4 Wastewater

Watercare Services Limited
Water and Wastewater Code of Practice

for Land Development and Subdivision
Content from the Standard NZS 4404:2010 Land development and subdivision infrastructure has been reproduced for use in
the Infrastructure Design Standards for Local Networks with permission from Standards New Zealand under Licence 000805

(Based on Section 5 of NZS 4404: 2010)
5 WASTEWATER
5.1 Scope............................................................................................................................................... 2
5.2 General ............................................................................................................................................ 2
5.2.1 Objectives ..................................................................................................................................... 2
5.2.2 Referenced documents and relevant guidelines .......................................................................... 2
5.3 Design.............................................................................................................................................. 2
5.3.1 Design life ..................................................................................................................................... 2
5.3.2 Structure plan ............................................................................................................................... 3
5.3.3 Future development...................................................................................................................... 3
5.3.4 System design .............................................................................................................................. 3
5.3.5 Design criteria............................................................................................................................... 3
5.3.6 Structural design........................................................................................................................... 6
5.3.7 System layout ............................................................................................................................... 8
5.3.8 Maintenance structures .............................................................................................................. 11
5.3.9 Venting........................................................................................................................................ 17
5.3.10 Connections.............................................................................................................................. 17
5.3.11 Pumping stations and pressure mains ..................................................................................... 18
5.3.12 Pressure sewers and vacuum sewers...................................................................................... 19
5.3.13 On-site wastewater treatment and disposal ............................................................................. 19
5.4 Approval of proposed infrastructure .............................................................................................. 19
5.4.1 Approval process........................................................................................................................ 19
5.4.2 Information to be provided.......................................................................................................... 19
5.5 Construction................................................................................................................................... 19
5.5.1A Excavation................................................................................................................................ 19
5.5.1 Pipeline construction .................................................................................................................. 19
5.5.2A Embedment .............................................................................................................................. 19
5.5.2 Trenching.................................................................................................................................... 20
5.5.3 Reinstatement............................................................................................................................. 20
5.5.4 Inspection and acceptance......................................................................................................... 20
5.5.5 Leakage testing of gravity pipelines ........................................................................................... 20
5.5.6 Leakage testing of pressurised sewers ...................................................................................... 20
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5 WASTEWATER
5.1 Scope
This section sets out requirements for the design and construction of wastewater
systems for land development and subdivision. Section 5 primarily addresses
reticulated systems. Reference is also made to on-site wastewater systems, but
responsibility for specifying and enforcing all aspects of an on-site system
rests with the Auckland Council.
If the scope of the development is sufficiently large to include its own pumping
station, then reference should be made to WSA 04-2005 Sewage Pumping
Station Code of Australia 2005
5.2 General
5.2.1 Objectives
The objectives of the design are to ensure that the wastewater system is functional
and complies with the requirements of Watercares wastewater systems.
In principle the wastewater system shall provide:
(a) A single gravity connection for each property;
(aa) No stormwater entry, except in areas defined by Watercare as served by
combined systems
(b) A level of service to Watercares customers in accordance with the Auckland
Councils policies;
(c) Minimum practicable adverse environmental and community effects;
(d) Compliance with all relevant resource consent and other environmental
requirements;
(e) Compliance with statutory OSH requirements;
(f) Adequate hydraulic capacity to service the full catchment;
(g) Long service life with minimal maintenance and least life-cycle cost;
(h) Zero level of infiltration into pipelines, ancillary structures and manholes on
commissioning of pipes;
(hh) Progressive reduction of inflow and infiltration (I & I) into private and
public sewers, ancillary structures and manholes;
(i) Low level of infiltration/exfiltration into pipelines, ancillary structures and
manholes over the life of the system;
(j) Resistance to entry of tree roots and avoidance of build-up of fats, oils and
grease;
(k) Resistance to internal and external corrosion and chemical degradation;
(l) Structural strength to resist applied loads; and
(m) Whole of life costs that are acceptable to Watercare;
(n) Compatibility with Watercares Network Operating and Maintenance
Procedures.
5.2.2 Referenced documents and relevant guidelines
Wastewater designs shall incorporate all the special requirements of Watercare
and shall be in accordance with the most appropriate Standards, codes, technical
policies and guidelines including those set out in Referenced Documents. Related
Documents list additional material that may be useful.
5.3 Design
5.3.1 Design life
All wastewater systems shall be designed and constructed for an asset life of at least
100 years. Some components such as pumps, valves, and control equipment may
require earlier renovation or replacement. Refer to WSA 02-2002 Sewerage Code of
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Australia 1999 and 2002 for the classification of life expectancy for various
components in conventional gravity systems.
5.3.2 Structure plan

The Auckland Council and/or Watercare may provide a structure plan setting out
certain information to be used in design, such as population to be served, flows, sizing,
upstream controls, recommended pipe layout, or particular requirements of Watercare.
Where a structure plan is not provided, the designer shall determine this information by
investigation using this CoP and engineering principles and by discussions with
Watercare as necessary.
5.3.3 Future development
Where further subdivision, upstream of the one under consideration, is provided for in
the district or regional plan, Watercare will require wastewater infrastructure to be
constructed to the upper limits of the subdivision to provide for the needs of this
development.
Additionally, Watercare may require additional capacity to be provided in the
wastewater system to cater for existing or future development upstream. Peak flows
and cleansing velocities should be taken into account when designing for additional
latent capacity.
All infrastructure proposed to service future development will require the approval of
Watercare.
5.3.4 System design
5.3.4.1 Catchment design
Pipes within any project area shall be designed to be consistent with the optimum
design for the entire catchment area and any future extension of the system shall be
accommodated. This may affect the pipe location, diameter, depth, and maintenance
structure location and layout. Designers shall adopt best practice to ensure a system
with lowest life-cycle cost.
Pipes shall be designed with sufficient depth and capacity to cater for all existing and
possible development of the catchment. Where future extension of the pipe is possible,
it may be necessary to carry out preliminary designs for large areas of subdivided and
unsubdivided land. This design shall use safety factors defined by Watercare for
hypothetical subdivision and service for layouts to determine the necessary depth and
diameter for an extension.
5.3.4.2 Extent of infrastructure
Where pipes are to be extended in the future, the ends of pipes shall extend past the
far boundary of the development by a distance equivalent to the depth to invert and be
capped off, unless otherwise agreed to by Watercare. This ensures that a future
extension of the pipe does not require unnecessary excavation within lots or
streetscapes already developed.
5.3.4.3 Topographical considerations
In steep terrain the location of pipes is governed by topography. Gravity pipelines
operating against natural fall create a need for deep installations which may require
trenchless installation. This shall be avoided as far as practicable and the pipe layout
shall conform to natural fall as far as possible.
5.3.4.4 Geotechnical investigations
The designer shall take into account any geotechnical requirements determined as part
of the investigations for the development.
5.3.5 Design criteria
5.3.5.1 Design flow
The design flow comprises domestic wastewater, industrial wastewater, infiltration, and
direct ingress of stormwater, although the last two shall be minimised to the greatest
extent practicable.
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The design flow shall be calculated by the method nominated by Watercare. In the
absence of information from Watercare the following design parameters are
recommended:
(a) Residential flows

(i) Average dry weather flow of 225 litres per day per person
(ii) Dry weather diurnal PF of 3.0
(iii) Peak wet weather flow (PWWF) of 1,500 litres per day per person
(iv) Number of people per dwelling: 3.0
(v) Special design factors for high rise/density apartments are to be
agreed with Watercare
C5.3.5.1(a)
For small contributing catchments, PFs can be significantly higher but, due to the
requirement for a minimum pipe size of DN 150, such flows will not govern the design.
(b) Commercial and industrial flows
Where flows from a particular industry or commercial development are known they
should be used as the basis of design. Where there is no specific flow information
available and Watercare has no design guide, table 5.1 is recommended as a
design basis. These flows include both sanitary wastewater and trade wastes and
include dry/wet weather peaking factors.
5.3.5.2 Hydraulic design of pipelines
The hydraulic design of wastewater pipes should be based on either the ColebrookWhite formula or the Manning formula. The coefficients to be applied to the various
materials are shown in table 5.2.
5.3.5.3 Minimum pipe sizes
As basic design criteria, while carrying the peak dry weather flow (PDWF) a
pipe must be no more than half full and this condition is used to check selfcleansing. The self-cleansing velocity shall be 0.75 m/s.
The full capacity of the pipe must be greater than the PWWF.
Note that for self-cleansing the PDWF is used, and NOT half pipe full.
Irrespective of other requirements, the minimum sizes of property connection and
reticulation pipes shall be not less than those shown in table 5.3
C5.3.5.3
For infill situations, particularly where upgrading of existing DN 100 connections in
sound condition and at reasonable grades would be impractical, it is common practice
for up to six dwelling units to use the existing connection. However, such connections
would not normally be taken over as public pipes by Watercare.
Table 5.1 Commercial, industrial or CBD flows
Industry type
(Water usage)
Design flow
(Litres/second/hectare)
Light, or up to 2 storeys
0.4
Medium, or 2 to 5 storeys
0.7
Heavy, or 5 to 10 storeys
1.3
CBD or high rise buildings
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To be designed for 1 person per 15 m2
floor area, water use of 65 litres/p/d and

peaking factors as for residential
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Table 5.2 Guide to roughness coefficients for gravity sewer lines

Material
Colebrook-White
coefficient
k (mm)
Manning roughness
coefficient
(n)
VC
1.0
0.012
PVC
0.6
0.011
PE
0.6
0.009 0.011
GRP
0.6
0.011
Concrete machine made to

AS/NZS 4058
1.5
0.012
PE or epoxy lining
0.6
0.011
PP
0.6
0.009 0.011
NOTE
(1) These values take into account possible effects of rubber ring joints, slime, and debris.
(2) The n and k values apply for pipes up to DN 300.
(3) For further guidance refer to WSA 02:1999 table 2.4; AS 2200 table 2; Plastics pipes for
water supply and sewage disposal (Janson), Metrication: Hydraulic data and formulae (Lamont),
or the Handbook of PVC pipe (Uni-Bell).
Table 5.3 Minimum pipe sizes for wastewater reticulation and property
connections
Pipe
Minimum size
DN (mm)
Connection servicing 1 dwelling unit
100
Connection servicing more than 1 dwelling unit
150
Connection servicing commercial and industrial lots
150
Reticulation servicing up to 200 residential lots
150
NOTE In practical terms, in a catchment not exceeding 200 dwelling units, and where no
pumping station is involved, DN 150 pipes laid within the limits of table 5.4 and table 5.5
will be adequate without specific hydraulic design.
5.3.5.4 Limitation on pipe size reduction

In no circumstances shall the pipe size be reduced on any downstream section.
5.3.5.5 Minimum grades for self-cleaning
Self-cleaning of grit and debris shall be achieved by providing minimum grades
specified in tables 5.4 and 5.5. (See also clause 5.3.5.3)
Table 5.4 Minimum grades for wastewater pipes
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Pipe size
DN
Absolute minimum grade

(%)
150
0.55 (No more than 200 dwellings at this minimum

gradient and specific design required below 1.00)
200
0.33
300
0.25
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Table 5.5 Minimum grades for property connections and permanent ends
Situation
Minimum grade
(%)
DN 100 property connections
0.83 (subject to accurate construction)
DN 150 property connections
0.50 (subject to accurate construction)
Permanent upstream ends of DN 150,

200, and 300 pipes in residential areas
with population 20 persons
1.00
5.3.5.6 Maximum velocity

The preferred maximum velocity for peak wet weather flow is 3.0 m/s. Where a
steep grade that will cause a velocity greater than 3.0 m/s is unavoidable refer to
WSA 02 for precautions and design procedures.
5.3.5.7 Gravity wastewater applications
See Appendix A for appropriate gravity pipe Standards for wastewater.
The pipe shall be designed to:
(a) Have adequate capacity, grades, and diameters;
(b) Have adequate grade for self-cleaning;
(c) Be deep enough to provide gravity service to all lots;
(d) Comply with minimum depth requirements to ensure mechanical protection and
safety from excavation;
(e) Avoid all underground services, while maintaining all the necessary clearances;
and
(f) Allow for various drops and losses through MHs.
(g) Be easily accessible for future operation and maintenance.
5.3.5.8 Pressure and vacuum wastewater applications
The use of pressure or vacuum systems in a network is not permitted without
specific written approval from Watercare.
Where such systems are approved, they shall be designed and constructed in
accordance with Watercares requirements.
5.3.6 Structural design
5.3.6.1 General
The design shall be in accordance with AS/NZS 2566.1, or AS/NZS 3725, including
the structural design commentary AS/NZS 2566.1 Supplement 1. Details of the final
design requirements shall be shown on the drawings.
Pipe bridge design shall be subject to specific structural design of the pipe
and supports for empty and full static loads, any dynamic loads and full
seismic provisions.
5.3.6.2 Seismic design
All pipes and structures shall be designed with adequate flexibility and special
provisions to minimise risk of damage during earthquake. Historical experience in
New Zealand earthquake events suggests that suitable pipe options, in seismically
active areas, may include rubber ring joint PVC or PE pipes. Specially designed
flexible joints shall be provided at all junctions between pipes and rigid structures in
natural or made ground
5.3.6.3 Structural consideration
Pipelines shall be designed to withstand all the forces and load combinations to
which they may be exposed including internal forces, external forces, temperature
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effects, settlement, and combined stresses. The design shall include the
selection of the pipeline material, the pipe class, and selection of appropriate
bedding material to suit site conditions.
5.3.6.4 Internal forces

Pipelines shall be designed for the range of expected pressures, including transient
conditions (surge and fatigue) and maximum static head conditions. In the case of
transient conditions, the amplitude and frequency shall be estimated. Mains subject
to negative pressure shall be designed to withstand a transient pressure of at least
50 kPa below atmospheric pressure.
5.3.6.5 External forces
The external forces to be taken into account shall include:
(a) Trench fill loadings (vertical and horizontal forces due to earth loadings);
(b) Surcharge;
(c) Groundwater, including the potential for flotation;
(d) Dead weight of the pipe and the contained water;
(e) Other forces arising during installation;
(f) Traffic loads;
(g) Temperature (expansion/contraction).
The consequences of external forces on local supports of pipelines shall also be
considered.
5.3.6.6 Geotechnical investigations
The designer should take into account any geotechnical requirements determined
during the investigations for the development. Where required, standard special
foundation conditions shall be referenced on the drawings.
Special design requirements may apply in any area susceptible to land
instability or soil liquefaction. A regional map showing such areas may be
accessed here.
Note: Information provided on the map is indicative only, based on the best
available material at the time it was produced. Geoprofessionals are to satisfy
themselves of the correctness of the information and apply current knowledge
and their skills when meeting any such special requirements on a proposal.
5.3.6.7 Pipe selection for special conditions
Pipeline materials and jointing systems shall be selected and specified to ensure:
(a) Structural adequacy for the ground conditions and water temperature;
(b) Water quality considering the types of industrial waste present, the potential
for hydrogen sulphide generation and the lining material;
(c) Compatibility with aggressive or contaminated ground;
(d) Suitability for the geotechnical conditions;
(e) Compliance with the Watercares requirements.
5.3.6.8 Trenchless technology
Trenchless technology may be preferable or required by Watercare as appropriate
for alignments passing through or under:
(a) Environmentally sensitive areas;
(b) Built-up or congested areas to minimise disruption and reinstatement;
(c) Railway and major road crossings;
(d) Significant vegetation;
(e) Vehicle crossings.
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Wastewater pipes used for trenchless installation shall have suitable mechanically
restrained joints, specifically designed for trenchless application, which may include
integral restraint, seal systems, or heat fusion welded joints.
Trenchless installation methods may include:

For new pipes:
(f) Horizontal directional drilling (HDD) (PVC with restraint joint/fusion welded PE)
(g) Uncased auger boring/pilot bore microtunnelling/guided boring (PVC with
restraint joint/fusion welded PE)
(h) Pipe jacking (GRP/vitrified clay (VC)/ reinforced concrete)
For pipe rehabilitation/renovation:
(i) Slip lining/grouting (PVC with restraint joint/fusion welded PE)
(j) Closefit slip lining (PVC with restraint joint/fusion welded PE)
(k) Static pipe bursting (PVC with restraint joint/fusion welded PE)
(l) Reaming/pipe eating/inline removal (PVC with restraint joint/fusion welded PE)
(m) Soil displacement/impact moling (fusion welded PE)
(n) Cured in place pipe (thermoset resin with fabric tube)
Any trenchless technology and installation methodology shall be chosen to be
compatible with achieving the required gravity pipe gradient refer to
manufacturers and installers recommendations.
The following details including location of access pits and exit points shall be
submitted to Watercare for approval:
(o) Clearances from services and obstructions;
(p) The depth at which the pipeline is to be laid to ensure minimum cover is
maintained;
(q) The pipe support and ground compaction;
(r) How pipes will be protected from damage during construction;
(s) Any assessed risk to abutting surface and underground structures.
Construction shall be undertaken by contractors acceptable to Watercare.
C5.3.6.8
Further information on trenchless technologies may be found in Trenchless
technology for installation of cables and pipelines (Stein), Trenchless
technology Pipeline and utility design, construction, and renewal (Najafi),
and Guidelines for horizontal directional drilling, pipe bursting, microtunnelling
and pipe jacking (Australasian Society for Trenchless Technology).
5.3.6.9 Marking tape or pipe detection tape
Appropriate marking tape or detection tape shall be installed at the top of the
embedment zone, or tied to the pipe during HDD, to aid future location of the pipe.
Refer to AS/NZS 2032 section 5.3.15 and figure 5.1.
For all installations of non-metallic pipes by directional drilling tracer wires
shall be installed and tested in accordance with the description and
illustrations accessible through this link.
5.3.7 System layout
5.3.7.1 Pipe location
The preferred layout/location of pipes within roads, public reserves, and private
property may vary and shall be to the requirements of Watercare and where
applicable, as agreed with the Corridor Manager.
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Pipes should be positioned as follows:

(a) Within the street according to the locally applicable utilities allocation code.
(b) Within public land with the permission of the controlling authority;
(c) Within reserves outside the 1 in 100-year flood area;

(d) Within private property parallel to front, rear, or side boundaries.
(e) Outside of the 1 in 100 year flood overland flow paths.
5.3.7.2 Materials
Appendix A sets out various acceptable pipe and fittings materials for wastewater
system uses.
Watercare has a strong preference for pipe systems using the maximum
number of full length pipes with a minimum of joints (especially for private
connections) or where this is not possible, for jointing systems with the
minimum risk of leakage potential.
5.3.7.3 Pipes in reserves and public open space
Pipes in reserves and public open space shall be located in accordance with
Watercares requirements and those of the controlling authority.
Crossings of roads, railway lines, waterways, and underground services shall, as far
as practicable, be at right angles
5.3.7.4 Pipes in private property
Where pipes are designed to traverse any vacant or occupied public or private
properties, the design shall as far as practicable allow for possible future building
plans, preclude maintenance structures and specify physical protection of the pipe
within or adjacent to the normal building areas and all engineering features (existing
or likely) on the site, such as retaining walls.
The design shall allow access for all equipment required for construction and future
maintenance. Except where obstructions or topography dictate otherwise, pipes
shall run parallel to boundaries at minimum offsets of 1.0 m.
Where pipes are designed to traverse properties containing existing structures such
as retaining walls, buildings, and swimming pools, the current and future stability of
the structure shall be considered. Pipes adjacent to existing buildings and
structures shall be located clear of the zone of influence of the foundations. If this
is not possible, protection of the pipe and associated structures shall be specified
for evaluation and approval by Watercare.
Where pipes to be vested to Watercare are designed to traverse private properties,
they should be protected by legal easements unless Watercare confirms in
writing that easements are not required.
5.3.7.5 Minimum cover
Pipelines shall have minimum cover in accordance with Watercares requirements
or as agreed with the Corridor Manager where the works are in the
transport corridor. Where Watercare does not have specific requirements, the
minimum covers as described in AS/NZS 2566.2 may be used.
5.3.7.6 Horizontal curves
Horizontal curves shall not be used unless authorised by Watercare.
The term curved pipes is used to describe either cold bending of flexible pipe
during installation or small deflections at joints for rubber ring jointed flexible and
rigid pipes. The radius of curvature and pipe deflection shall meet manufacturers
specifications. Curved alignments are used in curved streets to conform with other
services and to negotiate obstructions, particularly in easements. The use of curves
in locations other than curved street alignments shall be justified by significant
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savings in life-cycle cost. The straight line pipe is usually preferred as it is easier
and cheaper to set out, construct, locate, and maintain in the future.
5.3.7.7 Vertical curves

Vertical curves may be specified subject to Watercares agreement in writing,
where circumstances provide a significant saving or where maintenance structures
would be unsuitable or inconvenient. The curvature limitations for vertical curves
are the same as those for horizontal curves in 5.3.7.6.
5.3.7.8 Underground services
The location of underground services affecting the proposed pipe alignment shall be
determined. Where pipes will cross other services, the depth of those services shall
be investigated, and exposed where necessary. Services upstream of the project
area may affect the design. A future extension of the pipe that will cross existing
and proposed upstream services may determine the level for the current project
infrastructure.
5.3.7.9 Clearance from underground services
Where a pipe is designed to be located in a road which contains other services, the
clearance between the pipe and the other services shall comply with Watercares
specific requirements. For normal trenching and trenchless technology installation,
clearance from other service utility assets shall not be less than the minimum
vertical and horizontal clearances shown in table 5.6. Written agreement on
reduced clearances and clearances for shared trenching shall be obtained from
Watercare and the relevant service owner.
Table 5.6 Clearances between wastewater pipes and other underground
services
Utility (Existing
service)
Minimum
horizontal
clearance for
new pipe size
DN 300
(mm)
Minimum
horizontal
clearance for
new pipe size
DN 300
Minimum
vertical
(1)
clearance
(mm)
Gas mains
300(2)
600(2)
150
Telecommunication
conduits and
cables
300(2)
1000
150
Electricity conduits
and cables
500
1000
225
300(2)
600(2)
150
(3)
(3)
500
Drains
Water mains
1000 /600
1000
/ 600
NOTE
(1) Vertical clearances apply when wastewater pipes and other underground services
cross one another, except in the case of water mains when a vertical separation shall
always be maintained, even when the wastewater pipe and water main are parallel.
The wastewater pipe should always be located below the water main to minimise the
possibility of backflow contamination in the event of a main break.
(2) Clearances can be further reduced to 150 mm for distances up to 2 m when
passing installations such as poles, pits, and small structures, providing the structure
is not destabilised in the process.
(3) When the wastewater pipe is at the minimum vertical clearance below the water
main (500 mm) maintain a minimum horizontal clearance of 1000 mm. This minimum
horizontal clearance can be progressively reduced to 600 mm as the vertical
clearance increases to 750 mm.
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5.3.7.10 Clearance from structures

Pipes adjacent to existing buildings and structures shall be located clear of the
zone of influence of the building foundations. If this is not possible, a specific
design shall be undertaken to cover the following:
(a) Protection of the pipeline;
(b) Long term maintenance access for the pipeline; and
(c) Protection of the existing structure or building.
The protection shall be specified by the designer for evaluation and
acceptance by Watercare.
Sufficient clearance for laying and access for maintenance is also required.
Table 5.7 may be used as a guide for minimum clearances for mains laid in
public streets.
Table 5.6A Minimum clearance from structures
Pipe diameter DN
Clearance to wall or building (mm)
<100
600
100 150
1000
200 300
1500
375
2000
NOTE These clearances should be increased for mains in private

property (even with easements) as access is often more difficult and
damage risk greater.
5.3.7.11 Bulkheads for pipes on steep grades

For bulkheads, or anti-scour blocks, see 4.3.9.10 and Appendix B drawing WW58.
5.3.7.12 Construction of structures over pipelines
Structures shall not be constructed over any Watercare pipeline without
Watercares written consent and subject to appropriate conditions.
For the procedures to follow please look up the Works Over page under
Development and Connections on this website.
Structures shall not be constructed over any pressurised system.
5.3.8 Maintenance structures
5.3.8.1 General
This describes the requirements for structures which permit access to the
wastewater system for maintenance. All MS shall be accessible by CCTV
camera.
Maintenance structures include:

(a) Manholes (or maintenance holes) (MHs);
(b) Maintenance shafts (MSs); and
(c) Terminal maintenance shafts (TMSs).
5.3.8.2 Location of maintenance structures
The selection of a suitable location for maintenance structures may influence the
pipe alignment. Generally, a minimum clearance of 1.0 m should be provided
around maintenance structures clear of the opening to facilitate maintenance and
rescue. Wherever possible, maintenance structure shall be placed clear of
state highway carriageways, drainage and road furniture and preferably

within 2 m of the road reserve boundary. Watercare may determine other
specific requirements subject to the individual site characteristics.
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The design shall include maintenance structures at the following locations:

(a) Intersection of pipes except for junctions between mains and property
connections;
(b) Changes of pipe size;

(c) Changes of pipe direction, except where horizontal curves are used;
(d) Changes of pipe grade, except where vertical curves are used;
(e) Combined changes of pipe direction and grade, except where compound curves
are used;
(f) Changes of pipe invert level;
(g) Changes of pipe material, except for repair/maintenance locations;
(h) Permanent or temporary ends of a pipe;
(i) Discharge of a pressure main into a gravity pipe.
Table 5.7 summarises maintenance structure options for wastewater reticulation.
Table 5.7 Acceptable MH, MS, and TMS options for wastewater reticulation
Acceptable options(1)
Application
MH
MS
TMS
Intersection of pipes(2)
YES
NO
NO
Change of pipe grade

at same level
YES
YES for DN 150

pipe only and
using vertical
bend
NO
Change of grade at
different level
YES
MH with internal
drops
NO
NO
Change in pipe size
YES
MH is the only
option
NO
NO
Change in horizontal
direction
YES
within
permissible
deflection at MH
YES
MS prefabricated
units or MS used
with horizontal
bends of max 33o
deflection
Change of pipe
material
YES
NO
NO
Permanent end of a
pipe(3)
YES
YES
YES
YES
MH is the only
option and shall
include a vent
NO
NO
Pressure main
discharge point
YES
for DN 150 pipe
only
NOTE
(1) Where person entry is required down to the level of the pipe, a MH is the only option.
(2) This table refers to reticulation mains. DN 100 connections can be made to any
maintenance structure or, using a proprietary junction, at any point along the main.
(3) Watercare permits the use of London Junction or Rodding Eye at the end of the pipe, but
it is recommended that TMSs are used.
5.3.8.3 Maintenance structure spacing

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For reticulation pipes, the maximum distance between any two consecutive
maintenance structures shall be 100 m.
At the permanent end of a wastewater main, the distance from the end
maintenance structure to the nearest downstream MH shall not exceed 240 m (see
figure 5.1).
Where a combination of MHs and MSs is used along the same pipe, the maximum
spacing between any two consecutive MHs shall not exceed 400 m irrespective of
how many MSs are used between the two MHs (see figure 5.2).
5.3.8.4 Manholes
5.3.8.4.1 Manhole materials
MHs may be manufactured in concrete, or from suitable plastics materials, including
GRP, polyethylene, PVC or polypropylene, or from concrete/plastic lined
composites.
MH materials selected shall be suitable for the level of aggressiveness of the
wastewater and surrounding groundwater.
The number of vertical joints in manholes shall be minimised and all
practicable steps taken to ensure manholes remain watertight throughout
their life
All manholes shall be designed with the base 300 mm greater in diameter
than the manhole itself to assist in preventing uplift and to minimise leakage.
5.3.8.4.2 Base layout
Each MH base shall have:
(a) One minimum standing area of 350 mm x 350 mm or of 350 mm diameter
(where the ladder or step irons are located), and a second minimum width
standing area of 250 mm x 250 mm or of 250 mm in diameter, as shown in
Appendix B drawings WW12 through to WW18;
(b) A minimum working space of 750 mm clear of drop pipes, ladders, and step
irons; and
(c) Channels with a minimum inside channel wall radius of 300 mm (in plan).
Figure 5.1 Multiple MSs between MH and last MH/TMS (Total < 240m)
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Figure 5.2 Multiple MSs between consecutive MHs (Total < 400m)
5.3.8.4.3 Allowable deflection through MHs
A maximum allowable deflection through a MH shall comply with table 5.8.
5.3.8.4.4 Internal falls through MHs
The minimum internal fall through a MH shall comply with table 5.9.
Where the outlet diameter at a MH is greater than the inlet diameter, the minimum
fall through the MH shall be not less than the difference in diameter of the two
pipes, in which case the pipes shall be aligned soffit to soffit.
On pipes where the internal fall across the base of the MH is not achievable due to
a large difference between the levels of incoming and outgoing pipes (see
Appendix B drawings WW19 through to WW24), then internal drops shall be
provided.
Table 5.8 Maximum allowable deflections through MHs
Pipe size
DN
Maximum deflection
(Degrees ()
150 300
Up to 120 for internal fall along the MH channel

see table 5.9
Up to 150 where there is a large fall at MH using an
internal drop structure
150 - 300
Table 5.9 Minimum internal fall through MH joining pipes of same diameter
Deflection angle at MH
Degrees ()
Minimum internal fall

(mm)
0 to 30
>30 to 60
>60 to 120
30
50
80
5.3.8.4.5 Effect of steep grades on MHs

Where a pipe of grade >7% drains to a MH, the following precautions shall be taken
if the topography and the connection pipes allow for:
(a) No change of grade is permitted at inlet to a MH;
(b) Steep grades are to be continuous through the MH at the same grade;
(c) Depth of MH is to exceed 1.5 m to invert for DN 150, DN 200, and DN 225
pipes;
(d) Depth of MH is to exceed 2.0 m deep for DN 300 pipes;
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(e) Change of direction at the MH is not to exceed 45;

(f) No drop junctions or verticals are to be incorporated in the MH;
(g) Inside radius of channel inside the MH is to be greater than 6 times the pipe
diameter; and
(h) Benching is to be taken 150 mm above the top of the inlet pipe.
To avoid excessively deep channels within MHs, steep grades (>7%) shall be
graded-out at the design phase where practicable. Grading the channel of the MH
shall be limited to falls through MHs of up to 0.15 m. Where the depth of the
channel within the MH would be greater than 2 x pipe diameter, then an internal
drop structure shall be provided.
C5.3.8.4.5
For further guidance on handling steep grades, refer to WSA 02.
5.3.8.4.6 Flotation
In areas of high water table, all MHs shall be designed to provide a factor of safety
against flotation of 1.25.
5.3.8.4.7 Covers
Watertight MH covers with a minimum clear opening of 500 mm in diameter,
complying with AS 3996, shall be used, unless Watercare has an alternative
standard. AS 3996 gives direction for the class of cover for particular locations and
applications. (See Appendix B drawings WW37 through toWW41.)
Where underground structures are within the trafficable part of a state
highway road reserve they shall be designed in accordance with the NZTA
Bridge Design Manual. In particular, Section 3: Design Loading defines the
trafficable loading, which shall be HN-HO-72. The impact factor for dynamic
effect due to traffic shall be included and the covers shall be flush with the
adjacent ground level.
5.3.8.4.7A Safety of children
All new manholes shall be fitted with a stainless steel safety grille supported
by the manhole frame and capable of carrying a 100 kg point load anywhere.
The grille shall have a square pattern and with openings not exceeding 150
mm x 150 mm.
The grille does not require to be locked in place separately.
5.3.8.4.8 Bolt-down covers
Unless otherwise approved by Watercare, bolt-down metal access covers
(watertight type) shall be specified on MHs:
(a) In systems where the possibility of surcharge exists; and
(b) Along creeks subject to flooding above the level of the cover, in tidal areas, or in
any location where surface waters could inundate the top of a MH.
Sealed entry holes with restricted access should be used in geothermal conditions
and for deep manholes.
MHs should, where practicable, be located on ground that is at least 300 mm above
the 1 in 100-year flood level. Where this is not practicable, bolt-down access covers
may be required by Watercare. It will also be necessary to specify the tying
together of MH components where bolt-down covers are specified and precast
components are used.
5.3.8.5 Maintenance shafts
Where maintenance shafts (MSs) have been approved by Watercare, and where it
is expected that human access below ground will not be required, MSs can be used
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on DN 150, DN 200, and DN 225 pipes as an alternative to MHs, providing 5.3.8.5.1

and 5.3.8.5.2 are satisfied. See Appendix B drawings WW42, and WW46.
Typical MS configurations are:
(a) Straight through MSs; and

(b) Angled MSs see 5.3.8.5.2(a).
MSs can also be used in conjunction with a TMS (see 5.3.8.6).
5.3.8.5.1 Limiting conditions
The following conditions apply to the use of MSs:
(a) MSs shall only be used on DN 150, DN 200, and DN 225 pipes;
(b) MSs shall not be used instead of MHs at junctions;
(c) Depth of MSs shall:
(i) Be within the allowable depth limit for the particular pipeline system
(ii) Not exceed the MS manufacturers stated allowable depth limit, and
(iii) Be within the depth limit imposed by Watercare;
(d) MSs shall be restricted to pipeline gradients and depths where the deviation
from vertical of the MS riser shaft (that is, projected centre line of base to
centre line at surface) is a maximum of 0.3 m measured at the surface;
(e) MSs shall not be used at discharge points of pumping mains.
5.3.8.5.2 Design parameters
MSs shall only be used at the design locations detailed in figures 5.1 and 5.2. The
following requirements shall apply:
(a) Directional and gradient changes at MSs shall be achieved by using either:
(i) Close-coupled horizontal or vertical manufactured bends immediately
adjacent to the MS (maximum horizontal deviation of 33o), or
(ii) MS units specially manufactured with internal horizontal or vertical angles
to suit design requirements (maximum horizontal deviation of 90o);
(b) MSs at changes of grade shall be located on the pipe with the lesser of the two
gradients to minimise the deviation from the vertical of the riser shaft;
(c) Straight through type and angled MSs can incorporate up to two higher level
property connections discharging directly into the riser shaft.
5.3.8.6 Terminal maintenance shafts
Where terminal maintenance shafts (TMSs) have been approved by Watercare
and where it is expected that human access below ground will not be required,
TMSs may be used on DN 150, DN 200, and DN 225 pipes as an alternative to
MHs, providing the conditions detailed in this Standard are satisfied.
For construction details see Appendix B drawing WW42.
5.3.8.6.1 Design parameters
A TMS may only be used as a terminating structure under the following conditions:
(a) At the permanent end of a wastewater pipe;
(b) On DN 150, DN 200, and DN 225 pipes;
(c) After the last MH (with no intermediate MS) provided it is spaced no further than
120 m from that MH, as shown in figure 5.1;
(d) After an intermediate MS, as shown in figure 5.2;
(e) Subject to the limiting conditions detailed in 5.3.8.5.1.
5.3.8.6.2 Property connections into a permanent end
TMSs may incorporate a maximum of two higher level property connection
branches discharging directly into the riser shaft. Where a property connection is
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required directly ahead of the permanent end of the pipe (for example, a connection
at the end of a no-exit road), a MS may be used instead of a TMS to accommodate
the straight through connection. In such a case, a DN 100 connection will require a
reducer immediately adjacent to the MS.
5.3.8.6.3 Dead ends
Pipes need not terminate at a MH, MS, or TMS if the pipe is to be extended in the
future. However, the use of a terminal shaft with a metal cover for easier
location in the future in recommended.
5.3.9 Venting
In urban developments, pipes will normally be adequately ventilated within private
property. However, there are some situations where vent shafts will be required
such as:
(a) At pumping stations;
(b) At MHs where pumping stations discharge to a gravity pipe; and
(c) At entrances and exits to inverted siphons.
In such situations vent shafts shall be installed as per the requirements of WSA 02
and WSA 04.
5.3.10 Connections
Connections link private systems to the public system or other approved outlet
point. Private systems extend through to the public system, except where
Watercare accepts responsibility for that part of the pipe outside private property.
5.3.10.1 General considerations
The property connection should be designed to suit the existing situation and any
future development. Each connection shall be capable of serving the entire building
area of the property (unless specific approval is obtained from Watercare).
Property connections shall be constructed using a single length of pipe as far
as practicable, with the minimum number of joints.
5.3.10.1A Connections in combined sewer areas
Developments and redevelopments located in areas with combined
wastewater and stormwater sewer systems are required to have separate
internal wastewater and stormwater reticulation, which are joined just prior to
the discharge point at the property boundary. This requirement is intended to
facilitate the future separation of the combined public system.
All stormwater in combined areas shall be discharged via detention tanks to
the combined sewer connection.
5.3.10.2 Requirements of design
The design shall specify the requirements for the property connections including:
(a) Plan location and lot contours;
(b) Invert level at property boundary or junction with the main as applicable.
(c) Location of inspection point at property boundary
5.3.10.3 Number of connections
It is normal practice to provide one connection per lot. Provision of additional
connections shall be subject to justification by the developer and approval by
Watercare.
For multiple occupancies (unit title, cross lease, or company lease), service of the
whole property is normally achieved by providing a single point of connection to
Watercares system. Connection of the individual units is by joint service pipes
owned and maintained by the body corporate, tenants in common or the company
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as the case may require. In this instance the whole of the multiple occupancy shall
be regarded as a single lot.
Alternatively, if authorised by Watercare, developers have the option of providing

wastewater facilities to the individual titles or tenements in new developments by:
(a) Constructing individual connections which shall be owned and maintained by
the body corporate, tenants in common or the company; or
(b) Extending the public line into the lot and providing a separate connection to
each unit.
5.3.10.4 Location of connection
Watercares definition of the Point of Supply may be viewed here.
The connection shall be located to service the lowest practical point on the property
and where possible:
(a) Be clear of obstructions, such as trees, tree roots, paved areas;
(b) Be easily accessible for future maintenance;
(c) Be clear of any known future developments, such as swimming pools or
driveways;
(d) Avoid unnecessarily deep excavation >1.5 m where practicable;
(e) Be within or on the property boundary;
(f) Include an inspection point at the property boundary to allow checks to be
made of inflow and infiltration
5.3.10.5 Connection depth
Connection depths shall be set to drain the whole serviced area recognising the
following factors:
(a) Surface level at plumbing fixtures of buildings (existing or proposed);
(b) Depth to invert of pipe at plumbing fixture or intermediate points;
(c) Minimum depth of cover over connection for mechanical protection;
(d) Invert of public main at junction point;
(e) Allowance for crossing other services (for clearances see table 5.6);
(f) Provision for basements;
(g) Allowance for head loss in traps and fittings;
(h) Allowance for any soffit depth set by Watercare.
The designed invert level at the end of the connection shall be not higher than the
lowest calculated level consistent with these factors.
5.3.11 Pumping stations and pressure mains
Pumping stations and pressure mains shall be designed and installed in
accordance with the standards of Watercare. The interim guide can be found by
clicking on Watercares Local Wastewater Pumping Stations
Valves, if required on pressure mains, shall be designed and installed in line
with the principles and practices outlined in section 6.3.14 of this CoP. Valves
on pressure mains shall have a triangular spindle caps installed to
distinguish them from water supply valves.
Surge analysis and protection against surge pressures will be also required for
wastewater pump/ pumping main system.
For the modelling of pressurised wastewater systems Watercare prefers
information provided in INFOWORKS CS.
For requirements relating to pipeline restraint, thrust blocks and anchor
blocks refer to section 6.3.12.11
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5.3.12 Pressure sewers and vacuum sewers

The use of pressure or vacuum systems in a network is not permitted without
specific written approval from Watercare.
Where such systems are approved, they shall be designed and constructed in
accordance with Watercares requirements. Contact the New Developments
Team.
5.3.13 On-site wastewater treatment and disposal
Watercare is not responsible for on-site wastewater treatment and disposal.
Such systems require the approval of the Auckland Council. Information may
be accessed here.
5.4 Approval of proposed infrastructure
5.4.1 Approval process
Wastewater infrastructure, including all private connections, require approval
from Watercare, the Auckland Council and where the work falls within state
highway road reserve, also requires prior approval of NZTA.
5.4.2 Information to be provided
Applications for design approval shall include the information outlined in 1.8 of this
CoP. In addition the following information shall be provided:
(a) A plan showing the proposed location of existing and proposed wastewater
infrastructure;
(b) Detailed long sections showing the levels and grades of proposed wastewater
pipelines in terms of datum;
(c) Long sections shall include full details of pipe and manhole materials and sizes;
(d) Details and calculations prepared which demonstrate that agreed levels of
service will be maintained and how special provisions for earthquake and
unstable land, if any, will be made;
(e) Details and calculations prepared which clearly indicate any impact on adjacent
area or catchment that the proposed infrastructure may have; and
(f) Appropriate operating manuals, pump information and instructions for pump
stations and pressure systems if proposed.
5.5 Construction
A pre-construction meeting shall be organised with Watercare prior to the
commencement of construction.
5.5.1A Excavation
Excavation of existing carriageways shall conform to the National Code of
Practice for Utilities Access to the Transport Corridors road opening
procedures. All works within the road reserve shall comply with the relevant
code of practice for temporary traffic management.
Excavation in existing carriageways shall be carried out in a safe manner with
the minimum disruption to traffic and pedestrians.
5.5.1 Pipeline construction
The construction of pipelines shall be carried out in accordance with the
requirements of AS/NZS 2032 (PVC), AS/NZS 2033 (PE), AS/NZS 2566 Part 1 and
2 (all buried flexible pipelines), AS/NZS 3725 (concrete pipes), or AS 1741 or BS
EN 295 (VC).
All PE sewers shall be welded together by registered welders, punching the
registration number on all welds and de-beaded inside.
5.5.2A Embedment
Pipes and fittings shall be surrounded with a suitable bedding material in
accordance with Appendix B drawings WW6 and WW7.
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5.5.2 Trenching
See Appendix B drawings WW6 and WW7 for guidance.
Where a pipeline is to be constructed through areas with unsuitable foundations

such material shall be removed and replaced with other approved material or
alternatively, other methods of construction shall be carried out to the approval of
Watercare to provide an adequate foundation and side support if required for the
pipeline.
5.5.3 Reinstatement
5.5.3.1 Carriageways
Backfilling shall be in accordance with the requirements of the Auckland
Council and where the works are in the road reserve, they shall comply with
the National Code of Practice for Utilities Access to the Transport Corridors.
As a minimum, pipe trenches within a carriageway shall be backfilled using an
approved hardfill placed immediately above the pipe embedment and
compacted in layers not exceeding 200 mm in loose depth, as per Appendix B
drawing WW7.
In existing sealed roads, the top section of the trench shall be backfilled as
specified by 3.4.2.3 as quoted in brackets below. The depth of base course
and type of finishing coat seal shall conform to the standard of the existing
road construction.
(3.4.2.3 Basecourse
The thickness of the basecourse layer when used with other metal aggregate
layers shall not be less than 100 mm.
Acceptable basecourse specifications are:
(a) NZTA approved regional basecourse
This is a slightly lower quality material than NZTA specified M/4. It may be
used for roads of connector/collector class; or
(b) Local basecourse acceptable to Auckland Transport
This may be used for local roads in live and play areas and footpaths, kerb
crossings, and shared accessways.)
5.5.3.2 Berms
Pipe trenches under grass berms and footpaths shall be backfilled in
accordance with the requirements of Appendix B drawing WW2 and in
accordance with the National Code of Practice for Utilities Access to the
Transport Corridors.
5.5.4 Inspection and acceptance
Pipeline inspection and recording by closed circuit television (CCTV) shall be
carried out prior to acceptance by Watercare.
CCTV inspections and deliverables shall be in accordance with New Zealand pipe
inspection manual and the requirements of Watercare.
5.5.5 Leakage testing of gravity pipelines
Before a new pipeline is connected to the existing system, a successful field test
shall be completed. The test shall be carried out as specified in Appendix C. The
testing of manholes shall be in accordance with the requirements of Watercare on a
case by case basis.
5.5.6 Leakage testing of pressurised sewers
Requirements for field testing of pressurised sewers are given in Appendix C.
The connecting of all network extensions to the existing live wastewater
system shall be approved and authorised by Watercare.
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For land Development and Subdivision
Appendix A: Acceptable pipe and fitting materials

Table A1 and table A2 on the following pages give information on acceptable pipe and fitting materials.
The information is sourced with permission from the Water Services Association of Australia. Refer
also to WSA 02 (Sewerage Code of Australia) and WSA 03 (Water Supply Code of Australia) for
further information.
Version 1.2
December 2011
1 of 8
Content from the Standard NZS 4404:2010 Land development and subdivision infrastructure has
been reproduced for use in the Infrastructure Design Standards for Local Networks
with permission from Standards New Zealand under Licence 000805

Table A1 Acceptable pipe materials and Standards

Wastewater
(Pressure
sewer/ rising
main)
Wastewater
(Gravity)
Water supply
(Pressure)
Standard
applicable
PVC-U
AS/NZS 1260
(Class SN
16 as
required by
Watercare)
Gravity applications only.

Well established methods of repair.
Suitable for aggressive groundwater, anaerobic conditions
and tidal zones.
Can be used for trenchless installation with suitable end
load resistant joints.
PVC-U
AS/NZS 1254
(Class SN 4,
or 8, as
required by
Watercare)
Gravity stormwater applications only.
PVC-O
AS/NZS 4441
(Series 1 or
Series 2, as
required by
Watercare)
Improved fracture toughness compared with PVC-U.

Improved fatigue resistance compared with PVC-U and
PVC-M.
NOTE Use only DI fittings in pumped mains to achieve
full fatigue resistance. Has increased hydraulic capacity
compared with PVC-U and PVC-M. Suitable for
aggressive groundwater, anaerobic conditions, and tidal
zones. Specific design for dynamic stresses (fatigue)
required for pressure sewer applications.
PVC-U
AS/NZS 1477
(Series 1 or
Series 2, as
required by
Watercare)

Alternative installation techniques possible, for example
slip lining.
Suitable for aggressive groundwater, anaerobic
conditions, and tidal zones.
Can be used for trenchless installation with suitable end
load resistant joints.
Specific design for dynamic stresses (fatigue) required for
pressure sewer applications.
Version 1.2
December 2011
Notes
Pipe
materials
2 of 8

Table A1 Acceptable pipe materials and Standards (continued)

Pipe materials
Standard
applicable
PVC-M
AS/NZS 4765
(Series 1 or
Series 2, as
required by
Watercare)
PE
(PE 80B or PE
100 as required
by Watercare)
AS/NZS 4130
Wastewater
(Pressure
sewer/ rising
main)
Wastewater
(Gravity)
Water supply
(Pressure)
Notes
Improved fracture toughness compared with PVC-U.

Has increased hydraulic capacity compared with PVC-U.
Inferior fatigue resistance compared with PVC-U and
PVC-O.
and tidal zones.
Generally for pressure applications.
Can be easily curved to eliminate the need for bends.
pipe cracking, direction drilling, and slip lining.
Can be welded to form an end load resistant system.
Compression couplings and end load resistant fittings are
available in smaller diameters.
Pipe longitudinal flexibility accommodates large differential
ground settlement.
Fusion jointing requires skilled installers and special
equipment.
Retrospective installation of fittings/repair complicated.
DN 125 available in long coiled lengths for fewer joints.
or tidal zones.
Suitable for ground with high subsidence potential, for
example fill or mining areas.
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Pipe materials
Standard
applicable
PE
(Stiffness Class SN
16 as
required by
Watercare)
AS/NZS 5065
PP
(Stiffness Class SN
16 as
required by WSL)
AS/NZS 5065
GRP
AS 3571.1
Version 1.2
December 2011
Wastewater
(Pressure
sewer/ rising
main)
Wastewater
(Gravity)
Water supply
(Pressure)
Notes
Only for gravity applications.

Can be easily curved.
pipe cracking and slip lining.
Can be welded to form an end load resistant system.
Fusion jointing requires skilled installers and special
equipment.
Retrospective installation of fittings/repair complicated.
Smaller diameters available in long coiled lengths for
fewer joints.
conditions, or tidal zones.
Only for gravity applications.

slip lining.
UV resistant (special product).
Custom made fittings can be manufactured.
Suitable for use without additional corrosion protection in
areas where stray electrical currents occur.
Low impact resistance and ease of damage to
thermosetting resin, makes GRP susceptible to damage
during transportation, and installation, in above ground
installations, from vandalism, or when damaged as a
consequence of nearby excavation.
or tidal
4 of 8


Pipe materials
Standard
applicable
GRP
AS 3571.2
VC
BS EN 295
RRJRC (rubber ring

joint reinforced
concrete)
AS/NZS 4058
Version 1.2
December 2011
Wastewater
(Pressure
sewer/ rising
main)
Wastewater
(Gravity)
Water supply
(Pressure)
Notes

slip lining.
UV resistant (special product).
Custom made fittings can be manufactured.
Suitable for use without additional corrosion protection in
areas where stray electrical currents occur.
Low impact resistance and ease of damage to
thermosetting resin, makes GRP susceptible to damage
during transportation, and installation, in above ground
installations, from vandalism, or when damaged as a
consequence of nearby excavation.
conditions, or tidal zones.

Has benefits for particularly aggressive industrial wastes.
Not recommended for active seismic (earthquake) zones,
or unstable ground.
Requires protection from hydrogen sulphide attack in

sewer applications, by plastic lining or selection of
appropriate cement additives
5 of 8


Pipe materials
Standard
applicable
CLS (SCL) (concrete

lined welded steel)
NZS 4442
AS 1579
Version 1.2
December 2011
Wastewater
(Pressure sewer/
rising main)
Wastewater
(Gravity)
Water supply
(Pressure)
Notes
Cement mortar lined, PE coating below ground or heavy duty

coating above ground
High mechanical strength and toughness.
Available in long lengths.
RRJ and welded joints available.
Custom made, specially configured steel fittings can be made to
order.
Can be welded to form a system that will resist end load and joint
permeation.
UV resistant/vandal proof/impact resistant (where PE coated).
Cathodic protection (CP) can be applied to electrically continuous
pipelines to provide enhanced corrosion protection.
PE lined and coated RRJ
As above for CLS (SCL).
Suitable for conveying soft water.
Corrosion resistant under all conditions.
General notes
Standard Portland cement mortar not resistant to H2S attack, at
any high points or discharge points in the main. High alumina
cement has improved resistance.
Welded joints require skilled installers and special equipment.
Welded joints require reinstatement of protection systems on site.
Special design required for welded installations parallel, and
adjacent to high voltage (> 66 kV) transmission lines.
Cathodic protection requires regular monitoring and
maintenance.
Seal coating may be required over cement mortar linings, when
conveying soft water, or in low flow extremities of reticulation
mains, to prevent potentially high PH.
Suitable for high load applications such as railway crossings and
major roads.
Large diameters are available.
Suitable for aerial or suspended pipeline applications
6 of 8


Pipe materials
Standard
applicable
DI (ductile iron pipe)
AS/NZS 2280
AS 3681
Corrugated
aluminium pipe
AS/NZS 2041
Corrugated steel pipe
AS/NZS 2041
NZS 4405
NZS 4406
AS/NZS 3518
AS/NZS 3690
AS/NZS 3879
AS/NZS 1260
AS/NZS 1254
ABS
PVC-U
PVC-U
Version 1.2
December 2011
Wastewater
(Pressure
sewer/ rising
main)
Wastewater
(Gravity)
Water supply
(Pressure)
Notes
Fatigue analysis not normally required (pressure sewer

applications).
High mechanical strength and toughness.
Ease of jointing.
UV resistant/vandal proof/impact resistant.
Suitable for high pressure and above ground pipelines.
Restrained joint systems available.
Sufficient ring stiffness to not rely on side support, for
structural adequacy for the usual water supply installation
depths.
Elevated PH may occur when conveying soft water, or in low
flow extremities of reticulation mains.
PE sleeving is required, and must be carefully applied and
repaired when damaged.
Standard Portland cement mortar not resistant to H2S attack,
at any high points or discharge points in the main.
(Wastewater applications. High alumina cement has improved
resistance.)
Not suitable for aggressive groundwater, anaerobic conditions,
or tidal zones.
Generally of short length (for culverts and so on). Joints need

consideration in fine soils with high water tables. Invert may
need lining to extend life.
Generally only for short length (culverts and so on). Joints

need consideration in fine soils and high water tables. Invert
may need lining to extend life.
Specific design for dynamic stresses (fatigue required for

pressure sewer applications).
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Table A2 Acceptable fitting materials and Standards

Fittings
Materials
Standard
applicable
PVC-U
AS/NZS 1254
PE
AS/NZS 4129
PE pressure fittings, including mechanical

compression, butt fusion or electrofusion, as approved
by Watercare
Access covers
and grates
AS 3996
Ductile iron
AS/NZS 2280
Generally for pressure applications. Shall be coated

with a polymeric coating, applied in accordance with
AS/NZS 4158.
Ductile iron
unrestrained
mechanical
couplings
AS/NZS 4998
Generally for pressure applications.

Shall be coated with a polymeric coating, applied in
accordance with AS/NZS 4158.
Plastic or metallic
tapping bands
AS/NZS 4793
Generally for pressure applications. Tapping bands used on

flexible pipes shall be AS/NZS 4793 Type F that is, full
circle design.
Ductile iron tapping bands shall be coated with a polymeric
coating, applied in accordance with AS/NZS 4158.
Fire hydrants
NZS/BS 750
Generally pressure applications.
Resilient seated
gate valves
AS 2638.2
Generally pressure applications.
PE
(Stiffness Class SN
4, 8, 10 or 16 as
required by the TA)
AS/NZS 5065
PP
(Stiffness Class SN
4, 8, 10 or 16 as
required by WSL)
AS/NZS 5065
Version 1.2
December 2011
Wastewater
(Pressure sewer/
rising main
Wastewater
(Gravity)
Water supply
(Pressure)
Notes
8 of 8
WATERCARE SERVICES LTD

Geological Sensitive Areas
Maire Road (Orewa)
Scott Road
Glenvar
Albany
Pinehill
Kowhai
Cuthill
Forrest Hill
Sunset
Northcote
Ponsonby
Domain
Mt Hobson Low
Waitakere
Waikumete
St Johns
Mt Wellington High
Mt Albert
One Tree Hill
WAITAKERE DAM
Mt Roskill
UPPER NIHOTUPU DAM
UPPER HUIA DAM
LOWER NIHOTUPU DAM
East Tamaki
COSSEYS DAM
Papakura (Kaipara Rd)

UPPER MANGATAWHIRI DAM
HAYS CREEK DAM
MANGATANGI DAM
WAIROA DAM
Runciman Road
Harrisville Road
WAIKATO RIVER
Legend
Fault Line
Areas subject to Landslide
Soil Liquefaction
Class C
Class D
1.5
o
Kilometres
Waikato District
SCALE
DATE
GIS REF
MAP NO
1:115,000 @ A1
20 June 2011
JR08075_BS
JR08075_10B
DISCLAIMER
This plan is illustrative only and all information should be independently verified
on site before taking any action. Land Parcel Boundary Information from LINZ.
Whilst due care has been taken, Watercare Services Limited gives no warranty
as to the accuracy and completeness of any information on this plan and accepts no
liability for any error, omission or use of the information. Height datum: Auckland 1946.
Installation of tracer wire

Tracer wire is to be installed when undertaking directional drilling technique.
The Tracer wire shall be a continuous four-strand 4.0mm copper wire (polythene sleeved)
for underground application or similar approved.
a) Installation requirements:
Tracer wire shall be secured to the pipe at three metre intervals.

When placing tapping band ensure tracer wire is not placed between the pipe and
tapping band. The wire shall be protected from excavation works.
With exception of approved spliced connections the tracer wire shall be continuous
from Valve chamber to Valve chamber or hydrant.
No breaks or cuts shall be permitted.
Spliced or repaired connections to the tracer wire shall be made using a wire
connector and insulated.
A wire closure shall be attached at the beginning and end of the buried wire.
The tracer wire shall be secured to the outside of the valve sleeve and brought up to
the valve box to a point 100mm below the surface and an additional 500mm of slack
shall be bought into the valve box and placed in such a manner as not to interfere
with the working of the valve or damage the wire.
The main line tracer wire shall follow and be secured to the hydrant lateral up to and
back from the hydrant and then continue along the watermain. The tracer wire shall
be wrapped neatly around the hydrant with at least two metres of slack in the tracer
wire.
The tracer wire shall extend a minimum two metres beyond any watermain end caps.
The wire shall be coiled and secured for future connections.
Spliced connections are allowed only at watermain tees and crosses. The branch
connector tracer wire shall be a single tracer wire properly spliced to the main tracer
wire lead.
b) Testing of Tracer for continuity between beginning and end points.
The testing for functionality will only be undertaken after confirmation from the
Contractor that the installation has been completed in accordance with the installation
process.
The test will be organised by the Contractor and executed under supervision of
Project Manger or Engineer supervising the works.
The Project Manager or Engineer supervising the works shall inform Water Supply
Operations of the outcome of the test.
For photographic illustration of tracer wire installation: Click Here. (NOTE: Large file, 9 MB)
Continious
Two Pair Cable 4 Strands Polythene sleeved
Strapped to the outside of pipe wall by means of HD
Basically on the weld and
4.5 -5.0 mm2
100mm Diameter
One end
Other end
Connector used for testing
Detection Services
No problem both 50mm & 100mm checked
Point of Supply Detailed Rules

Point of supply
The point of supply is the point where Watercare's network connects to the private network. At this
point, the responsibility for ownership and maintenance of assets and equipment transfers from
Watercare to you.
We own and have maintenance obligations in respect of the meters, backflow prevention devices,
pipes, and other network assets on our side of the point of supply (even if these meters, pipes or other
assets are on your property).
Point of supplywater
The point of supply for water is based on the location of the master meter, regardless of where the
master meter is in relation to the property boundary. The point of supply is the outlet of the last fitting
of the master meter, which is usually a downstream isolation valve. All equipment and fittings
upstream of this point are owned by Watercare and are considered part of the Watercare network.
Page 2 of 7
Point of supplywastewater
The point of supply for wastewater is the closest of the following to the buildings on the property (as
determined by us):
the connection to the public sewer (that is, the first pipe joint from the manhole connected to
the public drain); or
the point where the wastewater pipe exits private land.
All equipment and fittings downstream of this point are owned by Watercare and are considered part
of the Watercare network.
Page 3 of 7

Local Wastewater Pumping Stations

Watercares standard for Local Wastewater Pumping Stations shall be the Sewage Pumping Station
Code of Australia, WSA 04-2005, published by Water Services Association of Australia (WSAA), as
modified and supplemented by the present document.
For any aspect of design, construction, materials and equipment not covered in the following, please refer
to WSA 04-2005.
Design of pumping stations shall be carried out by person/s qualified and experienced in this field of
expertise. While general requirements are covered in this standard, the Developer will need to consult
Watercare as early as practicable.
1.1 General Requirements

1.1.1
Design considerations
This Standard does not cover the requirements of Trunk Sewer Pumping Stations, which are covered by
Watercares Guidelines for Design of Wastewater Reticulation and Pumping Stations available for
reference from Watercare.
Pumping stations will be only considered and approved by Watercare when all other options are
impracticable. Where required, pumping stations shall be provided at the entire expense of the
Developer. If properly designed and constructed to Watercares approval, Watercare will take over their
future operation and maintenance after they have been commissioned and vested in Watercare.
Pumping stations shall be provided with:
a)
b)
c)
d)
e)
f)
A freestanding low height weatherproof control cabinet to house electrical equipment.

Where the station serves more than 50 households, an architecturally designed control building to
house electrical equipment, to allow servicing in all weather conditions.
All-weather vehicle access, including an adequate turning area near the station structure.
Suitable (swing-arm type davit or similar) equipment for lifting pumps and heavy equipment, or
adequate access for mobile lifting plant.
Stack to disperse exhaust ventilation air. This may be combined with the lifting davit if approved.
Provision for installation of odour control facilities
Note; The choice between e) and f) shall be based on the characteristics of individual stations, e.g. the
length of rising main, flow rates, etc.
g)
h)
i)
j)
Metered water supply (minimum service line diameter of 32mm) for wash-down purposes.
Backflow prevention shall be provided for the stations water supply using a 25mm backflow
prevention device. See G12/AS1 of the Building Code, for the methods and devices required to
comply with the Watercare requirements.
Dedicated underground mains power supply.
Building doors, switchboards, control cabinets and chamber cover-plates able to be securely
locked and vandal proof.
Electrical connection facilities for the provision of a temporary generator.
1.1.2
Station Site
Watercare will require that the station have its own dedicated lot, provided exclusively for the purpose of
housing the station and all related structures and equipment. It will however be permissible for the access
right-of-way to the station lot to be shared with other lots. If the site has shared access, provision is to be
made for parking a service vehicle on the site, so that the shared 0right-of-way is not obstructed.
Watercare may also require the lot to be designated as a utility reserve or similar.
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This is a controlled electronic document uncontrolled on printing
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1.1.3

General Design Standards of Local Wastewater Pumping Stations
Pumping station design standards shall be the standards contained in Sewage Pumping Station Code of
Australia, WSA 04-2005, published by Water Services Association of Australia (WSAA), except as
amended in clause 1.1.4 below. Should there be any discrepancy between this Standard and WSA 042001, the requirements of this standard shall take precedence.
1.1.4
Particular Design Standards of Local Wastewater Pumping Stations
For the purpose of this Standard, the requirements of WSA 04-2001 shall be amended as per Table 1.
Table 1: Amendments to WSA 04-2001
WSA 04-2001 Clause Number
Amendment
1.3 Referenced Documents
Add: NZS 4203 General structural design and design loadings for
buildings
2.1 Concept Design Plan
Substitute: EPA with Auckland Council and Watercare
2.3 Due Diligence Requirements:

Standards
Add: New Zealand Standards
3.4.3 Emergency Structures
Add: Comply with the Watercare Standards for Storage Volumes

(refer clause 1.1.5)
Comply with Watercare Standards for Storage Tanks (refer clause
10.1)
4.2 1 Pumping System, General
Add to WSA 02 as amended by this Watercare Standard

Water agencys with Watercares
4.2.3.4 Junction Boxes
Delete
4.2.5 Starters and Variable Speed

Drives
Delete (refer clause 1.8.9 of this standard)
4.3 Power System
Delete
4.5.2 Wet Well Design
Add: All interior walls of the wet well structure shall be coated. The
coating system shall be in accordance with Watercares Technical
Specification 281 and shall be approved by Watercare.
4.5.5.1 Emergency Storage
Add: Comply with the Watercare Standards for Storage Volumes

(refer clause 1.1.5)
Comply with Watercare Standards for Storage Tanks (refer clause
10.1)
4.5.7 Wet Well Access Covers
Add: Covers over chamber openings shall be a standard hatch cover

from the Watercare range
4.6.4 to 4.6.6 Pressure Mains,

Valves
and
Pressure
Main
Structural Design
Delete (refer this Standards clause 9 Rising (Pressure) Mains for

Local Stations)
4.6.7.1 Odour Control
Delete (refer this Standards clause 9.7.9)
4.6.7.2 Septicity Control
Add: Watercare may require a contribution towards the operation and

maintenance of remedial measures such as air / oxygen / chemical
injection.
4.7.7 Buildings
Substitute: Building Code of Australia with New Zealand Building

Code
4.8.1.1 Water
Delete (refer this Standards clause 8.1 General Requirements)
4.8.1.4.1 Lifting Equipment
Delete (refer this Standards clause 8.1 General Requirements)
4.9.2 Operation and Maintenance

Requirements
Substitute: Appendix D of WSA 101 with Appendix F of this

Standard)
4.9.6 Detailed Design Drawings
Add: All electrical and mechanical equipment shall be coded as per

Watercares Technical Specification 7 and 503
1.1.5
Storage Volume
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Storage volume shall be provided according to the following criteria:

a)
b)
c)
For population equivalent of up to 200 - minimum of 6 hours at ADWF (ADWF up to 0.5 litres/sec),
with a minimum volume of 1 cubic metre.
For a population equivalent 200 to 5000 persons minimum of 4 hours at ADWF (ADWF from 0.5
to 12.5 litres/sec).
For stations with an ADWF greater than 12.5 litres/sec, storage or other measures to avoid or
contain overflows shall be specifically designed.
1.2
Electrical and Controls

1.2.1
a)
b)
c)
d)
e)
f)
g)
This standard provides the requirements for the design, fabrication, supply, installation, testing,
commissioning and handover to Watercare of small sewage pump station switchboards and
associated pump station control and security systems for use in Watercare area for pump stations
requiring motor sizes up to and including 15.0 kW.
All requirements stated in this standard shall be complied with unless written approval has been
received from Watercare to vary particular features.
Outdoor switchboards shall consist of a pad mounted sheet metal enclosure in which is mounted
powder coated aluminium multibox enclosures housing all pump motor starters, controls, telemetry
units and tariff metering equipment.
Indoor switchboards housing pump motor starters, controls, telemetry units and tariff metering
equipment shall consist of wall mounted powder coated aluminium multibox enclosures.
All switchboards shall have provision for the connection of a remote generator to provide backup
electric power.
Some areas of the installation may be classified under AS2430 as a flammable gas or flammable
vapour hazard. Confirm the Hazardous Area Classification with Watercare. Equipment, cables
and accessories installed in Hazardous Areas shall comply with AS 2380.
The Works includes the design, supply and installation, testing and commissioning and all material
and labour required for all electrical equipment, services controls, telemetry and security systems
as specified herein and as shown on the drawings, including all accessories reasonably necessary
to ensure the proper and safe functioning of all equipment
1.2.2
a)
c)
d)
Design Requirements
The following sewage pump switchboard types are described in this standard:
b)
General
Two pump switchboard with Direct on Line starters.

Two pump switchboard with electronic Soft starters.
Generally, unless otherwise required by the Power Authority or Watercare, all pump stations with
pump motor sizes less than 10 kW shall be designed for Direct on Line starting. All switchboards
shall include soft starters for all pumps with motor sizes greater than 10kW.
Actual sizes for pumps, starters and enclosures are to be determined at the time of enquiry.
Written approval of motor starter equipment type and enclosure sizes is to be obtained prior to
switchboard construction.
Watercare will require the Contractor to use standard equipment or component types and sizes in
certain instances, even if this requirement increases the cost of the Works. These requirements
are detailed in this specification, watercares Technical Specifications 509 and shown on the
drawings. This does not relieve the Contractor of any design responsibilities. Watercare is under
no obligation to reimburse the Contractor for any additional costs in relation to this requirement.
1.2.3
Pump Station Control
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a)
b)
c)
The primary control of the pump start/stop shall consist of a wet well level sensor, normally
connected to a pump level controller located in the controls multibox within the switchboard. The
present sites use a ten-stage Multitrode level sensor and a Multitrode MT2PC Duplex pump
controller. This level sensing and level control arrangement is to be used for any new sites.
The Contractor shall design and configure the switchboard and control system equipment to meet
the requirements of the pump station. The Multitrode controller shall be configured to operate on
level control with a duty and a standby pump operating in alternating pump mode.
Particular care is required for the selection of the pump and the wet well size to ensure that:
d)
e)
f)
b)
c)
d)
e)
A float level switch (LSH1) shall be installed in the wet well to detect excessive wet well water
level. This level switch shall be connected to the telemetry input Wet Well Level High.
A float level switch (LSHH) shall be installed in the wet well to detect impending overflow. This
level switch shall be installed to operate at a wet well level rising 50 mm below the overflow
invert. Connect to the telemetry input Wet Well Overflow.
For pump stations with dry wells, a separate float level switch shall be installed to detect
excessive dry well water level. This level switch (LSH2) shall be connected to the telemetry
input Dry Well High Level.
Instrument devices and level switches etc shall be identified, both on site and on the drawings,
using the tag numbering conventions described in Watercares Technical Specification 503.
1.2.4
a)
wet well overflows do not occur,

each pump is selected to provide sufficient capacity to meet the peak wet weather flow,
pump run cycle times are within the limits specified by the pump manufacturer. In no case
shall the installation exceed 15 pump starts per hour during the design maximum wet weather
flow.
Each wet well shall also be provided with an ultrasonic level transmitter with 4 20 mA output
connected to the telemetry analogue input. The ultrasonic level sensor shall be rated IP68. The
transmitter shall be mounted in the switchboard enclosure and be supplied from a suitable 24 VDC
battery backed source.
In addition to the primary pump station controls describe above, the telemetry system has the
facility to allow remote control of the pumps and a wet well spray washer. The telemetry system
also monitors various conditions within the pump station and the switchboard. This specification
includes details of the supply, installation and commissioning of these devices and of the telemetry
equipment.
The following level switches shall be provided:
g)

Design and Construction
The pump station switchboard and electrical works design shall conform to the requirements of this
standard.
The materials used in the construction of the Works shall be new, of high quality and shall meet the
required duties. Workmanship and general finish shall be of high trade quality. The Contractor
shall ensure that the completed switchboard is vermin and insect proof and is constructed to
minimise corrosion.
The Contractor shall be responsible to ensure that any design completed by him is safe, suitable
for the purpose intended and in accordance with the relevant Regulations, Codes and Standards.
Acceptance of the completed works by Watercare shall in no way relieve the Contractor from such
responsibility. Such responsibility shall also apply to the Contractor if inferior materials are used in
place of the specified grades without the written approval of Watercare.
The design and workshop drawings shall be submitted to Watercare for approval. Watercare may
require up to four weeks for checking and approval.
For indoor switchboards, design and supply switchboard mounts as specified herein.
For all
outdoor switchboards and remote generator connection switchboards, design, supply and install
the switchboard concrete base and cable access ducts within the concrete base as shown on the
concrete plinth arrangement drawings. The design of this base shall be submitted for Watercare
approval before the work proceeds at least four weeks prior to the requirement.
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f)
g)
The switchboard fixings, to walls or to concrete bases, shall be 316 stainless steel bolts 12mm
minimum diameter and shall also comply with the seismic design requirements.
Refer to the General Arrangement drawing for the typical layout of small pump station multi-box
switchboards and for remote generator connection switchboards. The multi-box switchboard panel
layout may change according to actual site locations of pumps and mains cable entry etc. Final
panel layout and the location of the generator connection plugs shall be approved by Watercare
before assembly of the switchboard at least four weeks prior to the requirement.
1.2.5
a)
b)
c)
Typical drawings and Bill of Materials
Cabinet and door equipment layouts shall be in accordance with standard layout drawings
(obtainable from Watercare)with due regard to the equipment clearances required by the
manufacturers. The Contractor shall provide workshop drawings to Watercare for approval prior to
switchboard fabrication at least four weeks prior to the requirement .
Note that motor starter types and pump sizes are to be approved by Watercare prior to design
detailing at least four weeks prior to the requirement.
Typical drawings are included with this specification as follows:
d)

Switchboard layouts,
Power single line diagram for remote and local generator connection switchboards,
DOL starter motor schematic diagram,
Soft starter motor schematic diagram,
Level control circuit schematic diagram,
Kingfisher Telemetry connection diagram,
Wet well spray washer,
Concrete plinth arrangement.
Cabinet and door equipment layouts
A Bill of Materials at the end of these Specifications lists equipment reference, type and supplier.
1.2.6
Earthquake Strength
The Works shall be designed to ensure that the installation and its component parts will withstand a
horizontal force, acting through the appropriate centre of gravity to 0.4 times the relevant component
weight without suffering deformation or breakage that will interfere with its operation. All plug-in units
shall be adequately restrained.
1.2.7
a)
b)
c)
d)
e)
f)
g)
Equipment Identification and Labeling
Watercare has adopted an equipment coding system for identification of major equipment items such
as pumps, valves, switchboards, control panels etc. These equipment items are to be labelled with
purpose made stainless steel labels in accordance with Watercares Coding System standard,
Technical Specifications 7 and 503.
The Contractor shall supply all nameplates, caution plates and labels needed for the safe and
effective operation of the Works.
Panel mounted components shall be labelled with a function description. All apparatus within
enclosures shall be labelled with either a brief description of the function or a non-ambiguous code
corresponding to the schematic diagrams.
Danger and warning notices shall be displayed where the removal of covers exposes any parts live
at a voltage exceeding extra low voltage. Danger labels shall be red lettering on white background.
They shall be of adequate size and be easily readable.
Stainless steel screws shall permanently attach labels on multi-box exteriors. Stainless steel screws
shall be used for engraved label attachment inside the multi-box enclosures. Self-adhesive labels
shall not be used.
For all wastewater sites labels shall be made of 316 stainless steel, etched and black colour filled.
Labelling on the outside of enclosures shall be engraved stainless steel fixed with stainless steel
threaded nuts and bolts, silicone sealant shall be applied between the label and the outside surface
to give a complete weatherproof seal.
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h)

The label inscription shall be a description of the function of the item or an equipment code
corresponding to the drawings. The Contractor shall provide a switchboard label schedule at the
time the electrical drawings are submitted to Watercare at least four weeks prior to requirement.
1.2.8
Electrical Regulations, Codes and Standards
The Contractor shall comply with all statutory and other requirements applicable to the Works
including the Electricity Regulations 1997, the New Zealand Electrical Codes of Practice and all
relevant New Zealand and other national and international standards declared as suitable for the
purposes of the Wiring Regulations by the Secretary of Energy.
b) All electrical work shall comply with the current revisions of the New Zealand Electrical Codes of
Practice and AS/NZS3000.
Unless another Standard is specifically mentioned in the Contract, the Works shall be designed,
manufactured and tested in accordance with current editions of the relevant New Zealand and Australian
Standards. Standards issued by the International Electrotechnical Commission are also applicable.
a)
For example:
AS 3439-1
IEC 60158
IEC 60185
IEC 60947-4
BS 60947-2
IEC 60529
BS 88
60269);
BS 89
BS 142
BS 5419
BS 5424
BS 5486
1.2.9
Low-voltage switchgear and control gear

Low-voltage control gear;
Current Transformers;
Low-voltage switchgear and control gear: Contactors and Motor starters;
Circuit Breakers
Classification of degrees of protection provided by enclosures;
Cartridge fuses for voltages up to and including 1000 V AC and 1500 V DC ( IEC
Specification for direct acting indicating electrical measuring instruments and their
accessories;( IEC 51);
Electrical Relays
Specification for air-break switches, air-break disconnectors, air-break switch
disconnectors and fuse-combination units for voltages up to and including 1000 VAC and
1200V DC; (IEC 60408)
Specification for control gear for voltages up to and including 1000 V AC and 1200 V DC;
( IEC 60158-1)
Low-voltage switchgear and control gear assemblies; ( IEC 60439)
Environmental Conditions
Materials and equipment shall be suitable for operation in outdoor ambient temperature from 5 C to
35C and an indoor maximum air temperature of 40 C.
Allowance shall be made for the effects of solar heating on the cabinets and on the ratings of cables
exposed to sunlight.
The design shall take account of the increase in ambient temperature in any room or enclosure due to
heat generated by equipment within or adjacent to that enclosure.
1.2.10 Materials and Components
All materials and components used shall be new and of the high quality and class fully suitable for the
duty they will be required to perform and shall comply with the latest issue and amendments of the
relevant NZS, AS, IEC or BS standards.
Sewage generates H2S gas, which is heavier than air. This gas forms a corrosive acid when wet and is
especially aggressive to silver and copper and their alloys. Specific precautions shall be taken to avoid
corrosion by H2S. All copper work shall be tinned. Silver contacts shall be gold flashed or gold plated.
Extra low voltage contacts for switches and relays shall be selected specifically for the voltage and
current conditions applicable to the circuit in which they are connected.
Protection against corrosion, deterioration, absorption of moisture and the like shall be provided for all
materials, and all materials and equipment shall be finished in approved colours and qualities of finish.
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All fixings, both inside the switchboard compartments and throughout the installation shall be stainless
steel. This requirement also includes conduit saddle fixings and the like.
During manufacture, no repairs of damaged or defective parts will be permitted without written approval
from Watercare.
1.2.11 Mains Cables and Pump Motor Cables
Mains cables shall be sized for a maximum 1% volt drop calculated with one pump running and the other
starting. Pump motor cables shall be sized for a maximum running volt drop of 1.5%.
Unless otherwise shown on the drawings, the distances, measured between the cables, specified below
shall separate cables run along the same route from other cables:
(a)
(b)
(c)
(d)
400/230V and 24 Vdc cables

400/230V cables and communication cables
400/230V cables and instrument cables
11kV cables and 400/230V, instrument or communications cables
50mm
250mm
150mm
1,000mm
Where the 1,000mm separation cannot be maintained a continuous vertical 300mm high concrete tile
barrier shall separate LV and MV cables. This also applies to dual 11kV supplies of 1,000mm separation
with vertical 300mm concrete tiles installed between these cables.
Cables shall be run not less than 300mm clear of other services whether running parallel to or
transversely to the cable route.
The Contractor shall provide all cable boxes, gland plates and the like as required for terminating cables
at transformers, switchboards, motors and other equipment. The Contractor shall provide all jointing
materials, glands and accessories necessary for the correct connection of cables to the equipment.
Cables insulated with PVC, XLPE or elastomeric compounds shall be terminated through correctly sized
compression glands. Glands for armoured or screened cables shall be provided with properly designed
clamping devices for the armour or screen wires. Cable glands shall be manufactured by CMP Glands
Ltd. Glands shall be threaded ISO metric. The Contractor shall drill and tap all necessary holes in gland
plates for the fitting of cable glands. All unused openings shall be plugged with screwed plugs.
All electrical terminations shall be shrouded to IP20 (finger touch proof) or better.
1.2.12 Underground Cables
All underground cables shall be installed in rigid UPVC cable ducts. Cable ducts shall be laid at the
depths as specified by NZS/AS3000. Power cables shall also be separated by at least 300mm from any
low voltage or instrument cabling.
Ducts shall be clean and free from obstructions before cable installation commences. Installation of
cables in ducts shall be carried out by hand; winches shall not be used. The ends of ducts shall be
sealed after the installation of cables with "Denso Mastic" applied in accordance with the Manufacturer's
instructions.
Cover cable ducts with a layer of 150 mm of sand or selected soil, which shall extend 75mm on either
side of the cable. Place concrete cover tiles or Magslab or protective timbers of 25mm thick rough sawn
tanalised pine of H4 treatment over the entire length of the cable providing 75mm overlay on each side.
Place a continuous proprietary orange plastic warning strip 200mm above the tiles/Magslab/timber.
Backfilling shall be carried out in 200mm thick layers, each layer being individually compacted. Reinstate
trench surfaces to match surrounding surfaces to original condition as practicable. Make due allowance
for settlement including overfilling trench and temporary reinstatement prior to contract completion or by
stabilising backfill.
Make all necessary arrangements for removal, suitable storage and the replacement of plants and pay all
associated costs.
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1.2.13 Instrument Cables

Instrument cables shall be those screened cables connected to the switchboard and field instruments for
the purpose of sequential or process control excluding communications cables. Cables runs shall be
vertical or horizontal and parallel or perpendicular to the principal axis of the building. Cables shall be run
between fittings, accessories or equipment enclosures without joints.
Conductors shall be terminated with tinned pre-insulated compression bootlace pins. A maximum of two
cable cores shall be connected to any equipment terminal
Instrument cable shall conform to the Belden industrial instrumentation series cable specification for
screened multicore cables. All cores shall use tinned copper stranded conductors. Cable cores shall be in
white and black pairs for loop powered or active instruments, or red, white and black for RTDs or DC
powered instruments.
2
Single paired or single triple conductors shall have a cross sectional area of approximately 1.5mm ,
Belden catalogue number 1030B and 1031B respectively.
Multicored paired conductors shall have a cross sectional area of approximately 0.55 mm2, 2 pair and 4
pair overall screened, Belden catalogue number 3016B and 1056B respectively.
1.2.14 Security System Cables
Security system cables shall be those cables connected to the security panel and remote switchboards
for the purpose status or analogue monitoring. Cables runs shall be segregated from power cables by a
minimum distance of 300 mm. Cables shall be run between fittings, accessories or equipment enclosures
without joints.
Cable from the generator switchboard to the pump station switchboard shall be General Cables
B5504ES/CS 1.5 mm2 4 pair individual screened and overall screened PVC. Install the cable in a 25 mm
UPVC buried conduit.
1.3
Outdoor Switchboard Enclosures

1.3.1
Construction
The Outdoor Enclosure shall house a Multibox Switchboard. The enclosure shall be free standing, front
access, manufactured from heavy duty fully welded aluminium sheet on a self supporting channel section
framework, suitable for direct mounting onto a concrete plinth. In areas where salt water/spray corrosion
is possible, 316L stainless steel shall be used for all cabinet metalwork. With all doors closed the
complete assembly shall have a degree of protection to IP55 in accordance with IEC60529, unless
otherwise specified.
Outdoor Enclosures shall be to standard modular size. Double and triple module sized enclosures shall
be used as required by constructing a single enclosure with multiple doors. Right hand doors are to be
hinged on the right hand side. The overall height of the switchboard cabinet, including the base shall not
exceed 1,500 mm.
The roof of the outdoor enclosures shall slope away from the front (doors) of the enclosure to lessen
rainwater run-off when the doors are open. The roof slope ratio shall be 400mm horizontal 20mm
vertical.
A ventilated (multi-louvered) cable base shall be provided. Underground cables will enter the ventilated
base and their ducts shall be sealed at grade with the base. Cables will then enter the enclosure via a
6mm full depth split aluminium gland plate. See the general arrangement drawing for concept.
Where a remote generator connection switchboard is required, the outdoor enclosure shall be
manufactured to the same standards and concepts as the enclosure that houses the pump station
switchboard, except that the maximum size shall be 1,000 mm wide and 1,250 mm high.
The housing will have two top-hat sections welded horizontally onto the inside back of the enclosure. One
top hat section at the top of the board and the other at the bottom in line with the top and bottom of the
multiboxes.
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Two 50mm x 6mm bars shall be fixed to the respective top hat sections with two M10 stainless steel
studs per bar. The four M10 studs are to be accessible at each end of the multibox assembly. The
multibox assembly will be bolted to the 50mm x 6mm bars with a minimum of two M6 stainless steel bolt
per multibox to form a rigid structure. The two 50mm x 6mm bar shall have tapped M6 holes for the
multibox fixing bolts. Each multibox will be bolted to its neighbour multibox with M6 stainless steel bolts.
A single 50mm long M10 stainless steel earthing stud shall be welded to the LHS base plate.
1.3.2
Outdoor Enclosure Doors
The metal sheets forming the enclosure doors shall be of minimum 2 mm thick if stainless steel, or a
minimum of 3 mm thick if aluminium. Doors are to be finished semi-flush with the enclosure and fitted
with three substantial stainless steel hinges. Hinges shall be fitted with stainless steel screw fixings,
inaccessible when the doors are closed. Hinge pins shall be fixed and have pins that cannot be driven
out.
Single door enclosures and the left hand door of two door enclosures are to be fitted with handles with
rod latches top and bottom. The handle shall incorporate a staple suitable for Watercare standard
padlock. Lock handles shall be Selectrix 1107SS or approved equal.
For the right hand door of two door enclosures, the locking shall be by way of substantial stainless steel
internal padbolts fitted top and bottom. No external fixings are to be visible.
Door seals formed in the enclosure shall consist of a double return channel and drip catcher of minimum
size 22 x 16 x 8mm, all round. The door edges shall be of double return construction, bearing on the
neoprene enclosure seal. All doors shall be hung true and square, with sealing and locking verified prior
to acceptance.
Doors shall be constructed to open at least 120 degrees and fitted with substantial stops or stays to
prevent damage due to over opening.
1.3.3
Surface Finish
The enclosure and doors shall have all welds cleaned and polished, and all external welds polished to
match the 2B buff external finish. All edges shall be deburred.
Stainless steel cabinets generally shall not be coated, however all aluminium enclosures shall be powder
coated. For some specific areas, as instructed by Watercare, the stainless steel outdoor enclosures shall
be powder coated to make the enclosure less conspicuous. Powder coat colour shall be Deep Brunswick
Green, (Orica 959/81879), and rated for at least a 15 year outdoor life.
1.3.4
Enclosure Cable Base and Anchoring
The base shall be constructed to maximise the space for cable access. Each end of the enclosure base
(End-base) shall be constructed as an open U shape, 200mm high x 450mm deep x 220mm long on the
front and back dimensions, with 50mm returns top and bottom and ends.
Each End-base shall be fabricated and welded from 2mm thick stainless steel.
A full size doubler plate of 2mm stainless steel shall be spot welded to the inside of each face (three
doubler plates for each End-base) to provide stiffening for each End-base.
A 25mm x 25mm x 6mm stainless steel angle shall be welded to each End-base, front and back at grade,
to which the four stainless steel ventilated (louvered) base covers attach. Two central supports, one front
and back, consisting of a 25mm x 25mm x 6mm RHS shall be welded to the 25mm x 25mm x 6mm
stainless steel angle to provide central support for switchboard and to provide a attachment points for the
ends of the four ventilated base covers.
For anchoring the board to the concrete base a 450mm long, 50mm x 50mm x 6mm angle shall be bolted
to the end of each End-base. This angle shall be bolted to the each End-base by three M12 stainless
steel bolts, with the bolt heads to the outside of the board.
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Fixings through the 50mm x 50mm angle into the concrete base shall be 3 x M12mm stainless steel
Dynabolts at each end of the switchboard, with at least 50mm embedment into the concrete plinth and at
least 100mm from the concrete edge. The arrangement of the anchoring and attachment stainless steel
bolts holes in the 50mm x 50mm angle shall be a minimum offset such the six bolt/nuts do not clash. The
switchboard builder shall drill the 50mm x 50mm angle holes for the anchoring bolts, offset as noted
above.
1.4
Multibox Switchboard assemblies and enclosures
The designations within Australian Standard NZS/AS3439.1 Low-voltage switchgear and control gear for
the switchboards detailed in this Standard are multi-box assemblies A NZS/AS3439.1 defines multi-box
assemblies as a combination of boxes mechanically joined together with or without a common supporting
frame, the electrical connections passing between two adjacent boxes through openings in the adjoining
faces. For outdoor use, multi-box assemblies shall be installed in appropriate enclosures.
To achieve adequate dust, moisture and insect protection for the multi-box enclosures, the cable entries
into all enclosures within these pump station switchboards shall use cable glands. The multiboxes shall
also be installed to achieve an IP54 rating to IEC 60529.
All multi-box enclosures installed in either pump station buildings or outdoor stainless steel enclosures
shall be manufactured from 3mm aluminium, continuously welded and finished with powder coating. The
powder coat shall be applied to each multi-box at the factory after fabrication. The powder coating shall
be light straw colour, applied on the inside and outside of all faces and shall have a minimum life of
10 years.
The multi-box enclosures shall be fitted with dust seals for all doors and penetrations to obtain as asinstalled rating of IP54 or better. Multi-box hinges and latches/locks shall be stainless steel. Doors shall
not foul enclosure supports or other equipment.
Multi-box enclosures containing power dissipating equipment shall each be fitted with two self-draining
side louvers or vents fitted with 1 mm aperture stainless steel mesh. When the multi-box switchboards are
installed in outdoor enclosures, the multibox enclosures and shall be bolted to sections welded to the
main enclosure. For indoor use i.e., inside pump station buildings, the multi-box switchboard shall be
mounted with stainless steel fixing brackets to the pump station wall.
Each multibox shall be fitted with a 6mm aluminium gear plate and a full depth gland plate. The gear and
gland plate edges and corners shall be rounded so it has no sharp edges. Cable entry for outdoor
multibox switchboards shall be bottom entry only.
The switchboard shall be segregated into separate multi-boxes as follows (refer also to the typical
switchboard general layout drawings):
Main Incomer
Power supply Metering
Generator-Mains selector switch
Power Distribution MCB distribution
Motor Starters direct-on-line or soft starters
Kingfisher Telemetry system
Field device marshalling cabinet and aux controls
Control power supplies, including batteries and control relay interface
Access security with keypad.
1.5
Cable Entry
1.5.1
General
All cables shall be selected with a circular outer sheath for gland sealing. Flat TPS cables shall not be
used. Cables entering multibox enclosures shall be glanded through the multibox gland plates. All
penetrations between the multiboxes shall be effectively sealed by the switchboard manufacturer apart
from a single proprietary insect proof air vent/moisture drain installed at the bottom of each multibox.
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Motor cables shall be terminated directly into the motor starter multiboxes. Field cables from the
Multitrode level sensor, wet well level switches, proximity switches and the like shall be terminated into
rail mounted terminals in the Field device marshalling cabinet and aux controls multibox.
1.5.2
Segregation and shielding of wiring and sensitive equipment
All wiring and equipment both inside and outside the switchboard shall have the necessary segregation,
screening, and filtering to prevent malfunction of the equipment.
Power Supplies
1.5.3
General
The switchboard shall have two incoming power supplies: one from the 3 phase and neutral 400/230 VAC
street distribution system and the other, via a plug/inlet from a three phase 400/230 VAC portable
generator. Ensure that the cable terminations are correctly sized for the power supply cable conductors
and for the system fault current.
Telemetry, instrument and radio power supplies shall be battery backed 24 V DC.
Wet well level switches and other wet well equipment shall only be supplied at extra low voltage.
1.5.4
Front Panel Controls and Indications
Provide all control and monitoring equipment shown on the drawings. All indicators and selector switches
shall be visible when the outer enclosure doors are open.
1.5.5
Tariff Metering
Take delivery of and mount and wire the Electricity Supply Company tariff meter, (and current
transformers, test blocks and the like) to the requirements of the Supply Company. Fit transparent
polycarbonate windows in sealed auto-rubber mouldings to provide adequate viewing of the kWh reading
without the need to open any doors.
Make provision for fitting of Supply Authority seals to meter panel and potential fuses.
1.5.6
Isolation Switches
Provide a Terasaki 125A Moulded Case Circuit Breaker for the switchboard main switch and a motor
isolation switch for each pump. Provide a generator/off/mains changeover switch, 126 Amp rated K & N.
Where a remote generator panel is provided, the main switch in the generator panel shall be a Terasaki
125A Moulded Case Circuit Breaker. The main switch for the Pump Station switchboard shall be a 125
Amp non-auto MCCB rated for AC3 operation.
All main switches, pump isolating switches and three position mains changeover switches shall:
be fitted with rotary handle with a padlock facility. Switches and handles shall fully comply with
IEC 60947-3 for use as isolation switches and be rated for 600 Vac AC3 operation,
have IP20 rated terminal shrouds fitted to both line and load side connections.
All MCBs and switches shall be padlockable and have a hole for an Isolation tag to be fitted once
switched off.
1.5.7
400/230 VAC Equipment
The 400/230 VAC three phase power supplies, terminations and connections shall be shrouded to
achieve an IP20 rating to IEC 60529.
The following 400/230 VAC equipment shall be mounted in the enclosure and shall be segregated from
the low voltage control equipment:
(a) three phase, 400VAC, BS88 HRC fuses for indicators and monitoring instruments,
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(b) miniature circuit breakers for the Motor starters, enclosure anti condensation heater, cabinet light
and combined wet well, area and cabinet light switch, 10 Amp single phase power outlet, RCDs
and other equipment as required,
(c) three phase 400 VAC lockable motor isolator to IEC 60947-3 for each motor,
(d) neutral bar,
(e) earth bars,
(f) motor starters as shown,
(g) power factor correction contactors, capacitors and current limiting air cored chokes,
(h) cable terminations,
(i) fluorescent panel light,
(j) time delayed off lighting control switch.
1.5.8
Generator Connection and Pump Plugs/Sockets
Provide and install a 63 Amp 5 pin, surface mounting, polycarbonate, Gewiss IEC 60309 generator inlet
receptacle. The generator inlet receptacle shall be mounted under a weatherproof padlockable shroud as
shown on the general arrangement drawings. The actual side location of the generator receptacle i.e.,
LHS or RHS of the switchboard shall be agreed with Watercare during the switchboard design stage.
1.5.9
Power Factor Correction Capacitors.
Confirm requirements for power factor correction capacitors (PFCs) with the Power Authority and
Watercare representative. If required, PFCs shall be installed in the switchboard for each pump. The
PFCs size shall be selected, based on the pump manufacturers data sheets, to correct the full load power
factor to the value specified by the Power Authority to avoid any reactive power charges (normally no less
than 0.96PF).
Capacitors 2kVAr and above shall have an overpressure disconnect system for use in the event of
internal faults. The capacitors shall be manufactured and tested to comply with IEC 60831-1/2.
The connection of power factor connection capacitors shall be switched by a contactor connected to the
line (upstream) side of the motor starter protection and CT modules.
Fit air cored inductors to each capacitor phase to limit capacitor inrush current. Capacitor contactors shall
be rated for capacitor switching. Rating of the capacitor contactor(s) is to be verified by the Developer.
Power factor correction capacitors shall be installed outside the switchboard multi-boxes as follows:
Indoor pump-stations in stainless steel enclosures mounted on the wall away from the multi-box
switchboard.
Outdoor pump-stations in the ventilated cable base of the outdoor enclosure. The capacitors shall
be installed in stainless steel containers.
Power factor capacitors 2kVAr (at 400V) and above shall be 440 Volt rated Vishay-Estaprop brand
mounted in stainless steel enclosure with air chokes and cable terminations Supplier, Lees
Technology.
Power factor capacitors below 2kVAr (at 400V) shall be 440 Volt rated epoxy-cased capacitors
mounted in stainless steel enclosure with air chokes and cable terminations - Supplier, Metalect
Industries.
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1.5.10 Anti-Condensation Heaters

Each multibox containing switchgear or control equipment shall be provided with an anti-condensation
heating operating at 230V AC.
Heaters of black heat type shall be continuously energised and shall be designed to maintain the
enclosure temperature at 3C above ambient temperature at all times.
Thermostatic temperature control shall not be used. The heater circuit shall have its own anticondensation heater circuit-isolating switch and neon indicating light. Heaters that have operating
surface temperatures exceeding 60 C shall be fitted with expanded metal mesh protective screens to
prevent personnel contact with the hot surfaces.
The preferred heating arrangement is for a 10 Watt aluminium body, TS35 rail mount, Rittal SK3105.000
heater located at the bottom of each multibox. This heater is supplied with a 300 mm connection cable.
For larger enclosures, the 20 Watt SK3106.000, or the 30 watt SK3115.000, may be more appropriate,
depending on the heat load from the equipment.
1.5.11 Enclosure Power Outlets
Each switchboard shall be provided with one, single phase 230 VAC switched 10 amp socket outlet,
complying with AS/NZS 3112 for general purpose use. The outlet shall be mounted vertically and
protected by A Class, 30mA Residual Current Devices (RCD) located in an IP66 enclosure. In addition,
non-RCD protected outlets shall be provided for dedicated power supplies to equipment.
1.5.12 Enclosure Earthing
All enclosure metal work including multiboxes shall be electrically bonded to a single enclosure earth
stud. All non-current carrying metalwork installed and the metalwork of the structure, plumbing pipes,
fittings and the like, shall be effectively earthed.
All earth wiring within enclosures shall be covered and coloured green or green/yellow. The earth cable
to the earth electrodes shall be green PVC insulated stranded copper conductor.
1.6
Telemetry, security and wiring

1.6.1
Station Telemetry
The Contractor shall provide all telemetry equipment, data radio, aerial, mounting equipment, power
supplies, relays and cabling including the field or control devices shown on the drawings.
The telemetry and radio system shall be purchased from Watercare approved supplier.
Mount and wire the telemetry system in a multibox of the switchboard. Provide power supply, batteries,
antenna and antenna mounting to the standard Watercare design. Provide, install and connect a six
element vertically polarised UHF Yagi antenna for the telemetry unit. The antenna and accessories are
available from Marsa Consultants ph 815 3274 Mark Flower.
All telemetry module inputs and outputs will be wired to rail mounted terminals within the telemetry
cabinet. Refer W Arthur Fisher CP10 Telemetry Baseplate Layout drawing number 02007 sheet 1,
and CP10 Telemetry Cross section drawing number 02007 sheet 2, for typical telemetry mounting
details.
Input and output devices and connection details are shown in the W Arthur Fisher schedule Kingfisher
PC1 for 2 pump, Sewage Pump Stations. Ensure that adequate wetting current is used for the Flygt
level switches to ensure reliable switching. To achieve this, it may be necessary to connect additional
resistors to each telemetry input.
Power supplies and battery capacity shall be selected to provide a backup duration of 12 hours for all
telemetry and instruments.
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Configuration of the telemetry software will be by Marsa Consultants as a subcontractor to the Contractor.
Test and commission the complete telemetry system in conjunction with Watercare representative.
1.6.2
Station Security System
Watercare pump station security system consists of a keypad/controller, backup battery, door switches,
various sensors and output items, which shall be supplied by the Contractor. All equipment shall be
installed and wired by the Contractor. Configuration of the security system software will be by a
competent software company as subcontractor to the Contractor.
The Security controller space allowance is 300mm wide, 300mm high and 100mm deep. It shall be
installed in a multibox in the switchboard for outdoor pump station switchboards, or wall mounted in pump
station buildings. For pump station buildings, allow space and provide mounting brackets and mount the
Controller/keypad enclosure on the inside of the first-opening door.
Allow installing the Security system in the switchboard multibox before dispatch to site, i.e. Keypad,
controller, and door proximity switches that connect back to the controller enclosure.
1.6.3
Power Wiring
Wiring size between 400/230 V terminals, fuses and MCBs shall be selected for accommodate the
maximum fault rating from the upstream circuit protection device. Circular sheathed cabling only shall be
used.
1.6.4
Secondary and Control Wiring
All secondary and control wiring shall use flexible, tinned copper conductors with flame retardant
insulation. Wiring shall be adequately sized for the circuit load but not less than 1.0 mm2.
All current transformer, voltage transformer, and AC supply wiring shall be appropriately sized for the duty
and of the appropriate phase colour.
Every wire shall be numbered at each end with Grafoplast TRASP or equal slip-on ferrule crimped pins
with labels reading from left to right or top to bottom. The ferrule shall be readily visible without any
disconnecting or dismantling, and be firmly attached to the wire.
All flexible control wiring shall be terminated in tinned copper insulated crimp pins of the appropriate size
to match the wire size. Suitable ratchet operated crimp tools are to be used for the crimp pins.
Low voltage enclosure wiring shall generally be contained in PVC fire retardant slotted trunking. Trunking
shall be adequately sized to contain all low voltage enclosure wiring and external field wiring. On
completion, trunking shall be no more than 50% filled. Internal wiring shall not be run in trunking intended
for field wiring. A minimum of 40mm space shall be allowed between slotted trunking and the adjacent
terminals.
Wire looms may be secured with plastic buckle ties or Nylon spiral wrap. Self adhesive tie bases shall
not be used. A wiring loom between moving parts shall not exceed 12 wires.
All wiring between multibox enclosures shall be via glanded circular PVC/PVC cables. Glass fibre-filled
Nylon IP65 glands of the appropriate size are suitable for this duty.
1.6.5
Control Wiring Colours
400/230 V Phase conductors

230 V ac active control circuits
400/230 V ac neutral
ELV dc Telemetry Digital outputs
ELV dc Telemetry Input circuits
ELV common
1.6.6
RED, YELLOW, BLUE

ORANGE
BLACK
PURPLE
WHITE
GREY
Terminals
Terminal blocks for all low voltage wiring shall be TS35 rail mounted modular terminals complying with
the following standards:
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VDE 0611

Part 1 : Terminal blocks for connection and joining of copper conductors up to 1000VAC
and 1200VDC. (Feed through terminals up to 230mm2 )
Creepage and clearance dimensions
Clamped screw connections for connection of copper conductors up to 230mm2.
VDE 0110
VDE 0609
Mounting rails shall be extruded with a TS35 profile in accordance with DIN 46277/EN. All terminals shall
be individually labelled with an unambiguous code relating to the schematic diagrams. All enclosure
wiring shall be terminated on the same side of a given terminal block.
Twenty five percent spare terminals of each type shall be provided with the enclosures to allow for
additions and revisions to the wiring during commissioning and subsequent changes.
The terminal rails in the Enclosures shall have terminals segregated into the following groups:
(a) Instrumentation
(b) 24 VDC Control Inputs
(c) 24 VDC Control Outputs
(d) 230 VAC Control/Indication
(e) 400/230 VAC Power
The terminal block requirements for particular types of circuit shall be as follows:
1.6.7
Control
Terminals for interconnections between internal and external control circuits shall be capable of accepting
2 x 1.5mm2 crimp pins. Purpose made bridging accessories are to be used when additional bridged
terminals are required. Adequate terminals plus 20% spare (with a minimum of 5) shall be provided for
each terminal block group. Terminals shall be Klippon WDU 2.5 with all necessary accessories or
approved equal. Diode terminals are to be WTR 2.5D or approved equal, with 1N4007 diodes fitted.
1.6.8
Instrumentation
Terminals shall be Klippon WDU 2.5 with all necessary accessories. All outgoing instrumentation circuits
shall have dedicated terminals. Loops between outgoing instrumentation circuits shall be provided on the
enclosure side. Where a single analogue loop is to be connected to more than one field device,
dedicated terminals shall be provided for each loop. A matching instrument earth terminal for the cable
screen shall be provided for each outgoing circuit.
1.7
400/230 V Power Circuits

1.7.1
General
The distribution board MCBs shall be supplied from a NHP Din-T fully insulated coloured Red, White,
Blue, 3 phase 415V copper bus bar chassis rated at 250A with a fault withstand rating of 25 kA for 0.2
second.
Terminals used for the connection of power circuits shall be sized for a conductor with a current rating at
least 150% the full load current of the supply. All AC mains terminals shall be fully shrouded, marked with
a red label indicating the highest voltage present, and segregated from control terminal blocks. Terminals
shall be Klippon with minimum rating of WDU 2.5 complete with all accessories.
1.7.2
Auxiliary and Control Relays
Control relays, contactors and auxiliary contacts shall be as specified in the drawings and schedules. All
control equipment shall be mounted on TS35 rails. Control relays shall incorporate a three-pole
changeover contact set in a sealed relay housing. Only gold flashed or gold plated contacts shall be used.
Provide front-wired 11 pin base and hold down clips.
1.7.3
Electrical Measuring Transducers
All transducers shall provide an isolated 4 to 20 mA output and accuracy over the specified operating
range shall be 1 % or better. The output signal for each transducer shall be wired via rail mounted
terminals as described above. Transducers shall be as specified on the drawings.
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1.7.4

Indication Lamps
Indicating lamps shall be IP66 rated 22mm diameter, multi LED high intensity BA9S type. Lamp lenses
shall be prismatic and have a minimum diameter of 22mm. Lamps shall be sufficiently bright to be clearly
visible in shaded sunlight. Klockner RMQ 22 LED series or similar.
Unless shown on the drawings, lamps shall be coloured as follows:
Green Energised or operative condition
Red
Overload/Unenergised or inoperative condition
Amber Status indication
1.7.5
Control Switches, Push Buttons and Emergency Stop Button
Control switches shall be IP66 22 mm diameter industrial lever switches of the add on contact block
type. Where switches have an Auto position, they shall be oriented so that the lever points in a vertical
position with Auto selected.
Push buttons shall be of the 22.5mm diameter industrial add on contact block type.
An Emergency Stop pushbutton shall be latching, 40mm or 50mm mushroom head type, coloured red.
It shall be equipped with at least one normally open and three normally closed contacts and connected to
stop both pumps i.e. denergise the motor line-contactor for both DOL and Soft-starters. A contact from
the E-Stop button shall be connected to the telemetry digital input.
Control switches and pushbuttons shall be readily accessible for maintenance. Contacts shall be suitable
for the required 230 VAC or 24 VDC duty. Gold plated or gold flashed contacts shall be used for 24 VDC
or extra low voltage service.
1.7.6
Indicating Instruments
Unless individually specified, all indicating panel instruments shall comply with IEC 51 with dimensions to
DIN Specification 43700. Instruments shall be of flush pattern with a 72mm square bezel and 90 scale
unless otherwise stated.
Motor ammeter scales shall be selected so that the motor full load current reads between 60% and 80%
of scale length. Motor ammeters shall be overscaled to 2 times nominal current. Multi turn phase
conductors through the CT is an acceptable method for scaling ammeter primary current. Each pump
motor ammeter shall have a self-adhesive red line indicating the normal maximum running current.
1.7.7
Low Voltage Fuses, Circuit Breakers and Co ordination
1.7.7.1 Fuses
Unless otherwise stated, all fuses shall be of the high rupturing capacity cartridge type conforming to BS
88. Each fuse carrier shall be labelled with its circuit function and current rating. Fuses in direct current
circuits shall be in both positive and negative poles and located in individual holders. Fuses and links
shall be provided as required to ensure adequate protection for equipment and to provide isolation of
control and protection circuits.
1.7.7.2 Miniature Circuit Breakers
Miniature circuit breakers shall be fitted with magnetic and thermal trip devices. Miniature circuit breakers
shall only be used in applications requiring a rating of less than 63A. They shall have provision and
accessories necessary for padlocking the mechanism in the open position. The minimum short circuit
breaking capacity of miniature circuit breakers shall be 15kA Ultimate breaking capacity (Icu). Small 1A
MCBs that supply indicating instruments etc shall be backed up by a 2A HRC fuse. Where the
prospective short circuit rating of the miniature circuit breaker is less than 15kA Icu then the miniature
circuit breaker will be supplied via a HRC fuse of an equivalent rating. MCBs shall be Terasaki faultcurrent limiting breakers.
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1.7.7.3 Moulded Case Circuit Breakers

Low voltage circuit breakers of rating 63A and above shall be of the moulded case type with clear
indication of the open, closed or tripped positions. They shall be fitted with magnetic and adjustable
thermal trip devices. They shall have a normally open auxiliary contact and shall include provision, and
accessories necessary for padlocking the mechanism in the open position. As a minimum all moulded
case circuit breakers shall have a short circuit breaking capacity of 30kA Service Breaking Capacity (Ics).
Prior to purchase of moulded case circuit breakers the local power supply authority shall be asked for
prospective short circuit levels for the area. Where the prospective short circuit level is within 20% of the
35kA rating, 50kA Ics breakers shall be used. MCCBs shall be Terasaki fault-current limiting type.
1.7.7.4 Protection Device Tripping and Co ordination
The Developer shall select and size fuses and circuit breakers to achieve coordination between protection
devices. The object is to allow down-stream faults and overloads to effect only that circuit, e.g. for a
pump motor short circuit or arcing fault only that pumps circuit breaker will trip and not any upstream
protection. The Developer shall produce protection device curves and a protection setting schedule that
show co-ordination has been achieved. If complete co ordination cannot be achieved the curves and
setting schedule will show what coordination level has been achieved. These curves, breaker types,
fuses sizes and breaker setting schedule shall be submitted to Watercare for approval prior to purchase
of the protection devices. The prospective short circuit level for the installation shall also be shown on the
coordination curves.
1.7.7.5 Contactors
Contactors shall be of the block, air-break, electromagnetic type having inherent under-voltage release
characteristics and provision for replacement of fixed and moving contacts and operating coils.
Contactors shall be suitable for Class 0.1 duties, utilisation category AC3 (IEC 60158-1) with a minimum
rated electrical life at full load current of 1 million operations. Contactors shall be equipped with at least
one normally open auxiliary contact wired to the telemetry as shown. Contactors shall be Telemecanique
brand.
1.7.8
Motor Thermal Overload Protection
For Direct on Line starters, three-element thermal overload protection with unbalanced phase tripping
shall be used. There shall be no permanent distortion of the operating element as a result of over current
conditions. Thermal overload relays shall be of the hand and remote reset type and shall be equipped
with at least one normally open auxiliary contact. Protection co-ordination shall be to Type 2 to IEC
60947-4. Fuse sizes shall be selected to match the motor full load current and IEC 60947-4 type 2
requirements. All Thermal overload relays shall be fitted with 230 V ac electric reset solenoids connected
to a blue RESET pushbutton within the multibox. Thermal overloads are to have a manually tripable
overload contact for testing the alarm function. Thermal overload units shall be Telemecanique brand.
1.7.9
Electronic Motor Starters
Where required, electronic motor starters shall be provided in addition to the motor contactors. All
electronic motor starters shall be provided with line side overvoltage protection. Pump applications will
require both soft starting and soft stopping. To ensure adequate cooling, enclosure clearances shall be
provided for these motor starters as recommended by the equipment manufacturer.
Aucom IMS series IP42 rated soft starters shall be used. The minimum starter size shall be IMS20018.
Soft starters are to be sized as follows unless Watercare or the Pump Vendor advises otherwise:
(a) Current to be limited to 3.5 times full load current.
(b) Soft-start time as short as possible to limit heat dissipation in enclosure, typical 2.5 seconds.
(c) Soft-stop - not generally required, but allow for 3.0 seconds for minor water-hammer reduction in
higher head applications. Again, to minimise heat dissipation in the starter enclosure.
(d) Duty Cycle 1: 10 starts per hour for 3 hours twice per 12hr daylight day. Run time 3 minutes,
Rest time 3 minutes.
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(e) Duty Cycle 2: 15 starts per hour for 1 hour twice per 12hr daylight day. Run time 3 minutes 20
seconds, Rest time 40 seconds.
The Line switching contactor shall be controlled from the soft starter Main Contactor auxiliary contact.
Bypass and power factor capacitor switching contactors shall be provided and controlled from the soft
starter RUN auxiliary contacts.
Configure the soft starter to utilise the following features:
Line contactor,
Bypass/capacitor contactor,
Soft start,
Soft stop,
Phase sequence trip (fault output),
Underload trip (fault output),
Thermal trip (fault output),
Motor analogue output to the telemetry input.

1.7.10 Submersible Pump Motor Protection
All pump motors shall be provided with thermal sensors, either in the form of thermistors or a thermal
switch in each winding. Thermal protection shall be connected to the soft starter thermistor input or a
thermistor relay and configured to trip the starter on over temperature.
Where a thermistor relay is connected to motor thermal switches, a 1 watt 100 ohm resistor shall be
connected in series with the sensor wiring, at the switchboard terminal rail, to prevent false tripping.
Thermal switches shall be either connected to the digital input of the soft starter or connected to a
proprietary control relay located in the motor starter multibox. These shall be configured to trip the starter
on over temperature. Water-in-oil sensors can also be connected to the thermal protection relay or to a
Flygt MiniCASS on Flygt pumps.
An NHP earth fault relay shall be installed to provide earth fault protection for each pump starter. Earth
fault relays shall be configured to be normally energised. Refer drawings for details.
1.7.11 Voltmeter, Ammeter, Hour meter and Generator Phase Rotation Indicator
Provide a switched voltmeter scaled 0 - 500 V, connected to the load side of the switchboards incoming
400 V ac mains supply switch. Provide and connect a phase failure relay, with time delayed relay output,
to the mains supply. Both the voltmeter and phase failure relay shall be supplied via 2 Amp HRC fuses
and a local 1 Amp 3 pole MCB.
Provide an ammeter for each motor starter and mount it so it can be clearly read through the
polycarbonate window in the pump motor starter multibox. Connect in the Yellow phase line side.
Provide an hour run meter for each motor starter and mount it so it can also be read through the
polycarbonate window in the pump motor starter multibox. The hour meter shall be non resetable and
shall be at least five digit (0-99,999 hours) and shall operate at 230VAC.
Provide a Crompton 243-12PG phase rotation indicator marked with the correct phase rotation. The
phase rotation indicator shall be connected to the line side of the generator incomer isolator. Three 2 amp
HRC fuses and a local 3 pole 1A MCB shall be provided to protect the phase rotation indicator supply.
Provide and connect a Crompton 252-PVR phase failure relay as shown.
Three LED indicator lamps RED, WHITE, BLUE shall be fitted below the Main-switch incomer switch
handle. The indicator lamps shall be labelled: Mains Available. Each indicator light will be connected as
follows - R to N, W to N, B to N. The three Mains Supply Present LED indicator lights shall be Klockner
type: RMQ 22-ML R/W/B 240V 50Hz. For site with remote generator connection switchboards, the Mains
Supply Present Indicator lamps will be installed in the Remote Generator Connection switchboard.
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1.7.12 Site Installation

1.7.12.1
Overview
In addition to installing the switchboard(s) and plinth(s), the works shall include the provision and
installation of field instruments, level switches, pump plug sockets, cables, conduit, ducting, security
system switches, lighting and all other items necessary to complete the works.
1.7.12.2
Project management meetings
The Contractor shall prepare and submit, to Watercare, a detailed programme of works in Gantt chart
form that includes all tasks prior to and during installation and commissioning. The Gantt chart shall be
updated regularly by the Contractor showing the percentage completion of all tasks.
At the request of Watercare, during the installation and commissioning phases of each pump station the
Contractors representative shall attend coordination meetings with Watercare as required, at the
nominated Watercare offices.
At the meeting the Contractor shall present an updated Gantt chart and a written report on progress,
problems and the work proposed for the following week.
Testing and commissioning dates shall be agreed to suit all parties.
1.7.12.3
Permit and Fees
The Contractor shall obtain all necessary permits in connection with the works unless otherwise specified.
The Contractor shall pay all fees and other charges in connection with the works unless otherwise
specified.
1.7.13 Setting Out
1.7.13.1
General
Drawings provided show the general arrangement of plant and equipment with principal dimensions.
The Contractor shall set out the Works in detail having regard to all the circumstances pertaining at the
time of commencing work, including the coordination with the civil works, the running of other services,
the provision of conduits and ducting, spare space for future services and proposed methods of
construction and installation.
1.7.13.2
Installation of Switchboards, Pumps, Telemetry, Controls and Security system
The Contractor shall coordinate delivery and installation of all switchboards, control, telemetry and
security equipment in a timely manner and in accordance with the agreed programme of planned work.
Coordinate with all other suppliers, contractors and Watercare to provide a programme of work for the
completion of this installation. For all outdoor switchboards and remote generator connection
switchboards, design, supply and install the switchboard concrete base and cable ducts within the
concrete base as shown on the general arrangement drawings.
All locations of the cable ducts in the concrete switchboard foundation shall be designed so that that no
cables crossovers occur in either the ventilated switchboard base or in the outdoor enclosure for the
multibox switchboard. Any proposed cross-overs, either in the ventilated base or within the outdoor
enclosure shall be fully discussed before construction of the concrete foundation starts. The same design
and Watercare approval process shall apply to cable conduits or ducts and cables entering pump station
buildings to switchboards and control panels.
All underground cable ducts and cableways from the wet well into the ventilated base of the outdoor
enclosure shall be sealed after construction to be gas and water tight. A suitable seal would consist of a
50mm plug of non-hardening, flame retardant compound, Flame-safe FSP1000 Firestop putty available
from Electropar Limited, or Fyreflex sealant available from Grinnell Supply Sales (Tyco).
The switchboard fixings, to walls or to concrete bases, shall be 316 stainless steel metric bolts, 12mm
minimum diameter and shall also comply with the seismic design requirements.
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All cables entering the ventilated switchboard base shall have circular outer sheaths for gland sealing.
Flat TPS cables shall not be used. All cables entering multibox enclosures shall be glanded through the
multi-box gland plates. These glands shall provide an IP55 seal on the outer-sheath of the cables.
Gland all cables between the ventilated base aluminium gland plate and the internal space of the outdoor
enclosure to provide an IP55 degree seal on the outer sheath of the cable.
1.7.13.3
Pump Plug sockets
For pump motors with separate thermistor cable and a full load current of less than 16 amps, provide a
PDL unswitched socket outlet, IP66, 500 V, minimum size 56SOx20 for the motor cable. Provide a
separate 56SOx20 plug socket for the thermistor cable.
For pumps with a full load current greater than 16A, plug sockets shall be interlocked such that the plug
cannot be withdrawn with the switch in the on position. Marechal DSN IP67 type to suit pump (Pins
3P+E+2C) are suitable, supplied by Cutler Hammer.
The sockets shall be mounted well above flood level in the wet well at a location that is accessible from
the wet well access hatch. Route the pump cables to allow either pump to be removed from service
without disturbing the other pump. Watercare is to approve locations and cable routes before installation
commences.
Provide angled matching plugs for the pump cables and matching plugs for the thermal sensor cables.
The motor and thermistor plug sockets may be incorporated in a single multipin plug socket for each
pump. Prior approval by Watercare is required before purchasing plugs and mountings to ensure
compatibility with existing installations.
1.7.13.4
Security System Cabling
For sites that include a remote generator switchboard, install a General Cables B5504ESCS 1.5 mm2 4
pair individual screened and overall screened PVC cable from the generator switchboard to the pump
station switchboard. Install the cable in a 25 mm UPVC buried conduit maintaining at least 300 mm
separation from power cables and other services.
Install IP68 proximity type door switches on the first of any of the opening doors, to detect the opening of
the following:
Outdoor switchboard doors
Generator switchboard door
Pump station building doors
Wet well access covers
Valve chamber access covers.

Each proximity switch shall be wired to the security controller and each switch shall activate when the
respective door is between 60 mm and 200 mm open.
1.7.13.5
Switchboard Earthing
A minimum of two 1.5m driven 16mm diameter copper coated steel earth rods spaced at 2 metres and
associated earth cable shall be provided and installed to comply with the NZ Wiring Regulations.
Two electrodes shall be installed at each switchboard location. For remote generator connection sites,
two electrodes shall be installed at the remote generator switchboard and two electrodes shall be
installed at the pump station switchboard.
Earth cables from the switchboard to the electrodes shall be green PVC sheathed stranded copper
conductor. A separate earth cable shall be run from the switchboard earth to each electrode.
Inspection toby boxes shall be provided and installed at grade to access the switchboard earth
electrodes. The toby boxes shall be concreted in with a 150mm surround of concrete. Protect the earth
rod earthing cable with UPVC conduit/fittings buried at least 300mm below finished ground level.
Corrugated conduit shall not be used.
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1.7.13.6

Site Lighting
Provide and erect a single, 50mm diameter galvanised pipe, with pole mounted 160 W self ballasted
narrow beam luminaire mounted 3m above finished ground level. The luminaire shall be located so that it
provides light in the wet well to allow inspection and maintenance. Erect the lighting pole in a poured
concrete base at a location agreed with Watercares representative. Protect the lighting cable with UPVC
conduit buried at least 600mm below finished ground level. Connect the luminaire to the time off-delay
manual light switch, set to 5 minutes.
The light fitting shall be an Iwasaki Lighting (EYE), KO lampholder with cast metal guard and 160 W
PAR38 Self Ballasted MV Lamp and F7 flanged base. Bolt the F7 base to a 50mm Galvanised screwed
flange on top of the 50mm galvanised pole. All fastenings shall be 316 Stainless steel, including the
bolts, nuts and locknuts for the KO lampholder hinge and the guard clamp ring.
1.7.13.7
Telemetry Antenna
Provide and erect a single, 40mm diameter galvanised pipe, with pole mounted six element vertically
polarised UHF Yagi antenna mounted 4m above finished ground level. The pipe shall be attached to the
switchboard enclosure with galvanised clamps and stainless steel fasteners. Refer Watercare Standard
Drawing 2001979.033 The bottom of the pole is to rest on the concrete plinth. Routing of the antenna
coax to the Telemetry unit shall be down the inside of the pipe and be vandal resistant. A drainage hole
shall be provided at the base of the pipe.
1.7.13.8
Level switch cabling
Wet Well level switch cables shall be selected to:
allow adjustment over the full range of wet well water level;
be adjustable from the wet well access hatch without having to enter the wet well;
have no cable joints.

1.7.13.9
Wet well washer
Provide a 230V/24V isolation transformer with earthed screen, AUTO/OFF/MANUAL control switch,
auxiliary relay, indicating light and other items as shown on the drawings. Provide field cabling and
conduit to a wet well spray washer solenoid valve. The cable shall be 3 core tinned copper 2.5mm2
600/1000V PVC/PVC of circular construction.
If the washer system is installed, connect the cable to the solenoid valve coil using an IP68 connection.
Connect the other end of the cable as shown on the drawings. If the wet well wash is not installed at the
time of switchboard commissioning, install sufficient cable to reach the location of the wet well washer
solenoid valve and leave the cable neatly coiled and tied inside the switchboard ventilated base.
1.7.14 Testing and Commissioning
1.7.14.1
General
This clause includes testing, commissioning and acceptance of all items and switchboard(s) supplied.
This clause of the Works also includes level controller configuration, setting the position of the wet well
level switches and the like. Configuration of the Kingfisher telemetry system and the security system will
be by the respective Subcontractors.
After construction work has been completed, the entire installation shall be in a clean and tidy condition
ready for testing and commissioning.
1.7.14.2
Switchboard Inspection and Testing
The switchboard shall be completely assembled at the manufacturers works for testing.
Tests and inspections shall be undertaken by the Contractor on completion of manufacture as agreed
between Watercare and the Contractor. Watercare representative may witness all tests and inspections.
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Tests on the complete switchboard shall be carried out at the manufacturers premises in accordance with
Section 8.3 AS3439-1 Routine Tests and the results recorded on works test certificates.
In addition to AS3439.1 Routine Tests, the Contractor shall perform the following tests:
checking of equipment type, layout, and connections against the approved drawings,
check labels, lens colours, physical size against the approved drawings,
visual inspection of installation standard,
check that all electrical terminations are rated IP20 (finger touch proof) or better,
point to point visual and electrical wire checking against the approved drawings,
insulation tests and checks,
functional check and operation using simulated field connections,
check foundation drawings against actual fixing dimensions.

1.7.14.3
Site Testing
Following installation of the switchboard, pumps, field equipment and earthing system, the whole of the
equipment provided under this specification shall be made available for a programme of inspections and
tests. Watercare shall be advise at least 7 days prior to testing and the testing shall be coordinated so
that representatives from Watercare could inspect the installation and also witness the tests.
The Contractor shall be inspect and test the complete installation as per the list in Section 6 of
AS/NZS3000 to ensure compliance. All tests and test results shall be recorded in a schedule and a
signed copy of the test schedule shall be included in the manuals.
1.7.15 Commissioning and Handover
The Contractor shall commission the works. Allow for checking that all equipment and functions conform
to the requirements of the drawings and this specification and that the installation is in a safe and fully
operational condition. Record all commissioning settings and configuration details. Operating training
shall be provided by the Contractor to Watercare maintenance staff and contractors during and after
commissioning.
Once the pump station is fully operational, both in manual and automatic operation, the pump station shall
be offered for acceptance to Watercare by the Contractor with full supporting documentation and
manuals, which include copies of all test results and as-built drawings. The installation and equipment
shall be handed over complete and in perfect working order and condition.
1.7.16 Operation and Maintenance Manuals
The works are not complete until three bound copies of the operation and maintenance manuals are
delivered to and approved by Watercare. The spine of the Manual shall be identified by the Contract
number, Site name and Installation date (month and year). The site name is to be agreed with the
Watercare and shown on the title block of all drawings, diagrams, Bill of Materials and other documents.
Two hole or three hole punched pages will not be accepted.
All drawings shall also be provided in AutoCAD format to a numbering system approved by Watercare.
The Operation and Maintenance manual shall include the following documentation, in logical sections:
An index
As-built scaled drawings of the switchboard enclosure(s).
As-built scaled drawings of the panel layouts, internal equipment and trunking, with all equipment
identified.
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As-built electrical schematic diagrams showing all equipment identification, labels, wiring
interconnections, terminal numbers, wire numbers, wiring cross section area and wiring colour
codes.
The Switchboard Works test certificates.
The Installers name, address and contact details.
The Installers Electrical Work Certificate of Compliance.
As-built bill of materials for all equipment and electrical components showing equipment
manufacturer, model numbers and supplier name for all equipment.
Equipment data sheets for all equipment supplied, with all non-applicable information deleted or
clearly crossed out.
A record of pump motor start currents and the duration of starting and stopping.
A record of pump motor running currents.
Record confirmation of motor overload settings. NB thermal overloads to be set to the motor full load
current.
Records of all soft-starter, level transmitter and level controller configuration settings.
Soft and hard copy records of as-built pump station telemetry system configuration.
A copy of the site inspection and test schedules.
Verification that the generator phase rotation meter is correctly indicated
As-built, scaled, underground cable drawing showing all cables and routes.
Earth Electrode test results.
Manufacturers operation and maintenance requirements for all equipment.
Hazardous Areas document dossier (if applicable to the particular site), shall comply with AS 2380.
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December 2011
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Bill of Electrical Materials:

Two Pump Station, Electronic Soft Starter or DOL starters.
The Contractor shall supply the following equipment types. All dimensions are to be confirmed by
Contractor on receipt of the equipment and prior to switchboard construction:
Reference
Quantity
Description
Supplier
Outdoor
Enclosure
Enclosure
light
Multibox
Enclosures
1
As required
DB1
MCCB1
Generator
Changeover
Switch
MCB1
3mm Aluminium fully welded IP54 powder coat

enclosures for mounting all electrical equipment.
Colour light straw.
NHP Din-T fully insulated 3 phase 415V copper bus
bar chassis rated at 250A
Terasaki XS125NJ for incomer main switch
Versalux Lighting
NHP
NHP
3 pole three position 126 A Kraus & Naimer lockable

rotary handle. Type KG126-E Gen/Off/Mains
N Z Solenoid
NHP
Carrel & Carrel
V1
Terasaki Fault current limiting distribution MCBs

Type DTC B15
Voltmeter, 0-500V AC 72 mm square
PFR
Phase Failure Relay; Crompton 252-PVR
Electrade
PRI
Phase Rotation Indicator; Crompton 232-12PG
Electrade
VS1
4-position AC voltmeter Selector Switch CG8-A007
N Z Solenoid
A1, A2
CT1, CT2
C1A - C2C
IT1, IT2
THOL1, 2
HS1, 2, 4
HS3
F1 etc
HR1, 2
Reference
As required
Stainless steel or powder coated aluminium IP54

enclosure for mounting all control cabinets (confirm
powder coat requirements with NSCC)
Versalux AD240/13 slimline Fluorescent
Motor Ammeter, moving iron 72 mm square

overscaled to 2x. Direct reading or multi turn
through 60/5 CT
2
60/5A 5VA type 1.0B Current Transformers for
ammeter (if required)
4 or 6
Contactor, 3 pole, 240VAC coil, Telemecanique LC1D series selected for the required switching duty
For DOL
Loop powered CT Current Transmitter. Carrel &
starters only Carrel T-ILC Range selected for motor FLC.
For DOL
Motor Thermal Overload relay, 3 pole,
starters only Telemecanique LRD series to suit full load current
2
2 pole 3 position 230VAC/24V DC, 10A Control
Switch, Kraus and Naimer CA4-1/FS
1
2 pole 2 position 230VAC/24V DC, 10A Control
Switch, Kraus and Naimer CA4-1/FS
as required BS88 HRC, 32A Fuse holders 400/230 VAC
2
Hour run meter 240 V 50Hz, 5 digit non-resettable,
Panel mount
Quantity
IS1, IS2
L1 etc
housings
L1 etc
lamps
as required
Version 1.0
December 2011
as required
Carrel & Carrel
Carrel & Carrel

Schneider
Carrel & Carrel
Schneider
NZ Solenoid
NZ Solenoid
Carrel & Carrel
Description
Supplier
3-Pole 63A lockable main isolator, 1 NO Auxiliary,

KG series with lockable rotary handle
Indicator housings, 22mm, Klochner RQM22-ML
LED, voltage and colour as specified
24 V BA9S Multi LED lamps, colour as specified
NZ Solenoid
Bremca
Bremca
24 of 26
Reference
Quantity

Description
Supplier
Electricity
Supplier
Bremca
M1
3 Phase 80A max Revenue Meter
ES
PB1, 2, 3
PFC1, 2
EFR1, 2
2
2
4 pole Latching Push button 22 mount, Mushroom

head, Klockner
Push button 22 shrouded, contacts and colour as
required, Klockner
3 phase Power Factor Correction Capacitors
Terasaki TZS-AD 120240 earth fault relay with TZS
15 or 24 CT Current Transformer, 15 or 24 mm hole
to suit cable size
Aucom IMS2 Series IP42 soft starters
SS1, 2
Relays R1
For Soft
Starter
version only
as required Omron four pole plug-in relays shall be used for the
Pump fault relays i.e. R1 (replaces R1&R1A) and R2
(replaces R2&R2A). Omron type LY4N AC 240V
that include a LED indicator. Front screw terminal
Omron base to fit DIN TS35 rail, Socket type
PTF14A-E.
Finder Relay type 60.13 for 230V AC coil 3 pole
AgNi change over with LED indicator;
Telemetry
RTU
Power
Supplies,
Antenna
T1
S1
1
As required
1
1
Finder Relay type 60.12 for 24V DC coil 2 pole AgNi

change over with LED indicator.
Finder base type 90.20 and 90.21 Relays shall be
fitted with retaining clips.
Kingfisher RTU enclosure, radio, power supplies,
with mounting hardware and connections
Power supplies, UHF antenna with mounting pole,
hardware and cables
Wet Well Washer 240V/24VAC 60VA Isolating
Transformer with earthed screen
1 phase RCD IP66 Switched socket outlet, 3-pin 10
A 30 mA
Weidmuller WDU 2.5 with all accessories
Terminals
as required
THERM
DOL
Manual reset Thermistor relay with two output
starters only contact sets
Anti Cond.
Heaters
Anti Cond.
Heater
Thermostat
(R10)
MT2PC
one per
multibox
1
Multitrode MT2PC pump controller
Level Probe
Security
system
Multitrode Ten sensor probe (length to be

determined by wet well pump start/stop levels)
Station Security controller with remote keypad for
flush fitting on multibox door
Generator
connection
Version 1.0
December 2011
Rittal SK3105.000 rail mounted 10 Watt 230 VAC

anti-condensation heater,
Cosmotec thermostat. 0 -60 degrees C. Cat No
KTS 01141. 6A 250V AC.
Gewiss IEC 60309 generator inlet receptacle

5 pin 63 amp
Bremca
Refer spec 2.5.12
NHP
Danfoss
Omoron
Electrade or NHP
W A Fisher
Marsa
Consultants
Transformer
Specialties Ltd
PDL56C310ELCB
Cuthbert Stewart
Schneider or
Rockwell
Automation
Rittal
NHP
Applied
Instruments
Applied
Instruments
Instrumentation
Systems Ltd. Ph
021 293 7608.
Ideal Electrical
25 of 26
Reference
Quantity
Pump Plugs
2
and switchsockets
(non
hazardous)
(R10)
Pump Plugs
2
and switchsockets
(non
hazardous)
(R10)
Door switches as required
Float
switches
Wet Well
washer
solenoid
valve
Wet well Area
flood-lighting
as required
Wet well area

flood light
timer
(R10)
Version 1.0
December 2011

Description
Marechal DSN type 32A to suit pump motor and
thermistor (Pins 3P+E+2aux)
Supplier
Bremca. Chch
PDL 56 Series type to suit pump motor and Schneider

thermistor (Pins 3P+E+2aux)
P & F IP68 Inductive proximity switch for enclosure

doors and wet well and valve chamber covers
Flygt ENM-10, SG 0.95 1.1, cable length as
required to reach switchboard
IP68 24 VAC solenoid valve coil for potable water
spray washer
EYE 160 Watt 240 V self ballasted MV PAR38 lamp,

with cast guard and F7 flanged base on 50 mm
galvanised pole.
Delayed-off time set to 120 seconds. Omron,
22.5mm wide DIN rail mount, range 1-120 seconds.
Contacts single pole 5A @ 250V C/O.
Model: H3DE-H L200-230VAC
Unilink
Trimate Industries
TBA
EYE Lighting
Omrom
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for Land development and Subdivision
Appendix C: Field testing of pipelines

C1 Scope
Appendix C is based on some of the test methods in AS/NZS 2566.2,
section 6, and associated appendices. This appendix specifies suggested
methods of test and their application to field testing of pipelines for the
purpose of determining pipeline acceptability. Field testing includes leak or
hydrostatic pressure testing, as appropriate, for pressure and non-pressure
pipelines. Testing may also be carried out in accordance with the materialspecific and application-specific test methods of AS/NZS 2032, AS/NZS
2033, and AS/NZS 2566.2.
C1.1 Purpose of field testing
The purpose of field testing is to:
(a) Reveal the occurrence of faults in the laying procedure, for example,
joints incorrectly installed or pipes damaged;
(b) Reveal the occurrence of faults in the assembly procedure of pipeline
components, for example, tapping bands, maintenance structures,
frames, and covers;
(c) In the case of pressure pipelines, determine that the pipeline will sustain
a pressure greater than its design pressure without leakage;
(d) In the case of non-pressure pipelines, determine that the pipeline
satisfies the requirements for infiltration and exfiltration; and
(e) Test the installed structural integrity of the pipeline.
Field testing is not intended to supplement or replace the test requirements
of product standards.
C2 Non-pressure pipelines Field leakage testing
Leakage testing is used to reveal locations of potential infiltration and
exfiltration due to the inclusion of damaged pipes, seals, or incorrectly
made joints in the pipeline at the completion of installation.
Leakage testing for acceptance of non-pressure pipelines shall be carried
out by at least one of the following methods:
(a) Low pressure air testing;
(b) Hydrostatic testing
NOTE Air tests provide qualitative data only, as air pressure losses
cannot be related directly to water leakage rates.
For pipeline test sections installed below the water table, and for submarine
pipelines, the test pressure used for the hydrostatic test, and for the air test,
shall be increased to maintain the required differential between internal and
external pressure.
A pipeline failing to meet the requirements of the air tests may be retested
using the hydrostatic test method.
NOTE Failure is still probable.
C2.1 Low pressure air test
The test length shall be acceptable where the gauged pressure exceeds 18
kPa (or not more than 7 kPa less than the pressure at the start of the test)
for the time interval shown in table C1 after the shut-off of the air supply.
Table C1 is based on an air test pressure of 25 kPa (in excess of any
external hydrostatic pressure due to groundwater) and, on this basis, air
volume losses shall not exceed the greater of:
(a) A rate of 0.0009 m3/(min x m2) of pipe wall area; and
3
(b) A rate of 0.056 m /min, which is regarded as the lowest detectable
individual air leak.
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Column 2 and column 3 of table C1 give the times and lengths up to which
(b) prevails over (a).
NOTE For safety reasons air test pressures in excess of 50 kPa should not be
applied.
Table C1 Low pressure air and vacuum tests Minimum time intervals for 7 kPa pressure
change in pipeline
DN
Minimum
time
(minutes)
Maximum
length for
minimum
time to
apply
(metres)
80
1.5
231
100
Test length (metres)

50
100
150
200
250
Minimum test duration (minutes)
185
1.5
2
1.5
2
1.5
2
1.5
2
1.6
3
150
123
225
82
10
13
300
62
14
18
23
375
49
14
22
29
36
450
41
10
21
31
41
52
525
10
35
14
28
42
56
70
600
11
31
18
37
55
73
92
675
13
27
23
46
70
93
116
750
14
25
29
57
86
115
143
900
17
21
41
83
124
165
207
1000
28
12
51
102
153
204
255
1050
20
18.8
56
112
169
225
281
1200
23
15
73
147
220
294
367
1500
28
12
115
230
344
459
574
NOTE The time interval may be reduced for a proportionate reduction in the allowable pressure drop.
Where there is no detectable change in pressure after 1 hour of testing, the section under test shall be
deemed acceptable. This table is based on the following equation: T = 1.02DikLq where T = time for a 7
kPa pressure drop, in seconds Di = pipeline internal diameter, in metres q = allowable volume loss in
cubic metre/minute/square metre taken as 0.0009 m3/min.m2 k = 0.054DL but not less than 1 L = length
of test section, in metres. Columns 2 and 3 have been calculated with k = 1.0. The appropriate air or
vacuum test/pressure method for pipes larger than DN 750 should be established by reference to the
specifier.
C2.1.1 Low pressure air test procedure
The procedure shall be as follows:
(a) Pump in air slowly until a pressure of 25 +5,0 kPa is reached. Where
the pipeline is below the water table this pressure shall be
increased to achieve a differential pressure of 25 kPa. In no
circumstances should the actual pressure exceed 50 kPa;
NOTE Rapid pressurisation may cause significant air
temperature changes, which will affect the testing accuracy.
(b) Maintain the pressure for at least 3.0 minutes;
(c) Where no leaks are detected, shut off the air supply;
(d) Where the pipeline fails the test, re-pressurise to 25 +5,0 kPa and
check for leaks by pouring a concentrated solution of soft soap and
water over accessible joints and fittings;
(e) Repair any defects, then repeat steps (a) to (c);
(f) With the air supply shut off, monitor the pressure for the time intervals
given in table C1.
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The test length shall be acceptable where the pressure drops by 7 kPa, or
less, over the required (tabulated) test period.
NOTE
(1) The test length of pipeline should be restricted to pipeline sections
between maintenance holes (the most convenient places for inserting
test plugs or fixing temporary bulkheads). The method should not be
used for test lengths in excess of 250 m and for pipe diameters larger
than 1500 mm.
(2) The procedure for low pressure air testing of large diameter pipelines
is potentially hazardous because of the very large forces to be resisted
by temporary plugs or bulkheads and the serious consequences of
accidental bulkhead blow-out. A relief valve, with a 50 kPa maximum
setting, should be installed on all pressurising equipment.
C2.2 Hydrostatic test
The test length shall be acceptable where the specified allowable make up
water is not exceeded. Where not specified, the allowable make up water
shall be 0.5 L/hour per metre length per metre diameter.
C2.2.1 Hydrostatic test procedure
(a) The test pressure shall be not less than 20 kPa, or 20 kPa above the
groundwater pressure at the pipe soffit at its highest point, whichever
is the greater, and not exceed 60 kPa at the lowest point of the
section;
(b) Steeply graded pipelines shall be tested in stages where the maximum
pressure, as stated above, will be exceeded if the whole section is
tested in one length;
(c) The pressure shall be maintained for at least 2 hours by adding
measured volumes of water where necessary;
(d) Any visible leaks detected shall be repaired and the pipeline shall be
retested.
C3 Pressure pipelines Field hydrostatic pressure testing

The hydrostatic pressure test method shall be as specified.
Hydrostatic pressure testing requires selecting an appropriate configuration
of method, pressure, and length of test section.
Test parameters and details shall be determined with due consideration to
the following:
(a) Pipe material;
(b) Pipe diameter;
(c) Length of test section;
(d) Duration of the test;
(e) Magnitude of test pressure and rate of pressurisation;
(f) Presence of air in the pipeline;
(g) Time required for saturation of porous liners;
(h) Potential movement of pipeline thrust restraints;
(i) Design pressure for thrust and anchor supports;
(j) Accuracy of test equipment;
(k) Ambient temperature changes during testing;
(l) Presence of leaks in equipment used for testing or equipment
attachment points (such as sealing plugs);
(m) Potential for leaks in the pipeline.
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NOTE It is advisable to begin testing early in the pipeline installation to

confirm adequacy of laying procedures and, where appropriate, to
increase the length tested progressively as experience is gained.
C3.1 Selection of test pressure
The hydrostatic test pressure at any point in the pipeline shall be:
(a) Not less than the design pressure; and
(b) Not more than 25% above the rated pressure of any pipeline
component.
NOTE The design pressure is the maximum system pressure at a
point in the pipeline, considering future developments, static pressure,
dynamic pressure, and an allowance for short-term surge pressure
(water hammer), as determined by analysis.
Compressed air testing shall not be permitted for pressure pipe.
C3.2 Selecting test lengths
The pipeline length tested shall be either the whole, or a section (capable of
being isolated), of the pipeline depending on the length and diameter, the
availability of water, and the spacing between sectioning valves or blank
ends.
The pipeline shall be divided into test sections such that:
(a) The hydrostatic test pressure at any point in the pipeline is:
(i) Not less than the design pressure; and
(ii) Not more than 25% above the rated pressure of any pipeline
component; and
(b) Water is available for the test together with facilities for its disposal, in
accordance with regulatory requirements, after the test.
NOTE
(1) Pipelines longer than 1000 m may need to be tested in several
sections. Where long lengths are to be tested, radio or other electronic
means of communication between test operatives, to coordinate test
procedures and thus minimise the test duration, is desirable.
(2) Long test sections may incorporate a large number of mechanical
(that is, flanged) joints, which should be checked for leakage. The
longer the test section the harder it is to locate a leak, or discriminate
between a leak and the other effects, such as the absorption of air into
solution under pressure.
C3.3 Pre-test procedures
The pre-test procedures are as follows:
(a) All required temporary and permanent thrust blocks, or other pipeline
thrust-resisting methods, including integral joint-restraint systems,
shall be in place, and all concrete shall be adequately cured (normally
a minimum of 7 days);
(b) Blank flanges or caps shall be installed at the beginning and end of the
test section. Testing shall not take place against closed valves unless
they are fully restrained and it is possible to check for leakage past
the valve seat. Mechanical ends that are not end load resistant shall
be temporarily strutted or anchored, to withstand the test pressures
without movement;
NOTE Temporary supports should not be removed until the pipeline
has been depressurised. All test personnel should be informed of the
loading limits on temporary fittings and supports.
(c) Where practicable, all bolted joints shall be left exposed to allow for retensioning during or after testing;
(d) Compacted embedment and fill material shall be placed to leave all
joints, service connections and ball valves exposed wherever
possible;
(e) For PE pipelines, the pressurising time shall not exceed 45 minutes;
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NOTE The pressurising time affects the duration of the PE pipeline

test.
(f) The test equipment shall be placed in position and checked for
satisfactory operation;
(g) The pump shall be of adequate size to raise and maintain the test
pressure;
NOTE A pump that is too small may increase the test duration or
where too large it may be difficult to control the pressure.
(h) Two calibrated test gauges shall be used to cross check gauge
accuracy;
(i) Slowly fill the test length of pipeline with water, preferably from the
lowest point, ensuring air is vented at the high point valves. Allow a
period, in the range of 3 hours to 24 hours, for the temperature of the
test length and the test water to stabilise and for dissolved air to exit
the system. The recommended rate of filling shall be based on a flow
velocity of 0.05 m/s, calculated from the following equation:
Qf 12.5D2
where
Qf = filling rate, in litres per second
D = pipe diameter, in metres
NOTE The slow rate of 0.05 m/s avoids air entrainment when the
filling water is cascading through downward gradients along the
pipeline.
The period of stabilisation will depend on pipe dimensions, length, material,
longitudinal profile, and air exit points. For cement-mortar lined pipe, the
pipeline shall be filled at least 24 hours before the commencement of the
test, to allow the lining to become saturated.
NOTE A firm foam swab may be used ahead of the fill water to assist
air removal especially where the pipeline undulates. Extract the swab at
a high-point wash-out.
Typical pressure test equipment and location are shown in figures C1
and C2.
C3.4 Post-test procedures
After testing, pipelines shall be depressurised slowly. All air venting facilities
shall be open when emptying pipelines. The test water shall be drained to
an approved waterway and all connection points shall be reinstated.
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Figure C1 Typical pressure pipeline under field hydrostatic test
Figure C2 Typical field pressure test equipment layout

C3.5 Constant pressure test (water loss method) PVC, DI, GRP, and steel
pipelines
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This test is applicable for PVC, DI, GRP, and steel pipelines. The test
length may be several kilometres in length (see C3.2).
C3.5.1 Procedure
(a) Close all valves apart from the test pump input and pressurise the test
length to the specified test pressure (STP) (see C3.1);
(b) Apply and then maintain the test pressure by the addition of measured
and recorded quantities of make-up water at regular intervals over a
period, in the range of 1 hour to 12 hours;
(c) Where pressure measurements are not made at the lowest part of the
test length, make an allowance for the static head, between the
lowest point of the pipeline and the point of measurement,
The quantity of make-up water necessary to maintain the test pressure shall
comply with the following equation:
Q 0.14LDH
where
Q = allowable make-up water, in litres per hour
L = length of the test length, in kilometres
D = nominal diameter of the test length, in metres
H = average test head over length of pipeline under test, in metres
NOTE The make-up water is not a leakage allowance, but is an
allowance to cover the effects of the test head forcing small quantities of
entrapped air into solution. Normally the test should last for a minimum
of 2 hours and be concluded within 5 to 8 hours. The make-up water
requirement should reduce with time as air goes into solution. Where,
after 12 hours the make-up water still exceeds the allowable limit,
testing should cease and the cause of loss investigated.
C3.5.2 Acceptance
(a) The test length shall be acceptable where there is no failure of any
thrust block, pipe, fitting, joint, or any other pipeline component;
(b) There is no physical leakage;
(c) The quantity of make-up water necessary to maintain the test pressure
complies with C3.5.1.
C3.6 Constant pressure test (water loss method) for viscoelastic pressure
pipelines
This test is applicable to PE, PP, and ABS pressure pipelines. The test
lengths may be several kilometres in length.
NOTE This method is based on VAV P78, as outlined in AS/NZS
2566.2, Appendix A.
C3.6.1 Procedure
(a) Purge the air from pipeline;
(b) Apply the specified test pressure (STP) (see C3.1) to the test length;
(c) Shut off main and allow pressure to settle for 12 hours (pressure will
drop significantly);
(d) Re-apply and maintain test pressure for 5 hours by successively
pumping a sufficient amount of water;
(e) Measure and record water volume (V1 in litres) required to maintain this
pressure between Hour 2 and Hour 3;
(f) Measure and record water volume (V2 in litres) required to maintain this
pressure between Hour 4 and Hour 5;
(g) Calculate:
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0.55V1 + Q
where Q is the allowable make-up volume obtained from C3.5.1.
C3.6.2 Acceptance
The test length shall be acceptable where:
(a) The test length shall be acceptable where there is no failure of any
thrust block, pipe, fitting, joint, or any other pipeline component;
(b) There is no physical leakage; and
(c) V2 0.55 V1 + Q.
C3.7 Pressure rebound method for visco-elastic pressure pipelines
This test is applicable to PE, PP, and ABS pressure pipelines up to and
including DN 315, where a short test time is required.
NOTE This test is based on BS EN 805:2000, Appendix A (refer to
AS/NZS 2566.2).
C3.7.1 Pressure measurement rig
The test rig shall be a recently calibrated pressure transducer, data logger,
and check pressure gauge that has a dial of at least 100 mm diameter and
a pressure range that places the specified test pressure (STP) (see C3.1) in
the range 35% to 70% of the gauges full scale. The transducer and the
check gauge shall read within 5% of each other. If they do not agree within
this tolerance, the equipment shall be recalibrated or replaced.
C3.7.2 Procedure
The test procedure has the following three phases:
(a) A preliminary phase in which the pipeline is
(i) Depressurised and allowed to relax after the C3.3 pre-test
procedure
(ii) Pressurised quickly to the test pressure and maintained at this
pressure for a period of time without further water being added
(iii) The pressure is allowed to decay by visco-elastic creep, and
(iv) Provided the pressure drop does not exceed a specified
maximum, the pressure test can proceed to the second phase;
(b) A phase in which the volume of air remaining in the pipeline is assessed
against an allowable maximum;
(c) The main test phase in which the pipeline is maintained at the test
pressure for a period of time and decay due to visco-elastic creep
commenced. The creep is interrupted by a rapid reduction of the
pressure in the pipeline to a specified level. This rapid reduction in
pressure results in contraction of the pipeline with an increase
(rebound) in pressure. If, during the rebound period, the pressure
versus time record shows a fall in pressure, the pipeline fails the test.
C3.7.3 Preliminary phase
(a) Reduce pressure to just above atmospheric at the highest point of the
test length, and let stand for 60 minutes. Ensure no air enters the line;
(b) Raise the pressure smoothly to STP in less than 10 minutes. Hold the
pressure at STP for 30 minutes by pumping continuously, or at short
intervals as needed. Do not exceed STP;
(c) Inspect for leaks during the 30 minute period, then shut off pressure;
(d) Allow the pressure to decay for 60 minutes;
(e) Measure the pressure remaining at 60 minutes (P60);
(f) If P60 70% of STP the test is failed. The cause shall be located and
rectified. Steps (a) to (e) shall be repeated. If P60 > 70% of STP,
proceed to the air volume assessment.
C3.7.4 Air volume assessment
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(a) Quickly (<5 min) reduce pressure by P (10%15% of STP);

(b) Measure water volume bled out (V);
(c) Calculate Vmax allowable as follows:
Vmax allowable = 1.2 V P (1/EW + D/ER)
where
1.2 = air allowance
V = pipe volume, in litres
P = measured pressure drop, in kilopascals
D = pipe internal diameter, in metres
ER = pipe material modulus, in kilopascals (see table C2)
EW = bulk modulus of water, in kilopascals (see table C3);
(d) If V > Vmax allowable the test has failed. The cause shall be located
and rectified. The preliminary phase shall be repeated. If V Vmax
allowable, proceed to the main test phase.
NOTE V and P should be measured as accurately as possible,
especially where the test length volume is small.
C3.7.5 Main test phase
Observe and record the pressure rise for 30 minutes.
In the event of failure, locate and repair leaks. If failure is marginal or
doubtful, or if it is necessary to determine leakage rate, use a reference test
(see C3.6).
NOTE Figure C3 gives an example of a full pressure test with the
main test phase extended to 90 minutes.
Table C2 Pipe E material modulus for PE 80B and PE 100
Temp
(C)
PE 80B E Modulus (kPa103)
PE 100 E Modulus (kPa103)
1h
2h
3h
1h
2h
3h
740
700
680
990
930
900
10
670
630
610
900
850
820
15
600
570
550
820
780
750
20
550
520
510
750
710
680
25
510
490
470
690
650
630
30
470
450
430
640
610
600
Table C3 Bulk modulus Ew Water
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Temperature (C)
Bulk Modulus (kPa103)
2080
10
2110
15
2140
20
2170
25
2210
30
2230
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Figure C3 Typical successful modified rebound test for a PE

pipeline
C3.7.6 Acceptance
The test length shall be acceptable if:
(a) There is no failure of any thrust block, pipe, fitting, joint, or any other
pipeline component;
(b) There is no physical leakage;
(c) The pressure rises or remains static in the 30-minute period.
If doubt exists about the pressure recovery, the monitoring period may be
increased to 90 minutes, and any pressure drop that does occur shall not
exceed 20 kPa over the 90-minute period.
If the pressure drops by more than 20 kPa during the 90-minute extended
period, the test fails.
Repetition of the main test phase shall only be done by carrying out the
whole test procedure, including the relaxation period of 60 minutes
described in C3.7.3.
C3.8 Visual test for small pressure pipelines
This test is applicable for small pipelines of all materials (less than 200 m in
length), and pipelines where pipeline joints have been left exposed for the
test operation (such as coiled pipe).
C3.8.1 Procedure
(a) The test pressure (see C3.1) shall be applied and the test section
isolated by closing the high point air release valves and the pump
feed valve;
(b) The test section shall be visually inspected for leakage at all joints,
especially bolted joints, all fittings, service connections, and ball
valves;
(c) Pressure gauges shall be checked to ensure that pressure has not
fallen significantly indicating an undetected leak;
(d) Any detected leak shall be repaired and the section shall be retested;
(e) Where no leak is detected, high point air release valves shall be
opened, the pipeline shall be depressurised to slowly drain the line
into an approved waterway and all connection points shall be
reinstated.
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C3.8.2 Acceptance
The test length shall be acceptable where:
(a) There is no failure of any thrust block, pipe, fitting, joint, or any other
pipeline component;
(b) There is no physical leakage; and
(c) There is no pressure loss indicative of a leak.
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5.3.2 Structure plan

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(a) Residential flows

CBD or high rise buildings

To be designed for 1 person per 15 m2

floor area, water use of 65 litres/p/d and

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Table 5.2 Guide to roughness coefficients for gravity sewer lines

Concrete machine made to

Connection servicing 1 dwelling unit

Connection servicing more than 1 dwelling unit

Connection servicing commercial and industrial lots

Reticulation servicing up to 200 residential lots

5.3.5.4 Limitation on pipe size reduction

Absolute minimum grade

0.55 (No more than 200 dwellings at this minimum

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DN 100 property connections

0.83 (subject to accurate construction)

DN 150 property connections

0.50 (subject to accurate construction)

Permanent upstream ends of DN 150,

5.3.5.6 Maximum velocity

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5.3.6.4 Internal forces

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Trenchless installation methods may include:

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Pipes should be positioned as follows:

(c) Within reserves outside the 1 in 100-year flood area;

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5.3.7.7 Vertical curves

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5.3.7.10 Clearance from structures

Clearance to wall or building (mm)

NOTE These clearances should be increased for mains in private

5.3.7.11 Bulkheads for pipes on steep grades

Maintenance structures include:

state highway carriageways, drainage and road furniture and preferably