maintenance Planning Process 6
Figure 3-1: Schematic Section of Spring Development with Spring Box 11
Figure 3-2: Schematic Plan of Spring Development with Spring Box 12

List of Boxes

Box 2-1: Borehole O&M Tasks 3

Box 4-1: Things to be checked when staring the pump operation 31
Box 4-2: Things to be checked when stopping the pump operation 34
Box 4-3: Things to be checked when stopping the pump after power failure/tripping 34
Box 4-4: Daily Maintenance Tasks for Motor 39
Box 4-5: Monthly Maintenance Tasks for Motor 39
Box 4-6: Quarterly Maintenance Tasks for Motor 39
Box 4-7: Haft Yearly Maintenance Tasks for Motor 40
Box 4-8: Annual Inspection and Maintenance Tasks for Motor 40

DEMEWOZ CONSULTANCY
vi
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Box 4-9: Checking during starting of Generator Engine 49

Box 4-10: Checking during operation of Generator Engine 49
Box 4-11: Checking after operation of Generator Engine 50
Box 5-1: Function of different Valves 68
Box 5-2: Repair procedures of galvanized Iron Pipes 70
Box 5-3: Repair procedures of uPVC Pipes 71
Box 5-4: Repair procedures of Polyethylene (PE) Pipes 71
Box 5-5: Pipe Flushing Procedures 73

List of Annexes
Annex A: References 101

DEMEWOZ CONSULTANCY
vii
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Definition of Terms

Pump A pump is a device, which raises or transfers liquids at the expense of power
input or a unit that transfers the mechanical energy of a motor or an engine
into potential and kinetic energy of a liquid.

Centrifugal Pumps Centrifugal pumps are commonly used for low and high service to lift and
transport water. The two essential parts of a centrifugal pump are rotating
membrane with vanes and the impeller and surrounding case
Booster pumps are pumps which take water from a supply main and
Booster Pump
discharge it at a higher pressure to another point in the same pipeline, and
are also used to increase pipeline pressure in outlying areas when loss of
head is too great along the line
Throttled operation At times if motor is continuously overloaded, the delivery valve is throttled to
increase head on the pump and reduce power drawn from motor. Such
operation results in inefficient running as energy is wasted in throttling

Pressure gauge is an instrument used to measure the pressure of the pipe system

Priming is the process of filling the pump casing and suction line from external source
or by pouring water.

History Sheet History sheet of all pumps shall be maintained. The history sheet shall
contain all important particulars, records of all maintenance, repairs,
inspections and tests etc

Generators Diesel generators are frequently used as a stationary power source. The
main parts of the engine are the cylinders, pistons, valves and crankshaft. Air
is compressed by a piston inside a cylinder and diesel fuel is injected into it
by a high pressure pump, which results in an explosion that moves the
piston. In turn, the piston turns a crankshaft

Preventive Refers to an activity that includes checking the status of water supply
Maintenance facilities components at regular fixed intervals
Rehabilitation Is the correction of major defects and the replacement of equipment to
enable the facility to function as originally intended.
Repair It is the restoration of a defective component to return the facility to
acceptable working condition. The cost of the repair should be borne by the
community.
Rural Area “Areas of population outside urban and peri-urban using point or surface
water sources for which the community is responsible for the O&M”. in
addition, low population densities characterize rural areas, with small houses
isolated from each other.
Rural Piped System It is a water supply system feeding various villages and small towns by
gravity, pumping and a combination system through public taps and yard
connections
Scheme (Water) The entire facility (concrete works, pipes, pumps) established to extract
water from a water source, and distribute it to (close to) people’s homes

DEMEWOZ CONSULTANCY
viii
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Source (Water) The natural water source only, i.e. spring, groundwater, river, etc
Transmission Line is to deliver raw water from the source to the treatment plants, and transmit
treated water from treatment plants to the storage reservoirs

DEMEWOZ CONSULTANCY
ix
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Acronyms and Abbreviations

D.C Direct Current

G.I Galvanized Iron Pipe

HDPE High Density Polyethylene Pipe

NGOs Non Governmental Organizations

O&M Operation and Maintenance

PM Preventive Maintenance
POM Preventive Operation and Maintenance
PVC Polyvinyl Chloride Pipe
RPS Rural Piped System
SR Service Reservoir
WASH Water Supply Sanitation and Hygiene

WASHCO Water Supply Sanitation and Hygiene Committee

DEMEWOZ CONSULTANCY
x
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

1 SESSION – A: INTRODUCTION TO RURAL PIPED

SYSTEM OPERATION &
MAINTENANCE
MODULE – C TECHNICAL O&M MANAGEMENT REQUIREMENTS FOR
RURAL PIPED SYSTEM

1.1. Session Outline This session covers the following core topics:
 Introduction to RPS
 Feature of RPS in Ethiopia
 Configuration of Rural Pipes System in Ethiopia
 Classification of Maintenance
 Maintenance Planning Process
 Inputs, Spare parts and tools required for maintenance
 Technical Assistance Requirements

1.2. Objective The Water Board, Water Administration office staff understands what
rural piped system and O&M management means. At the end of the
session, participants understand the concept of RPS configuration and
different types of O&M, the process of maintenance planning, inputs,
tools and spare parts requires.

Output  An O and M schedule

 List of tools
 List of suppliers with contact details
 Contact numbers for individuals and organizations that can provide
technical
 assistance or services for maintenance tasks or in case of
unexpected breakdowns

Timing Approximately 2 hours

Methodology  Presentation, discussion and group exercises

 Demonstrate graphically different configuration of rural pipes system.

Materials  Flip charts, markers, pens, even overhead projector

Session Guide and Content

1.3. Introduction Rural piped system is a water supply system which serves more than
one rural village and small towns in combination from a single source or
combination of sources; with gravity or pumping or combination system;
with a distribution system that is managed by elected community
representatives and operated by recruited scheme operators (local
service providers – water administration office). Now days such system
is well known and expanded in Ethiopia like Etosa, Bale Robe-Melliyu,
Wulbareg, Dalocha, Etege Tayitu and so many.

DEMEWOZ CONSULTANCY
1
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

1.4. Special Explain the RPS schemes in Ethiopian context that are distinguished
Features of RPS through the following characteristics:
in Ethiopia  One source supplies several rural villages and possibly one or more
small towns,
 The source is located far away from the users and their villages,
 The systems have large installations such as head works, pumping
stations, long transmission lines, service reservoir, distribution
system, water points and connections,
 Users are organized to form an association and select
representatives to ensure effective oversight of the scheme,
The management of the scheme requires professional operator.

1.5. Configuration Two different types of RPS configuration predominately exist. These are
of Rural Piped presented in Attachment 1.1 and 1.2.
System Attachment 1.1 is showing the water sources are mainly from the rural
area, like that of Robe-Melliyu and Hetosa, which feeds the various
villages and end to the urban areas.
The other one is the sources belongs to urban area like dams and deep
boreholes, which mainly feed to the urban community and extended to
the various nearby villages as presented in attachment 1.2.
The two systems are totally having different service delivery models.
The former one is fully managed by community elected management
bodies, while the later, delivery the service by urban water utility. This
report focuses on the community managed rural piped system.

1.6. Classification of Discuss the two maintenance classification: 1) Scheduled (preventive

Maintenance Maintenance) and 2) Un-schedules (breakdown) Maintenance.
1.6.1. Scheduled (Preventive Maintenance)
It may be defined as the care and servicing by individuals involved with
maintenance to keep equipment/facilities in satisfactory operational state
by providing for systematic inspection, detection, and correction of
incipient failures either prior to their occurrence or prior to their
development into major failure.
Explain why Preventive Operation & Maintenance is required?
 enhance capital equipment productive life,
 reduce critical equipment breakdowns,
 allow better planning and scheduling of needed maintenance
work,
 minimize production losses due to equipment failures, and
 promote health and safety of maintenance personnel
The most important principle to keep continuous management support
is: “If it is not going to save money, then don’t do it!”
Discuss on the following elements of Preventive Operation and
Maintenance (POM) as described in Table 1-1. What activities are done
when we mean POM.
Table 1-1: Elements of Preventive O&M

DEMEWOZ CONSULTANCY
2
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

No Elements Description
1 Inspection Periodically inspecting materials/items to
determine their serviceability by comparing
their physical, electrical, mechanical, etc.,
characteristics (as applicable) to expected
standards
2 Servicing Cleaning, lubricating, charging, preservation,
etc., of items/materials periodically to prevent
the occurrence of incipient failures
3 Calibration Periodically determining the value of
characteristics of an item by comparison to a
standard; it consists of the comparison of two
instruments, one of which is certified
standard with known accuracy, to detect and
adjust any discrepancy in the accuracy of the
material/parameter being compared to the
established standard value
4 Testing Periodically testing or checking out to
determine serviceability and detect
electrical/mechanical-related degradation
5 Alignment Making changes to an item’s specified variable
elements for the purpose of achieving optimum
performance
6 Adjustment Periodically adjusting specified variable
elements of material for the purpose of
achieving the optimum system performance
7 Replacement Periodic replacement of limited-life items or the
items experiencing time cycle or wear
degradation, to maintain the specified system
tolerance
Explain the following items that are necessary to be considered for
effective POM program:
 accurate historical records of equipment,
 manufacturer’s recommendations,
 skilled personnel,
 past data from similar equipment,
 service manuals,
 unique identification of all equipment,
 appropriate test instruments and tools,
 management support and user cooperation,
 failure information by problem/cause/action,
 consumables and replaceable components/parts, and
 Clearly written instructions with a checklist to be signed off.
An O and M schedule is based on the understanding that performance is
measured by the quality of service being provided.
Indicators of performance include:
 frequency of disruptions to supply

DEMEWOZ CONSULTANCY
3
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

 length of disruptions to supply

 quality of water provided
 Cost of water production versus payment charged and paid.

The training facilitator raises the issue and debate on the idea
with the participants.
Preventing a problem is much cheaper than fixing a problem.
Preventing a problem keeps the system working. If the
objective of the system is to provide a reliable service, then it
is unacceptable for the system to break down or stop working.

It is better to stop the system briefly for routine maintenance than to wait
until it breaks down.
The O and M schedule provides information on what has to be done, by
whom and when.
1. Developing an O and M schedule
To develop an O and M schedule, go through each component of the
system and discuss the tasks to be done, filling in the table below as
required.
Task Responsibility How Often

2. Developing monitoring tools

It makes no sense to develop the O and M Schedule without ensuring
that the tasks have been done. The easiest way to make sure that the
tasks are carried out is to require the person responsible to sign off on a
form when the task is completed. This means that a form or forms
should be designed to suit the O and M schedule – this will be scheme
and component specific.
The example below provides an indication of a monitoring tool for
routine monthly maintenance tasks.
Task Frequency Meskerem Tikemet Hidar Tahissase
Change
Oil
Patrol
pipeline
Inspect
reservoir

1.6.2. Un-scheduled (Breakdown) Maintenance

DEMEWOZ CONSULTANCY
4
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Un-scheduled maintenance helps in preventing breakdown of equipment

but totally avoiding is impractical. Some failures could not be identified
easily but needs fault tracing and correction in other words trouble
shooting.
Repairing the failed part cannot be a full solution to the problem as long
as reasons of failure are not known. Knowing the exact problem will
assist in preventing repetitive failures.
As in all repairs and maintenance activities, correct procedures must be
followed in repairing break downs. These procedures must be followed
in repairing break downs.
These procedures include testing by instruments, trouble shooting or
any other means but the manufacturer maintenance manual is the best
reference to follow correct repair procedures.

DEMEWOZ CONSULTANCY
5
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

1.7. Maintenance Maintenance has to be planned as preventive maintenance and

Planning breakdown maintenance. The training facilitator explains the
Process maintenance planning process with the help of Flow Chart in Figure 1.1
described the process of maintenance planning.
Figure 1-1: Maintenance Planning Process

Determine Maintenance Strategy

for each component

Scheduled (Preventive Remedial (Breakdown)

Maintenance) Maintenance

Fixed Time Maintenance Condition-Based Maintenance

Identify: Identify:

 Maintenance Task  What to Inspect

 How to Inspect
 Frequency
 When to Inspect
 Trigger Criteria for Maintenance
 Trigger Criteria for
Develop Fixed Time Rehabilitation/Replacement
Maintenance
Program/Schedule Develop Condition Develop Breakdown
Monitoring Response Plan
Program/Schedule

Determine Resources Determine Resources

Determine Resources and
and Costs to Lead a discussion around the following topics: and Costs to
1.8. Inputs, spares, Costs to implement
implement
tools and implement
1. Inputs for Routine Operations
technical
assistance Depending on the scheme or technology used, the project may require
Priorityproperly.
various supplies to operate
These may include:
 fuel Implement
 lubricants – oils and grease Review
 chemicals

DEMEWOZ CONSULTANCY
6
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

 electricity
 meters for new connections
 fittings for new connections
 Filters, etc.
Discuss the arrangements required to ensure that sufficient supplies are
stockpiled and what measures need to be put in place to make sure that
the availability of the supplies is not interrupted.
Issues include:
 stores – adequacy, access into, safety, security
 stores register
 Requisition forms.
2. Spare Parts and Materials
Discuss which spare parts are required for routine maintenance and to
handle emergencies. Draw up a list of the spare parts that the project
should have available at all times.
These may include:
 filters for oil, fuel and air
 washers
 materials for pipeline repairs – glue, piping, fittings
 taps and tap washers
 spare locks
 replacement meters
 valves
 painting materials, solvents
 Construction materials.
3. Supply Chain
It is unwise to consider what spare parts are required without
considering where these components are sourced. It is helpful to draw
up a list of suppliers and to decide what minimum quantity of the spare
parts and materials should be kept in the store.
When this minimum amount is reached, then a requisition form should
be prepared to start the process of procuring additional spare parts and
materials.
Minimum Name and Name and Expected
Spare
required in contact of contact of cost per
Store Supplier 1 Supplier 2 unit on
delivery

DEMEWOZ CONSULTANCY
7
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

4. TOOLS
Discuss the tools required by every member of O and M staff. Draw up a
list. Tools can be kept in the store room or officially issued to the
appropriate Water Administration Office/ WASHCO.
Sample Tool List

Tools Purposes

1. Tool box Storing tools

2. Wooden float Masonry work

3. Steel float
4. Plastering trowel
5. Masonry trowel
6. Spirit level
7. Masonry hammer
8. Shovel
9. Steel brush For GI (Galvanized Iron) pipe
10. Die-stock work
11. Joining compound
12. Pipe cutter
13. Chain spanner
14. Pipe wrenches
15. Pipe vice
16. Oil can
17. Heating plate For PVC and HDPE pipe work
18. Pocket-knife
19. File
20. Welding machine
21. Measuring tape Multi-purpose tasks
22. Hacksaw
23. Pliers
24. Sisal fibre

See Attachment 1-3: Essential tools for maintenance of water supply

systems.

5. Technical Assistance and Services

Discuss with the participants how and from whom additional technical
assistance should be obtained (e.g., Woreda Water Office, Zone Water
Office, Regional Water Bureau, NGOs operating in the vicinity, private
company etc).
This information should be established before there is an emergency.
Technical assistance includes the services that are sourced from time to
time or those individuals or offices to be contacted in case of a system

DEMEWOZ CONSULTANCY
8
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

breakdown. Draw up a list similar to the one shown below.

Name of Contact Back-up Contact
Component
Technical details for
details contact
assistant back-up
Pump
Repair

Generator
Repair

Electrician

Water
Quality

Attachments

Attachment 1-1: Water sources from rural area RPS distribution

Attachment 1-2: Water sources from urban area RPS distribution

DEMEWOZ CONSULTANCY
9
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Attachment 1-3: Essential tools for maintenance of water supply

systems

DEMEWOZ CONSULTANCY
10
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

DEMEWOZ CONSULTANCY
11
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

2 SESSION – B: TECHNICAL O&M REQUIREMENTS AT

WATER SOURCES

Module – C TECHNICAL O&M MANAGEMENT REQUIREMENTS FOR

RURAL PIPED SYSTEM

2.1 Session – B1 Boreholes with Submersible Pumps

2.2 Session This session address the following core topics:

Outline  Introduction
 Components of borehole
 Specific O&M Tasks at Borehole
 Troubleshooting for Borehole
 Tools, Spare parts and Technical assistance required

Appropriate Water Engineer or electromechanical engineer or technician with

Facilitator experience on operation and maintenance of boreholes and associated
pumps.

2.3 Objectives of  Participants will be able to identify the different components of the
the Training borehole system including submersible pump
 Participants will have developed an Operation and Maintenance Plan
for borehole and submersible pump.

Output An Operation and Maintenance Plan

Timing Session should take approximately 4 hours

Target Groups The target groups for whom this training manual has developed for Water
Administration Office for RPS and WASHCOs as well as Woreda Water
Offices

Appropriate Any place where existing boreholes are available for practical
Venue demonstration.

Methodology Brainstorming, Group Discussion/ presentation, Role Play, Question &

answer and Site walk for demonstration

Training Materials  Facilitator’s and Participant’s Manuals

 Flipchart, markers, flipchart stand and masking tape
 Computer, LCD Projector

Session Guide and Contents

2.4 Introduction Borehole systems typically include a number of different components.

Most of these components are discussed individually under the sessions

DEMEWOZ CONSULTANCY
1
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

on generators, tanks, public water point and pipelines. This session is

intended to be an INTRODUCTION to Boreholes.

2.5 Step 1: The first activity to be done by the facilitator will be in combination with a
System site walk, ask the participants to identify each component of their borehole
Overview system and discuss the purpose of the component. The following borehole
components are typically found as indicated in Table 2-1:
Table 2-1: Typical Component of Borehole

Item Purpose

Borehole Protected hole which penetrates to the aquifer and

which is filled by water from the aquifer.

Wellhead Prevents surface water from seeping down the edge

of the casing and entering the aquifer or borehole

Borehole Casing prevents the hole from collapsing.

casing

Screens Perforated parts of the casing to allow water from the

aquifer to enter the borehole.

Seal Prevents seepage water from moving from higher

aquifers or near surface to lower aquifers

Submersible Raise water from aquifer to tank. The pump is located

electrical pump in the hole and is protected by the borehole casing

Rising Main Water is raised from the pump to the tank through the
rising main

Dipper tube Dipper tube allows the water level in the borehole to
be measured

Meter Measures volume of water extracted by the borehole

from the aquifer

Pump House Structure which usually contains the control panel. If

the pump in use is an electrical submersible, then the
pump house is also likely to contain the generator or
the circuit board for the mains electricity power

Generator Provides electricity to run the pump. Generator may

(Genset) also be a standby for when mains power is not
available. Generator is driven by a motor/engine
which may be diesel powered

Control panel The control panel is a set of electrical circuits whose

purpose is to control the power to the pump.

Fuel Store A well ventilated and secure store for fuel

Tank Borehole water is typically raised to ground or

elevated tank from which water is distributed to the
DEMEWOZ CONSULTANCY
2
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

consumer points

The facilitator explains the borehole components with the aid of figure in
attachment – 1 below.

2.6 Step 2: O & M Discuss the tasks relevant to the operations and maintenance of the
tasks specific system components. Note that specific sessions have been provided for
to Boreholes generators, solar-voltaic powered systems, wind pumps, tanks, and public
water points.

Box 2-1: Borehole O&M Tasks

Tasks may include:
 Check pump house and fuel store structures for defects and
repair as required.
 Sweep and clean pump house;
 Read and record current to pump;
 Read and record voltage to pump;
 Read and record electricity meter reading (daily);
 Read and record water meter readings (daily);
 If no meter, measure discharge from borehole using either a
bucket and stopwatch or recording the time to fill the
storage tank (remember to close all outlets to the tank);
 Calculate the power production ratio on a monthly basis
(m3/Kw-hr). This is the water quantity produced by one KW-
Hr. A reduction in the ratio indicates that the pump is not
working efficiently or there is increasing resistance in the
rising main; Use the format in Annex for practical
demonstration;
 Once per year, take a 2 litre water sample (use a clean
drinking water bottle) and send for chemical analysis.
Changes to the water quality can provide early indication of
borehole or aquifer problems;

2.7 Step 3: Discuss the potential unexpected problems and what might be the cause
Trouble and solution. In general, all remedial action should be taken by skilled and
Shooting qualified staff. Use Table 2-2 below the solution for different causes of
problems.
Table 2-2: Borehole Troubleshooting

DEMEWOZ CONSULTANCY
3
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Problem Probable cause Possible solution

Pump fails to  Broken or loose electric
start connection  Check power source
 Blown fuse- check the  Check switches
installation before  Check fuses
replacing fuses
 Call for Technical
 Motor overload Assistance
 Low voltage
 Damaged supply cable
insulation- check insulation
resistance
 Cable- cable joint or motor
windings may be wet or
earthed
 Impeller plugged (Pump
blocked with sand)
No water  No power to pump  Check power source.
from Check switches
 Pump is faulty and not
borehole
working  Check fuses
 Pump not submerged  Check depth of water in
(pump set too high or borehole
water level has fallen)  Call for Technical
 Pump rotating in the wrong Assistance
direction
 Leak(s) in riser pipe joints
or corroded pipe
 Riser pipe joint threads
corroded and disconnected
 Non-return valve in pump
blocked or corroded
 Valves or discharge line
blocked, damaged or not
full open
 Worn pump due to
pumping sand or other
particles
 Strainer or impellers
blocked with sand or
chemical deposits
 Blocked or damaged
borehole screen
 Pumping head too high for
pump
Pump turns  Excessive drawdown. Call Technical Assistance
on and off to investigate in detail. This
 Capacity of pump exceeds
frequently may require test pumping,
borehole yield so water
level drops below level of monitoring water level in
pump borehole, changing pump,
or lowering pump in

DEMEWOZ CONSULTANCY
4
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

borehole
Pump  Current overload/motor Call Technical Assistance
overload temperature sensor-
switch trips possible causes: blockage,
out insufficient flow of water
over motor, overload due
to mechanical problems,
low voltage
 Under-voltage- Low
voltage on supply system
 Incorrect oil level in
dashpot operated
overloads
 Low-level cut-out –
excessive drawdown
 Incorrectly set overloads-
check settings.
Borehole  Screens are blocked Leaks Call Technical Assistance
delivering in riser pipe to determine whether
less water plunging borehole will
than result in improved yield.
expected Remove riser pipe and
repair/replace
Persistent  Sediments are passing Depending on the nature
case of through the screens of the sediments, the
sediments in sediments may be
borehole damaging to the pump.
water (i.e. not Check water quality
immediately
after
borehole
development)
Water quality  Water in the aquifer is This is a feature of the
is too saline saline aquifer and only surface
treatment of the water
(through reverse osmosis)
can be used to make water
potable

2.8 Step - 4:  See Modules related to pumps, tanks, pipelines and public water points.
Spares, Tools, Technical Assistance – technical assistance should be sought from a
& Technical hydro-geologist (available hydro-geologists at Zone or Region Water
Assistance Bureau) in the event of down borehole problems. A specialised or
electrician is required for generator or electric problems and a specialised
mechanic is required for problems with the motor/engine to the generator.
Borehole rehabilitation requires high skill personnel at Regional and
Zones. The O&M for borehole rehabilitation is found in the main manual.

Review Question  What is a borehole or deep well?

DEMEWOZ CONSULTANCY
5
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

 What does the borehole requires for rehabilitation do?

 What is a submersible pump? How it works?

Attachments Attachment 2-1: Typical Component of Borehole

Minimum of 5 x
Earthed low-level cut-out Non-return
pipe dia.
valve
Power supply from Minimum of 3 x
Pressure
generator Motor starter pipe diameter Gate valve
gauge

Flow meter
Borehole seal & rising
Support of the
main support Rising main pipe
pipe & fittings
Cement grouting

Low-level electrode Cable clip

cable

Supply cable to Dip tube for measuring water levels

motor

Low-level cut-out Minimum ground

electrode water level

Minimum
2m Electric
depth of
submersible pump
water above
set
pump inlet
when
Borehole casing
pumping

Pump shroud: For Gravel packing

submersible pump
installed in a large
diameter borehole
against
overheating

Figure –: Electric submersible borehole

pump

Attachment 2-2: Typical Borehole Water Supply System

DEMEWOZ CONSULTANCY
6
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Typical Submersible Pump

DEMEWOZ CONSULTANCY
7
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

DEMEWOZ CONSULTANCY
8
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

3 SESSION – C: TECHNICAL O&M REQUIREMENTS AT

WATER SOURCES
TECHNICAL O&M MANAGEMENT REQUIREMENTS FOR RURAL
MODULE – C
PIPED SYSTEM
3.1 Session – B2 O&M Requirements for Intakes

3.2 Session This session cover the following core topics:

Outline  Introduction to different water source intakes
 Identification of different intake systems
 Specific O&M Tasks for Intakes
 Troubleshooting for different Intakes
 Preventive Maintenance Checklist
 Spare parts, Tools and Technical Assistance Requirements

Appropriate Technician familiar with the maintenance tasks associated with intakes
Facilitator
background

3.3 Objectives At the end of the session, the participants will be able to:
 Identify the main components of an intake
 Describe the functions of the key components
 Carry out intake maintenance

Output An O & M Schedule

Timing Session should take approximately 4 hours excluding the site walk

Target group Maintenance staff, operator and caretaker of the WASH committee members

Appropriate At the water supply intake

Venue

Methodology This is intended to be a PRACTICAL session. The components will be taught

by demonstration on the system itself. The PowerPoint presentation or flip
chart can be used to illustrate details if necessary. Reinforce the learning by
allowing participants to handle components and describe their functions to
each other.

Materials  Valve key/wheel

 pipe wrench
 Tools – shovel, rake
 Facilitator’s and Participant’s Manuals
 Flipchart, markers, flipchart stand and masking tape
 Computer, LCD Projector

Session Guide and Contents

DEMEWOZ CONSULTANCY
9
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

3.4 Introduction This session covers intakes in general. There are many kinds of intakes and
the facilitator should keep the discussion focused on the intake of the water
supply system in question. Different kinds of intakes include:
 River intakes
 Spring intakes
 Lake intake
 Infiltration gallery

3.5 Step –1: 1. Catchment Area Maintenance

System Discuss why vegetation is important to the catchment area:
Identification
 Vegetation holds soil in place and so reduces erosion/siltation
 Vegetation slows down runoff and helps water to soak into soil
Inspect the catchment area for signs of harmful activities (charcoal burning,
over-grazing, de-forestation, etc). Refer Water Safety Plan Manual for detail.
 Discuss how the catchment area could be improved;
 Discuss which other institutions should be alerted in regard to
catchment degradation and lobbied for collective action.
Note: Water point that rely on a catchment that extends beyond the
boundary of the community will need to recognise that catchment
conservation activities require a multi-stakeholder approach and should link
up or form a Zonal or Woreda offices to develop a platform for collective
action on catchment conservation.
2. Intake Components
Table 2-1 below explains the components of intake and the Facilitator
explain to the participants the function of each component.
Table 3-1: Typical Intake Components

Component Function

Catchment Surface area where water flows towards the source

Area

Source Where the water originates – e.g. spring, river

Intake The structure to abstract the water from the source

Intake Collects water from the source

chamber

Valve chamber Protects the control valve

Weir (river Wall that regulates the level of the river

intake)

Infiltration Perforated pipe and filter material that enables water

gallery to enter pipe and be channelled to the sump

DEMEWOZ CONSULTANCY
10
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Sump Collection chamber from which water is drawn

Screen/ Sieves objects entering the pipeline

strainer

Washout Pipe and valve that is opened to allow cleaning of the

chamber

Perimeter Boundary to stop livestock & children from entering

Fence source area

Compensation Pipe at the bottom of the intake weir to allow for

pipe downstream flow regardless of level of water above
weir

Refer attachment for explaining the components of different type of intakes.

3.6 Step – 2: Discuss the tasks relevant to the operations and maintenance of the system
Intake components. These may include:
Specific O &  Patrol catchment area for damage/harmful activities;
M tasks
 Report catchment degradation to Woreda Water Office;
 Patrol perimeter fence and repair;
 Clear weir wall and screens of any debris;
 Check walls or supports for any damage, undercutting, bypassing and
repair;
 Any gate or sluice should be examined every month to ensure that
they are in working order.
 After flood flows the banks and bed of the river adjacent to the intakes
should be examined for signs of erosion. Any scouring or erosion
should be repaired immediately.
 Open washout on weir wall and remove accumulated silt;
 Open washouts to clear out silt from chambers;
 Clear screen of any material and replace if damaged;
 Disinfect spring box if someone has entered;
 Read master meter.
3.6.1 Spring Intake
3.6.1.1 Components of Spring Chamber
In most cases the water sources for water supply for rural community is
spring, so that the facilitator first explains the various component of the
spring chamber as described in Figure 3.1 and 3.2.
Figure 3-1: Schematic Section of Spring Development with Spring Box

DEMEWOZ CONSULTANCY
11
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Compacted clayey Minimum

soil static water
Ventilation
Manhole level

Overflow pipe

Pervious formation
Outlet
Gravel
pipe
pack Drainage
ditch

Impervious
stratum
Dry masonry Drainage pipe
wall
Figure 3-2: Schematic Plan of Spring Development with Spring Box

Surface water diversion

ditch

Ventilatio Manhole Drainage

n pipe
Drainage ditch

Wing
walls Outlet pipes

Dry masonry wall

3.6.1.2 O&M Task at Spring Chamber

The following tasks are needed to be carried out as routine activities by
WASHCO or Water Administration to use the spring for long time without
depleting and contaminating.
 The spring should be protected from surface water pollution by
constructing a deep diverting ditch,
 The spring and collecting basin should have a water tight top,
preferably concrete,
 Access and inspection manholes, when provided, should be tightly
fitted and kept locked,
 Drainage ditches intended to keep surface water away from the
spring should always be clear,
 When there is a distinctive wet and dry season the ditches should be
cleared of any rubbish or vegetation before the first rains are due. Any
overflow channel should also be cleared eliminate to the possibility of
water backing-up.
 The collecting chamber should be inspected at least once a month to
check whether cleaning is necessary. Depending upon the origin of
the spring and the collecting chamber constriction it will be necessary
to empty and clean out the chamber at regular intervals. The walls

DEMEWOZ CONSULTANCY
12
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

should then be scrubbed down with a solution of bleaching powder

giving chlorine strength of at least 50 ppm,
 A vegetation should be kept clear of the spring,
 Stock should be kept at a distance by means of a fence or wall. The
fence and the wall shall be kept in good repair,
 Periodic bacteriological examination should be conducted and the
water disinfected,
 Water should be withdrawn only through a pipe by natural flow or by
pumping; dipping or bailing should be prevented.
Routine Inspection to be carried out:
 Check the general condition. Are there cracks in the concrete or
signs of leaks?
 Is there wet ground around the spring box? This may indicate a leak.
 Is water flowing out of the overflow pipe? If so this may indicate a
blocked outlet pipe.
 Is there stagnant water around the spring box? If so proper drainage
must be provided,
 Is the spring box having algae? If so clean and disinfect the spring
box
 Is the spring box properly protected from external pollutants? If so
properly protect the spring box.
 Open the manhole cover and look inside. Does it look clean and in
good condition? Is there anything in there such as leaves, sticks or
other vegetation?
The Facilitator should summarize the O&M tasks schedule, materials and
equipment requires as indicated in Table 3-2.

Table 3-2: Summary of O&M Tasks for Spring Protection

Activity How Often Who by Materials & Tools &
Spare Parts Equipment
Clean Spring Weekly Community Broom, bucket,
surroundings hoe, machete
Repair fence Monthly Caretakers & Wood, rope, Machete, axe,
and clean Community wire knife, hoe,
surface drains (as spade, pickaxe
necessary)
Repair pipes As needed Water Supply Spare pipes, Bucket, trowel,
and taps Service valves, joints, spanner
Office/Careta taps, (wrench), flat
ker washers, spanners
cement,
sand, gravel
Check water Monthly Water Supply Bucket, watch
quantity Service
Office
Check water After each Water Supply
turbidity heavy rain Service
or flood Office/Careta
ker

DEMEWOZ CONSULTANCY
13
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Check water Annually or Zone &/or Laboratory Laboratory

quality after repair Woreda supplies
Wash and Annually or Water Supply Chlorine Bucket, wrench,
disinfect after repair Service brush
spring Office/Careta
ker
Repair faucets When the Water Supply Spare faucet Wrench
need arises Service and thread.
Office/Careta
ker
Repair cracks When the Water Supply Cement, sand Bucket, trowel,
need arises Service gravel hoe, spade,
Office/Careta wheel barrow
ker

3.6.1.3 Troubleshooting for Spring Intake

Explain the causes and the solution for unexpected problem at spring intakes
as presented in Table 3.3.
Table 3-3: Troubleshooting for Spring Intake
No. Problem Probable Cause Possible Solution
1 Leaking gate Worn out valve Replace stuffing box
valve packing in gate valve or
replace entire valve

2 No/ little water Inlet pipe blocked Inspect source and

flowing into intake unblock pipe
chamber
3 Overflow from  Gate valve blocked  Remove and clear
intake chamber Blockage in valve (replace if
pipeline (e.g. necessary)
airlock)  Check/open nearest air
 Damaged strainer  Valve Replace strainer
Clogged strainer  Clean strainer
4 Dirty water Silt in chamber Clean out chamber

3.6.2 River and Lake Intakes

The facilitator should first describe the various river intake components as
presented in Table 3-1 above.
3.6.2.1 Troubleshooting for River Intake
Table 3.4 present the problems, potential causes and solutions for the river
intake with weir wall or sump. The facilitator explains the troubleshooting
using Table 3.4 below.
Table 3-4: Troubleshooting for River Intake with Weir or Sump
No. Problem Probable Cause Possible Solution
1 No/ little water Screens on inlet Clean screens
flowing into chamber clogged
intake chamber
or sump
2 Erosion around Insufficient height of Construct or raise wing
side of weir wall wing and cut off walls and cut off walls to

DEMEWOZ CONSULTANCY
14
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

to prevent flow around prevent flow around weir

the weir
3 Undercutting of Excessively turbulent Provide protected apron
weir flow over weir wall and (Concrete, grouted rip
wall on insufficient width of rap, etc) at toe of weir
downstream downstream apron wall or around base of
toe or sump.
undercutting of
sump
4 Dirty water  Excessive  Clean out sediments
sediments upstream from area immediately
of weir wall  upstream of weir
 Silt in intake  Clean out chamber
chamber or sump Protect catchment from
severe erosion.

3.6.3 Impounding Reservoirs

A dam impounding water is another type of source where operational staff
can also undertake the activities, which is strictly maintenance type of
work.
All matter likely to affect the quality of the water should be cleared form the
reservoir site, particularly vegetation that on decay might cause
unpleasant tastes and odours in the water.
The catchments area should be kept free from cattle and should be
guarded also against trespassers who might cause any pollution.

Discuss the components of embankment dam.

Table 3-5: Components of Impounding Reservoir
No. Items Purposes

1 Catchment Area Area above the source where rain falls and the
runoff comes from

2 Source Where water is taken from, e.g. river or stream

3 Inlet channel A channel that conveys water from the source

and puts it into the dam

4 Pan Wall of excavated material

Embankment

5 Dam Wall that is built and compacted to hold the

Embankment water

6 Storage area The volume that is filled with water

7 Spillway sill Wall in the spillway to control top water level

8 Spillway channel Channel to safely discharge excess water to

water course or away from the dam/pan

DEMEWOZ CONSULTANCY
15
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

9 Outlet/draw-off Pipe-work to take water out of the dam

10 Perimeter fence Constructed to prevent livestock, wild animals

and children from entering the dam/pan area
and contaminating the water

3.6.3.1 Catchment Area Maintenance

Where does the silt come from? Which part of the catchment contributes the
most silt and why? Are soil erosion features (e.g. gullies), exposed roots of
bushes and trees, etc) visible?
Inspect the catchment area for signs of harmful activities (charcoal burning,
over-grazing etc). The catchment area could be improved through proper
watershed management such as terracing, check dam, gabion, a forestation,
etc activities over the catchment area. Such issues well discussed in Water
Supply Safety Plan of the point source manual.
3.6.3.2 O&M tasks for Catchment area
 Patrol perimeter fence and repair,
 Clear bush from and repair inlet channel (an eroded inlet channel can
become the main watercourse),
 Inspect and de-silt silt trap(s) and inlet channels
 De-silt pan before top water level reaches embankment (Note: inlet
channel needs to be blocked during de-silting)
 Clear bush from spillway
 Check spillway sill for damage and repair as necessary
 Check spillway channel for signs of erosion and take steps to prevent
erosion by improving grass cover, stone pitching, spreading flow in the
channel by building horizontal sill(s)
 Check dam embankment for cracks and erosion and repair
 Check dam embankment for tree or bush growth and remove, improve
grass cover on embankment
 Check downstream side and toe of dam wall for leaks.
 Open and close all outlet valves once a month
 Monitor leakage from dam
 Check for rodents nesting in embankment and remove
 Read meter to monitor abstraction from dam
 Read staff gauge to establish water level.
3.6.3.3 Trouble shooting for Impounding Reservoir
The following are potential unexpected problems and what might be the
cause and solutions for impounding reservoir.
Table 3-6: Trouble Shooting for Impounding Reservoir
No. Problem Probable cause Possible solution
Leakage Poor design and Monitor leakage
1
along toe of construction
dam wall
Water does Reservoir area has Remove silt from reservoir
2
not last long accumulated a area Reduce erosion in

DEMEWOZ CONSULTANCY
16
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

after end of significant amount catchment area. Apply and

rains of silt, Erosion of mix in clay, preferably
catchment area, bentonite clay to
Excessive seepage impoundment area
due to pervious soil
in reservoir area
No water from Outlet pipe blocked Clear blockage at mouth of
3
outlet draw off pipe. ; Protect pipe
by placing ballast surround
to mouth of draw off pipe;
Note a blocked pipe through
a dam can be very difficult to
unblock. Do NOT remove
the pipe
Polluted water Livestock in Fence pan/dam Control
4
dam/pan access; discourage open
Contamination from defecation in the catchment
catchment area

Excessive High nutrient Address source of nutrients,

5
weed concentration in possibly by controlling
growth water access to dam/pan or
catchment area by livestock

3.7 Preventive The following PM checklists are based on the information obtained from the
Maintenance existing manufacturer's operation and maintenance manuals. It provides
Checklist instructions for inspecting, cleaning, lubricating and adjusting equipment
used in different water supply systems.
Table 3-7: Preventive Maintenance Checklist for Water Sources
Facilities
No. PM Checklists D W M Q S A
1 Boreholes
1.1 Record time and rate of pumping
1.2 Measure water levels and draw
down and keep record
1.3 Take water samples for chemical
analysis
1.4 Make sure that concrete apron
around the well is water tight.
Make the necessary minor repairs.
1.5 Clean well, screen and gravel
packing, when required (by
qualified personnel only)
1.6 Keep a running tabulation of
pumping
1.7 Test yield of borehole
2 Springs
2.1 Inspect sanitation conditions

DEMEWOZ CONSULTANCY
17
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

2.2 Check concrete structure for

cracks
2.3 Check the manhole cover is well
secured and tight
2.4 Check concrete structure and steel
parts repair if required
2.5 Clean sediment and disinfect
spring box
2.6 Check that spring is suitably
protected from surface water
pollution
2.7 Take water samples for analysis

3 Lake and River Intakes

3.1 Check the Water Quantity and
Quality Regularly
3.2 Check the depth of the Lake and
estimate the amount of silt flowing
in
3.3 Examine intake opening and
screen, clean vegetation and
remove silt, leaves and debris
4 Dams and Impounding
Reservoirs
4.1 Inspect spill way clean as
necessary
4.2 Inspect concrete and masonry
dam for leakage and make repairs
4.3 Inspect slopes and repair and
erosion
4.4 Inspect water shed and clean as
necessary
4.5 Inspect for algae and aquatic
weeds and take measures as
necessary
4.6 Inspect sediment flowing into the
water storage and take necessary
measures
4.7 Take water samples and send for
analysis
4.8 Inspect fences, and repair

Attachment Attachment 3-1: Typical Spring Intake

DEMEWOZ CONSULTANCY
18
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Attachment 3-2: Typical River Intake with Weir Wall and Sump

Attachment 3-3: Typical Embankment Dam

DEMEWOZ CONSULTANCY
19
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Workout exercises how to record the condition of spring chamber on monthly check sheet.

DEMEWOZ CONSULTANCY
20
Ministry of Water, Irrigation and Electricity Training Module For
Rural Piped System Operation and Maintenance Management Technical O&M Requirements

Monthly Check sheet for spring Type-1

Site Name: Technician/Plumber Name

Date Facility Work Condition Crack Leak/Broken Wet Clean Drainage Overflow Pipe Valve Remark
Check In case of “Non- Yes/No Yes/No Ground in/outside Ok Ok Ok Ok
Functioning Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No
When When
Stop Repair
Functioning/
Spring Box
Non---functioning
Functioning/
Tap Non---functioning
Functioning/
Spring Box
Non---functioning
Functioning/
Tap
Non---functioning
Functioning/
Spring Box
Non---functioning
Functioning/
Tap
Non---functioning
Functioning/
Spring Box
Non---functioning
Functioning/
Tap
Non---functioning

DEMEWOZ CONSULTANCY
21
Ministry of Water, Irrigation and Electricity Training Module For
Rural Piped System Operation and Maintenance Management Technical O&M Requirements

Monthly Check sheet for spring Type-2

Site Name: Technician/Plumber Name

Date Facility Work Condition Crack Leak/Broken Wet Clean Drainage Overflow Pipe Valve Remark
Check In case of “Non- Yes/No Yes/No Ground in/outside Ok Ok Ok Ok
Functioning Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No
When When
Stop Repair
Spring Box Functioning/Non---
Tapstand- Functioning/Non---
No.1
Tapstand- Functioning/Non---
No.2
Spring Box Functioning/Non---
Tapstand- Functioning/Non---
No.1
Tapstand- Functioning/Non---
No.2
Spring Box Functioning/Non---
Tapstand- Functioning/Non---
No.1
Tapstand- Functioning/Non---
No.2

DEMEWOZ CONSULTANCY
22
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Daily Water Production Record

Month: ______________ Name of Operator: _________________________

Year: _______________ Borehole/Spring No. _____________

Day Meter reading Water Day Meter reading Water

Start End Production Start End Production
(m3/day) (m3/day)
1 16

2 17

3 18

4 19

5 20

6 21

7 22

8 23

9 24

10 25

11 26

12 27

13 28

14 29

15 30

Total Water Production (m3/month)

Checked by: ____________________

Signature: ______________________

Date: __________________________

DEMEWOZ CONSULTANCY
23
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Daily Water Distribution Record

Month: ______________ Name of Operator: _________________________

Year: _______________ Reservoir Name: __________________________

This data measured at the outlet of the reservoir

Day Meter reading Water Day Meter reading Water
Start End Distributed Start End Distributed
(m3/day) (m3/day)
1 16

2 17

3 18

4 19

5 20

6 21

7 22

8 23

9 24

10 25

11 26

12 27

13 28

14 29

15 30

Total Water Distributed (m3/month)

Checked by: ____________________

Signature: ______________________

Date: __________________________

DEMEWOZ CONSULTANCY
24
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

4 SESSION – D: O&M REQUIREMENT

FOR ELECTRO – MECHANICAL
EQUIPMENT
MODULE – C TECHNICAL OPERATION AND MAINTENANCE REQUIREMENTS
FOR RURAL PIPED SYSTEM

4.1 Session Outline This session covers the following core topics:
 Introduction to Electro-mechanical Equipment
 Identification of different components at pumping station
 Defining some important terms
 Types of Pumps and Generators
 Brands of Pumps and Generators exist in Ethiopia
 Important consideration in operation of E-M Equipment
 Preventative Maintenance requirements for E-M Equipment
 O&M tasks for driving Equipment
 Facilities required for maintenance and repair works
 Troubleshooting for E-M Equipment
 Safety Rule

Appropriate Appropriate trainer for this session shall be Electro-mechanical Engineer

Facilitator with a very good theoretical and practical background and experience.

4.2 Objective At the end of this session training participants will be able to:
 Understand different components of pumping station and equipment;
 Acquire knowledge on pump operation and maintenance as well as
preventive maintenance
 Understand different type of pumps
 Identify the roll of pump and generator

Outputs Familiarization with those instruments and equipment

Timing Approximately 32 hours

Target Group Mechanics and Technicians

Methodology  Observation of components

 Conducting practical training
 Group work
 Short presentations/question and answer

Materials  Manuals
 Practical demonstration of components;

DEMEWOZ CONSULTANCY
25
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

 Flip Charts and marker pens;

 Dented parts etc

Session Guide and Contents

4.3 Introduction Pumping equipment and pumping station are very important components in
water supply system. Pumping machinery is subjected to wear, tear,
erosion and corrosion due to their nature of functioning and therefore is
vulnerable for failures. Generally, more number of failures or interruptions
in water supply is attributed to pumping equipment than any other
component. Therefore, correct operation and timely maintenance and
upkeep of pumping stations and pumping machinery are of vital importance
to ensure uninterrupted water supply.
Sudden failures can be avoided by timely inspection, follow up actions on
observations of inspection and planned periodical maintenance. Downtime
can be reduced by maintaining inventory of fast moving spare parts.
Efficiency of pumping machinery reduces due to normal wear and tear.
Timely action for restoration of efficiency can keep energy bill within
reasonable optimum limit. Proper record keeping is also very important.
Obviously due attention needs to be paid to all such aspects for efficient
and reliable functioning of pumping machinery. This session discusses
procedures for operation and maintenance and addresses pertinent issues
involved in O&M of pumping equipment.
This part of the manual deals with the operation and maintenance
requirements for pumping equipment, driving equipment, pumping station
and ancillary equipment.

4.4 Component in Components in pumping station are divided in to three groups: 1) Pumping
Pumping Station Equipment, 2) Ancillary Equipment and 3) Pumping station.
The Facilitator explains these three component as:
4.4.1 Pumping Equipment
These are:

Pumps and other mechanical equipment, i.e. valves, pipe work,
vacuum pumps
 Motors, switchgears, cable, transformer and other electrical
accessories.
When do use pumps?
i) When water must be raised from one level to another,
ii) When the pressure in the main must be increased,
iii) When the elevation of the source is such that water will not flow by
gravity into the tank.
4.4.2 Ancillary Equipment
These are equipment to use for installation, dismantling, flow control and
generation etc.
 Lifting equipment,
 Water hammer control device,
 Flow meter,

DEMEWOZ CONSULTANCY
26
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

 Diesel generating set,

4.4.3 Pumping Station
 Sump/intake/well/borehole,
 Pump house,
 Screen,
 Gate/Valve

4.5 Definition The facilitator explains important definition of pump terms as:

No. Term Definition

1 Submersible For deep-well applications, centrifugal pumps

Pump are housed with the electric engine in a single
unit that is designed to be submerged.
Usually, a multiple-stage pump is used. The
multiple-stage pump is placed above a motor
and under a check valve that leads to the
rising main.

2 Horizontal Horizontal Centrifugal pumps are that the

Centrifugal pump is drive by a horizontal shaft and
Pumps commonly used for low and high service to lift
and transport water. The two essential parts of
a centrifugal pump are rotating membrane with
vanes and the impeller and surrounding case.

3 Horizontal All the definitions used above for horizontal

Centrifugal centrifugal pumps are relevant to pumps
Pumps operating vertically. The pump is driven by a
vertical shaft, which is usually coupled, to a
driving unit above floor level.
Pumps commonly used in such installations
are:
 Vertical enclosed- shaft pump
 Vertical opened-shaft pump
The suction pipe is usually connected to a wet
well (wet pit) structure, which means that the
location of the pump is almost lower than wet
well water level and suction pressure is
positive.

4 Booster Pump Booster pumps are pumps which take water

from a supply main and discharge it at a
higher pressure to another point in the same
pipeline, and are also used to increase
pipeline pressure in outlying areas when loss
of head is too great along the line. They may
operate in conjunction with filling of elevated
storage tanks.
For a very long pipeline or for large elevation
difference between the entry and exit points,

DEMEWOZ CONSULTANCY
27
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

the pumping head is excessive and pipes

withstanding such a high pressure may not be
available, or the provision of high-pressure
pipes may be uneconomical. In such a case,
instead of providing a single pumping station,
it is desirable to provide a number of pumping
stations.

4.6 Types of Pump Explain the types of pumps used for water supply system with practical
demonstration including their difference and similarity.
The types of the pumps mainly are:
1. Centrifugal pumps
2. Vertical turbine pumps
 Oil lubricated
 Self water (pumped water) lubricated
 Clear water lubricated
3. Submersible pumps
 Vertical borewell type pump-motor
set
 Monobloc open well type pump-motor
set
4. Jet pumps
5. Reciprocating pumps
Surface water pumps mainly consist of:
Submersible Pumps
(i) Horizontal centrifugal pumps
(ii) Vertical centrifugal pumps
(iii) Vertical submersible motor pumps

4.6.1 Potential Problems

4.6.1.1 Submersible Pumps
The facilitator explains the potential problems that could be happen at
submersible pump. Identifying the problems helps to indicate the solution
1. sand or other particles may enter the pump and cause abrasion
damage,
2. the rising main may corrode due to poor water quality,
3. the pipeline system can be damaged by the severe pressure surges
that result when the pump is started or stopped abruptly,
4. The main limitations of a submersible centrifugal pump are its price, the
need to maintain a reliable supply of electricity or fuel, and the high
level of technology involved.

4.7 Brands of The training facilitator should brief the available brands of pumps and
Pumps and Generators mostly used for water supply system in Ethiopia.
Generators

DEMEWOZ CONSULTANCY
28
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

under operation 4.7.1 Submersible Pumps

in Ethiopia The following submersible brand pumps are available in the Country. Each
of these pumps has merit and demerit based on the specification. Discuss
with the participants.

Lowara CMS Frankline

Grundfos Stac TATA

Caprari Pleuger

4.7.2 Surface Pumps

The following surface pumps are existing in Ethiopia which are used by
many water utilities.

KSB Cimonath Hydraulic Ram

Caprari CMS TATA

Rovatti

4.7.3 Engine and Alternators (generators)

The following generators brands are existing in Ethiopia which is used by
many water utilities.
Engine Alternator
Lister Lister
Deutz Mecc alte
Sun Marelli
Lombardini Linz
Daewoo
Johndeer
Perkins
Fiat
Sleunz
Kelesker

4.8 Important Points The training facilitator should describe to the trainee operators very
in Pump important points to be considered during the operation of pump to minimize
Operation risk and breakdown. Explain using the graph for pump characteristic curve.
a) Dry running of the pumps should be avoided,
b) Centrifugal pumps have to be primed before starting,

DEMEWOZ CONSULTANCY
29
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

c) Pumps should be operated only within the recommended range on the

head-discharge characteristics of the pump,
 If pump is operated at point away from duty point, the pump
efficiency normally reduces.
 Operation near the shut off should be avoided, as the operation
near the shut off causes substantial recirculation within the pump,
resulting in overheating of water in the casing and consequently, in
overheating of the pump.
d) Voltage during operation of pump-motor set should be within + 10% of
rated voltage. Similarly
current should be below
the rated current as per
name plate on the
motor.
e) Whether the delivery
valve should be opened
or closed at the time of
starting should be
decided by examining
shape of the power-
discharge characteristic
of the pump.
Pump of low and medium specific speeds draw lesser power at shut off
head and power required increases from shut off to normal operating
point. Hence in order to reduce starting load on motor, a pump of low or
medium specific speed is started against closed delivery valve.
Normally the pumps used in water supply schemes are of low and
medium specific speeds. Hence, such pumps need to be started
against closed delivery valve.
The pumps of high specific speed draw more power at shut off. Such
pumps should be started with the delivery valve open.
f) The delivery valve should be operated gradually to avoid sudden
change in flow velocity which can cause water hammer pressures.
It is also necessary to control opening of delivery valve during pipeline -
filling period so that the head on the pump is within its operating range
to avoid operation on low head and consequent overloading. This is
particularly important during charging of the pumping main initially or
after shutdown. As head increases the valve shall be gradually opened.
g) When the pumps are to be operated in parallel, the pumps should be
started and stopped with a time lag between two pumps to restrict
change of flow velocity to minimum and to restrict the dip in voltage in
incoming feeder. The time lag should be adequate to allow to stabilize
the head on the pump, as indicated by a pressure gauge.
h) When the pumps are to be operated in series, they should be started
and stopped sequentially, but with minimum time lag. Any pump, next in
sequence should be started immediately after the delivery valve of the
previous pump is even partly opened.
Due care should be taken to keep the air vent of the pump next in
sequence open, before starting that pump.

DEMEWOZ CONSULTANCY
30
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

i) The stuffing box should let a drip of leakage to ensure that no air is
passing into the pump and that the packing is getting adequate water
for cooling and lubrication. When the stuffing box is grease sealed,
adequate refill of the grease should be maintained.
j) The running of the duty pumps and the standby should be scheduled so
that no pump remains idle for long period and all pumps are in ready-to
run condition. Similarly unequal running should be ensured so that all
pumps do not wear equally and become due for overhaul
simultaneously.
k) If any undue vibration or noise is noticed, the pump should be stopped
immediately and cause for vibration or noise be checked and rectified.
l) Bypass valves of all reflux valve, sluice valve and butterfly valve shall
be kept in closed position during normal operation of the pumps.
Frequent starting and stopping should be avoided as each start causes
overloading of motor, starter, contactor and contacts. Though
overloading lasts for a few seconds, it reduces life of the equipment.
4.8.1 Inspection before starting up of pumps
The facilitator expalin what checks should be carried out before staring
up the pumps by the operators in regular manner.

Box 4-1: Things to be checked when staring the pump

operation
Following points should be checked before starting the
pump.
 Power is available in all 3 phases,
 Trip circuit for relays is in healthy state
 Check voltage in all 3 phases,
 The voltage in all phases should be almost same and within
+ 10% of rated voltage, as per permissible voltage variation,
 Check functioning of lubrication system specifically for oil
lubricated and clear water lubricated VT pumps and oil
lubricated bearings,
 Check stuffing box to ensure that it is packed properly,
 Check and ensure that the pump is free to rotate,
 Check over current setting if the pump is not operated for a
week or longer period,
 Before starting it shall be ensured that the water level in the
sump/intake is above low water level and inflow from the
source or preceding pumping station is adequate.

DEMEWOZ CONSULTANCY
31
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

4.8.2 Inspection REQUIREMENTs during staring and Operation

of Pumps
The operators should inspect the pumps during starting and operation in
regular manner.
The following procedures shall be explained to the trainees for starting and
operation of different types of pumps are described below:
4.8.2.1 Centrifugal Pump (low and medium specific speed)
i) To start a centrifugal pump, the suction pipes and the pump should
be fully primed irrespective of the fact whether the pump is with
positive (flooded) suction or suction lift.
 The centrifugal pump with positive suction can be primed by
opening valve on suction side and letting out air from the casing
by opening air vent.
 Centrifugal pump on suction lift necessitates close attention to
prime the pump fully.
o To achieve this, the suction pipe and the pump casing must
be filled with water and entire air in suction piping and the
pump must be removed. If vacuum pump is provided, the
pump can be primed by operating vacuum pump till steady
stream of water is let out from delivery of vacuum pump. In
absence of vacuum pump, priming can be done by pouring
water in casing and evacuating air through air vent or by
admitting water from pumping main by opening bypass of
reflux valve and delivery valve. Check all joints in the suction
pipe and fittings.
ii) Close the delivery valve and then loosen slightly.
iii) Switch on the motor, check that direction of rotation is correct. If the
pump does not rotate, it should be switched off immediately.
iv) Check vacuum gauge, if the pump operates on suction lift. If the
pointer on gauge gradually rises and becomes steady the priming is
proper.
v) Pressure gauge should be observed after starting the pump. If the
pump is working correctly, the delivery pressure gauge should rise
steadily to shut off head.
vi) When the motor attains steady speed and pressure gauge becomes
steady, the delivery valve should be gradually opened in steps to
ensure that the head does not drop below recommended limit. (In
the absence of recommendations, the limit shall be about 85% of
duty head for centrifugal pump).
vii) Check that ammeter reading is less than rated motor current.
viii) Check for undue vibration and noise.
ix) When in operation for about 10-15 minutes, check the bearing
temperature, stuffing box packing, and leakage through mechanical
seal and observe vibrations, if any.
x) Voltage should be checked every half an hour and should be within
limit.

DEMEWOZ CONSULTANCY
32
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

4.8.2.2 Vertical Turbine Pump (of low and medium specific

speed)
i) Close delivery valve, and then loosen slightly.
ii) If pump is oil-lubricated, check the oil in the oil tank and open the
cock to ensure that oil is flowing at the rate of 2-4 drops per minute.
o If the pump is self water-lubricated and length of column
assembly is long (15m or above), external water shall be
admitted to wet and lubricate the line shaft bearings before
starting the pump.
o If the pump is external clear water lubricated, the clear water
lubricating pump should be started before starting main pump.
iii) Open the air vent in discharge/delivery pipe.
iv) Switch on the motor and check correctness of direction of rotation. If
the pump does not rotate, it should be switched off immediately.
v) Check that oil is flowing into the pump through the sight glass tube.
The number of drops/min. should be as per manufacturer’s
recommendations (normally 2-4 drops/minute).
o For clear water lubricated pump, check that lubricating clear
water is passing into the column assembly.
vi) Check pressure gauge reading to ensure that pump has built up the
required shut off head.
vii) When the motor attains steady speed and pressure gauge becomes
steady, the delivery valve should be gradually opened in steps to
ensure that the head does not drop below recommended limit. (In
absence of recommendation, the limit shall about 75% of duty head
for VT & submersible pump).
viii) If steady water stream is let out through air vent, close the air vent.
ix) Check that ammeter reading is less than rated motor current.
x) Check for undue vibration and noise.
xi) When in operation for about 10-15 minutes, check bearing
temperature, stuffing box packing and observe vibration if any.
xii) Voltage should be checked every half an hour and should be within
limit.
4.8.2.3 Submersible Pumps
Starting of a submersible pump is similar to vertical turbine pump
except that steps- ii, v, and xi are not applicable and since motor is not
visible, correctness of direction of rotation is judged from pressure
gauge reading which should indicate correct shut off head.
4.8.2.4 Jet Pump
The procedure for starting jet pumps is similar to centrifugal pump
except that priming by vacuum pump is not possible. Priming needs to
be done by filling the pump casing and suction line from external source
or by pouring water.
4.8.2.5 Vacuum Pump

DEMEWOZ CONSULTANCY
33
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

The procedure for starting vacuum pump is similar to centrifugal pump

except that priming is not necessary and valves on both suction &
delivery side of vacuum pump should be fully open.
4.8.2.6 Reciprocating Pump
The steps stipulated for centrifugal pump are equally applicable for
reciprocating pump. However exceptions as follows are applicable.
 The pump should be started against partially open delivery valve.
 The pump should never be started or operated against closed
delivery valve.
4.8.3 Inspection Requirement during stopping of pumps
The training facilitator explains the steps to be followed for stopping a
pump of low and medium specific speed as follows in normal and power
failure/tripping conditions.
4.8.3.1 At Normal Condition

Box 4-2: Things to be checked when stopping the pump

operation
i) Close the delivery valve gradually (sudden or fast closing should
not be resorted to, which can give rise to water hammer
pressures).
ii) Switch off the motor.
iii) Open the air vent in case of V.T. and submersible pump.
iv) Stop lubricating oil or clear water supply in case of oil lubricated
or clear water lubricated VT pump as applicable.
4.8.3.2 Stopping after Power Failure/Tipping

Explanation note to the Training Facilitator

If power supply to the pumping station fails or trips, actions stated below
should be immediately taken to ensure that the pumps do not restart
automatically on resumption of power supply. Though no-volt release or
under volt relay is provided in starter and breaker, possibility of its
malfunctioning and failure to open the circuit cannot be ruled out.
In such eventuality, if the pumps start automatically on resumption of power
supply, there will be sudden increase in flow velocity in the pumping main
causing sudden rise in pressure due to water hammer which may prove
disastrous to the pumping main.
Secondly, due to sudden acceleration of flow in the pumping main from no-
flow situation, acceleration head will be very high and the pumps shall
operate near shut off region during acceleration period which may last for
few minutes for long pumping main and cause overheating of the pump.
Restarting of all pumps simultaneously shall also cause overloading of
electrical system.
Hence, precautions are necessary to prevent auto-restarting on resumption
on power. Following procedure in Box 4-3 should be followed.

Box 4-3: Things

DEMEWOZ to be checked when stopping the pump after
CONSULTANCY
power failure/tripping 34

i) Close all delivery valves on delivery piping of pumps if

necessary, manually as actuators cannot be operated due to
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

4.9 Preventive 4.9.1 General

Maintenance of This section describes what preventive maintenance for pumps is and the
Pumping prevailing effects for unsuccessful preventive maintenance like:
Equipment
Lack of preventive and timely maintenance or poor maintenance can cause
undue wear and tear of fast moving parts, and premature failure of the
equipment.
The shortcomings in maintenance can also result in increase in hydraulic
and power losses and low efficiency. Inefficient running of the pump
increases burden of power cost. Importance of preventive maintenance,
therefore, need not be overstressed.
Appropriate maintenance schedule and procedure need to be prescribed
for all:
 electrical and mechanical equipment based on manufacturers’
recommendations,
 characteristics of the equipment,
 Site and environment conditions i.e. temperature, humidity, dust
condition, etc.
The preventive maintenance schedule shall detail the maintenance to be
carried out at regular intervals i.e. daily, monthly, quarterly, half yearly,
annually etc. or operation hours. The schedule shall also include
inspections, services and tests to be performed at appropriate interval or
periodicity.
General guidelines for maintenance schedules for pumps and associated
electrical and mechanical equipment are enlisted below. The guidelines
should not be considered as total, full-fledged and comprehensive as
characteristics of equipment and site conditions differ from place to place.
4.9.2 Maintenance Schedule for Pumps
Discuss pump maintenance to be carried out on daily, weekly, monthly
quarterly and annually. After identifying the pump maintenance schedule
from the participants, the training facilitator, explain the schedule as
described below.
4.9.2.1 Daily Maintenance

DEMEWOZ CONSULTANCY
35
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Operator should perform the following every day in regular manner.

 Clean the pump, motor and other accessories,
 Check coupling bushes/rubber spider,
 Check stuffing box, gland etc.
4.9.2.2 Routine observations of irregularities
The pump operator should be watchful and should take appropriate action
on any irregularity noticed in the operation of the pumps. Particular
attention should be paid to following irregularities:
1. Changes in sound of running pump and motor,
2. Abrupt changes in bearing temperature,
3. Oil leakage from bearings,
4. Leakage from stuffing box or mechanical seal,
5. Changes in voltage,
6. Changes in current,
7. Changes in vacuum gauge and pressure gauge readings,
8. Sparks or leakage current in motor, starter, switch-gears, cable etc,
9. Overheating of motor, starter, switch gear, cable etc.
a) Record of operations and observations
A log book should be maintained to record the hourly observations, which
should cover the following items:
1. Timings when the pumps are started, operated and stopped during
24 hours,
2. Voltage in all three phases,
3. Current drawn by each pump-motor set and total current drawn at
the installation,
4. Frequency (50Hz),
5. Readings of vacuum and pressure gauges,
6. Motor winding temperature,
7. Bearing temperature for pump and motor,
8. Water level in intake/sump,
9. Flow meter reading,
10. Daily PF over 24 hours duration,
11. Any specific problem or event in the pumping installation or
pumping system e.g. burst in pipeline, tripping or fault, power
failure.
4.9.2.3 Monthly Maintenance
1. Check free movement of the gland of the stuffing box; check gland
packing and replace if necessary,
2. Clean and apply oil to the gland bolts,
3. Inspect the mechanical seal for wear and replacement if

DEMEWOZ CONSULTANCY
36
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

necessary,
4. Check condition of bearing oil and replace or top up if necessary.
4.9.2.4 Quarterly Maintenance
1. Check alignment of the pump and the drive. The pump and motor
shall be decoupled while correcting alignment, and both pump and
motor shafts shall be pushed to either side to eliminate effect of
end play in bearings,
2. Clean oil lubricated bearings and replenish with fresh oil. If
bearings are grease lubricated, the condition of the grease should
be checked and replaced/replenished to the correct quantity. An
anti-friction bearing should have its housing so packed with grease
that the void space in the bearing housing should be between one
third and half. A fully packed housing will overheat the bearing and
will result in reduction of life of the bearing,
3. Tighten the foundation bolts and holding down bolts of pump and
motor mounting on base plate or frame,
4. Check vibration level with instruments if available; otherwise by
observation,
5. Clean flow indicator, other instruments and appurtenances in the
pump house.

4.9.2.5 Annual Inspection and Maintenance

A very thorough, critical inspection and maintenance should be performed
once in a year. Following items should be specifically attended:
1. Clean and flush bearings with kerosene and examine for flaws
developed, if any, e.g. corrosion, wear and scratches. Check end
play. Immediately after cleaning, the bearings should be coated
with oil or grease to prevent ingress of dirt or moisture.
2. Clean bearing housing and examine for flaws, e.g. wear, grooving
etc. Change oil or grease in bearing housing.
3. Examine shaft sleeves for wear or scour and necessary
rectification. If shaft sleeves are not used, shaft at gland packing
should be examined for wear.
4. Check stuffing box, glands, lantern ring, mechanical seal and
rectify if necessary.
5. Check clearances in wearing ring.
Clearances at the wearing rings should be within the limits
recommended by the manufacturer. Excessive clearance reduces
discharge and efficiency of the pump. If the wear is only on one
side, it is indicative of misalignment. The misalignment should be
set right, and the causes of misalignment should be investigated.
6. Check impeller hubs and vane tips for any pitting or erosion,
7. Check interior of volute, casing and diffuser for pitting, erosion, and
rough surface,
8. All vital instruments i.e. pressure gauge, vacuum gauge, ammeter,
voltmeter, wattmeter, frequency meter, tachometer, flow meter etc.

DEMEWOZ CONSULTANCY
37
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

shall be calibrated,
9. Conduct performance test of the pump for discharge, head and
efficiency,
10. Measures for preventing ingress of flood water shall be examined.
Ingress of flood water in sump, well, borehole shall be strictly
prevented. Seal cap shall be provided above borehole.
11. Check vibration level.
4.9.2.6 Overhaul/Service of Pump
It is difficult to specify the periodicity or interval for overhaul in the form of
period of service in months/years or operation hours, as deterioration of
pump depends on nature of service, type of installation i.e. wet pit or dry
pit, quality of water handled, quality of material of construction,
maintenance, experience with particular make & type of pump etc.
However generally, following operational hours may be taken as broad
guidelines for overhauling.
 Submersible pump – 5,000 – 6,000 hours
 Vertical turbine pump – 12,000 hours
 Centrifugal pump – 15,000 hours
4.9.2.7 History Sheet
History sheet of all pumps shall be maintained. The history sheet shall
contain all important particulars, records of all maintenance, repairs,
inspections and tests etc.
It shall generally include the following:
1. Details of the pump, rating, model, characteristic curves,
performance test report etc,
2. Addresses of manufacturer & dealer with phone & fax number and
e-mail addresses,
3. Date of installation and commissioning,
4. Brief details and observations of monthly, quarterly and annual
maintenance and inspections,
5. Details of breakdown, repairs with fault diagnosis, replacement of
major components i.e. impeller, shaft, bearings, wearing rings,
6. Results of annual performance test including discharge and
efficiency,
7. Yearly operation hours of the pumps,
8. Brief findings of energy audit.
4.9.3 Maintenance Schedule for Motors
Like the maintenance schedule for pumps, the same applied for motors as
describe below. First the training facilitator differentiate the pump and
motor and then explain the maintenance requirements on daily, weekly,
monthly and annual basis.
4.9.3.1 Daily Maintenance
The following activities presented in Box-4.4 below shall be carried out as a

DEMEWOZ CONSULTANCY
38
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

daily maintenance of pumping motor:

Box 4-4: Daily Maintenance Tasks for Motor

1. Clean external surface of motor,
2. Examine earth connections and motor leads,
3. Check temperature of motor and check whether
overheated. The permissible maximum temperature is
above the level which can be comfortably felt by hand.
Hence temperature observation should be taken with RTD
or thermometer. (Note: In order to avoid opening up motors,
a good practice is to observe the stator temperature under
normal working conditions. Any increase not accounted for,
by seasonal increase in ambient temperature, should be
suspected).
4. In case of oil ring lubricated bearing:
 Examine bearings to check whether oil rings are
working,
 Note bearing temperature,
4.9.3.2  Add oil Maintenance
Monthly if necessary.
5. Check for any abnormal bearing noise,
Discuss the following monthly maintenance to be carried out.

Box 4-5: Monthly Maintenance Tasks for Motor

1. Check belt tension. In case where this is excessive it should
immediately be reduced,
2. Blow dust from the motor,
3. Examine oil in oil lubricated bearing for contamination by
dust, grit, etc. (this can be judged from the colour of the oil),
4. Check functioning and connections of anti-condensation
heater (space heater).
5. Check insulation resistance by mongering

4.9.3.3 Quarterly Maintenance

Discuss the following quarterly maintenance to be carried out for motor of
the pump.

Box 4-6: Quarterly Maintenance Tasks for Motor

1. Clean oil lubricated bearings and replenishes fresh oil. If
bearings are grease lubricated, the condition of the grease
should
DEMEWOZbe CONSULTANCY
checked and replaced/replenished to correct
39
quantity.
An anti-friction bearing should have its housing so packed
with grease that the void space in the bearing housing
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

4.9.3.4 Half Yearly Maintenance

Discuss the following semi annually maintenance to be carried out for
motor of the pump.

Box 4-7: Haft Yearly Maintenance Tasks for Motor

1. Clean winding of motor, bake and varnish if necessary.
2. In case of slip ring motors, check slip-rings for grooving or unusual
wear, and polish

4.9.3.5 Annual Inspection and Maintenance

Discuss the following annual maintenance to be carried out for motor of
the pump.

Box 4-8: Annual Inspection and Maintenance Tasks for

Motor
1. Clean and flush bearings with kerosene and examine for
flaws developed, if any, e.g. wear and scratches. Check
end-play. Immediately after cleaning, the bearings should be
coated with oil or grease to prevent ingress of dirt or
moisture,
2. Clean bearing housing and examine for flaws, e.g. wear,
grooving etc. Change oil or grease in bearing housing.
3. Blow out dust from windings of motors thoroughly with clean
dry air. Make sure that the pressure is not so high as to
damage the insulation.
4. Clean and varnish dirty and oily windings. Re-varnish motors
subjected to severe operating and environmental conditions
e.g., operation in dust-laden environment, polluted
atmosphere etc.
DEMEWOZ CONSULTANCY
40
5. Check condition of stator, stamping, insulation, terminal box,
fan etc.
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

4.9.3.6 History Sheet

Similar to history sheet of pump, history sheet of motor should be
maintained. The history sheet should contain all important particulars,
records of periodical maintenance, repairs, inspections and tests. The
training facilitator explains the following points.
1. Details of motor, rating, model, class of duty, class of insulation,
efficiency curve, type test result and type test certificate etc.
2. Date of installation and commissioning.
3. Addresses of manufacturer & dealer with phone & fax number and e-
mail addresses.
4. Brief details of monthly, quarterly, half yearly and annual
maintenance and observations of inspections about insulation level,
air gap etc.
5. Details of breakdown, repairs with fault diagnosis.
6. Running hours at the time of major repairs.
4.9.4 Maintenance Schedule for Valves at Pumping Station
The following five types of valves in pumping installation exist, these are:
1. Foot valve,
2. Sluice valve,
3. Knife gate valve,
4. Non-Return (Reflux) valve, and
5. Butterfly valve.
Maintenance of valves at pumping station is presented in Table 4.1
Table 4-1: Maintenance of Valves at Pumping Stations
Type of Valves Maintenance Tasks
Foot Valve  Clean foot valve once in 1-3 months depending
on ingress of floating matters,
 Clean flap of the foot valve once in 2 months to
ensure leak proof operation,
 Inspect the valve thoroughly once in a year.
Check for leakage through foot valve after
priming and observing level in volute casing.
Sluice and  Check gland packing of the valve at least once
Knife Gate in a month. It should be ensured that pickings’
Valves inside the stuffing box are in good trim and
impregnated with grease.
 It may be necessary to change the packing as
often as necessary to ensure that the leakage is

DEMEWOZ CONSULTANCY
41
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

within limit.
 Grease should be applied to reduction gears
and grease lubricated thrust bearing once in
three months.
 Check tight closure of the valve once in 3
months.
 A valve normally kept open or closed should be
operated once every three months to full travel
of gate and any jamming developed due to long
disuse shall be freed.
 Inspect the valve thoroughly for flaws in guide
channel, guide lugs, spindle, spindle nut, stuffing
box etc. once in a year.
 Important DON’T for valve is that it should never
be operated with oversize hand wheel or cap or
spanner as this practice may result in rounding
of square top and hand wheel or cap or spanner
may eventually slip.
 An important DON’T for valve is that it should
never be operated under throttled i.e. partially
open condition, since such operation may result
in undue chatter, wear and failure of valve
spindle.
Non-Return  Check proper operation of hinged door and tight
(Reflux) Valve closure under no-flow condition once in 3
months.
 The valve shall be thoroughly inspected
annually. Particular attention should be paid to
hinges and pins and soundness of hinged door.
 Condition of dampening arrangement should be
thoroughly examined once in year and
necessary maintenance and rectification as per
manufactures’ instructions shall be carried out.
 In case of dampening arrangement, check for oil
leakage and replace oil once in a year.
Butterfly Valve  Check seal ring and tight shut-off once in 3
months.
 Lubricate gearing arrangement and bearing
once in 3 months.
 Inspect the valve thoroughly including complete
operations once in a year.
 Change oil or grease in gearing arrangement
once in a year.
General  Operate bypass valve wherever provided once
in 3 months.
 Flange adapter/dismantling joint provided with
valve shall be loosened and retightened once in
6 months to avoid sticking.

4.9.4.1 Annual Inspection and Maintenance

DEMEWOZ CONSULTANCY
42
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

1. Examine all components and wiring thoroughly and rectify as

necessary.
2. Change oil or grease in gear box and thrust bearing.
3. Check condition of gears & replace gears if teeth are worn out.
4.9.5 Maintenance Schedule for L.T. Starters, Breakers and
Panel
Note: Circuit diagram of starter/breaker should be posted on door of switch
gear and additional copy should be kept on record. Table 4.2 below is
presented the maintenance tasks for Starter, breaker and panel in the
pumping station.
Table 4-2: Maintenance Activities of L.T Starter, Breaker and Panel

Maintenance Activities
Duration

Daily  Clean the external surface.

 Check for any spark or leakage current.
 Check for overheating
Monthly  Blow the dust and clean internal components in
the panel, breaker and starter.
 Check and tighten all connections of cable,
wires, jumpers and bus-bars. All carbon
deposits shall be cleaned.
 Check relay setting
Quarterly  Check all connections as per circuit diagram.
 Check fixed and moving contacts and clean
with smooth polish paper, if necessary.
 Check oil level and condition of oil in oil tank.
Replace the oil if carbon deposit in suspension
is observed or colour is black.
 Check insulation resistance.
 Check condition of insulators.
Yearly  Check and carry out servicing of all
components, thoroughly clean and reassemble.
 Calibrate voltmeter, ammeter, frequency meter
etc.

4.9.6 Maintenance Schedule for Lifting Equipment

Relevant points in the maintenance schedule for lifting equipments,
depending on the type of lifting equipment i.e. chain pulley block, monorail
(travelling trolley and chain pulley block), manually operated overhead
crane and electrically operated travelling crane is presented in Table 4.3
below.
Table 4-3: Maintenance Activities of Lifting Equipment

Maintenance Activities
Duration

DEMEWOZ CONSULTANCY
43
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Quarterly  Check oil level in gear box and top up if required.

 Check for undue noise and vibration.
 Lubricate bearings and gear trains as applicable.
 Check insulation resistance of motors
Haft Yearly  Clean limit switches.
 Clean all electrical contacts
Yearly  Change oil in gear box.
 Conduct load test of crane for rated load or at least
for maximum load required to be handled. All fast
moving components which are likely to wear should
be thoroughly inspected once in a year and if
necessary shall be replaced.

4.9.7 Maintenance Schedule for Water Hammer Control Devices

Maintenance requirements of water hammer devices depend on type of
water hammer control device, nature of its functioning, water quality etc.
The training facilitator explains the different types of water hammer control
devices used in water pumping installations as follows:
 Surge tank
 One-way surge tank
 Air vessel (air chamber)
 Zero velocity valve and air cushion valve.
 Surge anticipation valve (surge suppressor)
 Pressure relief valve.
Discuss the general guidelines for maintenance of different types of water
hammer control devices as follows:
4.9.7.1 Surge Tank
The following maintenance activities shall be carried out at surge tank in
the transmission line.
 Quarterly: Water level gauge or sight tube provided shall be inspected,
any jam rectified,
all cocks and sight
tube flushed and
cleaned.
 Yearly: The tank
shall be drained
and cleaned once
in a year or earlier
if frequency of
ingress of foreign
matter is high.
 Valve
maintenance: Maintenance of butterfly valve, sluice valve and reflux
valve shall be attended as specified for valves on pump delivery in
section above,
 Painting: Painting of tanks shall be carried out once in 2 years.

DEMEWOZ CONSULTANCY
44
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

4.9.7.2 Air Vessel

Air vessel maintenance in the transmission line is presented in Table 4.4.
Table 4-4: Maintenance Activities of Lifting Equipment

Maintenance Activities
Duration

Daily  Check air-water interface level in sight glass tube.

 The air water level should be within range marked
by upper and lower levels and shall be preferably at
middle.
 Check pressure in air receiver at interval of every 2
hours.

Quarterly  Sight glass tube and cock shall be flushed.

 All wiring connections shall be checked and
properly reconnected.
 Contacts of level control system and pressure
switches in air supply system shall be cleaned.

Yearly  The air vessel and air receiver shall be drained,

cleaned and dried.
 Internal surface shall be examined for any corrosion
etc. and any such spot cleaned by rough polish
paper and spot-painted.
 Probe heads of level control system shall be
thoroughly checked and cleaned.

4.9.7.3 Zero velocity valve and air cushion valve

Foreign matters entangled in valve shall be removed by opening all hand
holes and internal components of the valves including ports, disk, stem,
springs, passages, seat faces etc. should be thoroughly cleaned and
checked once in 6 months for raw water and once in a year for clear water
application.
4.9.7.4 Surge anticipation valve (surge suppressor)
Pilot valves and tubes shall be flushed and cleaned every month
4.9.7.5 Pressure relief valve
The spring shall be checked and freed from jam every month.
4.9.8 Maintenance Schedule for Air Compressor
a) Daily :
 Clean external surface.
 Check oil level and top up if necessary.
b) Monthly :
 Clean oil filter
 Clean air filter
c) Quarterly :
DEMEWOZ CONSULTANCY
45
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

 Check condition of oil and change if dirty.

 Check grease in bearing housing and replenish/change if
necessary.
 Check condition of oil in air filter and change if dirty.
d) Half yearly :
 Change oil.
 Change oil filter element.
 Thoroughly clean air filter.
 Clean bearing and bearing housing and change grease/oil.
e) Yearly :
Thoroughly check all components, piping valve etc. and rectify if
necessary.

4.10 Maintenance of Maintenance of pumping station such as screens, gate, sump / intake / well
Pumping and pump house including civil works as described below:
Station 4.10.1 Screens
1. Screen should be cleaned at a frequency depending on ingress load
of floating matters. The frequency in monsoon season shall be more
than that in fair season. However, cleaning frequency should be at
least once in a week, or, if head loss in screen exceeds 0.20 m.
2. Care should be taken to remove and dump the screening far away
from the pump house.
3. Lubricate wheels and axle of wheel burrows.
4. The screen, catch tray and screen handling arrangement shall be
thoroughly inspected once in six months and any item broken,
eroded, corroded shall be rectified.
4.10.2 Sluice Gate
a) Monthly :
 The sluice gate normally remains in open position and closed
only when inflow is to be stopped. Since floating matters may
adhere to the gate and may accumulate in the seat, it should
be operated once in a month. In order to ensure that gate
remains free for operation.
b) Yearly :
 The gate should be thoroughly inspected once in a year
preferably after wet season and components found worn out
shall be replaced. Particular attention shall be paid to the seats
of the frame and gate.
 The gate should be closed to check the leakages. For this
purpose, the sump/intake shall be partly dewatered so that
differential head is created on the gate and leakage test at site
can be performed.
4.10.3 Sump/Intake Well
 All foreign floating matters in the sump/intake shall be manually
removed at least once in a month and shall be disposed off away

DEMEWOZ CONSULTANCY
46
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

from pump house,

 De-silting of intake/sump shall be carried out once in year preferably
after wet season. Care should be taken to dump the removed silt
away from pump house.
 It is generally observed that reptiles like snakes, fish, etc. enter
intake particularly in wet season. The intake should be disinfected.
 The sump/intake should be fully dewatered and inspected once in a
year.
 It is advisable to undertake leakage test of sump once in a year. For
this purpose, the sump shall be filled to FSL and drop in water level
for reasonably long duration (2-3 hours) should be observed. If
leakage is beyond limit, rectification work shall be taken.
4.10.4 Pump House
 The pump house should be cleaned daily. Good housekeeping and
cleanliness are necessary for pleasant environment,
 Entire pump house, superstructure and sub-structure shall be
adequately illuminated and well ventilated. Poor lighting, stale air
etc. create unpleasant environment and have an adverse effect on
will of the staff to work,
 Wooden flooring and masonry stone grating wherever damaged
should be repaired on priority,
 It is observed that at many places, roof leaks badly and at times the
leakage water drips on the panel/motor which is dangerous and can
cause short circuit and electric accidents. All such leakages should
be rectified on priority.
 All facilities in sub-structure i.e. stair case, floors, walkways etc.
should be cleaned daily.
 Painting of civil works should be carried out at least once in two
years.

4.11 Driving 4.11.1 Diesel/Gasoline Engines/Alternators

Equipment Diesel-powered generators are used in many boreholes and water intakes
to drive electrical pumps. There is a wide variety of makes, although Lister-
Peter and Perkins are common.
The principles of the O and M tasks required are similar, regardless of the
make or model. Specific requirements for each make and model should be
obtained from the manufacturer's Operators Manual for each engine.
Gasoline engines can be used for direct connection to centrifugal pumps
operating at a moderate heads, but need a reducing gear to low pumping
heads.
4.11.1.1 Identification of parts of a Diesel Powered System
Identify the different parts of the pumping system and explain the purpose
of each part.
Table 4-5: Different parts of Generator Engine and its purposes
Component Purpose

DEMEWOZ CONSULTANCY
47
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Pump House Keeps the engine and its control panel safe
from unauthorized access
Fuel store Keeps the fuel safe from uncontrolled access
Diesel engine Turns on the alternator
Alternator Generates electricity
Control panel Controls the current to the pump and protects
the pump from periods of high currents
Electrical pump (e.g., Pumps water to the tank
submersible
pump in bottom of
borehole)
Master meter Measures water from the borehole

Now focus on a diesel-powered engine and explain the names and

purpose of its different components.
4.11.1.2 Start Up Procedure
a) Before starting up diesel generator, the followings have to be
checked:
The training facilitator explains what checks should be carried out before
starting up of diesel generators using Table 4-6.
Table 4-6: Pre-Start Check and Service of Generator Engine

No. Description Checking

1 Oil Check the different types of oil, coolant and fuel

levels. The oil level may be checked with the
engine running or stopped. The recommended
method of checking is while the engine is not
running. Badly contaminated or deteriorated oil
shall be replaced immediately regardless of the
replacement interval, and the oil level has to be
maintained between the lower and upper marks of
the oil dip stick.
2 Radiator Check the coolant level on the control board
meter. If additional water is needed, remove fill
cap and add as necessary. In addition to this,
always check randomly radiator core, mountings,
hose, steam-relief tube and valve are in good
condition, correctly assembled, securely mounted
and do not leak.
3 Fuel Tank
Fuel can be added to the tank by removing the fill
cap on top of the fuel tank. After completion of
refuelling, be sure to tighten the fuel tank cap to
protect against vandalism.
4 Batteries
Check electrolyte level in each battery cell and
maintain the level to the bottom of the fill openings

DEMEWOZ CONSULTANCY
48
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

with distilled water.

Clean the top of the batteries with a clean cloth.
Keep the terminals clean and coated with
petroleum jelly.
Check the indicating meter located on the control
board, it is always expected to indicate at least
nominal battery rating unless and otherwise the
meter is faulty.
5 Instruments
Check the following meters at frequent intervals
and Gauges
under the full range of engine speeds for correct
readings, if unusual readings are observed stop
the equipment immediately and report to the
supervisor.
 Ammeters
 Voltmeters
 Speedo-meter
 Temperature gauge
6 Accessories
Check accessories such as fuel pump,
carburettor, generator, regulator, starter, fan belt
and water pump for loose connections or
mountings.

b) Start engine, make the following checks:

The training facilitator explains what checks have to be carried out during
the start of the diesel engine as described in Box 4 – 9.

Box 4-9: Checking during starting of Generator Engine

 Observe engine warm up.
 Check that the starter has adequate cranking speed and
engages
and disengages properly without unusual noise.
 Do not place engine under load before reaching normal
operation condition.
 Check oil pressure and all other instruments (Tachometer,
Voltmeter, Temperature gauge).

c) During Operation of the engine

During operation, operators must correct simple defects only and if the
defects are beyond their capacity the defects are to be reported to the
supervisor. Box 4 - 10 describes the checking’s to be carried out during the
engine in operation.

Box 4-10: Checking during operation of Generator Engine

 Check clutch (if applicable).
DEMEWOZ CONSULTANCY
 Check engine controls and watch for poor engine performance 49
such as the lack of usual power, misfiring, unusual noise,
stalling, overheating, or excessive exhaust smoke. Check that
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

d) After operation, make the following checks:

Box 4-11 lists checking requirements after operation of diesel engine. The
training facilitator explains these requirements.

Box 4-11: Checking after operation of Generator Engine

 Check any irregularities noticed previously.
 Check fuel, oil and water.
 Check instruments.
 Check battery.
 Check accessories and belts.
 Check fuel filters.
 Check for leaks.

4.11.1.3 Switching Off Procedure

1. Turn engine off,
2. Record end time on Log Chart,
3. Check for any oil leaks.
4.11.2 Schedule of Preventative Maintenance for Diesel Engines
In almost all cases, diesel engine prime movers are designed as standby
units, these must be given proper care to prolong their life and for their
efficient operation. In the absence of the equipment operating manual,
listed below are suggested preventive maintenance practices.
Table 4-7: Schedule of PM for Diesel Engines
O&M Duration Activities

Daily Operation/  Check fuel and engine oil levels, top up if

every 8 hours necessary
(to be carried  Check water level in radiator & top up if
out by Operator)

DEMEWOZ CONSULTANCY
50
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

necessary and secure the cap

 Check tension of alternator drive belt, check
battery condition/water level
 Check the lubricating oil pressure at the gauge
 Check for loose nuts and bolts, check and
correct any leaks or engine damage
 In very dusty conditions clean air cleaner
element, drain and clean dust bowl
 Check exhaust pipe
 Check foundation bolts
Every 100 hours  As for daily services.
or 3 months (to  Renew engine lubricating oil
be carried out
by skilled  Renew engine oil filter
mechanics)  Drain water from fuel filter and pre-filter
 Check the condition of the battery fitted
 When moderately dusty, empty bowl and clean
or replace the air cleaner element
 Clean the compressor air filter
 Check and adjust idle speed

Every 200 – 250  As for previous servicing

hours or 6  Change the engine oil and oil filter element
months (To be
carried out by  Clean fuel strainer, fuel tank breather. Renew
skilled fuel filter canister
mechanics)  Clean battery terminals

Every 400 hours  As for previous servicing

or 12 months  Replace air cleaner element
(To be carried
out by skilled  Renew fuel filter element
mechanics)  Check concentration of coolant
 Check the battery charging system. Check
alternator drive belt for wear, Check
 wiring harness & connections and tighten if
required
 Check injectors for performance
After 600 hrs or  As for 200 hour servicing and maintenance
18 months (to  Renew coolant
be carried by
skilled  Renew alternator drive belt
mechanics)  Tighten cylinder head
 Check and adjust valve clearances
 Check electrical system
 Check all nuts and bolts for tightness
 Check engine mountings

DEMEWOZ CONSULTANCY
51
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

4.11.3 Troubleshooting for Generator

Discuss the potential unexpected problems, what might be the causes, and
some possible solutions for diesel engine.
Table 4-8: Troubleshooting for Diesel Engines
No. Problems Possible Cause Remedy
1 WILL NOT Battery is flat or has (a) Check the liquid level;
START failed fill if necessary.
(b) Recharge the battery
(i) Engine does and check that all cells
not turn) are working.
(c) Replace the battery if it
has failed.
Starter circuit faulty (a) Check, clean and refit
the battery connections.
(b) Check the circuit relay
and starter solenoid.
Starter faulty (a) Replace the motor.
(b) Check that the starter is
engaging; attempt to
turn the engine by
hand.
Lubricating oil to thick Replace with the correct
grade of oil.
Engine or alternator Inspect and remove any
jammed obstruction.
(ii) Engine turns (a) No fuel atomizers (a) Check there is fuel
but does not (b) Air in fuel system available in the tank.
fire (c) Dirty fuel or water
(b) Check that all fuel
in
valves are open.
the fuel
(d) Faulty lift pump (c) Bleed the fuel system.
(e) Faulty injection (d) Clean or replace the
pump fuel filter.
(f) Injection timing (e) Check the fuel lift
wrong pump.
(f) Check the fuel injection
pump.
(g) Reset the injection
pump timing.
(iii) Engine fires (a) Limited fuel supply (g) Bleed the fuel system
but fails to start and check it thoroughly

DEMEWOZ CONSULTANCY
52
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

(b) Faulty lift pump for evidence of dirt or

(c) Faulty injection water.
pump (h) Service the fuel lift
(d) Fuel filter blocked pump.
(e) Air filter blocked (i) Service the injection
pump.
(f) Worn or dirty
injectors (j) Clean or replace the
fuel filter.
(k) Clean or replace the air
filter.
(l) Service or change
injectors.
2 Starts but (a) limited fuel supply (a) Bleed the fuel system
misfires (b) Faulty lift pump and check it thoroughly
for evidence of dirt or
(c) Faulty injection
water.
pump
(b) Service the fuel lift
(d) Fuel filter blocked
pump.
(e) Worn or dirty
(c) Service the injection
injectors
pump.
(f) Loose or broken
(d) Clean or replace the
pipes
fuel filter.
(g) Incorrect valve
(e) Service or change the
clearances
injectors.
(f) Tighten or replace the
pipes.
(g) Reset the valve
clearances.
3 Starts but (a) All possible Attention as shown in (a)
loses power causes shown to (g) above (under item 2
under 2 above above).
(b) Air filter blocked (i) Clean or replace the air
(c) Faulty cylinder filter.
head or inlet (j) Replace the gasket.
manifold joints (k) Clean or replace the
(d) Damaged or dirty filter.
turbocharger
4 Excessive fuel (a) Faulty injection (a) Service the fuel
consumption pump injection pump.
(b) Worn or dirty (b) Service or change the
injections injectors.
(c) Incorrect valve (c) Reset the valve
clearance clearance.
(d) Fuel pump timing (d) Reset the fuel pump
incorrect timing.
(e) Incorrect fuel (e) Check the fuel
(f) Excessive engine specification.
wear (f) Overhaul the engine.
5 Black exhaust (a) Faulty injection (a) Service the fuel
smoke pump injection pump.
(b) Worn or dirty (b) Service or change the
injectors injectors.
(c) Clean or replace the air

DEMEWOZ CONSULTANCY
53
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

(c) Air filter is blocked filter.

(d) Fuel pump timing (d) Reset the fuel pump
incorrect timing.
(e) Incorrect fuel (e) Check the fuel
(f) (Damaged or dirty specification.
turbocharger (f) Clean or replace the
(g) Excessive load turbocharger.
(h) Long running time (g) Reduce the load as
on light load necessary.
(h) Run on full load for a
one-hour period.
6 Blue/white (a) Engine misfiring (a) See remedy under item
exhaust smoke (b) Excessive engine 2 above.
wear (b) Overhaul the engine.
7 Low lubricating (a) Low oil level in (a) Add lubricating oil to
oil pressure sump normal level
(b) Oil pressure gauge (b) Replace the oil
faulty pressure gauge.
(c) Oil filter blocked (c) Clean or replace the oil
(d) Faulty relief valve filter.
(e) Oil pump worn (d) Clean or replace the
relief valve.
(f) Excessive oil temp
(e) Replace the oil pump.
(f) See the problem
outlined in item 8
below.
8 High Engine (a) Low level of (a) Refill the radiator and
temp coolant check for any leaks.
(b) Faulty thermostat (b) Check and replace the
(c) Fan belt slipping thermostat if necessary.
(d) Radiator matrix (c) Adjust the tension of
blocked the fan belt.
(e) Blockage in (d) Clean out the radiator
cooling system thoroughly.
(f) Low level of (e) Drain the system, flush
lubricating oil it out and refill.
(g) Fuel injection (f) Refill the lubricating oil
pump's timing is to the correct level.
incorrect (g) Reset the timing of the
(h) Cylinder head fuel injection pump.
gasket failed (h) Remove the cylinder
head and replace the
gasket.

4.11.4 D.C Battery

Explain the following maintenance schedule that shall be applicable for

DEMEWOZ CONSULTANCY
54
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

D.C. Batteries on differ time table:

i. Daily: Check voltage and specific gravity of the batteries and
battery supply for the tripping circuit.
ii. Monthly: Check the battery charging & fuses and clean contact
faces.
Apply petroleum jelly or grease to battery terminals.
iii. Quarterly: Check to ensure that battery is not overcharged/under
charged.
iv. Yearly: Check rectifier, diode, rheostat motor thoroughly.

4.12 Facilities for The following facilities should be provided for maintenance, inspection and
Maintenance repairs in the pumping installation:
and Repairs  Adequate stock of consumables and lubricants,
 Adequate stock of spare parts,
 Tools and testing instruments,
 Lifting equipment,
 Ventilated and illuminated adequate space for repairs.
4.12.1 Consumables and Lubricants
Adequate stock of gland packing, belts, gaskets, lubricating oil, greases,
transformer oil, insulation tape, sealing compound, emery paste etc. shall
be maintained.
Quantity shall be decided depending on consumption and period required
to procure and replenish the stock.
4.12.2 Spare parts
Adequate stock of spare parts should be maintained to avoid downtime due
to non-availability of spares.
Generally, spares required for one-two years maintenance as per list below
shall be kept in stock.
The list should not be considered as full-fledged and comprehensive and
should be updated and revised in light of manufacturers’ recommendations
and previous history of repairs undertaken.
Table 4-9: Lists of Spare parts need to be stock for O&M of Pumps
and Generators
No. Spare part Items No. Spare part Items
1 Set of wearing rings 12 Lantern ring
2 Shaft sleeves 13 Coupling for line shaft
3 Bearings 14 Slip ring unit
4 Gland packing’s and 15 Carbon brushes
gaskets
5 Coupling bushes and bolts 16 Fixed and moving contacts
6 Line shaft bearings and 17 Lugs

DEMEWOZ CONSULTANCY
55
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

spiders
7 Line shaft 18 Gland for cable termination
8 Pump shaft 19 Fluorescent tubes and lamps
9 Shaft enclosing tube 20 Fuses
10 Tube tensioning plate 21 Impeller

11 Gland nut 22 Rotating assembly of pump (for

large
pumping installation)

4.12.3 Tools and Testing Instruments

The pumping installation should be equipped with all necessary tools,
testing instruments and special tools required for repairs and testing. Their
quantity and special tools depend on size and importance of installation.
Generally the following tools and testing instruments shall be provided:
Table 4-10: Lists of Tools and testing Instruments required for O&M
No. Lists of Tools No. Spare part Items
1 Double ended spanner set 11 Bearing puller
and ring spanner set
2 Box spanner set 12 Torque wrench
3 Hammers (of various sizes 13 Clamps for column pipes, tube
and functions) and line shaft
4 Screw driver set 14 Specials tools such as grinder,
blower, drilling machine
5 Chisel 15 Tap and die set
6 Nose pliers, cutting pliers 16 Bench vice
7 Flies of various sizes and 178 Special tools for breakers
smooth/rough surfaces
8 Adjustable spanner 18 Fluorescent tubes and lamps
9 Pipe wrenches 19 Crimpling tool
10 Heating stove for heating 20 Rotating assembly of pump
sleeves (for large
pumping installation)
No. Lists of Tools No. Spare part Items
1 Insulation tester 1 Earth resistance tester
2 Tongue tester 2 Wattmeter, CT and PT
3 AVO meter 3 Dial gauge
4 Test lamp 4 Tachometer

4.12.4 Safety Rule

Discuss the safety rules with the participants.
i) Safety rules: general
1. Keep a fire extinguisher or a bucket of sand close at hand to deal

DEMEWOZ CONSULTANCY
56
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

with fire.
2. Smoking is not allowed in the pump house or fuel store.
3. Wear protective clothing that fits well: no loose clothes that can get
caught in the moving parts of the engine.
4. Never put cleaning rags or other loose items in your pockets when
you are in the pump house. They can get caught in the moving
parts.
5. Wear good protective shoes.
6. Keep the floors of the pump house and store clean and dry, so that
you will not slip or fall.
ii) Safety rules: fuel and lubricants
1. Keep spare fuel and lubricants in a secure, ventilated store.
2. Do not smoke in the fuel store or while refueling is being carried
out. Ensure the area is clear of any spectators or smokers.
3. Use a pump or tap to take diesel out of a drum. Transferring diesel
fuel by sucking it up with a hose is not good for your health.
4. NEVER put fuel or oil into the engine while it is running.
5. Do not use kerosene as a fuel. It reduces the life of the engine and
the fuel pump.
iii) Safety rules: during operations
1. Keep spectators out of the pump house while the engine is
operating.
2. Open the windows and ensure that the pump house is well
ventilated.
3. Do not open the radiator cap.
4. Do not top up the radiator by pouring cold coolant into a hot engine
as this may cause the cylinder head to crack.
5. Keep your fingers away from moving parts of the engine.
6. NEVER put fuel or oil into the engine while it is running.
7. Never clean the engine when it is running.
8. Do not operate the engine if the safety guard has been removed.
9. Only one person should control the engine.
iv) Safety rules: during maintenance work
1. Do not make any adjustments that you do not understand.
2. Maintenance operations must be carried out on a cold engine.
3. Maintenance operations must be carried out under sufficient
lighting.
4. Do not overfill the engine oil in the sump; this may cause the engine
to give off smoke.
5. Do not use salt water or any other coolant which can cause
corrosion in the closed cooling unit.
6. Disconnect the battery terminals before a repair is made to the
electrical system.
7. If you are working with chemicals, such as solvents, cleaners,
chlorine etc., be careful. Read the instructions on the container and
follow them closely. Some chemicals give out fumes that are

DEMEWOZ CONSULTANCY
57
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

poisonous if inhaled. Some of them will burn your skin.

Attachments Attachment 4-1: Typical Surface Pumps

Attachment 4-2: Engine Log
Attachment 4-3: Engine Service Form
Attachment 4-4: Diagram of the Lister TS3 diesel engine

Attachment 4-2: Typical Surface Pumps

1. KSB Surface Multi stage Centrifugal Pump

DEMEWOZ CONSULTANCY
58
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

2. Rovatti Surface Single Stage Centrifugal Pump

DEMEWOZ CONSULTANCY
59
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

3. Different Model of Groundfos Submersible Pump

Attachment 4-3: Engine Log

DEMEWOZ CONSULTANCY
60
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Attachment 4-4: Engine Service Form

DEMEWOZ CONSULTANCY
61
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Attachment 4-5: Diagram of the Lister TS3 diesel engine

DEMEWOZ CONSULTANCY
62
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Attachment 4-6: Diagram of the Deutz diesel engine

DEMEWOZ CONSULTANCY
63
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

5 SESSION – E: TRANSMISSION & DISTRIBUTION

PIPELINES
Module - C TECHNICAL OPERATION & MAINTENACE REQUIREMENTS FOR
RURAL PIPED SYSTEM

5.1 Session This session covers the following main topics:

Outline  Introduction of pipelines
 Description of different water supply system
 Identification of pipeline system
 O&M Tasks for pipelines and appurtenants
 Troubleshooting for pipelines and appurtenants
 Service line Repairs
Appropriate
This session of the training should be given by experienced Engineer.
Facilitators
background
5.2 Objective At the end of the session, the participants will be able to:
 identify the main components of a pipelines,
 describe the functions of the key components
 carry out pipeline operation and maintenance

Output  An O and M schedule

Training timing 8 hours

for this session

Methodology This is intended to be a practical session. The components will be taught by

demonstration of the system itself, not using drawings or descriptions. The flip
chart can be used to illustrate details if necessary. Reinforce the learning by
allowing participants to handle the parts and describe their functions to each
other.

Materials  Valve key/wheel, pipe wrench, tools, tap, gate valve, non-return valve

Session Guide and Content

5.3 Introduction Transmission pipeline is conveying raw water from the source to the treatment
plants, and transmit treated water from treatment plants to the storage
reservoirs. If the raw water source is groundwater, it conveys from borehole to
the service reservoir, in most cases it located at local hill. Transmission
through pipes can be either by gravity flow or by pumping system.
Distribution pipelines are conveying potable water from service reservoir to the
point of consumers via gravity or pumping system, the former is predominant in
Ethiopia. The line mainly branched in the case of RPS, seldom looped system
whenever deliver to towns.

DEMEWOZ CONSULTANCY
64
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

This training session is dealing with the operation and maintenance

requirements for transmission line, service reservoir, distribution system, public
water point, service line and appurtenants in the system.

5.4 System The training facilitator discusses the different types of water supply systems
Description and asks the participants which system belongs to their areas. There are 5
different water supply system predominantly exist in Ethiopia as described
below.
5.4.1 Option-1: Pumping System from Single Borehole
In this system water is conveyed from borehole through submersible pump to
service reservoir located relatively at higher altitude via pumping main pipeline.
From the service reservoir, water is distributed to the consumer by gravity
system. This system is the most applicable method in Ethiopia in provision of
water supply.
Along the pipeline, various valves and fitted such as gate valve, non-return
valve, pressure gauge, water meter, air release valve, washout valve, pressure
sustain valve etc fitted on the system.

Pumping Main Gravity

SR main

5.4.2 Option-2: Pumping -Gravity System from Multiple Boreholes

If multiple boreholes are involved, the system incorporate collection chamber
and booster pump. If the consumer’s location is at higher altitude compare to
the location of the collection chamber.

BH-1 CC
Gravity
Gravity Main SSR main
R

Distribution line

BH-2

This option is seldom encountered that the location of the well fields are at high
altitude and placing the collection chamber at higher elevation to facilitate
gravity water supply system to service reservoir, and then to distribution
system. Such arrangement is cheaper than the option-3 below.
In some cases, option-2 modified due to the topographic situation and
incorporated boost pump to boost the water to the service reservoirs as
presented in the sketch presented as option-3 below.

DEMEWOZ CONSULTANCY
65
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

5.4.3 Option-3: Pumping-Pumping-Gravity System from Multiple

Boreholes
Option-3 is more prevalent system in the Country from multiple groundwater
sources.

BH-1
CC
Transmission Gravity
SR main

Pump

CC= Collection Chamber

BH-2
5.4.4 Option-4: Gravity system from River and Reservoir sources
This option is ranked the 4th from the above 3 options, due to that this requires
treatment plant facilitates. This kind of arrangement may be adopted for urban
water supply provision where the demand is high and the availability of surface
water sources nearby.

5.4.5 Option-5: Pumping system from River and Reservoir sources

This kind of pumping system arrangement up to service reservoir is exist in
Ethiopia urban water supply. This system is the most expensive than the other
4 options.
Such configuration is preferred if groundwater scarce and surface water is
available in nearby area.

5.5 System 5.5.1 Gravity or pumped system

Identification
DEMEWOZ CONSULTANCY
66
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Using the diagrams in Attachment 1 and 2, discuss the basic arrangement of

the system:
 Is it a gravity or pumped system? (Note that many pumped systems
also have a gravity component.)
 Which parts of the pipeline are under pressure?
 How much pressure? (Make an estimate if there are no pipeline profile
drawings that show the pressure in different parts of the system.)
 How is the pressure controlled?
 What happens on a pumped scheme if there is a burst pipe? How about
on a gravity system?
 Where is storage tanks positioned within a system?
5.5.2 Pipeline components
Identify and demonstrate the functions of the different components of pipeline
as described in Table 5-1.:
Table 5-1: Pipeline components and their functions

No. Component Function

1 Source Where the water originates (e.g. Groundwater, river,

lake, pond etc)

2 Intake The structure to abstract the water from the source

3 Pumping main The pipeline that conveys water to the storage

or gravity main tank(s)
line

4 Distribution Pipeline branches from the main line or from the

lines storage tank to the individual connections or public
water points

5 Storage Constructed o store water to supply peak demand as

tanks/Service well as to facilitate gravity flow
Reservoir

6 Break- Decreases water pressure in the pipeline – brings

Pressure Tank pressure to atmospheric pressure by constructed the
tank or install pressure reducing valve.

7 Pipe supports Support the pipeline above ground; limit damage to

pipeline during floods and excess pressure

8 Pipe markers Mark the route of a buried pipeline

9 Control valves Open or close the pipeline

10 Air valves Release air from the high points in the pipeline

11 Washouts Opened to clean out silt, sand and mud at low points
in the pipeline

DEMEWOZ CONSULTANCY
67
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

12 Meters Master meter to measure abstraction; individual or

public water points meters to measure water
consumed

13 Water Points Public tap stands, cattle troughs and house

connections

5.5.3 Valves
Note: Many valves do not work properly. This is frequently due to improper use
or incorrect selection of the valve. Explain the differences between gate valves,
non-return valves, washouts, air valves and stopcocks or taps, as outlined
below:

Box 5-1: Function of different Valves

1. Gate valves are designed to be fully open or fully closed.
2. Gate valves allow us to start or stop the flow of water in a pipe.
3. Gate valves should be opened or closed slowly to reduce the
chance of hammer pressures.
4. Non-return valves control flow so that it goes in one direction
only.
5. Air valves are placed at high points along a pipeline to release
trapped air.
6. Washouts are placed at low points along a pipeline to drain the
pipeline at a controlled point and to flush out any silt that has
accumulated in the pipeline.
7. Stopcocks or taps can be used like a gate valve or to regulate
flow.
8. Taps are most appropriate at consumer points because they are
designed.
to be open and closed many times a day.

5.6 Specific Ask participants what problems might occur if maintenance of the pipeline is
Pipeline not carried out properly. Identify components that require maintenance.
O&M Tasks Typical maintenance tasks include:
 Repairing erosion around pipes and pipe supports.
 Repairing leaking or damaged pipes.
 Repairing damaged valve chambers.
 Checking for blocked or leaking air valves once a month.
 Opening washout valves once a month to clear silt (more often during
periods of rain). Washouts should be opened and left open for a
sufficient length of time to get water flowing fast to flush out all the silt.
Check to see that all silt has been removed (look at color of the water).
 Clearing any bush or shrubs along the pipeline route and keeping the
pipe markers in a good condition.
 Explain the importance of regular pipeline patrols. Ask how these

DEMEWOZ CONSULTANCY
68
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

patrols could be made easier.

A detailed session to demonstrate pipe repair may be necessary if the
maintenance staff are not competent with the kind of repairs that are frequently
needed. There are various ways of repairing pipe leakages, depending on the
kind of pipe and materials available.
Allow the operator or plumber to demonstrate the repair technique (see
Attachment 5-3 to 5.5):
 Repair of PVC pipes by heating pipe end to make a socket (OK for low
pressure pipes).
 Repair of PVC pipes using a socket with rubber
 Repair of PVC pipes using a glued socket
 Repair of PE pipes using ready-made sockets
 Repair of GI pipes involving threading the pipe ends and inserting a
union/joint fitting and replacement pipe length.
Discuss tasks to be considered during the preparation of an O and M schedule
including:
 patrolling pipeline route identifying leaks, illegal connections, exposed
pipe, damage to pipe cover, pipe markers or pipe supports
 opening washouts to clear out silt
 checking air valves to ensure all air has been released
 checking ball cocks and main valves
 reading the master meter
 reading individual or kiosk meters
 Checking that consumption is in accordance with agreed uses.
5.6.1 Preparation for Repairs
Ask the participants what should be prepared before departing to the site for
repair works and discuss on the following issues to be taken in to
considerations.
1. Post the phone numbers of key maintenance personnel conspicuously
in the pumping station or office,
2. Keep the following items available and ready for use at all times: valve
keys, hand tools, digging tools, pavement breakers, trench-shoring
material, a portable centrifugal pump, floodlights, an emergency
chlorinator, and calcium hypochlorite,
3. Keep a stock of split-sleeve and mechanical-joint repair fittings in sizes
that fit critical mains,
4. Keep an inventory of the type of equipment that is available at these
sources whether for borrowing or renting. The contact details of the
persons in charge of the equipment at these sources should also be
posted conspicuously at the pumping station.
After a pipe break is located, determine which valve is to be closed to isolate
the section where the break has occurred and should be notified about the
break.
After the closure of the valve the dewatering/mud pumps are used to drain the
pipe break points. The sides of trenches have to be properly protected before

DEMEWOZ CONSULTANCY
69
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

the workers enter the pit.

The damaged pipe is removed, and the accumulated silt is removed from
inside the pipe and the damaged pipe is replaced and the line is disinfected
before bringing into use.
A report shall be prepared following every pipe break about the cause of such
break, the resources required for rectification and the time and cost required for
repairing etc. so that the WAO/operators/plumbers can follow up with
measures for avoiding such breaks and also modify their plan to address such
breaks in future.
5.6.1.1 Repairing Pipe Leaks
The repair job then consists of sealing the leaks and/or replacing the defective
pipe section.
Explain different methods of fixing leaks as described below:
a) Using Epoxy (for Small Leaks)
1. Dry the surface of the area to be repaired,
2. File the surface to make it rough, and slightly enlarge the crack or hole,
3. Apply the epoxy, forcing some of it into the crack or hole to produce a
seal,
4. Normally, the epoxy will set in 2 to 4 hours before the pipe can be
disinfected and put back into service, However, be sure to check the
directions for use of the epoxy as some types may require more or less
time.
b) Using Sleeve Type Coupling /Repair Clamps
1. Put a split sleeve/repair clamp around the leak opening.
c) Using Strips from the Inner Tube (“Interior”) of a Rubber Tire
1. In emergency work when no other repair materials are available, cut a
discarded inner tube of a rubber tire into strips and wind the strong,
flexible rubber strips tightly around the pipe to cover the leak and its
surrounding surfaces.
2. If the leak is small hole, insert wood temporary until the main repair
start.
d) After the Leak is Repaired
1. Open the control valve to allow water to flow into the repaired section,
2. Observe carefully to verify if the leak is completely sealed,
3. After sealing, backfill the excavation and restore the surface to its
former condition,
4. Apply the disinfection procedures.
5.6.1.2 Replacing Damaged Sections of Pipelines
When the damage in a certain section of a water main is extensive, repair may
involve cutting off and replacing the damaged section. The procedures for
repairs are as follows:
a) For Galvanized Iron (G.I.) Pipes
Attachment 5-3 shows the procedures of galvanizing Iron pipe repairs. Please

DEMEWOZ CONSULTANCY
70
Box 5-2: Repair procedures of galvanized Iron Pipes
1. Isolate the defective section by closing appropriate control valves;
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

refer it for detailed explanation.

6. Thread the ends of pipe to be joined;

7. Install G.I. coupling and union parts;
8. Assemble them as shown in Attachment 5.3;
9. Open the control valve to allow water to flow into the repaired
section. Observe carefully if the repaired section is not leaking;
10. If there is no more leak, backfill the excavation and restore the
surface to its former condition;
11. Disinfect the repaired section.
b) For Polyvinyl Chloride (PVC) Pipes
Explain the detailed procedures for repairing uPVC pipeline as described in
Box 5-3 and attachment 5.4.

Box 5-3: Repair procedures of uPVC Pipes

1.
Isolate the defective section by closing the appropriate control
valves.
2. Excavate the water main;
3. Pinpoint the leak;
4. Measure and cut the defective portion of the pipeline. The
length of the pipe cut should have an equivalent commercially
available threaded nipple;
5. Install the PVC socket and adaptor union;
6. Join the two cut portions of the water main with the nipple in
between (In case PVC threaded nipple is not available, use the
equivalent G.I. threaded nipple);
7. Open the control valve to allow water to flow into the repaired
section and observe if it is not leaking;
8. If there is no more leak, backfill the excavation and restore the
surface to its former condition;
c) For
9. Disinfect the (PE)
Polyethylene Pipes
repaired section.
Explain the detailed procedures for repairing PE pipeline as described in Box
5-4 and attachment – 5.5:

Box 5-4: Repair CONSULTANCY

DEMEWOZ procedures of Polyethylene (PE) Pipes
71
1. Isolate the defective section by closing the appropriate valves
and excavate main;
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

5.6.1.3 Pipe Cleaning

The training facilitator identifies causes that requires pipe cleaning and
explains the problems both in terms of quantity and quality, and the need to
cleaning the pipelines.
 Water going through the pipelines may sometimes carry sand,
sediments, and organic and other objectionable matter.
 When water velocity is low, these tend to get deposited and build up
inside the pipes. The built-up deposits decrease the carrying capacity of
the pipes and increase internal friction, making the pipelines less
efficient.
 Less water can be delivered per given time, pumping costs increase,
and the added and uneven pressure within the pipelines increases the
likelihood of breaks and leaks.
 These effects are complicated when magnesium and calcium salts are
present in the water (hard water), as their precipitation results in scaling
inside the pipes. Likewise, when organic matter is present in the
deposits, bacteria grow, causing undesirable odours, and an off-taste
and colour in the delivered water.
 When disturbed, corrosion deposits in pipes or sediments caused by
improper treatment have to be removed in order to prevent water
quality deterioration.
The decision to conduct pipe cleaning results from the following situations:
 Consumers’ complaints about water quality (colour, turbidity),
 After a new pipe has been laid or an existing pipe has been repaired,
 The need for removal of excessive disinfectant used to kill bacteria or
living organism in pipes,
 Systematic cleaning as a part of regular preventive) network
maintenance.
Explain the three techniques of pipe cleaning which are commonly used:
 Flushing,
 air scouring and
 Swabbing (or pigging).
1. Flushing
The method for removing solids which are not cemented to the inside surface
of pipes is to flush with water at high velocity. Annual flushing is generally

DEMEWOZ CONSULTANCY
72
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

sufficient to maintain the pipelines clean. (But note that different water and pipe
materials may need a different schedule.)
The nature of rural piped system is dead end. Dead end pipes should be
flushed and disinfected at least once a year.
Furthermore, whenever mains are opened for repair, they should also be
flushed and disinfected.
By opening washout valves or hydrant on the main, an increase water flow is
generated to remove loose deposits. Approximate velocities required for
transport of sand particles (ρ=2650 kg/m3) as presented in Table 5.2 below.
Table 5-2: Required Flushing Velocity for sand particles, d=0.2mm
(Brandon, 1984)
Pipe Diameter (mm) V (m/sec) Q (l/sec)
50 1.3 2.7
75 1.6 7.2
100 1.8 15.0
150 2.2 41.0
200 2.6 83.0
As a general guideline, the approximate quantity of water needed is equivalent
to three full volumes of the pipe that is being flushed.

Box 5-5: Pipe Flushing Procedures

1. Isolate the water mains to be cleaned by closing the appropriate
control valves,
2. Empty the water mains by opening the blow-off valve or other
temporary outlet at the lower end of the pipeline. In some cases, to
expedite the emptying of water mains without pumping, compressed
air may be introduced at the highest point of the isolated system,
3. Inject water at high-induced velocity (as indicated in Table 5-2) until
the objectionable materials are expelled,
4. As needed, disinfect the pipelines. After disinfection, flush the
pipeline with clean water until the chlorine-odor is hardly detectable,
5. Putispipelines
Flushing back
a simple to operation.
method of cleaning, but not always efficient. The
disadvantages are:
 Large amounts of water used (particularly in large diameters),
 the velocity increase in the pipe being flushed may disturb the flow
and pressure pattern upstream of the cleaned section, in areas with
progressive corrosion, flushing offers only a partial improvement,
 Not all parts of the distribution system may be equally suitable for the
generation of high velocities (e.g. in low pressure areas).
Flushing pipes as a preventative measure requires good planning. The
following factors are to be taken into consideration:
 selection of the optimal pipe route,
 the location of valves that are operated in order to isolate the flushed
route from the rest of the system,
 total length of section that is flushed in one run,

DEMEWOZ CONSULTANCY
73
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

 choice of hydrants (number and location) that will have to be opened

in order to generate the necessary velocity,
 Proper sequence of routes to be flushed.
The target of any flushing plan is to clean the system efficiently i.e. with
the minimum quantity of water possible, as well as with the minimal
operation of hydrants and valves.
5.6.1.4 Operation of Valves
 If valves are not opened and closed at regular intervals, they may
become inoperative due to rust, corrosion or dirt.
 Valves should be operated at least twice each year. Records should be
kept of the number of turns required to open or close each valve and of
the position (open or closed) in which the valve was left.
 Kerosene or diluted lubricating oil poured down the valve key may help
in loosening a
valve stem which binds due to dry packing.
a) To check whether a valve is operational or not:
 First close the valve completely and then open it completely;
 Back off on the valve about one turn to avoid locking it in an open
position; and
 If the valve does not operate properly, repair or replace at once.

b) Things to check:

 Ensure that the valve boxes are not full of mud or debris, or become
buried;
 Inspect the valves for leaks around the valve stem;
 Ensure that the valve handles are intact;
 Ensure that each valve can be fully opened and fully closed;
 Record the inspection date, whether the valve is right- or left-handed,
and whether it is normally open or normally closed;
 Record any needed repairs or replacements.
5.6.1.5 Repair, Maintenance of Water Meters
The water meters are mechanical devices, which normally deteriorate in
performance over time. The fact that a meter does not show outward signs of
any damage and has a register that appears to be turning does not mean that
the meter is performing in a satisfactory way.
It is necessary to ascertain the following preventive cares for water meter after
proper installation.
a) Preventive maintenance:-
1. Proper handling, storage and transportation of water meters.
2. To clean the dirt box or strainer wherever installed.
3. To replace the gaskets, if any.
4. To clean the chamber in which the meter is installed and keep free from
flooding, & seepage.
5. To remove the meter for further internal repair/replacement if it does not
show correct reading pattern.

DEMEWOZ CONSULTANCY
74
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

b) Breakdown maintenance:-
Replacement of broken glass, lid and fallen wiper wherever provided:-
These are the only basic breakdowns observed during periodical inspection. If
a meter found not working, then it shall be removed immediately and sent to
meter service workshop. In meter workshops normally following steps are
performed to carry out the repairs.
1. Disassembling of water meters including strainer, measuring unit,
regulator, registering device, etc.
2. Clean all disassembled spare parts in detergent solution in warm water.
3. Inspect the cleaned parts and replace worn parts and gaskets, if any.
4. Inspect the meter body spur threads and cover threads.
5. Inspect the sealing surface on meter body and paint the meter body, if
necessary.
6. Inspect the vane wheel shaft pinion, bearing & pivot.
7. Inspect the vane wheel chamber.
8. Reassemble the water meter properly after reconditioning.
9. Calibrate & test the repaired water meter for leakage & accuracy as per
guideline (BS or other standards).
Make entry in the life register of that water meter for keeping history record.

5.7 Troubleshoo 5.7.1 Troubleshooting for Pipeline

ting Discuss the potential unexpected problems, what might be the causes and
some possible solutions.
Table 5-3: Troubleshooting for Pipelines

No. Problem Problem Cause Possible Solution

Numerous Pipeline laid too Consider relocating or
1
repeated shallow and pipe replacing the pipeline.
breakages in exposed to traffic (Consult with a water
pipeline loading Engineer, qualified
Wrong type of pipe water technician or
plumber.)
No water in  Breakage, burst Check pipeline carefully,
pipe  Blockage – air lock starting at the intake
level and check at
 Closed valve
various points whether
 Source is dry water is reaching each
 Design problem point. (Consult with a
water engineer or
qualified water
technician.)
Poor water Polluted raw water Investigate the problem
ÌÌ Burst that has and identify a suitable
quality
Introduced solution. Carry out a
Pollutants or water quality test if
sediments appropriate.

DEMEWOZ CONSULTANCY
75
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

ÌÌ Faulty treatment

Low pressure High friction losses Identify whether a

from movement of the maintenance solution
pipe work, restriction will resolve low
in pipes, bursts, low pressure; this may
include water rationing,
ÌÌ
or the problem is related
abstraction, excessive to a design issue.
consumption (Consult with a water
engineer or qualified
water technician.)

5.7.2 Troubleshooting for Water meter

Explain the troubleshooting requirements for water meter using Table 5-4.
Identifying the problems, the causes and remedial measure to make it
operational.
Table 5-4: Troubleshooting of Water Meter

No. Trouble Cause Remedies

Meter reads in
1 Might have installed Check the arrow of the
reverse direction
in reverse direction meter body and installed
the meter properly, if
necessary

2 Meter not Impeller to register Remove the meter for

recording link broken service and repair

3 Continuous Pointer and drum Remove meter for

moving link missing servicing and repairs
pointer/digit
Drum defect
rotates but not
change in indicator

4 Dial/glass foggy Climatic Condition Wait for climate change,

if it is rainy season

5 Meter suspected Inlet flow Clean the external

slow or fast disturbance, missing filter/dirt box where
internally defective, provided and the in-built
deteriorated strainer
magnets in case of
Ensure full open
magnetic meters
condition of upstream
valve, if doubt persists,
remove meter for testing,
servicing and repair

DEMEWOZ CONSULTANCY
76
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

6 Bush/Gland Gland deformity Remove meter for testing

leakage and servicing

7 Regulator, head, Regular washer Remove meter for

body leakage damaged, loose servicing and repair
screw

8 Physical damage Improper installation Remove meter for

to meter including testing, servicing and
broken seal repair

9 No water available Semi positive Meter is acting as a stop

past the water /positive valve.
meter even though displacement meter
Remove it for inspection,
inlet side is with jammed piston
servicing and repair
charged

In case of smaller size water meters, it is advisable to check cost benefit ratio
before getting them repaired.
5.7.2.1 Prevention of Tampering of Water Meters
In order to prevent tampering, following precautions should be taken:
1. The water meters, shall be installed properly in the chamber with lock and
key or in the C.I. covers with lock and key in order to avoid tampering.
2. The water meters must be sealed properly.
3. The water meters shall not allow reversible flow; it should register flow in
forward directions only.
4. The water meter dials should be easily readable without confusions.
5. The lid, glass of water meters must be made up of tough materials as per
any standard and shall be replaced timely.
6. The wiper or dial as far as possible is avoided.
7. In case of magnetically coupled meters, the proper material to shield
magnets must be provided in order to avoid the tampering of such meter by
outside magnets in the vicinity of meter.
8. Periodical inspection/checking at site is essential to ensure the proper
working of meter.
9. Special sealing arrangements may be necessary and provided for bulk
meters whereby unauthorized removal of the meter from the connection
can be detected.
In spite of above, to tackle the problems of tampering suitable penalty
provisions/clauses shall be there in the rules or the water supply agreement
with the consumer. This will also discourage the consumer tendencies of
neglecting water meter safety.
5.7.2.2 Trend of replacement of Water Meter
In general, if a water meter goes out of order due to any physical damage or
non operation of registration device and is beyond economical repair it should
be replaced with immediate effect. In Indian context, the performance of water
meter depends upon -
1. The quality of water meter produced by manufacturer and it differs from
manufacturer to manufacturer.

DEMEWOZ CONSULTANCY
77
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

2. the design of pipeline & fittings in line with meter;

3. the workmanship & care when handling and installing the meter;
4. the pattern of water passing through the meter;
5. the type of supply of water whether it is continuous or intermittent;
6. the meter maintenance, testing;
7. The proper selection of meter.
The performance of a water meter is required to be watched continuously with
suitable history sheets. Any abnormality noticed needs immediate action.
Timely removed faulty meter, & especially mechanical type meter, prevents
cascade and cumulative damages.
Looking at the amount of transactions involved, bulk meters shall be given
priority in replacements. Based on the experience gained for a specification
work, a well planned programme for periodical meter testing, servicing, repairs
and replacement wherever necessary shall be designed.

5.8 Service The causes of leakage and breakage in service pipes are: Shallow and
Lines Repair inadequate laying of service high water pressure in the system, internal and
external corrosion of pipes.
The following actions should be taken in the repair of service pipes.
 Leakage in service pipes should be located, if necessary, by sounding.
 Joint leakage should be repaired by cutting out the part and replacing it.
 Service lines clogged from sediment from mains should be cleaned by
dragging or
pushing a scraper through
them or by blowing with
compressed air.
 Service pipes uncared for
after a house demolition or
road widening should be
removed as they may
cause leaks.
Service line should be regularly
inspected for cross-connections.

5.9 Step 4: Spare Parts & Materials for pipelines include:

Spares,  Pipe lengths for the diameters common in project;
Tools, &  Fittings for appropriate diameters;
Technical
 Valves;
Assistance
 Taps & tap washers;
 Threading Tape; and
 Glue
Supply Chain – most pipeline materials can be purchased at a well provisioned
hardware store.
Technical Assistance – technical assistance should be sought if a pipeline
keeps bursting at a particular point. This may indicate:

DEMEWOZ CONSULTANCY
78
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

 Lack of anchor blocks or supports;

 Hammer pressures;
 Unusual stress on the pipe; and
 Poor design.

Review  Are participants able to carry out basic pipeline repairs?

 What are the factors that may cause problems in a pipeline?
 How are these factors prevented?

Session Attachments

Attachment 5-1: Typical Gravity System Pipeline

Attachment 5-2: Typical Pumping System Pipeline

DEMEWOZ CONSULTANCY
79
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Attachment 5-3: GI Pipes Repair Procedures

Attachment 5-4: Procedure for repair of broken PVC pipe

1. Isolate the leaking section by closing the

sluice or the gate valve.
2. Dig the trench along the leaking pipe to find
the leaking place that needs to be repaired.
Dig the trench wide enough to give yourself
working space. Dig the trench two meters on
each side of the leaking point, to allow you to
control the pipe.

DEMEWOZ CONSULTANCY
80
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

3. Cut out the leaking piece using a hack saw.

4. Cut out a new piece of pipe. The new piece
must be longer than the old one. Measure the
length of the old piece; add 75 millimeters on
both ends. This will be your “socket pipe”.
5. File the edges of the pipe where you cut.
Clean the cut ends of the pipes with the
mutton cloth. Also file and clean the ends of
the pipes in the trench.

6. Cut a short piece of the same diameter pipe to

use for forming the sockets. Make a small fire.

7. Heat the end of the socket pipe for a distance

of 75 mm as your mark shows. Keep rotating
the pipe so that it is equally heated all the way
round.

8. When the heated part is soft, insert the other

short piece of pipe and rotate it until a socket
is shaped. The socket should be 75 mm deep.

9. When the socket is correct, dip it unto a

bucket of water to cool. Make another socket
at the other end.

10. File the edges of the socket pipe. Clean the

ends of the socket pipe with mutton cloth.
Apply tang it inside the sockets and outside
the pipe in the trench. Be sure to read the
instructions on the tin of the tang it. Obey
the instructions.

11. Connect the pipes. Do not move the

connection for at least five minutes. Fill the
trench except for the part that has been
repaired. Do not let water go through for
some hours. Turn on the water and check
for leaks. If there are no leaks, cover the
rest of the pipe.
This kind of repair needs two people, you and
your relief operator.

DEMEWOZ CONSULTANCY
81
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Attachment 5-5: PE Pipes Repair Procedures

DEMEWOZ CONSULTANCY
82
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

6 SESSION – F: O&M REQUIREMENTS

FOR STORAGE TANKS
Module - C TECHNICAL O&M REQUIREMENTS FOR RURAL PIPED
SYSTEM

6.1 Session Outline This session covers the following core topics for technical O&M
management:
 Introduction
 Types of Service Reservoirs/Tanks
 Components of Service Reservoir
 Operation of Service Reservoir
 Specific O&M Requirements for concrete and steel service
reservoir
 Troubleshooting for service reservoir
 Spare parts, Tools and Technical Assistance Requirements

Appropriate This session is supposed to be offered by Water Engineer having

Facilitator theoretical and practical experiences.

6.2 Objective At the end of the session, the participants will be able to:
 identify the main components of service reservoir or a tank
 describe the functions of the key components
 Carry out operation and maintenance tasks.

Outputs An O and M schedule

Session Timing 4 hours

Methodology This is intended to be a practical session. The components will be taught

by demonstration of the system itself, not using drawings or
descriptions. The flip chart can be used to illustrate details if necessary.
Reinforce the learning by allowing participants to handle the parts and
describe their functions to each other.

Materials  valve key/wheel

 pipe wrench
 brush or broom
 materials to make tank repairs

Session Guide and Contents

6.3 Introduction Water supply provision is pumped from the water source to the system’s
water tank or service reservoir, from which it is delivered to the
consumers through the distribution pipelines.

DEMEWOZ CONSULTANCY
83
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

The service reservoirs can be constructed either:

 Underground,
 Ground level or,
 Elevated (water towers)
Different kinds of service reservoir/tanks are available depending on the
material of that makes them such as:
 Reinforced concrete (floor, walls, roof)
 Masonry walls on reinforced concrete floor & roof;
 Ferro cement;
 Plastic;
 Corrugated iron; and
 Steel (ground or elevated).
Tanks with different names occur in different kinds of projects relating to
their function and placement, e.g.:
 rainwater harvesting tank
 rock catchment tank
 Berkad (Somali name for an underground tank)
 storage tank
 Break-pressure tank.
The training session covers standard forms of tanks.

6.4 Components of The training facilitator should explain the various components of service
Service reservoir/tanks using attachment 6-1 and Table 6-1.
Reservoir Table 6-1: Components of Service Reservoir
No. Component Function

1 Inlet valve valve to control flow into the service

reservoir; if closed water does not enter
service reservoir

2 Inlet pipe lets water into tank above service

reservoir water level

3 Float valve valve on inlet pipe that automatically

closes when
the service reservoir / tank is full of water

4 Washout pipe and valve that is opened to allow

cleaning of the service reservoir /tank

5 Overflow disposes of excess water

6 Manhole/cover and allows inspection and cleaning of service

ladder (external & reservoir /tank
internal)

DEMEWOZ CONSULTANCY
84
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

7 Ventilation pipe allows circulation of air to keep the water

aerated; must have mesh/netting over
ends of pipe to prevent insects or animals
from entering tank

6.5 Operation of 6.5.1 General Procedures

Service The main function of Service Reservoir (SR) is to cater for daily
Reservoir demands and especially peak demands of water. Operators must be
concerned with the amount of water in the storage reservoir and the
corresponding water levels at particular times of the day.
Procedures for operating the Service Reservoir will depend upon the
design of its storage capacity and on the water demand.
 Reservoir water level should be read every 1 to 2 hours and
recorded, to secure
functioning of the reservoir.
 Daily water delivery and its hourly changes should be recorded by
self-recording flow
meters or main line meter.
 Water level in the reservoir should not fall below the limit in which air
and deposited
substance will be absorbed into the effluent pipe.
 Valves, water level meter, flow meter and gauges should be checked
regularly to ensure their proper operation.
 Reservoirs should be emptied, cleaned, repaired and disinfected at
regular intervals.
 Leakage in reservoir should be checked regularly. To investigate the
leakage, full the
reservoir to full and close influent and effluent valves. Then check for
any change in the water level. A fall in the water level indicates
leakage. If leakage is located, immediate repair should be made.

6.6 Specific Service 6.6.1 Concrete Reservoirs

Reservoir O and  Drain and clean reservoir by draining the stored water into the
M Tasks distribution system, until about 10 cm remains. Use this water
to clean and scrub tank floors and walls. Remove all water,
sediments and loose materials,
 Check for cracks in concrete reservoirs and repair,
 Check manhole cover (sufficiently tight fitting),
 Check interior piping for corrosion; clean and repaint,
 Disinfect tank after thoroughly rinsing the interior of the
reservoir by adding a chlorine solution to the water at a
sufficient rate to provide a chlorine solution of 2mglliter when
the tank is full. Keep the chlorinated water in the tank for 24
hours before putting the storage reservoir back into service.
The disinfected water is suitable for domestic consumption.
6.6.2 Steel Tanks
 Check general condition for loose scale, leaking seams and
rivets; repaint if necessary.

DEMEWOZ CONSULTANCY
85
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

 Inspect ladder, roof, and structure forms, base and stand tower
foundation.
 Inspect condition of paint work - empty tank, examine interior
paint. If heavy corrosion exists, arrange for withdrawing the
tank from service to permit repainting. Carry out proper
cleaning and repainting by suitable paint for drinking water.
After painting, carry out the disinfection for concrete reservoirs
as mentioned above.
6.6.3 Crack Maintenance
a) Repairs Using Cement Mortar
Cracks in concrete tank walls should be repaired from the inside; if at all
possible, by chiselling a cut in the cracked area and filling with a stiff
cement mortar (1:3 mixes by volume). Keep the repair wet for at least 24
hours before putting the tank back into operation. Remember to disinfect
the tank if necessary.
If it is not possible to reach the inside of the tank easily, try undercutting
(dovetailing) from the outside as follows:
 Drain to below the crack line.
 Using a cold chisel, make a cut on the reservoir cracked/leak with
the following dimensions: Width 19-25 mm and depth 19-25 mm
 Clean and wet the cut before applying a stiff mortar (1:3 mix).
 Clean and wet the holes cut in the reservoir and apply the
cement mortar paste.
 Keep the mortar wet for
at least 24 hours before
putting the tank back
into operation.
 Disinfect the tank;
 Rinse the tank with
clean water;
 Put the repaired tank
back into operation.
b) Repairs Using Proprietary
Fast-Setting Cements
There are a number of
proprietary fast-setting
hydraulic cements specially
formulated to quickly stop leaks and the seepage of moisture through
holes or cracks in concrete or masonry walls.
Some brands are “Quickrete”, “Parson Quick Plug”, and “Dry Lok Fast
Plug.” These are generally based on Portland cement, but have
ingredients that make the compound expand as it sets. Most of these
proprietary blends are supplied as a dry powder to be mixed with clean
water, and set within 3 to 15 minutes depending on the brand.
These formulations are durable and can be expected to last for the life of
the concrete structure being repaired. They do not contain toxic
elements, are highly impervious to water, and thus are suitable for use
with potable water systems.
DEMEWOZ CONSULTANCY
86
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Application Procedure:
1. Open up the crack or hole by making a cut along the damaged
area using a cold chisel. This will make it possible for the
compound to form a plug. As the compound sets, it expands to
complete the seal;
2. Before applying the compound, brush away all loose particles;
3. Mix the compound in accordance with the manufacturer’s
directions, which usually results in a paste of sticky consistency.
The compound is hydraulic cement that begins to bind once it
comes into contact with water. Once the water is mixed in, the
paste must be used within minutes;
4. Apply the paste and force it into the crack. Start from any edge;
5. When sealing leaks beneath the water level in an un-drained
reservoir, use a trowel or your hand with a glove. Hold the
mixture in place for 3 to minutes or until no water passes through
the leak;
6. Keep the repaired leak damp for 15 or more minutes (see
directions).
c) Repairs Using Epoxy
Epoxy is an adhesive sealant available commercially in plastic packs of
15 grams or more. It consists of two components: A (Resin) and B
(Hardener). Epoxy is generally used in repairing small leaks. Repairing a
reservoir using this compound requires the following steps:
1. Drain the reservoir;
2. Dry and clean the surface to be repaired. In the case of steel
tanks, roughen the surface to ensure good adhesion. In the case
of concrete surfaces, clean out all loose particles;
3. Squeeze equal amounts of component A (Resin) and B
(Hardener) on a suitable palette, and mix thoroughly;
4. Apply the mixture immediately to the leak;
5. Allow 2 to 4 hours for the epoxy to set. (Check instructions on the
package if more or less setting time is needed);
6. Put the reservoir back to operation.
d) Repairs on Steel Tanks Using Electric or Acetylene Welding
1. Drain the reservoir;
2. Dry the surface to be repaired;
3. Weld the hole or break directly if small. If the leak is large, cut a
metal plate with size lightly greater than the hole and then weld it
in place;
4. Clean and smoothen the welded surface;
5. Paint the repaired area;
6. Disinfect the reservoir;
7. Put the reservoir back into operation.
6.6.4 Cleaning of Service Reservoir
To ensure the quality of the water supply, the service reservoir must be
DEMEWOZ CONSULTANCY
87
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

cleaned and disinfected periodically. Failure to apply this routine will

result in the accumulation of solids and proliferation of bacteria in the
tank, making the water unsafe for drinking.
Cleaning is usually done once a year, but it always must be done
whenever the water in the reservoir contains an appreciable amount of
dirt.
Routine inspection is the best way to determine when a tank requires
maintenance and cleaning. A visual inspection can be made from the
roof manhole with water level lowered to about half full or less.
The following activities are normally involved in cleaning of service
reservoir/tank:
 Make alternate arrangement for water supply to consumers
served by the SR,
 Close the inlet line before commencing cleaning of SR,
 Draw the water from the SR till 20-30cm water is left in the SR.
 Close the outlet valve so that no water will be used while the tank
is being cleaned.
 Collect sample of water and silt/mud accumulated in the Tank
and get the biological analysis and for presence of snails and
worms. If snails and worms are found find the source and
eliminate it.
 Drain and dispose off the remaining water and silt.
 Wash the interior of tank walls and floor with water hose and
brushes.
 Inspect the interior of walls and ceiling of tank for signs of peeling
off or deterioration.
 Apply disinfectant (Supernatant of Bleaching powder) to the walls
and floor before start of filling the tank/SR.
Frequency of cleaning of SR depends on the extent of silting,
development of bio films and results from water quality monitoring.
6.6.5 Maintenance of Reservoir Appurtenances
a) Monthly Maintenance Tasks
 Lubricate float control pulleys.
 Inspect float for leaks.
 Check level indicator for free operation.
 Sweep roof, catwalks and ladder landings.
b) Manholes
Manholes should always be covered and locked to keep out foreign
materials that could contaminate the water supply and also to prevent
accidents.
c) Overflow Pipe and Air Vents
1. Covered reservoirs or tanks should be vented to allow the
passage of air to and from the reservoir as the water level
changes. Use fine screens on the vents to prevent the entrance
of animals and insects, and keep the screens in good repair.
2. Keep access manhole covers in place to prevent accidents and

DEMEWOZ CONSULTANCY
88
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

contamination.
3. Slope the ground away from the reservoir in all directions to
prevent surface water from flowing towards it.
4. Leaks in the cover or walls that allow surface water or shallow
groundwater to seep in are dangerous. Repair leaks at once.
 closing and opening the control valves once a month
 releasing a jammed float valve
 holding the float valve in the up position; there should be no flow
 holding the float valve in the down position; there should be
normal water flow
 checking the float valve for leaks and seal leaks
 replacing the rubber washer if there is a leaking float valve (see
Attachment-6.1)
 replacing the pin on the float valve arm
 Opening the washout and clearing silt from the tank once a
month. (Note: The tank should be almost empty and the outlet
valve must be closed before cleaning.)
 checking that the manhole is properly covered to prevent insects
and animals from entering tank
 repairing any cracked or damaged tanks and covers
 repairing the mesh or netting over the ventilation pipes
 checking the support tower for elevated tank for structural defects
 Checking the ladder in the tank to ensure it is safe to use.
6.6.6 Records at Service Reservoir
1. Records to be kept on the operation
 Water levels in the SRs (for all compartments) at hourly intervals.
 Time and relevant operation of control valves with time of
opening and closure or throttling position of the valves.
 Hourly flow meter readings both on the inlets and outlets.
 Hourly residual chlorine readings of inflow water and outflow
water.
 The man-hours spent on routine operations at the SR in previous
year and the cost thereof.
2. Maintenance Record
Maintain record on each of the following maintenance/repair works along
with the cost of materials and labour.
 When the gland ropes of the valves at the SR were changed,
 When the spares of the valves were changed,
 When the manhole covers were changed/replaced,
 When the water level indicator was repaired or replaced,
 When the reservoir was last cleaned,
 When the out-fall drain for scour and overflow was last cleaned,
 When the ladder was changed,

DEMEWOZ CONSULTANCY
89
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

 When the structure of the reservoir was last repaired to attend to

structural defects or arrest leakage,
 When the reservoir was last painted,
 When the piping at the reservoir was last painted,
 Total cost of repairs and replacements at the SR in previous year
along with breakup of material cost and labor cost with amount
spent on outside agencies for repairs and replacements.

6.7 Troubleshootin Discuss the potential unexpected problems, what might be the causes
g for Service and some possible solutions.
Reservoir
Problem Problem Causes Possible Solution

Overflow from  Failure of float valve  Replace the rubber washer

tank  Gate valve blocked (see Attachment 2).
(outlet side)  Replace the pin.
 Airlock in pipeline  Remove and clear the valve
(outlet side) (replace if necessary).
Check/open the nearest air
valve.
Repair on the inside – this will
Leaks from tank Crack in wall
depend on the type of tank.
wall
Cracks in roof  Settlement of roof  Seal all cracks; add
 Too much loading on additional support if
roof necessary.

6.8 Spares, Tools Tools:

and Technical  shovel and brush for removing silt
Assistance  masonry tools for cement plastered tanks
 pliers for repair of float valve
Spares – include:
 pin for float arm
 mesh, strainer
 Check requirements of fittings for pipe inlets and control valves.
Supply chain – most tank materials can be purchased at a well-
provisioned hardware store.
Technical assistance – this should be sought if the tank wall has major
leaks or if the roof shows significant cracks and the structural integrity of
the roof is in doubt.

Review  What are the main problems that can occur to the tanks within
the scheme?
 Can these problems be fixed by the WAO/EWB staff?
 Is there an O & M plan?

Session Attachment 6.1: Sketch of a typical storage tank

Attachments Attachment 6.2: Diagram for replacement of the rubber washer on a float
valve

Attachment 6-1: Sketch of a typical Service Reservoir/Tank

DEMEWOZ CONSULTANCY
90
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Attachment 6-2: Diagram for replacement of the rubber washer on a

float valve

DEMEWOZ CONSULTANCY
91
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

7 SESSION – G: O&M REQUIREMENTS FOR CONSUMERS

POINTS

MODULE – C TECHNICAL O&M REQUIREMENTS FOR RURAL PIPED

SYSTEM

7.1 Session Outline This session covers the following main topics
 Introduction to consumer points
 Identification of various components and types of consumer
points
 O & M Tasks for consumer points
 Troubleshooting for Consumer Points
 Records and Report requirements

Appropriate Facilitator This training session should be offered by well experience Water
Engineer.

7.2 Objective At the end of the session, the participants will be able to:
 identify the main components of consumer water points
 describe the functions of the key components of the water points
 Carry out water-point maintenance.

Outputs An O and M schedule

Session Timing 2 Hours

Methodology This is intended to be a practical session. The components will be taught

by demonstration of the system itself, not using drawings or
descriptions. Reinforce the learning by allowing participants to handle
components and describe their functions to each other.

Materials  Valve key/wheel

 Pipe wrench
 Brush or broom
 Bucket
 Clock or timer

Session Guide and Contents

7.3 Introduction This is a general discussion of the O and M tasks for various consumer
points which include:
 Public tap stand
 Cattle trough
 Individual connection.

7.4 Identification of 7.4.1 Water-point components

With reference to the drawings in Attachment 7 1, identify and

DEMEWOZ CONSULTANCY
92
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Components demonstrate the function of the key components:

Table 7.1 depicted the various components of public water points.
Table 7-1: Function of components of public water point
No. Items Function
1 Service/gate stopcock or gate valve that opens or closes
valve the water
supply
2 Pipe stand protects and supports the pipe at the water
point
3 Tap / bibcock valve to control flow at water point
4 Float To control water in cattle trough
valve/ball cock
5 Water Meter Measures flow though the pipe
6 Water Meter box To protect meter
7 Apron concrete surround to water point
8 Drainage channel leads the water away from the water point
to a soak-pit
or drain
9 Fence A barrier constructed around the water
point to prevent the entrance of authorized
persons and animals

1. Flow measurement
Measure the flow from the water point using a bucket and clock (how
long does it take to fill the bucket?) or record readings on the flow meter.
Measure the flow from another water point and compare the results.
Discuss why the flows may be different.
Reasons may include:
 location of water point; points close to tank may get more water
 water pressure; height of tank above water point gives pressure
 pipe leaks reduce pressure
 Blockages in pipes, valves or meter.
2. Water-point maintenance
A noticeable problem at many consumer points is associated with the
care and management of the taps.
Consideration should be given to:
 Using good-quality taps (brass – check against fake materials!)
 Consider the use of push-type (self-closing) taps where
appropriate.

7.5 Specific Water- Identify the O & M tasks associated with the water points. These may
Point O&M Tasks include:
 Check perimeter fence & repair
 Check water kiosk structure & repair

DEMEWOZ CONSULTANCY
93
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

 Check tap
 Check tap by opening and closing tap and check for leakage or
damage
 Replace washer if tap leaks (See Attachment 2) or replace tap
 Repair erosion around pipes or tap stand
 Repair leaking or damaged pipes
 Repair damaged valve chambers
 Close and open service valves once a month
 Repair cracked or damaged concrete surround or drain, Small
cracks should be repaired at once by filling them with cement mortar
(grouting),
 Check for stagnant water around water point and clear/open drain to
soak away
 Clear bush and
keep compound
around water point
clean and free of
rubbish and animal
or human waste
 Check meter is
working properly
 Check ballcock on
cattle trough &
repair pin and/or
washer if needed
 Remove meter,
clean sieve and
replace sieve and
meter.
Ask participants what problems might occur if maintenance of the water
points is not carried out properly. Identify any components that require
maintenance and demonstrate and discuss O and M procedures.
1. Repair of Globe Valves, Public Faucets and Other Related
Valves
a) Tools Needed:
1. Flat jawed or monkey wrench (large enough to fit the packing nut
of the valve/faucet)
2. Rubber sheet or soft cloth (to protect the finish of the faucet or
packing nut)
3. Screw driver
4. Faucet seat dresser.
b) Materials Needed:
1. New faucet washer or valve seat and disc,
2. Lubricated candle wick for stem packing,
3. Waterproof grease,
4. Washer screws.
c) Procedure:

DEMEWOZ CONSULTANCY
94
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

1. Familiarize yourself with the different parts of the faucet or valve,

2. Examine and find out the location of the leak. If water is coming
out from the mouth or outlets, the trouble is due to a damaged
washer or damaged seat or both. If water is coming out from
around the stem when the valve is open, the stem packing is
defective,
3. Close the control valve to cut off water supply to the defective
valve/faucet,
4. Open the packing nut with a wrench. Place a piece of rubber
sheet or cloth over the wrench jaws to avoid marring t he
valve/faucet finish,
5. Repair the defective valve/faucet,
6. Replace the handle and tighten the handle screw,
Turn on water supply and observe for leaks.

7.6 Troubleshooting Discuss the potential unexpected problems and what might be the
for Water Points cause.
Table 7-2: Troubleshooting of public water point

Problem Problem Causes Possible Solution

Leaking service or  Worn-out valve Replace the valve. Check

gate valve that the valve is not being
used where a tap is more
appropriate.

Little or no water  Storage tank  Check the flow in the

flowing empty transmission pipeline.
 Tank outlet pipe  Check the strainer and
blocked outlet valve.
 Distribution pipe  Repair the pipe.
leaking or
 Check/open the nearest
broken
air valve.
 Airlock in
 Remove and clear the
distribution pipe
valve (replace if

DEMEWOZ CONSULTANCY
95
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

 Service or gate necessary).

valve blocked or
 Remove and clean the
closed
sieve/filter in meter.
 Meter blocked

7.7 Scheduled 7.7.1 PM Programs and Schedules

Maintenance
The maintenance program is made up of a collection of individual
maintenance actions. Each major unit in a water facility has a specific
maintenance program designed for that particular unit. This program will
range from routine daily inspections and tasks, to others done weekly,
monthly, quarterly, semi-annually and annually. The columns at the right
of each page of the PM checklist, show the frequency of the
maintenance items, i.e. D = Daily, W = Weekly, M = Monthly, Q =
Quarterly, SA =Semi-annually, and A = Annually.
7.7.2 PM Checklist
The following PM checklists are based on the information obtained from
the existing manufacturer's operation and maintenance manuals. It
provides instructions for inspecting, cleaning, lubricating and adjusting
equipment used in different water supply systems.
Table 7-3: Preventive Maintenance Checklist for Transmission and
Distribution System
No. PM Checklist D W M Q S A
4.1 Transmission and
Distribution Mains
4.1.1 Check and update
system maps
4.1.2 Record daily water
production transmitted
and distributed
4.1.3 Regularly check mains
for inadequate pipe
diameter, corrosion, and
poor pipe network;
correct problem
4.1.4 Check for leakage in
distribution mains and
service connections for
inoperative meters and
water waste
4.1.5 Flush dead ends at
regular intervals
4.1.6 Check and update
records of distribution
mains and valves
4.1.7 Inspect transmission
and distribution mains
periodically; protect pipe
against electric
corrosion & erosion,
etc.
4.2 Service Reservoir
4.2.1 Keep premises clean

DEMEWOZ CONSULTANCY
96
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

4.2.2 Clean storage

reservoirs or elevated
tanks
4.2.3 Check for cracks or
leaks
4.2.4 Check float valves or
other control devices for
proper function
4.2.5 Inspect paint condition
of metal parts; repair if
necessary
4.2.6 After repair, disinfect
reservoirs and tanks
4.2.7 Check vent screen,
replace or repair if
necessary
4.3 Valves
4.3.1 Check for proper
functioning
4.3.2 Clean valve chamber
4.3.3 Lubricate valves using
kerosene or lubricating
oil
4.4 Service Connection
4.4.1 Inspect for cross-
connection
4.4.2
Check for leaking pipes
4.4.3 Check inoperative
meters
4.5 Public Stand Post
4.5.1
Inspect for leakage
4.5.2 Check function of taps
and meters
4.5.3 Inspect concrete plat
form
4.5.4
Keep area clean
4.6 Water Meters
4.6.1 Check for correct
installation
4.6.2 Check for proper
functioning (on-site
inspection)
4.6.3 Check for accuracy,
repair or replace (every
2 years)

7.8 Record and

7.8.1 Record System
Report
A record system has to be developed which should be realistic and
apply to the operating problems involved at the particular transmission,
distribution and service reservoir sites. The most efficient way to keep
records is to plan what data is essential and then prepare the formats
followed by the persons to fill the data, frequency and to whom the

DEMEWOZ CONSULTANCY
97
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

record is to be sent for review and report.

Sample records to be maintained at transmission, distribution and
service reservoir sites are given below for guidance.
The following details shall be recorded:
a) Transmission Lines
1. Updated transmission system maps with alignment plans.
Longitudinal sectional plans,
2. Record of daily readings of flow meter at upstream and downstream
end of pipeline,
3. Record of water level of reservoir at both upstream and downstream
end of transmission system.
4. Pressure reading of the transmission system.
5. Identification of persistent low pressure location along the pipeline.
6. Record of age of pipes.
7. Identify pipelines to be replaced.
8. Identify source of leaks.
9. Record of Bulk meter/water meter reading before the delivery into
overhead tank.
10. Record of residual chlorine.
11. Record on when the pipeline leaks were repaired or pipe changed
and the cost of materials and labour cost thereof.
b) Service Reservoir
1. Water levels in the reservoir,
2. Time and relevant operation of control valves with time of opening
and closure or throttling position of the valves,
3. Daily flow meter readings both on the inlets and outlets,
4. At least one a day Residual chlorine readings of inflow water and
outflow water,
5. Gland ropes of the valves/Spares at the SR were changed,
6. Manhole covers were changed / replaced,
7. Water level indicator was repaired or replaced,
8. Reservoir was cleaned,
9. Out-fall drain for scour and overflow was last cleaned,
10. Ladder was changed, when the structure of the reservoir was last
repaired to attend to structural defects or arrest leakage,
11. Reservoir/Pips was last painted,
12. Total cost of repairs and replacements at the SR in previous year
along with breakup of, material cost and labor cost with amount
spent on outside agencies for repairs and, replacements.
c) Distribution Lines
1. Updated system map,
2. Pressure and flow readings at selected monitoring points,
3. Persistent low pressure or negative pressure areas,
4. Age of pipes/quality of pipes,
5. Pipelines to be replaced,

DEMEWOZ CONSULTANCY
98
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

6. Presence of undesirable materials,

7. Water budget for each zone served by one SR,
8. Number of connections given,
9. Number of meters out of order,
10. Quantity measured at outlet of reservoir,
11. Quantity distributed/measured or billed,
12. Water budget for each zone served by one SR
13. Source of leaks and persistent leak points,
14. Status of bulk meters - functioning or not,
15. Status of consumer meters,
16. Facilities for repairs of consumer meters,
17. Number of unauthorized connections,
18. Residual chlorine levels at the pre-selected monitoring points,
19. Bacteriological quality of the water sampling points,
20. Persistent areas where residual chlorine is absent/where water
samples are found contaminated ,
21. Record of carrying out repairs on the following
22. The pipe line leaks or replacement of pipes.
23. Change of gland ropes of the valves in distribution system.
Record on man hours spent on routine operations in the distribution
system in the previous year and the cost thereof,

7.9 Spares, Tools, and Tools – See above for tools required.
Technical Spares – the following spares are usually required:
Assistance
 Tap washers
 Tap
 Spare meter
 Meter sieve
 Gate valve
 Ball valve

Spare Pin for ballcock

Supply Chain – most materials can be purchased at a well provisioned
hardware store.
Note: Check supplier and quality of taps and meters available.
Technical Assistance
 Technical assistance should be sought if the meter frequently
has air or gets blocked.
 Servicing of meters is a specialized skill and should be
undertaken by technician
 Persistent water quality problems should be investigated with a
water quality specialist, based on laboratory analysis of water
quality.

Session Review Check that the objectives of the session have been met by asking
participants to explain what they have learned and demonstrate that

DEMEWOZ CONSULTANCY
99
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

they can carry out the maintenance without assistance.

Attachment 1: Consumer water points
Attachments
Attachment: 2 Replacement of a worn-out washer on a tap stand

DEMEWOZ CONSULTANCY
100
Ministry of Water, Irrigation and Electricity Training Module - C
Rural Piped System Operation and Maintenance Management For Technical O&M Requirements

Annexes

Annex A: References

SNNP Region Water Bureau, Preventive Operation & Maintenance of Water Lifting
Devices in the SNNPRS, A General Guideline, SNV in collaboration with Hawassa
University, September, 2009.
Operation and Maintenance Manual for Rural Water Supplies, Government of India
Ministry of Drinking Water and Sanitation MAY, 2013
A Trainer’s Manual for Community Managed Water Supplies in Kenya, 2012

DEMEWOZ CONSULTANCY
101