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OPEN FIELD

DRIP IRRIGATION
GENERAL INSTALLATION
GUIDELINES

V 001.01 - MARCH 2018


© COPYRIGHT 2016, NETAFIM™

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FOREIGN LANGUAGES
In the event that you are reading this manual in a language other than the English language, you
acknowledge and agree that the English language version shall prevail in case of inconsistency or
contradiction in interpretation or translation.
CONTENTS
INTRODUCTION 5
The symbols used in this document 5

GENERAL PRE-INSTALLATION
Required documents 6
Work types, sections, stages and crews required 6

PRE-COMMENCEMENT ON SITE 7

PVC MAIN LINES INSTALLATION CREWS


Personnel, tools & general 9
Crew scope of work & general guidelines 9
Technical guidelines for the installation of PVC main line piping 11
Technical guidelines for the deployment of control tubes and cables 14
Technical guidelines – concrete anchors 16
Tools and machinery 16

PE SUB-MAINS DEPLOYMENT & INSTALLATION CREWS


Personnel, tools & general 17
Crew scope of work & general guidelines 17
Connection of dripperline outlets to sub-mains with saddles 19
Connection of dripperline outlets to sub-mains with start connectors 20
Notes 20

PE SUB-MAINS - CREWS FOR LAYING-IN-TRENCHES & BACKFILLING


Personnel, tools & general 21
Crew scope of work & general guidelines 21
Guidelines for execution of the work 21

PVC SUB-MAIN INSTALLATION CREWS


Personnel, tools & general 23
Crew scope of work & general guidelines 23
Technical guidelines for the installation of PVC sub-main piping 25
Technical guidelines for installing outlets for dripperlines – General 26
Technical guidelines for connecting dripperline outlets to sub-mains with saddles 27
Technical guidelines for connecting dripperline outlets to sub-mains with start connectors 28
Technical guidelines – General and excavations 28
Technical guidelines – Concrete anchors 29

PVC TRENCH BACKFILL CREWS


Personnel, tools & general 30
Crew scope of work & general guidelines for backfill 30
Crew scope of work & general guidelines for road crossings 32
Pipe bedding & lining 33

VALVE ASSEMBLY INSTALLATION CREWS


Personnel, tools & general 34
Crew scope of work & general guidelines for valve assemblies (field valves) 35
Crew scope of work & general guidelines for the installation of head control (HC) 37
CONTENTS (continued)
DRIPPER-LINE DEPLOYMENT CREWS
General 39
Mechanical deployment 40
Use of a manual layout device 41
Manual deployment of dripperlines without a layout device 42

INSTALLATION OF ELECTRICITY AND CONTROL


General 43
Details of electrical work to be performed at the pumping station/head control 43
Connection of sensors and 24 V controls from the electrical board 44
Sensor, output connections – Transmissions from the computer 45
Electrical connections at a head control without a pump 46

SDI - SUB SURFACE IRRIGATION INSTALLATION CREW


General 48
Preparation of the area prior to burial 49
Technical guidelines prior to burial 49
Burial guidelines 50

FLUSHING THE IRRIGATION SYSTEM FOLLOWING INSTALLATION


General 52
Preparation for flushing – General 52
Flushing of the head control 53
Flushing of the main lines 53
Testing the pressure of the main line 54
Guidelines for flushing the sub-mains 55
Guidelines for flushing the dripperlines 55

TESTING THE IRRIGATION SYSTEM (COMMISSIONING)


General 57
Testing the performance of the water distribution system 57
Procedure for identifying problems in the system 58
Testing the performance of the pump and its accessories 61
Testing of the functioning of filtration banks 61
Test the functioning of the fertilizing system 62
General testing of the head control 62
Testing the functioning of the electrical board and board protections 62
Automation 63
Delivery of the work to the customer 63

APPENDICES
Appendix 1 – PVC pipe storage & handling 64
Appendix 2 – Typical trench cross section 66
Appendix 3 – Concrete thrust blocks 78
INTRODUCTION
Open field irrigation systems and their environment-control systems are designed to work and provide the
grower with peace of mind and easy operation for many years. It is of the highest importance to install
the irrigation systems according to Netafim's initial design and guidelines, which are presented in this
document.

A good installation manager should be able to plan ahead and follow Netafim's guidelines, as well as
record the installation phase from start to finish. This will create a baseline for the As-made drawings at
the end of the project, for use by the grower's maintenance team, while also providing beneficial input to
improve the protocols.

The purpose of this document is to provide the basic guidelines for installation of open field irrigation
systems, ensuring uniformity of installation in every open field irrigation system installation around the
globe. It is designed to assist the organization in the efficient deployment and installation of piping and
accessories included in the [irrigation] system. The different types of installation tasks are divided into
sections; a separate crew should be assigned responsibility for implementing each section. In small
projects, a single crew may perform several or all of the tasks or sections.

This procedure is suitable for projects in the range of 50 ha or more. Of course, on very large projects or
where the required pace of the work is accelerated, several crews will be needed for each section.

These guidelines are not intended to replace project drawings or general guidelines and specifications, but
are rather intended to assist the installation crews perform the work properly, in a logical and efficient order.

The importance of thorough knowledge of the subjects discussed in this document for the effective
operation and maintenance of the project systems cannot be overemphasized.

Netafim makes every effort to provide its clients all over the globe with concise, comprehensible
documentation with the intent of facilitating the installation, operation and maintenance of the systems
while maximizing the resulting benefits – higher yield of superior-quality crops with higher market value
and shorter ROI.

The clients' managerial and operational personnel should be familiar with the systems, their components and
their functions, and carefully study all the operational and maintenance issues discussed in this document.

ATTENTION
This document is not a user manual. For detailed instructions on the operation, maintenance
and troubleshooting of the components of the project, please refer to the user manuals and
documentation of each component, which are supplied with the system.

The symbols used in this document refer to the following:


NOTE
Contains instructions aimed at emphasizing certain aspect of the installation.

ATTENTION
Contains instructions aimed at enhancing the efficiency of usage of the instructions in the
document.

TIP
Provides clarification, tips or useful information.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 5


GENERAL PRE-INSTALLATION
For purposes of executing, organizing and documenting the work, the installation manager should receive
the following documents and guidelines:

 Technical specifications, if they exist (x1).


 Planning maps (x3) (preferably with plastic lamination) + overlay of the design map over Google Earth image
 Excavation map.
 Automation & control maps.
 Flushing/commissioning map.
 Drawings of the different assemblies (x3).
 Chart of pressures and flow rates in the main network (IRRICAD report).
 Electrical board schematics and diagrams.
 Pump manufacturer data (curves, drawings, pump operations and maintenance manual).
 Installation and user guides of all the system components (filters, valves, etc.).
 Complete equipment bill of materials (BOM), organized in system sections (x2).
 Container packing list (x2).
 Logbook (x1).
 Netafim's list of requirements that the customer must meet to enable the installation.
 Guidelines for installation of the irrigation system.
 System flushing and commissioning guidelines (including maps and forms per project).
 Customer's work handover/acceptance document (COA, specific for each project).
 General guidelines (information about the customer and the area) –
under the responsibility of the regional manager.
 Material required for the purpose of training the customer's crews on irrigation issues
(technical specifications of the devices).
 Appendices to the contract/agreement related to project installation, system performance after
commissioning, etc.
 A set of special tools and various aids.

The following is a detailed list of the different work types, sections, stages and crews required for project
execution:

 Guidelines prior to commencement of work upon arrival at the site.


 Guidelines for the PE piping installation crew (sub-mains).
 Guidelines for the crew burying the PE piping in trenches.
 Guidelines for the PVC piping installation crew (main lines).
 Guidelines for the PVC piping installation crew (sub-mains).
 Guidelines and specifications for the valve-assembly installation crew.
 Guidelines for the trench-backfill crew.
 Guidelines for the dripperline deployment crew.
 Guidelines for the execution of electrical and control work in an irrigation project.
 Guidelines for the crew burying dripperlines (subsurface drippers).
 Guidelines for the crew connecting the subsurface dripperlines to the sub-mains and collector pipes.
 Guidelines for the installation of a pumping system and electrical board.
 System flushing and pressure testing process.
 Guidelines for the execution of system performance testing and various adjustments when installation
is completed (commissioning).
 Pump test performance procedure.
 Guidelines related to surpluses/shortages of project equipment.

6 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


PRE-COMMENCEMENT ON SITE
All preparations described below should be performed by Netafim's site foreman with the on-site
presence and assistance of the customer's project supervisor/contact person.

1. Arrival at the site and introductory meeting with the customer's representatives.

2. Inspection of the project site to get a general impression and study any potential obstacles to
commencement of the work.

 Review of preparations and execution of the various tasks described in the Requirements List sent to
the customer prior to project execution.

 Review of condition and storage of equipment.

3. Discussion with the customer's representatives regarding problems, missing items and changes that
were found during the inspection and review of the Requirements List. Determination of a timeframe for
addressing these issues.

4. Comparison and verification of the design map with actual conditions in the field:

 Emphasis should be placed on the size and layout of parcels.

 Location of the water source.

 Feasibility of excavations and placement of the main line piping in the routes planned by Netafim.

NOTE
The map-verification process is lengthy and must be thorough, to avoid unexpected problems later.

 Estimates of the time required for the map-verification process:


Project size Map-verification duration
up to 25 ha Several hours to one day
25-50 ha 1-2 days
50-100 ha 2-3 days
100-300 ha 3-5 days

 The map-verification process will be performed simultaneously with other activities required at the
project initiation stage.

 Problems of incompatibility between the map and the field will be resolved by the installation manager
(minor modifications) or by the project manager/project designer (major modifications).

5. Recruitment and organization of work team required for project installation.


Allocation of crews for missions will be based on the size and complexity of the project and the
installation guidelines below.

6. Organization of an equipment warehouse or storage area to enable quick and uncomplicated extraction
of equipment required for the work while also protecting and safeguarding the equipment. Appointment
of a warehouseman for large projects, at the discretion of the Installer.

 Organization of equipment storage area in projects where the containers are purchased:

In this situation, it is recommended that the containers be placed adjacent to one another in a U
configuration, with their doors facing inward. The entryway/gate leading to the interior space formed
by the containers must be wide enough for passage of a tractor and wagon. It is recommended that
the piping be unloaded from the containers onto a storage area outside of and next to the containers.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 7


PRE-COMMENCEMENT ON SITE (continued)
If the piping is removed, various accessories should be organized by type and/or association with
each particular system segment.

It is proposed that the interior space formed by the containers be covered with a shade net or similar
material. This also applies to the storage area for the PVC piping (outside of the containers).

 Organization in projects where the containers are unloaded upon arrival and returned to the port:

In this situation, guidelines are given to the customer in advance for preparing an enclosed lockable
storage area (warehouse) in which the various items can be kept. PVC and PE piping is usually stored
in a designated outdoor area. It is recommended that shading be provided for PVC piping that is liable
to be exposed to sunlight for several weeks or more.

 It is recommended that the warehouse-organization stage be executed simultaneously with the


equipment-inspection stage described in subsection 13 below.

7. Training of the work crews prior to the work (after review of their professionalism and experience).
Audited personal demonstrations and tests.

8. Organization of tools required for the various crews. (see the lists of tools according to crews on page 9.)

9. Preparation of copies of relevant drawings and map sections for the crew chiefs for the start of work
(although in the case of inexperienced laborers or local supervisors, the first stage of work will be done
with close supervision of the installation manager).

10.Determination of schedule for briefings and updates involving the installation manager, Netafim’s
regional representative and the customer (at the level of the farm manager and/or the customer itself).
Meetings should be held once or twice a week (preferably during the evening, over a glass of beer).

11. Setting out and marking of the location of the system head control, size of the concrete slab, alignment
of the main piping and location of valve/secondary filter assemblies.
On large projects, setting out of pipes routes and assemblies can be done in stages in accordance with
the workflow program.

12.Preparation of a "battle map" to be hung on the wall for marking the rate of progress and work priorities
(if work cannot be performed based on a natural sequence from the source of water onward).

13.Inspection of equipment delivered and its compatibility with the BOM, packing list and map.
Identification of shortages, surpluses, damaged equipment and review of options for solutions with
Netafim’s on-site representative and with the project manager.

14.Identification of a local source of spare parts and equipment required in the case of shortage.
Identification of local professionals who may be required to execute some of the work or solve
problems (surveyors, pipe welders, metalworkers, electricians, masonry builders, stand-by excavation/
backfill equipment, etc.).

15.Updating of the site manager/installation manager and the Netafim project manager/contact person on
means of communication: telephone, fax, email, various smartphone applications and convenient
contact times.

8 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


PVC MAIN LINE INSTALLATION CREWS
Personnel, tools & general
The PVC main line crew will include the following personnel and equipment:
 A crew chief + 3 workers – for diameters of up to 250 mm
 A crew chief + 5 workers – for diameters above 250 mm
 A tractor and wagon + operator during deployment of the piping in the morning hours (for sub-mains
deployment, as well).

Crew job description & work pace:


 The crew is responsible for placing about 500 m of PVC main line and all accessories & equipment
required in the same trench each 8-hour work day (under optimal conditions).
 The crew chief will also direct the excavation machine operator with regard to layout, excavation route,
width & depth of trenching, etc.
 The piping will be deployed and assembled in accordance with a map or section drawing provided to
the crew chief in advance and in accordance with the general guidelines below.

PVC crew tools and equipment:


 Saw + hacksaw  Half-barrel for carrying/preparing concrete
 Rasp  15/16" wrenches (x2)
 Cutting blade for manifold risers/accessories – flanges bolts
 Steel brush (up to 10" diameter; for larger-diameters, larger
 Lubricating paste + suitable brush wrenches are required)
 PVC primer and glue + suitable brush  Wood panels and rigid cartons
(in the case of glued PVC piping or fittings) for bordering concrete block areas
 Teflon sealing  0.5 m-long 2" x 4" thick wood board (x4)
 Hoes (x2)  A sack of rags
 Spades (x2)  A flashlight
 A narrow shovel for preparing pits  Black marker (for PVC)
 Digger/pickax  AS water jug
 Buckets (x2)

In the case of pipe diameters greater than 250 mm, additional tools will be required:
 A crowbar  3-5 kg hammer  2" band/strap 2 m long (x2).

Crew scope of work & general guidelines


1. The crew chief will receive an explanation in the morning (or the previous evening) about the segment
to be installed that work day. Accordingly, he will prepare the pipes, accessories and cables (if planned/
needed), together with the crew. The crew chief should receive a map or drawing of the relevant
segment.

2. At the beginning of the day, the farm foreman will deposit the accessories needed for installation in
their different places of installation (reducers, Ts, bends, etc.), according to the stakes markings
mounted during the setting out prior to the installation work. Therefore, the pipes will be lowered and
placed according to the accessories in the field and the pipe diameter will be changed wherever a
reducer is present.

3. If the project includes a control system, the crew will be divided in the morning. The crew chief
+ 2 workers will drive to the work site with the control tubes/cables and control fittings, while the
remaining 2-3 crew members will prepare the PVC piping for conveyance to the site.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 9


PVC MAIN LINE INSTALLATION CREWS (continued)
During the control tube and cable deployment works, the farm foreman must make sure that the pipes
intended to be placed that day are sent by tractor and wagon. The pipes will be lowered along the
designated alignment by the 2-3 members of the PVC crew while the tractor drives slowly.

4. The pipes will be loaded on the wagon so that all their bell sockets are facing the same direction (Fig. 1),
pipes with thicker wall width should be placed at the bottom, maximum height for the pipe pile should
be no more than 1 m) and the crew chief must check that every pipe has the gasket already inserted
(Fig. 2). The direction of travel of the tractor along the line route must be such that when unloading the
pipes from the wagon, the bell sockets are in the right direction for installation and there is no need to
turn them around.

Max. 1 m

Fig. 1: Pipes loaded on a wagon Fig. 2: Pipe with gasket inserted

5. The pipes will be placed next to the trench alignment (if the trench has not yet been excavated, about
3-5 m from the trench axis), where the overlap between pipes is compatible with the length of the
insert of the pipes into the bell sockets.

6. Following deployment, inspect the piping visually – do not use severely "burnt" piping (dark brown color).
Verify that there are no cracks in the pipe – a pipe that has been visibly damaged should be placed at
the side and its use (or at least that of the damaged section of pipe) should be avoided.

7. When the deployment of the pipes, tubes and cables has been completed, the pipe installation work in
the prepared trench can begin.

If there are many accessories along the designated line that require concrete-block anchoring (based on
the drawings or the crew chief's experience), connection of the pipes can begin in the trench even before
the control tubes/cables have been completely deployed, to allow time for execution of the concrete work
and install the assemblies along the way. In this case, 2 crew members will continue to deploy the tubes/
cables and 2 other team members will assemble the PVC pipes up to the next assembly that requires a
riser outlet from the ground.

NOTE
In projects where the trench backfill work can be performed at the end of the process or every few
of days (when there is no concern about rain, trench collapse, safety hazards or other hazards), all
the control work can be performed together, prior to backfill.

10 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


PVC MAIN LINE INSTALLATION CREWS (continued)

Technical guidelines for the installation of PVC main line piping


1. In principle, PVC piping should be assembled in the excavated trench by 2-3 workers (depending on the
diameters).

Glued PVC piping may also be assembled outside of the trench in long segments and then carefully
lowered into the trench, one segment at a time. Such an option is applicable under the following
conditions:
 The trench is too narrow to work inside (a manual or trencher excavation width of less than 35 cm).
 The piping diameter is relatively small, allowing flexibility and easy lowering into the trench (generally
up to Ø 160).

2. Before lowering the pipes into the trench, the crew chief must verify that the pipes and especially the
bell sockets are clear of soil.

3. Before lowering the pipes, the crew chief must check the soil conditions in the trench and verify:

a. Appropriate trench depth (usually about 1 m cover of soil above pipe, minimum 80 cm). If the trench
is too deep, add some compacted soil in the area of the assembly risers, so that the height of the
riser outlet above the ground surface will be sufficient and match the plan (applicable only in the
cases of prefabricated risers of fixed length). It is very important to make sure that the trench bottom
below the branching from the line is as compacted as possible, so that the soil doesn't become
consolidated and compacted later on (after rain, etc.), dragging the whole assembly down with it.

 Trench depth = minimum 80-100 cm coverage (as agreed with the customer) + diameter of the
pipe (see Appendix 2, page 66).

Minimum Minimum
Pipe trench trench
diameter width depth
63 mm 0.5 m 0.9 m Excavated trench width
Pipe Final
75 mm 0.5 m 0.9 m insertion backfill
90 mm 0.5 m 0.9 m depth
110 mm 0.5 m 0.9 m Pipe diameter
140 mm 0.6 m 1.0 m
160 mm 0.6 m 1.1 m
200 mm 0.6 m 1.1 m
250 mm 0.7 m 1.1 m Initial
315 mm 0.7 m 1.1 m Pipe backfill

Bedding
(optional)
Haunching

Fig. 3: Trench description

b. Relatively flat trench bottom without pits and mounds – if not, a worker should enter the trench to
flatten the trench with a hoe or mattock.

c. Clean soil without stones or hard clods – if there are any in the soil, make sure that the foreman
arrives, checks the conditions and provides instructions regarding bedding the bottom of the trench

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 11


PVC MAIN LINE INSTALLATION CREWS (continued)
with clean soil or sand. The pipe should also be covered with soil free of any stones or other hard
clumps, to a height of at least 20 cm above the pipe.

d. The excavation (trench bottom) should have as continuous a slope as possible.

4. The crew chief must be in the trench during assembly of the pipes to verify complete insertion of the
pipe into the bell. If the piping is marked for depth of penetration, it is essential to verify that the work is
performed according to the marking; if there is no marking, mark the insertion depth on each pipe with
a black marker.

5. Pipes for accessory installations will be cut with a saw at a 90° angle and then lightly filed or sanded to
obtain a bevel.

6. Any metallic devices to be assembled – flanged bell, cast T, bend or line end – should be checked
visually and/or by touching, to verify that insertion of the pipe has not caused the rubber gasket to be
pushed out of its seating. If so, the pipe must be extracted and reinserted using the technique specified
below.

7. Rubber seal pipes & fittings - Pipes should be cleaned of soil before the installation itself. After that:

 Spread lubricating paste on the pipe gasket with a paintbrush immediately before inserting the pipe.

 While the already installed pipe is supported on a wood board (to keep it away from the soil),
2 laborers should align the new pipe to be inserted with the installed one and push it into the socket
until the insertion marking line reaches the socket.

 In case of large diameters and/or hard rubber seals, pushing the pipe might not be enough and other
methods will be required to facilitate insertion of the pipe. The following are 3 popular methods:
 Using a hammer - Put the new pipe's male side inside the socket and align both pipes, hold the
wood board adjacent to the socket of the new pipe and knock it with the heavy hammer until the
pipe is all the way in.
 Using a crowbar - Put the new pipe's male side inside the socket and align both pipes, hold the
wood board adjacent to the socket of the new pipe, insert the crowbar into the bottom of the
trench adjacent to the wood board and push it towards the wood board with a rotational movement
until the pipe is all the way in.
 Using a pipe as a battering ram - Put the new pipe's male side inside the socket and align both
pipes, hold the wood board adjacent to the socket of the new pipe, and have 2 laborers lift the new
pipe with 2 straps, move the pipe backwards and then forward to hit the wood board and knock it
all the way into the other pipe socket.

8. Glued PVC pipes and fittings - In the case where the piping or the accessories are assembled by
gluing, it is essential to verify that the instructions in the glue manufacturer's manual are followed in
addition to the following general guidelines:

 Gluing should be done with the right type of glue and brush. Attention should be paid to large-diameter
accessories (250 mm and above) which require special larger brushes in order to apply glue faster and
avoid drying of the glue.

 The socket of one pipe and the male end of the other pipe should be cleaned with a dry rag and
primer until completely free of any contaminants and, in particular, oils.

 After that, spread the glue in a uniform and complete layer on both the male and female sides and
insert the pipe immediately into the socket, turning it 1/4 of a rotation to improve glue distribution.

12 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


PVC MAIN LINE INSTALLATION CREWS (continued)

 Do not over-glue, which could cause leftover glue in the pipe and weaken it. Whenever possible, wipe
surplus glue with a rag.

 Let the glue cure and gain strength by allowing it to rest without moving, as per manufacturer's
instructions.

9. "Naked" outlets should be installed by the crew in the field. The threaded or glued valve assemblies
should be installed in two stages. In the first stage, the outlet only will be glued or threaded to the
branching tee in the ground. In the second stage, the rest of the assembly will be threaded or glued to
the outlets by a different crew that is in charge of assembling and installing the valves.

In some cases, according to design drawings, branching from the main line will not be straight up, but
horizontal, to the side, in order to place the assembly in a better location than the road, planting bed or
row of trees.

After the final location of the line end is determined in the field, it should be installed on top of the last
pipe outside of the trench. After everything is assembled and a pit has been dug for the concrete block,
lower the pipe and the line end into the ground, connect it to the last PVC pipe and cast the concrete
(see Appendix 3, page 78).

The location of the line end outlet (for flushing) should be determined in coordination with the foreman
to avoid a situation in which it interferes with work procedures and [vehicular] travel.

10.A curve can be made in the PVC piping up to the maximum allowed angle (see the table below).
An angle or curvature beyond this value requires the use of a dedicated bend or elbow device. At a
temperature of less than 5°C, bending of the pipes to obtain such arcs is prohibited.

It is essential to verify gradual offset of the pipes to form the curve.

Diameter Deviation of the end of the


(mm) pipe from a straight line (m)
(Grade 6 6 m long pipe 8 m long pipe
piping) (5.85 m)
63 1.4 1.92
75 1.15 1.54
90 1.0 1.3
110 0.9 1.08
140 0.55 0.85
160 0.5 0.74
225 0.27 0.53
280 0.20
315 0.19 Fig. 4: Deviation of the end of the pipe from a straight line

11.A line end/flushing assembly should be installed at the end of the PVC pipe – in both main lines and
supply lines – at a distance of at least 2-3 m past the last outlet/valve assembly unless it is planned that
the flushing valve will be placed on an aboveground assembly such as a separation valve between wells
or a head control or irrigation valve assembly.

12.After placement of the pipes, tubes and cables, ensure manual backfill around the risers to prevent
breaking of the risers and to allow good bedding around the risers and the control tubes/cables attached
to them. Tie the protective sleeve (usually a PE/PVC pipe) with the "control braid" inside it to the riser at
a minimum of two points.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 13


PVC MAIN LINE INSTALLATION CREWS (continued)
The riser must be completely covered and exit at 90° from the ground; cover the opening of the riser
with a plastic bag.

Minimal initial coverage should also be provided at the concrete anchors and at the outlet of the
manifolds from the soil.

13.If at the end of the work day, the PVC main line installation has not reached a manifold outlet, but rather
at a simple pipe in the ground, the pipe should be covered with a plastic bag. Since this section will not
be backfilled with soil, make sure that the length of the excavated trench beyond the pipe end does not
exceed 1-2 m and a small dike of soil is assembled around the open top part of the trench, especially
when rain is expected (to avoid the collection of water from rainfall during the night).

Technical guidelines for the deployment of control tubes and cables


1. It is highly recommended that electrical continuity testing be performed for the cables at the warehouse
or after their deployment and before lowering them into the trench, to detect detachments and other
potential problems.

2. The control tubes or cables should be deployed during the morning hours in accordance with the
automation control map or drawing, while carefully checking the numbers and colors of the cables
(according to the plan) and ensuring a distance of about 3-5 m from the trench alignment. The tubes
or cables should be deployed so that an excess of about 20 m is left at the head control starting point
(to be calculated according to the head control drawing), as well as a sufficient surplus at the last valve
assembly along the tube or cable reaches.

The proper amount of excess length of tubes or cables is about 4 m for each valve assembly the tube or
cable passes through. In other words, a tube or cable that reaches the third riser in a line must continue
another 12 m past that riser to enable pulling the cables back afterwards to create a loop around each
riser or valve assembly.*

*The loop required for each riser can also be made during the deployment itself; in this case, there is no
need for excess length at the last valve assembly.

3. Following deployment of the tubes, each roll of unfinished control tubes should be tied in 3 places and
put aside. The tube or cable control braid itself should be tied with adhesive insulating tape every 5-10
m, to facilitate the lowering of the braid into the trench and to avoid scattering of the tubes or cables
inside it.

4. When deploying the tubes or cables in the trench, the installer will take in consideration a rising loop at
each assembly or riser along the main line. An assembly is defined as any outlet from the main line to
ground level (including outlets for air valves etc.)

5. The cable should be pulled from the drum located in the area of the head control as follows:

 The drum should lie at an angle of about 45° relative to the ground (supported from below on one
side) or be supported by a horizontal pipe that passes through the core of the drum, enabling it to
rotate freely to release the cable.

 The crew chief must verify that the cable is released from the drum in a circular movement.

 Crew members should tow the cable to its intended end location allowing the 20 m surplus of
cable indicated in subsection 2 above.

14 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


PVC MAIN LINE INSTALLATION CREWS (continued)

 For the towing, an extra worker should be added for every 150 m, to enables pulling the entire length
of cable! Do not tow the entire line with 3 people at the line end; instead, deploy a worker every
150 m along the cable. Having each worker tow one section will avoid over-tension along the cable.
Mild snaking is recommended to allow for flexibility and slight contraction of the braid.

m
150
150 m

Fig. 5: For the towing, an extra worker should be added for every 150 m.

NOTE
For long cables routes, loading the cable drum on a wagon or backhoe and releasing the cable
during travel along the desired alignment is recommended. This requires only one more person
in addition to the driver/operator.

6. Before lowering the tubes or cables into the trench, the crew chief must verify that the tubes or cables
are undamaged, are numbered and labeled as required and ready for insertion.

7. After the concrete anchor blocks for the piping have been installed (or before that, if a decision is made
to install all blocks at the end of the process), lower the control tube or cable braid into the trench, while
strictly verifying the following:

 The bottom of the trench is flat without stones or hard clumps of soil that could cause damage.

 The tubes or cables are always placed on the same side of the pipe – the side that faces the field or
orchard, and not the side that faces the road (when the main line is located along a road).

 Allow mild snaking when deploying during hot hours of the day.

 Make an ascending loop (of all the tubes or cables) at each riser, with a double loop at the top, so that
the loop reaches a height of about 0.3 m above the natural ground surface. Then insert the loop into
a protective sleeve of appropriate diameter and long enough to reach from the bottom of the trench
to 10 cm below the top of the riser. The sleeve should be tied to the riser in at least 2 places using
plastic tape (or clamps).

8. After lowering the tubes or cables, make sure the braid is placed freely without any tension;

9. If the cables and/or tubes must cross the pipe itself, pass over a concrete anchor or turn at an elbow
or branching, first verify that about 10 cm of soil bedding are placed above the pipe or concrete and then
place the tube or cables above the bedding. In the case of an elbow or branching, verify that the tubes
or cables are loose and do not pass adjacent to the corner of the trench wall. In any case, the "corner" of
the trench should be cut to avoid damage to the tube/cables at the corner.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 15


PVC MAIN LINE INSTALLATION CREWS (continued)

Technical guidelines – Concrete anchors


1. Anchoring blocks should be installed at any elbow, bend, horizontal branching, change in diameter
(in lines longer than 200 m), connections at a line start/end assembly, etc. The following are general
guidelines:

 The concrete should be cast against native undisturbed soil; plywood or cardboard should be placed
between the block and the device.

 Minimum anchoring dimensions should be 25 x 80 x 100 cm, or in accordance with the design.

 The blocks should be reinforced with a 20 cm x 20 cm x 8 mm steel grid, or similar; the block should
have a minimum thickness of 25 cm, but, as stated above, it should always be cast against
undisturbed native soil (see Appendix 3, page 78).

 It is recommended that the pits for the blocks in the undisturbed trench soil (bottom and side wall) be
excavated prior to installation of the pipes, to enable easier work and less risk of damage to the pipes.

 Placement of a reinforced steel hook at the top of the block for future tying and hoisting (for purposes
of maintenance or modifications) is recommended.
2. After completing deployment of the tube or cables and installing the required piping with its accessories
in the trench, the anchoring blocks should be prepared as follows: Two crew members should prepare
the concrete itself, while the other two members complete the excavations for the concrete blocks.

Transport of workers to prepare the concrete and transport of the concrete afterwards are the
responsibility of the foreman. The foreman should also be present while the concrete anchors are
prepared.

3. If it is possible to receive a concrete mixer truck, all the anchoring sites should be prepared for casting
and the mixer truck should be summoned only after there are enough sites ready to fully exploit the
truck.

Fig. 6: Through line connection, tee - top view Fig. 7: Direction change, elbow - top view

Tools and machinery


All cables not used during the day and the tools & equipment should be loaded at the end of the day and
taken to the warehouse.

16 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


PE SUB-MAIN
DEPLOYMENT & INSTALLATION CREWS
Personnel, tools & general guidelines
The PE sub-main crew will include the following personnel:
 A crew chief + 3-4 workers
 A tractor and wagon + operator during deployment of the piping in the morning hours (to be used for
main line deployment, as well).

PE sub-mains crew - Tools and equipment:


 Saw + hacksaw  Pruning shears
 Rasp  Plasson wrenches for the designated diameters (x2)
 Cutting blade  Chargeable electric drill + spare battery
 Reamer to prepare bevels  Dedicated drill for the PE start connectors and saddles
 Lubricating paste + suitable brush  Conical bit for saddles
 Hoes (x2)  Dedicated bit for start connectors
 Standard shovel (x2)  8 mm for standard start connectors
 Digger/pickax (x1)  12 mm for screw start connectors
 Buckets (x2)  A drinking water jug
 A sack full of rags

Crew job description & pace of work:


The crew’s job is to place sub-mains and all required accessories and equipment in the same trench;
including installation of the start connectors and the outlets on the ground surface. The crew chief must
make sure that the pipes are partially covered with soil at the points indicated below.

The crew chief will also direct the excavation machine operator regarding setting out, excavation route,
depth of trenching, etc.

In each 8-hour work day, the pace of work of the crew will be:
 Deployment of approximately 750m of complete PE sub-mains in an existing orchard with limited work
abilities (under optimal conditions).
 Deployment of approximately 1,000m of complete PE sub-mains in open field crops (under optimal
conditions).

If the piping cannot be deployed in the sub-main trench by vehicles, it is recommended that several
additional workers be recruited for manual distribution of the pipes during the early morning hours.

In case of sub-mains installed in trenches that are used for the main line, as well, cooperation of the two
teams should be considered.

The piping should be deployed and assembled in accordance with a map or section drawing provided to
the crew chief in advance and in accordance with the guidelines below:

Crew scope of work & general guidelines


The foreman is responsible for marking the supply line and the sub-mains alignment from the exiting riser
one day ahead of the PE pipe deployment. The marking should be done with stakes, chalk or marking cord.

1. All couplers required for performing the deployment and installation works and several 2-way couplers
(for correcting mistakes, etc.) should be put together in a plastic box, to be delivered to the crew chief each
morning. This preparation is the responsibility of the farm foreman. The same pertains to saddles and/or
start connector outlets to be mounted in the afternoon. The crew chief is responsible for supplying these tools.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 17


PE SUB-MAIN DEPLOYMENT & INSTALLATION CREWS (continued)
The saddles and start connectors must be put together in crates or containers without holes, to avoid
loss of bolts and gaskets that could fall from the saddles. Saddles of different diameters should be
placed in different crates or sacks.

2. The crew with the pipes, equipment and tools should be brought to the field by the foreman. Once
there, they will work independently under the full supervision of the crew chief and the superior or
partial supervision of the foreman.

3. The piping should be deployed from the valve assembly to the line ends of that same sub-main during
the morning, making sure that a surplus length of 1 m remains at the start and at the end of the pipe
(to serve as a reserve, in case of mishaps or errors). Deployment of the piping in the morning will also
include fastening all required couplers. The starting point of the pipe will therefore be 1-2 m before the
valve riser or, if not yet installed, the point where the valve riser is to be installed. The end of the pipe
will extend 1-2 m past the last tree row or planting bed.

4. Whenever a butt-welding method is used to connect pipes, follow the instruction manual of the specific
machine type.

5. During the afternoon, the saddles or start connectors and outlets should be installed on the piping that
was assembled the previous day, to allow the piping to reach its final position and avoid deformations in
the pipe that could cause rotation of the saddles or start connectors.

TIP
Highly recommended - Install the outlets on the piping only after the trench for that same piping
has already been excavated or at thye same time as the excavation, to avoid a situation in which
the outlets deviate from the row/planting bed line due to elongation and shortening of the PE piping
during the day. Immediately after completing installation of the outlets, the sub-main piping must
be inserted into the trench and anchored at several places with a soil covering. If there is a special
independent crew for burying the piping in the trenches, it is important to make sure it will bury the
piping soon after the preparation of the outlets has been completed.

6. Cutting and preparation of PE outlets (12, 16, 17, 20 and 25 mm) of the desired length in accordance
with the drawings and assembly specs and the quantity of piping actually sent (usually about 1m per
outlet) can be performed in the warehouse or at the work area site with pruning shears.

7. In any case of indecision or doubt, the crew chief must stop the piping work and consult with the
foreman. If such consultation is not feasible at the time, the crew should move on to work on the next
line until the problem is solved.
8. Do not leave pipe cuttings or leftovers in the field – any cuttings/ leftovers that are not used to deploy
the neighboring line should be collected along the main road of that same site (the road along which the
PVC main line passes).

9. Do not leave equipment and tools in the field. At the end of each work day, they should be taken
organized in their designated place at the warehouse.

10. The field must stay be left clean at the end of the day; all garbage must be taken away.

18 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


PE SUB-MAIN DEPLOYMENT & INSTALLATION CREWS (continued)

Technical guidelines – General


1. Pipe reels (usually 100m long) or PE rods should be deployed in the most convenient alignment for the
work, i.e., directly in the final intended alignment in areas with immature trees or open areas. In areas
with mature trees that make passage difficult, the sub-main pipes should be deployed along the
roadway and then towed into the intended alignment. If trenches have already been dug for the piping,
the piping should be placed at a sufficient distance from the trench to prevent soil from falling into the
trench and blocking parts of it during the work.

2. Saddles and start connectors should be assembled so that they are precisely in the line of trees or the
planting bed and facing directly upward, except for the last saddle (in an orchard only), which should be
assembled about 40 cm before the last row of trees to enable placement of the line end nearby without
protruding from the row of trees.

3. After assembling the last saddle/start connector, assemble the end line of the PE pipe (in an orchard,
about 20 cm past the saddle/start connector). Install the end line assembly as per drawings and backfill
the trench around it.

4. PE outlets (12, 16, 17, 20 or 25 mm) should be assembled so that their natural turning direction is toward
the connection with the designated dripperline.

5. If the outlet is a single pipe (that feeds dripperlines in both directions with a T), it should be installed
vertically. In any case, a surplus of about 50 cm should be left above the ground.

6. During the last hour of installation of saddles/start connectors and outlets on any particular work day,
the crew chief should make a quick inspection along the deployed and assembled pipes to verify that
nothing is missing, that all the couplers and outlets have been assembled properly and that the pipe
is undamaged (dislocated, kinked or cut). If a defect is found in the pipe, a saddle + plug should be
installed (in the case of a hole), a 2-way connector should be inserted (in the case of a cut or dislocation)
or, if the damaged section is lengthy or has damages nearby, the pipe segment should be replaced.

7. At the conclusion of the work – if excavation for the piping has not yet been performed – the pipes
should be moved to the side to enable undisturbed mechanical or manual excavation or trencher/
backhoe movement and excavation. The pipes should be moved carefully to avoid damaging the PE
outlets to the dripperlines. In the case of lines that are comprised of a supply line connected by a T to a
sub-main, the supply line should be disconnected from the T to enable moving it and to enable work by
the trencher/backhoe.

Connection of dripperline outlets to sub-mains with saddles


1. The saddle screws should be fastened until the two parts of the saddle are fitted together and only
then should the holes be drilled. Verify visually or by inserting a finger that the piece of pipe that has
been drilled has been extracted or has fallen into the pipe.

2. The crew chief is responsible for verifying that all the holes have been drilled before assembling the
couplers on the saddles.

3. If the coupler on the saddle is a Y type (as for example 16 x 3/4" x 16) and the trench is excavated with a
trencher, it should be adjusted so that the opening direction of the Y is facing the axis of the trench and
not perpendicular to it, since the trenches formed by a trencher are very narrow and could create kinks
in the pipes. In aboveground applications, the use of a single outlet + T attachment is preferable to Y
connectors. (In any case, the work must be performed in accordance with the plan detail.)

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 19


PE SUB-MAIN DEPLOYMENT & INSTALLATION CREWS (continued)
4. To insert a 16 mm or 20 mm pipe into a Plasson coupler, do not open the coupler nut all the way, but
rather only halfway, and then push the pipe forcefully into the coupler. Note that insertion of the pipe
to the end of the coupler is performed in two stages! Other types of couplers may require different
methods of insertion.

Connection of dripperline outlets to sub-mains with start connectors


1. The holes (for the start connectors) must be drilled radially (vertically) into the pipe, to create a good seal
between the start connector and the pipe.

2. It is recommended that the outlets for the dripperlines (the short PE pipes with start connectors
assembled on them) be prepared at the warehouse to facilitate work in the field.

Fig. 8: Take-off is too long Fig. 9: Take-off is too short Fig. 10: Correct

NOTES
1. If there is a blind supply line connected by a T to the sub-main, the T should be connected to the
supply line only and the sub-main itself should not be cut. The final connection of the supply line
to the sub-main will be done after excavation, by the crew that lays the PE in the trench and the
backfill crew.

2. Make sure to provide a precise and clean bevel before attaching piping to the accessories.

3. Do not use any paste other than original vegetable-based installation paste for insertion of fittings
into pipes.

4. At least two people are needed to deploy reeled PE piping, which is performed in a wide circular
motion, to prevent breaking the pipes, or by rolling out the entire roll in the direction in which it is
deployed on the ground while maintaining its coiled structure.

5. It is recommended that a PE piping deployment machine be used on large projects

20 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


PE SUB-MAINS -
CREWS FOR LAYING-IN-TRENCHES & BACKFILLING
Personnel, tools & general
Personnel, job description & work pace:
This crew should consist of two workers whose job is to place the prepared pipes in the prepared and
excavated trench and to verify that the pipes are anchored by covering the trench with soil at several
points. The rate of work by this crew should be sufficient to place the piping required into all the trenches
that have been dug on that same work day.

Crew work tools:


 Spade/shovel (x2)  Hoe (x2)  Plastic bags (for covering the start of the line)  A small jug of water

Crew scope of work & general guidelines


Lowering of the prepared piping into the trenches should be timed to take place as close as possible to
completion of installation of the outlets on that piping. This is very important and must be implemented
precisely to prevent the outlets from shifting from their proper location as a result of elongation or
shortening of the PE piping (due to temperature fluctuation).

Guidelines for execution of the work


1. The crew chief responsible for laying of the piping must verify that the bottom of the trench is free
of any stones and obstacles and is flattened as much as possible before lowering the piping into the
trenches.

2. The pipes should be placed in the trench carefully, to avoid damage to the assembled outlets and to
avoid the collapse of soil from the side walls/embankments into the trench. Make sure that the saddles/
start connectors are properly oriented in line with the plants rows.

3. After all of pipes are in the trench, the pipe should be pulled so that the saddles/start connectors reach
their precise location in the row of trees or planting bed. The locations of the outlets must be checked
in several places along the line, and not only at the beginning. A situation may occur where the start of
the line is precise and further on, the saddles/start connectors deviate from the line of the row. In such
case, the proper positioning of the pipe needs to be found so that, on average, the outlets are in the
best location.

NOTE
If the deviation of the outlets from the line of the row further down the line is in the direction of
the continuation of the line (the gaps are too large between outlets), the line can be placed in a
serpentine configuration (snaking) to bring the outlets closer to the rows or the piping can be placed
in the trench when the temperature is lower and the pipe has contracted.

4. After the final location of the pipe has been determined, the area of the first outlet, the last outlet and a
few other locations along the line should be covered with backfill.

When covering the pipe at the first and last outlets, it is essential to verify that the outlets are facing
precisely upward. The pipes tend to rotate the outlets at the ends when being lowered into the trench.
Therefore, one worker must hold the pipe in the desired position and prevent it from rotating while the
other worker covers and compacts the soil around the outlet with his feet.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 21


PE SUB-MAINS - CREWS FOR LAYING-IN-TRENCHES & BACKFILLING (continued)
5. Whenever the line-end does not include an elbow that provides a line-end riser: When covering the
last outlet on the line, the crew must make sure that the line-end (usually a 32-63 mm diameter pipe) is
covered so that it does not deviate from the line of trees by more than 20 cm. To do this, the line-end
pipe must be rotated carefully (to prevent breaking of the pipe) and covered simultaneously above and
below the pipe – while compacting the soil. In the end, the pipe and valve/plug must protrude from the
ground directly upward next to the row of trees or the bed of plants. If there is an elbow that provides a
line-end riser, this procedure is not necessary.

The outlets (12, 16, 20 and 25 mm), should also be rotated so that they are in line with the tree rows or
the plant bed when they exit the ground surface.

NOTE
If there is a supply line from the valve to the sub-main and they are connected with a T, the sub-main
must be cut at the point where the trench of the supply line meets the trench of the sub-main, and
the sub-main must be connected to the T assembled on the supply line.

22 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


PVC SUB-MAIN INSTALLATION CREWS
Personnel, tools & general
Personnel:
The PVC sub-main crew will include the following personnel and equipment:
 A crew chief + 4 workers
 A tractor and wagon + operator during deployment of the piping in the morning hours (used for main
line deployment, as well).

Crew job description & work pace:


The crew’s job is to place the sub-mains and all accessories and equipment required in the same trench;
this also includes installation of the start connectors and the outlets to the ground surface. The crew chief
must make sure that the pipes are anchored with concrete blocks and covered with soil at the points
indicated below.

The crew chief will also direct the excavation machine operator regarding the setting out, excavation route,
depth of trenching etc.

In each 8-hour work day, the team's rate of work will be:
 Completion of about 600 m of PVC sub-mains in an existing orchard with limited work abilities.
 Completion of about 800 m of PVC sub-mains in open field crops.

If the piping cannot be deployed in the sub-main alignment with vehicles, it is recommended that several
additional workers be recruited for purposes of manual distribution during the early morning hours.

In case of sub-mains installed at trenches that are used for the main line, as well, cooperation of the 2
teams should be considered and planned.

The piping should be deployed and assembled in accordance with a map or section drawing that will be
provided to the crew chief in advance and in accordance with the following guidelines:

PVC sub-mains crew - Tools and equipment:


 Saw + hacksaw  Plywood and rigid cartons for bordering concrete
 Rasp blocks area
 Cutting blade  0.5m long 2" x 4" thick wood board (x4)
 Steel brush  A sack full of rags
 PVC primer and glue + suitable brush  Black marker (for PVC)
 Lubricating paste + suitable brush  Pruning shears
(in the case of rubber seal piping)  Chargeable electric drill + spare battery
 Hoes (x2)  Dedicated drill for the PVC start connectors
 Standard shovel (X2)  A 16 mm conical or cup bit for 16 and 17 mm
 Narrow shovel for preparing pits (x1) start connectors (x2)
 Digger/pickax (x1)  A tool for fastening start connectors
 Buckets (x2)  A water jug.
 Half-barrel for transporting and preparing
concrete

Crew scope of work & general guidelines


1. The crew chief will receive an explanation in the morning about the segment to be assembled that work
day and, as necessary, will prepare the pipes and accessories together with the crew. It is
recommended that the pipes be collected in the wagon according to the number of pipes of each
diameter required (according to the map) and not by length, to facilitate counting and distribution.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 23


PVC SUB-MAIN INSTALLATION CREWS (continued)
2. All the couplers required for performing the deployment and installation works in the morning + several
sockets (as a reserve in case of mishap) should be placed in a plastic box every morning by the crew
chief, under the responsibility of the farm foreman. The same should be done with the saddles and
outlets. The crew chief will be responsible for transporting the tools.

The saddles (if required) must be put together in crates or containers without holes, to avoid loss of
bolts and gaskets that could fall from the saddles. Saddles of different diameters should be collected in
different crates or sacks.

3. The pipes should be loaded on the wagon with all of the sockets of the pipes facing one direction (pipes
with a thicker wall width should be placed at the bottom; maximum height for the pipe pile should be
no more than 1 m). The crew chief must check that every pipe has a gasket already inserted. Later, they
should be unloaded in the direction of travel of the tractor, and placed so that the pipes descend from
the wagon with their sockets in the desired direction for installation (so that they don't have to be turned
around). See Fig. 1, page 10.

4. The crew with the pipes, equipment and tools should be brought to the field by the foreman, where
it will then work independently under the supervision of the crew chief. If the option exists for placing
the sub-main alignment in the wagon with pipes inside it – the piping should be distributed in the sub-
main alignment according to required diameter and number of pipes per each section. The pipes should
then be lowered along the designated alignment by 2-4 members of the PVC crew while riding in the
tractor. If the vehicle cannot hold the alignment, all the pipes should be unloaded at a convenient point
(or points) and manually deployed from there.

5. The piping should be deployed from the valve assembly to the line ends of the same valve assembly,
making sure that a surplus length of 1 m is left at the start and end of the pipe route. Deployment of
the piping in the morning will also include gluing all required fittings and couplers. 1-2 m will serve as a
reserve in case of mishaps and errors. The starting point of the pipe will therefore be 1-2 m beyond the
riser or, if a riser has not yet been installed, the point where there will be a riser. The end of the pipe will
extend 1-2 m past the last row of trees or planting bed.

6. The pipes should be placed next to the trench alignment (if the trench has not yet been excavated,
about 3-5 m from the trench axis), where the overlap between pipes is compatible with the length of
pipe inserted into the socket.

7. Following deployment, visually inspect the piping – do not use "burnt" piping (dark brown color). Verify
that there are no cracks in the pipe – pipe that has been visibly damaged should be placed aside and its
use (or at least that of the damaged section of the pipe) should be avoided.
8. Cutting and preparation of PE outlets (12, 16, 17, 20 and 25 mm) of the desired length in accordance
with the drawing/assembly specs (usually about 1m long) can be performed in the warehouse or in the
actual work area with pruning shears.

9. When the pipe deployment has been completed, installation of the pipes in the prepared trench (if it is
wide enough) or at the side of the trench (in most cases) can begin.

If concrete blocks are required for anchoring along the planned line (based on the crew chief's
experience), these should be prepared only after placement of the piping in the trench, installation of all
the outlets and line ends and partial covering of the line with backfill for anchoring.

10.In any case of indecision or doubt, the crew chief must stop the piping work and consult with the
foreman. If such consultation is not possible, the crew should move on to work on the next line until the
problem is solved.

24 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


PVC SUB-MAIN INSTALLATION CREWS (continued)
11. Do not leave pipes and pipes cuttings in the field – any pipes of cuttings that are not used for the
neighboring line should be collected along the main road of the same site (the road along which the
PVC main line passes).

12. Do not leave equipment and tools in the field. At the end of each work day, they should be collected
from their designated place and transported to the warehouse.

13. The field must stay be left clean at the end of the day; all garbage must be taken away.

Technical guidelines for the installation of PVC sub-main piping


1. In principle, glued PVC piping should be assembled on the side of the excavated trench (or future trench)
by 2 crew members in long segments and then continuously lowered with maximum care into the
trench, one segment after the other.

2. Prior to gluing or inserting one pipe into another, the pipe should be lifted into a vertical position and
knocked, to remove any dirt that has entered the pipe.

1. Before lowering and assembling pipes into the trench, the crew chief must check the soil conditions in
the trench and verify:
a. That the trench is the right depth (usually about 0.6 m cover of soil above pipe).
Trench depth = minimum 50 - 60 cm coverage (as agreed with the customer) + diameter of the pipe.
b. That the trench bottom is relatively flat, without pits and mounds – if not, a worker should enter the
trench to flatten it with a hoe or mattock.
c. That the soil is clean, without stones/hard clods – if there are any in the soil, make sure that the
foreman arrives, checks the conditions and provides instructions regarding bedding the bottom of the
trench with clean soil or sand. The pipe should also be covered with soil that is free of any stones or
other hard clumps, to a height of at least 20 cm above the pipe.
d. The excavation (trench bottom) should have as continuous a slope as possible.

3. The crew chief must be in or next to the trench during assembly of the pipes, to verify correct and
complete insertion of the pipe into the bell. If piping has a mark for depth of penetration, it is essential
to verify that the work is performed in accordance with the marking; otherwise, mark the insertion
depth on each pipe with a black marker.

4. Glued PVC pipes and fittings - be sure to follow the manual instructions of the glue manufacturer as
well the following general guidelines:

 Gluing should be done with the right type of glue and brush.

 The ends of the pipes (male and female) should be lifted above the ground surface (by the supporting
wood boards), to prevent any possibility of soil touching the gluing area.

 Pipes should be cut for installation of accessories using a saw at a 90° angle and then be slightly filed
or sanded to obtain a bevel.

 The socket of one pipe and the male end of the other pipe should be cleaned with a dry rag and a
primer until completely free of any contaminants and, in particular, oils.

 Afterwards, glue should be spread uniformly in a complete layer on both the male and female sides
and the pipe should be inserted immediately into the socket, while turning it by 1/4 of a circle to
improve glue distribution.

 Do not overglue to avoid leftover glue being pushed into the pipe and weakening it. Whenever
possible, wipe surplus glue with a rag.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 25


PVC SUB-MAIN INSTALLATION CREWS (continued)

 After the male end has reached the end of the bell, use moderate force on the pipes for an additional
10 seconds and carefully place the pipes on the ground.

 Let the glue cure and gain strength by letting it rest without moving, as per manufacturer's
instructions. Avoid moving or curving the pipe for at least 4 hours after gluing.

NOTE
As a rule, avoid moving pipes (PVC piping, in particular) after their placement.

5. A curve/turn can be made in the PVC piping up to the maximum angle allowed (see the table below).
An angle or curvature beyond this value requires the use of a dedicated elbow device. In any case, the
pipe must not be bent at temperatures lower than 5° C to create such an arc.

It is essential to verify gradual offset of the pipes to form the curve.

Diameter in mm Deviation of the end of the pipe from a straight line (m)
(Grade 6 piping) 6 m long pipe (5.85 m) 8 m long pipe
32-50
63 1.4 1.92
75 1.15 1.54
90 1.0 1.3
110 0.9 1.08
140 0.55 0.85
160 0.5 0.74
See Fig. 4, page 16

6. If the installation of the PVC sub-mains pipes at the end of the work day has not reached a line end
outlet, but rather ends at a simple pipe in the ground, the pipe should be covered with a plastic bag.
Since this section will not be backfilled with soil, it is important to make sure that the length of the
excavated trench beyond the pipe end does not exceed 1-2 m and a small dike of soil is assembled
around the open top part of the trench, especially when rain is expected. Line end outlets above the
ground surface that do not have plugs should also be covered with a plastic bag.

Technical guidelines for installing outlets for dripperlines – General


1. After completing installation of the sub-mains to a given valve assembly, the saddles or start connectors
+ outlets should be assembled on the piping of that valve. To avoid displacement and lack of precision at
the outlets, do not begin drilling holes in piping that has not been completely installed to the line end.

2. Drilling holes:

Drilling should be performed using a special dedicated bit – usually a cup bit or a conical bit. Hold the
bit vertically with respect to the pipe and its center (use only an electric drill) and press down with
moderate force (particularly on small-diameter pipes). Avoid vibrations or lateral movement of the
drill. If the workers performing the drilling are inexperienced and not professionals, the use of a cup
bit is recommended; this greatly reduces the risk of drilling a hole that is not round or too wide due to
movements during drilling.

For start connector outlets, closely verify that the diameter and type of bit are compatible with the
designated start connector. (It is recommended that the foreman obtain the appropriate bits for the
specific project from the Netafim warehouse). It is recommended that a test drilling and connection

26 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


PVC SUB-MAIN INSTALLATION CREWS (continued)
be executed, preferably under water pressure, to test for leaks before making perforations in the entire
project.

The start connector must be inserted with sufficient force; if it enters too smoothly, that is an indication
that the hole is too large.

The following table specifies the bit diameters required by type of start connector:
Type of start connector › 12 mm 16 mm 17 mm 20 mm 25 mm Lay flat 20 mm
Bit diameter for PE
Bit diameter for PVC

3. Saddles and start connectors should be assembled so that they are precisely in the row of trees or
planting bed and facing directly upward, except for the last saddle (in an orchard only), which should be
assembled about 30 cm before the last row of trees, to enable placement of the line end nearby without
its protruding from the row of trees.

4. After assembling the last saddle/start connector, assemble the end of the PVC line (about 20 cm past
the last saddle/start connector in an orchard). Install the end line assembly according to the drawings
and backfill the trench around it.

5. Outlets from PE pipe - 12, 16, 17, 20 or 25 mm (blanks) should be assembled so that their natural
turning direction is towards the connection with the designated dripperline.

6. If the outlet is a single pipe that feeds dripperlines in both directions with a T, it should be installed
vertically. In any case, a surplus of about 50 cm should be left above the ground.

7. In the last hour of installation of saddles/start connectors and outlets on any particular work day, the
crew chief should make a quick inspection along the deployed and assembled pipes to verify that
nothing is missing, that all the couplers and outlets have been assembled properly and that the pipe
is not damaged (dislocated, kinked or cut). If a defect is found in a pipe, a saddle + plug should be
assembled (in the case of a hole), a socket should be inserted (in the case of a cut or dislocation) or the
pipe segment should be replaced if the damaged section is lengthy or close to other damages.

8. After preparing outlets in a particular block – if excavation for the piping has not yet been performed –
the pipes should be moved to the side to enable excavation. The pipes should be moved carefully to
avoid damage to pipes or kinks in the PE outlets to the drippers. On lines that are comprised of a main
line connected by a T to a sub-main, do not connect the main line to the T, so that it can be moved and
trenching work can be performed.

Technical guidelines for connecting dripperline outlets


to sub-mains with saddles
1. Saddles may be used as an option. This is not commonly done and there is concern about rotation of
the saddle around the pipe. If such a connection is designed in the project, pay careful attention to
ensure that the saddle and its screws are tightened until it is well fastened.

2. The saddle screws should be fastened until the two parts of the saddle are fitted together and only
then should the holes be drilled. Verify visually or by inserting a finger that the piece of pipe that has
been drilled has been extracted or has fallen into the pipe.

3. The crew chief is responsible for verifying that all the holes have been drilled before assembling the
couplers on the saddles.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 27


PVC SUB-MAIN INSTALLATION CREWS (continued)
4. If the coupler on the saddle is a Y type (e.g., 16 x 3/4" x 16) and the trench is narrow, it should be
adjusted so that the opening direction of the Y faces the axis of the trench and is not perpendicular to
it; a narrow trench creates kinks in the pipes. For aboveground applications, the use of a single outlet
+ T attachment is preferable to the use of Y connectors. (In any case, the work must be performed
according to the plan details.)

5. For purposes of inserting a 16 mm or 20 mm pipe into a Plasson coupler, do not open the coupler nut
to the end, but rather only halfway, and then push the pipe forcefully into the coupler. Note that
insertion of the pipe into the end of the coupler is performed in two stages! Other types of couplers
may require different methods of insertion.

Technical guidelines for connecting dripperline outlets to sub-mains with


start connectors
1. Drilling of holes (for the start connectors) in the pipe must be performed radially (vertically), to ensure
a good seal between the start connector and the pipe. Verify the setting and anchoring of the pipe or
make sure the drill points have been marked before beginning to drill the holes, to avoid rotation and
displacement of the pipe.

2. It is recommended that the PE outlets for the dripperlines with a start connector assembled on them
be prepared at the warehouse, to facilitate work in the field.

3. The following is the recommended sequence when connecting outlets to a line:


a. One worker should mark the location of the hole. (If this is not done, the pipe must be set in place
before drilling.)
b. A second worker should drill the holes, one after the other (only after all the outlets have been
marked).
c. A third worker should insert the rubber start connectors into the drilled holes.
d. A fourth worker should insert the prepared outlets (start connectors + PE pipes) into the holes with
the gaskets (while strictly maintaining the natural curve direction of the designated dripperline).
See Fig. 8, 9, 10, page 20.

Technical guidelines – General and excavations


1. If there is a supply line to the sub-main connected by a T, the T should be connected to the supply line
only and the sub-main should not be cut until all pipes are in the trenches with the outlets in the right
position. The final connection of the supply line to the sub-main should be made by the PVC installation
crew (following excavations).

2. The crew chief should also direct the excavation machine operator regarding setting out, excavation
route, depth of trenching, etc.

3. Do not use any primer or glue that is not the manufacturer's original and intended for gluing PVC piping.

4. Before lowering the pipes into the trench, the crew chief should verify that all the pipes that have been
assembled are serviceable, without defects and without any "burnt" pipes on the line.

5. Before lowering and anchoring the pipes, the crew chief must check soil conditions in the trench,
according to the instructions in Section 5.2.3 above.

6. The sub-main PVC crew is responsible for lowering the sub-mains into the trenches after installation of
all the outlets and completion of the excavation of the trenches.

28 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


PVC SUB-MAIN INSTALLATION CREWS (continued)
The crew chief is responsible for verifying the proper location of the line so that all the outlets are
opposite the planting rows. After this, the line should be partially covered manually about 5 m from
its starting point, at its end and at several points along the line, to prevent any movement during
the mechanized backfill operation. After this stage, check the placement of the concrete anchors (if
necessary) at elbows, Ts, and end lines. Concrete anchoring at the beginning of the line should be
prepared by the crew installing the valve assemblies when the valve is connected to the sub-main.

7. All tools and equipment should be loaded at the end of the day and taken to the warehouse.

8. The field must stay be left clean at the end of the day; all garbage must be taken away.

Technical guidelines – Concrete anchors


1. PVC piping with rubber gaskets should be anchored in any elbow, bend, horizontal branching, change
in diameter (in lines longer than 200 m), connections at a line start and end assemblies, etc. The
concrete should be cast against native undisturbed soil; plywood or cardboard should be placed
between the block and the device.

Anchoring dimensions (minimum):


140 Ø –160 Ø 80 x 100 x 20 (or as designed)
90 Ø – 110 Ø 60 x 80 x 20 (or as designed)
75 Ø or less 50 x 60 x 20 (or as designed)

The blocks should be reinforced with 20 cm x 20 cm x 8 mm steel grid, or similar; the block should have
a minimum thickness of 20 cm, but as stated above, always against undisturbed native soil.
(see Appendix 3, page 78)

2. In glued PVC pipes – no anchoring should be provided for small diameter piping (up to Ø75 mm).
For larger diameters, concrete anchoring should be provided only at the end and start of the line and
in 60°-90° elbows.
90 Ø – 110 Ø Anchoring block size should be 50 x 60 x 20 cm
140 Ø –160 Ø Anchoring block size should be 60 x 80 x 20 cm
See Fig. 6, 7, page 12.

3. It is recommended that the excavation of pits for the blocks in the undisturbed trench soil (bottom and
side wall) be done prior to actual pipe installation, to allow easier work with less damage hazards to the
pipes.
If the above procedure was not followed, then after deployment and installation of the required piping
with its accessories in the trench + the line end riser are completed, the concrete anchors should be
prepared in the following manner: two crew members should prepare the concrete itself while the other
two members prepare/adjust the excavations required for the concrete blocks.

Transport of personnel to prepare the concrete and transport of the concrete afterwards is the
responsibility of the foreman. The foreman should also be present while the concrete anchors are
prepared.

4. If the option exists for receiving a concrete mixer truck, all the anchoring sites should be prepared for
casting and the mixer truck should be summoned only after there are enough sites ready to fully exploit
the truck. (It is recommended that the casting of the concrete blocks also be coordinated with the main
piping crew and installation of the head control).

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 29


PVC TRENCH BACKFILL CREWS
Personnel, tools & general
Personnel:
The composition of the trench backfill crew should be based on the field conditions on site.

The backfill crew will include the following personnel and equipment:

1. Minimal condition – when there is no problem of vegetation ground cover, crossing of existing
infrastructures and utilities or stones in the excavated trench material, the backfilling crew will include:
Backfill equipment (tractor with bucket, trencher with bucket, backhoe (JCB), front loader, excavator,
etc.) + 1 experienced operator and 1 – 2 workers with a hoe and shovel/spade.

2. In other problematic conditions:

Backfill equipment compatible with field conditions should be used:


 In open areas – unrestricted.
 In existing orchards and in areas with limited navigation – preference for a trencher or tractor + small
bucket loader + experienced operator.

Personnel required, by case:


Excavation and backfill by trencher (0.2 – 0.3 m trench width) 2-3 workers with a hoe and shovel/spade
Excavation and backfill by backhoe (0.4 - 0.6 m bucket) 4-5 workers with a hoe and shovel/spade
Excavation and backfill by excavator (0.8 m bucket or more) 5-7 workers with a hoe and shovel/spade

If bedding and backfill must be performed using selected/imported clean fill (when there are stones in
the local soil), several more workers should be employed in manual bedding & backfilling according to
conditions and experience in the field.

Crew job description & work pace:

The role of the crew is to verify backfill of all the excavated trenches in which piping has been placed (both
main lines and sub-mains). It is recommended that all the trenches be backfilled on the same day that the
pipe is placed in them.

In any case, where a trench cross-section contains stones or hard big clods, the project foreman should be
called to decide whether bedding and/or selected material backfill is required.

In cases where moisturizing and compaction of the soil are required – see instructions and guidelines in
the corresponding manual.

Crew scope of work & general guidelines for backfill


1. In any case where stones or foreign objects are found in the excavated soil, the farm foreman should
make the decisions regarding backfilling and bedding. Backfill should be performed manually using soil
free of any stones. Make sure there is a reserve of soil and sand (free of any hard objects), and then
backfill with the equipment.

2. Prevent moving of the pipes in the trench as much as possible in the first backfill stage.

3. It is possible to cover PVC pipe in two stages (in places where rain is not expected during the work):
a. Pile soil between the bells at a distance of 0.5 m from the bell in each direction to a backfill height of
about 50 cm above the pipe until execution of the pressure testing stage.
b. Final coverage, with all the backfill soil and maximum compaction, should be done after the pressure
testing.

30 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


PVC TRENCH BACKFILL CREWS (continued)
4. It is essential verify full coverage + a supplementary mound. After backfilling to the ground-surface
level (and with a minimum 60 cm layer above the pipe) – compact well under optimal moisture
conditions: verify that the soil is wetted well (but not muddy) and then compact well by driving the
heaviest vehicle available on site (usually this is the backhoe/excavator with a full bucket load) in the
excavation alignment until obtaining maximum compaction (relevant to main lines only, without outlets
to the dripperlines). Then add a mound of soil. Form the mound at the desired height only after initial
backfill compaction has been completed.

5. When backfilling next to a riser, perform manual backfilling very carefully and keep the machinery away
from the riser.

One worker should hold the riser vertically or at right angles to the ground (in a sloped area) while other
personnel perform the backfill operation.

6. When backfilling a sub-main trench near an outlet to a dripperline, the worker must hold the PE
outlet upright without any break or buckling and the backfill operation should be performed gradually
and carefully by another crew member using the backfill equipment. It is recommended that the backfill
soil be compacted around the outlet by continuously stepping on it while filling the excavation in the
area. The area of the start connector and blank PE pipe rising from the sub-main to the ground can
be protected by setting a Ø 40 or Ø 50 PVC pipe over the outlet and removing it after completing the
backfill and compaction operation. This method is suitable for constructing a straight outlet – without
the natural curvature of the PE pipe towards the plants row/bed.

7. When backfilling, verify that all the anchors in the line are set against undisturbed native soil and if, for
any reason whatsoever, soil has been excavated at the back of the anchoring block, avoid covering
the pipe in the area and notify the farm foreman. The foreman should see to casting of concrete in the
entire area of the excavation.

8. If rain has fallen or water has entered the trench before completing the backfill operation, thoroughly
check that the pipes are still at the bottom of the trench and were not lifted by the water. If there is
any concern whatsoever regarding uplift or "floating" of the pipes in the trench, extract the pipes, re-
excavate (if necessary – after filling the existing trench) and re-introduce the pipes into the new trench.

Do not take any shortcuts in this matter – it is essential to verify that the pipes remain in the excavated
alignment at the necessary depth and in the required and uniform gradients, even after backfilling!!

9. If more than one pipe + control tube has been placed in the excavated alignment, it is essential to
verify maximum possible separation between them before backfilling. In any case, if the drawing shows
the cross-section of the trench with piping, act in accordance with the drawing.
10.When backfilling, it is essential to avoid creating a trench/excavation at the sides of the pipe alignment
when taking backfill material. The site should be returned to its former condition (except for the mound
that must be left in the track of the trench when backfilling).

Fig. 11: Before backfilling Fig. 12: Wrong Fig. 13: Correct

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 31


PVC TRENCH BACKFILL CREWS (continued)
11.Make certain to cover all piping that has been placed on that same day. Do not leave a trench open
until the next day unless local conditions allow it (no rain during the work, the sidewalls of the trench do
not tend to collapse, etc.).

Fig. 14: Partial backfilling Fig. 15: Complete backfilling

ATTENTION
In an emergency situation (concern regarding sudden rain, lack of time, etc.), partial backfilling can
be provided by piling soil in the center of each pipe to prevent it from floating.
12. When the last pipe installed during a day work is placed next to a riser or valve assembly at the line
end, make sure the line end has been covered with a plastic bag tied to the pipe and the pipe covered
with soil up to about 1 m from the open end. The rest of the trench (about 2 m long) should be left
without coverage, for continuation of the work the next day.

2m 1m

Plastic bag

Fig. 16: Pipe end coverage

Crew scope of work & general guidelines for road crossings


It is recommended that one of the following options be taken at a main road crossing (vehicular and truck
traffic):
1. Place the piping in a PVC or steel pipe sleeve having a diameter that is at least 4" larger than the
diameter of the piping crossing the road (for crossing pipes up to 110 mm) and 6" larger than the
diameter of the piping crossing the road (for crossing pipes larger than 110 mm). In such cases, the
sleeve can be placed in the trench with a coverage depth of only 0.8 – 1.0 m.

2. Cross the road with high-pressure-rating piping (if available) and/or bury it to a greater depth
(1.1 – 1.3 m cover). In any case, the piping should be provided with a sand bedding and backfill should
be well-compacted, clean or specially selected soil material.

3. Deepen the trench until obtaining a 1.3-1.5 m-deep coverage above the pipe. This deepening must be
performed gradually, starting approximately 30 m before and after the crossing. Line the bottom of the
trench with a 15-20 cm layer of sand. Provide preliminary coverage of 40 cm of sand or soil free of any
granular material and then continue backfilling in 20-cm layers while compacting (by manual compactor
or damper) and a final backfill layer of up to 20 cm above the ground level.

32 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


PVC TRENCH BACKFILL CREWS (continued)

30 m 30 m
Road
Ground level 20 cm

1.3-1.5 m

20 cm sand layer

Fig. 17: PVC pipe, road crossing

Pipe bedding & lining


1. If the excavated soil contains stones, make sure sand or clean soil is used for the pipe lining. In general,
provide a 15-cm layer below the pipe for bedding and another 30 cm above the top of the pipe, unless
other instructions have been given for this project.

2. In most cases, the pipe lining will be provided with the use of sand, fine-grained pumice or other clean
soil imported from a nearby site.

Maximum particle size vs. pipe size


Nominal pipe size (in) 2-4 6-8 10 - 15 ≥ 16
Maximum particle size (in) ½ ¾ 1 1½

When such a site is not available sufficiently close by and the cost of transport is too high, native trench
soil (extracted from the trench) may be used for lining purposes, using a screen to filter stones and other
hard and large objects.

The screen should be bought or purchased locally, with the following dimensions:
 Width – according to the width of the excavated trench + approximately 0.5 m
(so that it can rest on the sides of the trench).
 Length – 1.0 -1.5 m.
 Mesh size – ~3 - 5 mm.

The screen frame should be constructed so that it is stable and allows convenient lifting and holding by
two workers while shaking and vibrating the screen to filter the soil that is poured on it for the purpose
of backfill.

3. Occasionally, a certain soil layer in the soil cross-section may contain stones when another layer is free
of them. In such cases, clean soil from the layer free of stones can be raked, carefully and manually, into
the trench (if the clean soil layer is above the one with stones).

Another option is to separate the extracted soil and instruct the machinery operator to place the
different extracted soil profiles in different piles along the trench (applicable for manual or backhoe
excavation only). When backfilling the trenches, the bedding/lining soil should, of course, be taken from
the clean pile only.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 33


VALVE ASSEMBLY INSTALLATION CREWS
Personnel, tools & general
Personnel:

The valve assembly crew will include the following personnel and equipment:
 A crew chief + 1 workers for an assembly of 63–75 mm diameters
 A crew chief + 3 workers for an assembly of 90–160mm diameters
 A tractor and wagon + operator for deployment of the assemblies will be borrowed from the piping
deployment teams after their "rush hours."

Crew job description & work pace:


The crew’s job is to create the assemblies in the workshop/warehouse with all accessories and equipment,
but without the risers. The risers will be glued and adjusted for height and direction by the crew on site to
be compatible to existing main line and sub-mains.

In each 8-hour work day, the team rate of work will be:
 About 8-15 complete PVC assemblies at the workshop/warehouse (depending on diameter and number
of valves in assembly).
 About 5-10 complete PVC assemblies connected to sub-mains and main line outlets on site (depending
on diameter and number of valves in assembly).

The assemblies should be deployed and assembled on site in accordance with a map or section drawing
provided to the crew chief in advance and in accordance with the following guidelines:

PVC valve-assembly crew - Tools and equipment:


 Large working table with mounted vise (at workshop)  Black marker (for PVC)
 Saw + hacksaw  Large pipe wrench (for Ø 3” threading)
 Rasp  Small pipe wrench (for up to Ø 1” threading)
 Cutting blade  Leveling device
 Steel brush  Teflon tapes
 PVC primer and glue + suitable brush  A water jug
 A sack full of rags

If concrete anchors must be constructed at the valve assemblies on site by this team, the following
additional equipment will be needed:
 Backhoe + operator  Digger/pickax (x2), buckets (x2)
 Wide bends/straps 3 m long (x3)  Half-barrel for transporting and preparing concrete
 Hoes (x3)  Plywood and rigid cartons for bordering concrete block area
 Standard shovel (x3)  0.5-m long 2" x 4" thick wood board (x8)
 Narrow shovel for preparing pits (x2)

In addition, this crew may assist in assembling the head controls together with the foreman and/or under
his direction according to the guidelines specified in the Crew scope of work & general guidelines for the
installation of head control chapter, page 37.

Tools required for working on the head control assemblies (additional):


 A pair of 15/16" and/or 11/8" box wrenches  Zip ties
 Large adjustable wrench  Wood blocks or logs for temporary support of the
 Small adjustable wrench assemblies
 Screwdriver  Graphite grease for the screws
 Adhesive electrical insulating tape  Primer paint + topcoat

34 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


VALVE ASSEMBLY INSTALLATION CREWS (continued)

Crew scope of work & general guidelines for valve assemblies


(field valves)
1. The crew should inspect all the valves in the warehouse and verify the serviceability of the valves and
control loops, if included.

2. The crew should construct the valve assemblies in the warehouse with clamps in accordance with
drawings received from the foreman. While constructing the assemblies, strictly observe the following
points:

 The first assemblies should be constructed together with the farm foreman.

 Apply linen and/or Teflon wrapping on the threads according to the tightening direction of the device.

 Recommended number of Teflon windings to be applied is as follows:


a. On white PVC nipples (including 2"- and 3"-diameter PVC risers in the field), the Teflon wrapping
should have approx. 20 windings around the back part of the threading when the threading enters
into a gray PVC accessory (such as a T or angle).
b. When the threading enters a metallic valve, approx. 12 windings may be sufficient. A thin layer of
linen can be wound on top of the Teflon windings, in this case - only 20% of the above-mentioned
Teflon can be applied).

 In threaded connections, do not use excessive force when closing to avoid cracking the device.

 Control valves should be assembled according to the flow direction arrow.

 It is essential to make sure the valves are glued or rotated until the precise horizontal position is
achieved.

 After constructing the valve assemblies in the warehouse, they should be placed in an orderly manner
in a designated place in the warehouse.

3. While installing the pre-assembled valve assemblies on site, strictly observe the following points:

 Carefully transport them to the site to prevent damage to the prepared assemblies.

 A threaded assembly should be threaded onto the risers after winding the Teflon (as indicated in the
Crew scope of work & general guidelines for backfill paragraph, subsection 2, page 30) with
maximum care to prevent damage to the threading of the riser. If more than one riser is of threaded
type, union couplers must be utilized.

 If the inlet riser is a glue type pipe, the pre-installed riser should be cut at the required height above
the ground and the assembly that has been prepared at the warehouse should be glued vertically to
the riser/s.

In the absence of any other instructions, the assembly centerline should be 30-40 cm above the
ground level or the assembly floor level (in case a compacted foundation or concrete slab is planned).

 In the case of threaded connections of the assembly to the risers, it should be bolted to the inlet
riser almost to the end of the threading (to allow fine-tuning of direction later). The final position of
the assembly (threaded or glued) should have temporary support (to avoid damage due to moment
forces) and be in the correct direction, with the valves parallel to the roadway or the row direction.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 35


VALVE ASSEMBLY INSTALLATION CREWS (continued)

 The outlet risers should be placed into the ground at their final location vertically. Then the location of
the required cut of the sub-main should be marked, for purposes of correct installation of the angle
and the risers. Afterward, the sub-main should be cut in the place marked and the angle + riser
should be assembled to form the outlet above the ground.

 All risers must be perpendicular to ground level and aligned with the assembly. The assembly itself
will be parallel to the ground surface at its location.

ATTENTION
It is essential to verify that the bottom of the sub-main trench in the area of the risers is
thoroughly compacted to prevent future settlement of the sub-main pipe, failure to do so will
result in settling of the sub-mains and risers, forcing the assembly to bend and, in extreme
cases, even break.

 After completing connection/gluing of the couplers/fittings to the sub-mains, the trenches should be
backfilled next to the risers while continually compacting the backfill by walking on each backfill layer
(20 cm) to warm it up. A trench that is covered but not compacted will settle afterwards with the
rains! A small mound should be created in the area of the assembly, so that any dripping or moisture
will drain away from the area of the assembly.

Fig. 18: Field valve set, linear Fig. 19: Field valve set, parallel

4. Concrete anchors

In the case of PVC sub-mains that require concrete anchors at the start of the line, the crew should
prepare the required excavations for the concrete block (behind and below the descending risers),
before connecting the riser to the sub-main. Then the riser should be connected to the sub-main and
assembly, and finally the block should be cast in the prepared pit.

NOTE
If connection of the descending risers to the valve assembly can be postponed until after the rains
(which will cause compaction and settlement), such an option is preferable. In this case, the
PE/PVC risers should be cut about 20 cm longer than required, to allow settlement afterwards.

36 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


VALVE ASSEMBLY INSTALLATION CREWS (continued)

Crew scope of work & general guidelines for the installation of


head control (HC)
The foreman must be present for the purpose of installing the head assembly.

The foreman will decide if it is necessary to add additional personnel for assistance, according to the
diameter of the head control.

The HC should be installed while strictly making sure of the following:

1. Complete drawings of the HC and its sub-systems including foundation (a concrete slab, in most cases)
and housing are mandatory for the execution. If for some reason, there are no drawings or drawings are
not updated, the HC and its connections to the water source and the delivery lines should be marked
prior to actual execution, to verify compatibility (test installation of the assembly may be performed).
The concrete slab (if planned) should be constructed in accordance with these dimensions.

2. The sleeves + pull cord should be prepared for electrical and communications cables in the concrete
slab (if a slab and sleeves are planned) prior to casting, in the required alignments for the locations
required, all prior to casting and installation.
3. The HC should be precisely parallel to the existing concrete slab directions or, if there is no concrete
slab, parallel or perpendicular to the roadways in the area.

4. The HC should be parallel to the ground surface in the area, or horizontal if a concrete slab has been
constructed. The concrete slab itself should always be designed with a 1% lateral or transverse
gradient, or both, for draining water from the slab. The top of the slab should always be raised above the
foundation layer underneath it by at least 10 cm and the foundation layer raised above ground level in
the area by at least 20 cm (or as per drawings).

5. Flanges bolts should be tightened gradually and equally on each bolt in several cycles until reaching final
tightening. The bolts should be tightened with the two flanges parallel to one another and force should
not be applied to the flange in any direction whatsoever (i.e., heavy devices should be supported during
their installation).

6. Support should be provided under or next to any heavy devices, such as hydraulic valves, water meters
or filters. This support may be provided temporarily (with blocks, timber logs, etc.) until the final
supports are introduced, if they are intended to be made from concrete.

7. Victaulic couplings should be installed in a manner in which the bolts sit precisely on the two sides of
the pipe in a horizontal line. These bolts should be tightened gradually (a different bolt each time), and
not to the end, to allow free play during the installation process. Following installation, all the Victaulic
couplings should be fully tightened.

8. It is essential to verify the connection of the devices according to the water flow direction arrow of each
accessory.

9. All openings that have not yet been closed at the end of installation of the HC should be plugged with
plastic/nylon caps to prevent entry by animals and dirt.

10.Gravel filters should be set and installed without gravel. The filters should be filled with gravel only after
completing installation of the entire HC, its connection to the main line, performance of visual inspection
of level, straight and neat installation of the HC, and water pressure testing.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 37


VALVE ASSEMBLY INSTALLATION CREWS (continued)
11.It is recommended to first install the major heavy components and leave all small delicate work (small
vales, air valves, Fertigation piping, pressure gauges and automation system) to be done later, closer to
the time of the final delivery of the system to the customer. In any case, special care should be taken to
protect the HC equipment against theft and damage (locking the HC room is the best solution).

12.After completing wiring of the cables and connecting the control tubes in the area of the HC, all the
aforesaid should be attached to the HC piping using clamps or to the walls/floor/service canals of the
structure using collars, in straight lines and in a manner that prevents potential damage to the pipes and
cables by irrigation operators working in the area of the HC.

It is recommended that all tubes/small pipes and cables that are not inside planned service canal or
sleeves, be inserted into a PVC or annular protective tube/sleeve.

13.Paint repairs should be performed in all locations in which paint appears to be peeling in the prepared
manifolds. All pipes that have been cut, welded and connected in place should be painted in 2-3 coats
(primer + topcoat) after cleaning the surface with a steel brush. The topcoat should have the same color
as that of the prepared manifolds.

14.Make sure that large "Netafim" stickers are applied on the filters or other large surfaces of the HC.

38 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


DRIPPERLINE DEPLOYMENT CREWS
General
The dripperline deployment crew should be comprised of a crew chief and several workers and equipment/
tools according to the dripper-line deployment method.

The crew's job is to deploy the dripperlines or sprinkler/sprayer lines near the row of trees or on the
planting beds in accordance with instructions from the farm foreman regarding the location of the work
and the required pace of the work.

There are three principal methods for deploying dripperlines:

1. Mechanical deployment using a tractor + drums or dripper rolls that have been installed on dedicated
deployment equipment drawn by a tractor.

This method is suitable for large projects and primarily for field crops. It requires compatibility between
the deployment equipment and the drums.

Fig. 20: Mechanical deployment with a tractor

2. Deployment with a manual layout device + small drums/rolls

In this case, the layout device + drum/dripper roll are placed


at the deployment starting point and a worker pulls the
dripperline along the row/planting bed.

This method is suitable for medium-sized projects.

Fig. 21: Deployment with a manual layout device

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 39


DRIPPERLINE DEPLOYMENT CREWS (continued)
3. Deployment of dripperlines by manually pulling
without any device

This method is suitable for small projects and for thick-walled


equipment.

Fig. 22: Manual deployment


Mechanical deployment
1. This crew will include:
 A skilled tractor operator
 One worker for deploying with a single drum and two workers for deploying with 3 drums.

2. Tools and equipment:


 Large tractor with suitable hydraulic accessories appropriate for carrying dripper-line drums.
 Dedicated tools for deploying the dripperlines.
 Pruning shears and a sack of dripper-line couplers for each worker.
 Water jug.

3. Required speed of operation:


 For a layout machine with 3 drums – approximately 15 ha per day (suitable for field crops only).
 For a layout machine with a single drum –
 Approximately 8 ha per day (field crops).
 Approximately 6 ha per day (orchards).

4. Work guidelines

 When working with small drums, several reserve drums should be placed behind the tractor to enable
replacement without returning to the starting point.

 The worker (or 2 workers) should sit on the back of the layout machine facing backward (away from
the direction of travel) and verify that the deployment is continuous, without any malfunctions in the
dripperlines.

As necessary, the driver will be told to stop to replace a drum and connect the dripperlines at the coupler.

 Before beginning travel in the row/planting bed, tie the free ends of the dripperlines to stakes that
have been prepared near the row/bed.

 The roll should be placed so that the drippers in the line face upward.

 When stopping the tractor, the worker should verify braking of the rotating drum, to avoid release of
the dripperline when no movement is taking place.

5. Deployment in an existing mature orchard

In this case, the tractor cannot get close to the row of trees, so the dripperline must be deployed in the
middle, between two rows of trees.

40 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


DRIPPERLINE DEPLOYMENT CREWS (continued)
The dripperlines can be brought closer to the row of trees with the use of a protective tube or by
directing the dripperlines with cylinders so that the pipe exits the layout machine at a short distance
from the row of trees (about 1 m).

The option of directing it to a distance from a point where the dripperline exits the central axis of the
tractor should be planned ahead, so that the layout machine is adapted to the given conditions.

Use of a manual layout device


1. This crew should include:
 A crew chief who stands next to the layout device and operates it.
 2 workers who gradually pull the dripperlines while walking.

2. Tools and equipment:


 Manual layout device adapted to the size of the dripper-line rolls.
 Pruning shears and a sack of dripper-line couplers for each worker.
 Water jug.

3. Required speed of operation:


Field crops 3-4 ha per work day
6-8 ha per day – in dense planting
Orchards
8-12 ha per day – in wide planting

4. Work guidelines

 The crew chief should make sure the layout device is placed opposite the row of field crops/planting
bed and the dripper roll is placed correctly on the layout device.

 If the dripperline rolls are tied or wrapped, free them from the tape or nylon only after they are
placed on the layout device.

 The first worker should take the free end of the dripperline and pull it to the end of the row or bed.
 In an orchard, pull the dripperline beyond the last tree to a distance equal to about one-half of the
space between the trees.
 In field crops, pull the dripperline another 1-2 m.
After reaching the end of the row, the worker should place the dripperline on the ground and return to
the layout device.

 If the worker feels resistance while pulling the dripperline, this indicates that the dripperline in the
layout device has run out and the crew chief must replace the roll. Wait until receiving a sign agreed
upon in advance (such as three quick tugs) and then continue to pull the dripperline until the end of
the row of field crops.

 When pulling of the dripperline has stopped, this indicates that the worker has reached the end of the
row. The crew chief should cut the dripperline, making sure to leave the above-mentioned desired
surplus and the layout device should move on to the next row with the dripperline remaining on it.

 At this stage, the second worker should begin to pull the dripperline in a similar manner, while the
first worker makes his way back to the layout device.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 41


DRIPPERLINE DEPLOYMENT CREWS (continued)

Manual deployment of dripperlines without a layout device


 This method is very similar to manual deployment with a layout device but here, no layout device is
used and the crew chief is responsible for release of the dripperline from the roll (from the interior part
of the roll), to avoid complications and knots in the dripperline. If a small drum is used rather than a
roll, the dripperline should, of course, be released from the exterior circumference of the drum, which
requires the use of a suitable device or pipe to drill a hole in the center of the drum for the purpose of
rotating it while deploying the dripperline.

 In the case of a dripper-line roll (not drums), the roll itself will not rotate during deployment; instead, it
will be placed on the ground. In this situation, the worker must pull the dripperline to rotate it each time
in a spiral movement compatible with the direction of rotation of the dripperline in the roll, to straighten
twists that are created in the dripperline during deployment.

 Crew, tools and equipment – as noted in subsections 1 and 2, page 41, other than the layout device.

 Required speed of operation:


Field crops Approx. 2-5 ha per day
Approx. 4-6 ha per day – in dense planting
Orchards
Approx. 6-8 ha per day – in wide planting

42 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


INSTALLATION OF ELECTRICITY AND CONTROL
General
When the foreman and crew reach the farm, verify that the farm manager takes measures to prepare the
necessary infrastructure for the supply of electricity (electrical lines, transformers, connections from the
transformer to the pump room). The electrical work at the farm should begin when the construction of the
head controls in that same farm has been completed and after the following conditions have been met:

1. A concrete floor for the structure is present and there is a building finished or in the process of construction
(for purposes of protecting the electrical boards and attaching electrical conduit to the walls). Verify the
insertion of sleeves for electrical/communications cables in the floor and walls as necessary.

As a rule, sleeves for electrical cables for pump motors should be Ø 4" (introduced in floor castings)
from the wall closest to the motors.

2. A price quotation has been obtained for performance of all the work in as complete a manner as
necessary (if the work will be performed by an outside contractor).

3. There is an agreement with the customer regarding how and where the electrical conduit, computer,
fertilizer tanks and fertilizer unit will be placed (for purposes of connecting fertilizer meters with
electrical output, a booster for Venturi pumps and electrical valves). The layout of devices and systems
and the cable alignment must appear in the control and electrical drawings.

4. There are points of connection from the farm's internal electrical grid.

5. The price quotation for the electrical work must be detailed and differentiate between work that is
performed under Netafim's responsibility and work that is the responsibility of the customer (even if all
the work will be performed by our contractor).

As a rule, unless expressly indicated otherwise, in projects in which Netafim supplies the electrical
boards, the customer is responsible for the following electrical work:
a. Installation of high voltage lines and transformers near the pumping stations.
b. Moving electrical lines into the building itself and their connection with our electrical board.
c. Lighting and power outlets inside the building.
d. Grounding of the electrical board.

Details of electrical work to be performed at the pumping station/head control


1. Provide supports for the electrical board (based on the board dimensions) while casting the concrete
floor of the building or, at the very least, introduce a plate for welding the supports later on (if a room
with walls will not be built). The supports should be placed near the pump in accordance with the
drawings. The supports should also be placed as close as possible to a planned wall of the building if
the intention is to build a room in the future.

2. Insert cables for a submerged pump inside a flexible protective tube to the building and to the electrical
board.

When installing cables for a pump (vertical/horizontal) located inside the building the cables must be
contained and protected:
 A suitable sleeve (annular pipe) reaching from the pump location to the nearest wall
should be prepared in the concrete casting of the floor.
 A protective tube (plastic or metal) or a metal duct/dedicated support (if there is an electrical plan for
the room in accordance with the drawing) should be prepared on the wall/s, from the floor pipe outlet
to the electrical board.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 43


INSTALLATION OF ELECTRICITY AND CONTROL (continued)
3. Insert control floats and/or electrodes – as above. In pits with level control electrodes, the cable with
the electrode itself + additional cable/strand (1.5 mm²) should reach the board. All Floats or electrodes
must connected to the pump pressure piping.

4. It is highly recommended that a 380-400 W power feeder cable from the grid (for which the customer
is responsible) be inserted above the wall of the building and from there, in a metal conduit, into the
board. If not possible (when the distance between the electric pole and the building exceeds what the
standard allows), insert the electrical line into a PE conduit in the ground (marked well with a layer of
sand above it and a colored marking strip).

NOTE
It is essential to make sure that an electrical and communications line diagram has been prepared.

5. Connect the electrical board to a grounding cable, which should be connected to copper electrodes in
the ground (for which the customer is responsible). The dimensions and depth of burial of the
electrodes should be in accordance with the electrical engineer's instructions. Alternatively, the board
can be connected to the building's reinforcement based on an electrician's approval and drawing.

6. Install a lightning arrester next to the building (in lightning-prone areas only) but not too close to the
electric pole that feeds the electrical board (for which the customer is responsible). The lightning
arrester should be comprised of a wood pole with a metal rod on the top and a cable connecting its
lower part into the ground at the required depth. (Note: in the case of a water-saturated area, use a
concrete pole.)

7. Provide lighting and power points in the building based on its size and the extent of natural lighting
(this is the customer's responsibility).

As a rule, 2 lighting points and 2 power outlets are sufficient. Semiautomatic breakers for power outlets
should be at least 25 A – for purposes of performing welding in the building.

Connection of sensors and 24 V controls from the electrical board


The following are common and acceptable types of connections. Reference should be made to those that
exist in the current project only.

1. Pressostat connection:
To be provided using a 2-strand cable to the pressostat from a control terminal.
The pressostat relay operates when there is no contact (pump idle).
2. Connection from the pump body:
One 4-strand cable or two 2-strand cables (1.5 mm²) should be connected between the electrical board
and the pump valve in accordance with the following detail:

 A control terminal to be connected to the valve solenoid and provide a 24 V AC feed,


for purposes of opening the valve.

 A control terminal to be connected to the flow switch of the valve (micro switch) so that contact from
the switch will be broken in a condition of lack of flow/malfunction (indicator down).

44 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


INSTALLATION OF ELECTRICITY AND CONTROL (continued)
3. Connection to a level indicator float:
To be provided with a 2-strand cable to be connected with the float cable, or by direct connection of
the float cable itself to the board if the distance at which the float is installed is less than 10 m from the
board. The strand pair should be connected to a control terminal. The type of float control depends on
whether the float is NO or NC (see the electrical board drawing).

 Minimum float – usually NO, i.e., contact is broken when water is lacking.

 Maximum float – usually NC, i.e., contact is broken when the water reaches the maximum level.

4. Connection to a flow sensor: (Micro switch to back-check valve)

To be provided with a 2-strand cable that will be connected to a micro switch on one side and to a
control terminal on the other (in the board).

The switch will usually be NO, i.e., breaks contact in a condition of lack of flow or malfunction.

5. Computer:

A 4-strand cable (1.5 mm²) to be connected between the electrical board and the computer in
accordance with the following detail:
 A control terminal controls remote operation of the pump (start up, shut down).
 Another control terminal feeds power to the computer (24 V) for its operation.

Note the importance of direction. The first control terminal should be connected to the + phase and the
other to neutral (common).

 If the station has more than one pump, provide a 2-strand cable from the computer to the electrical
board for each pump at the station, to control each one separately (this may be provided using a multi-
strand cable according to the number of pumps + a 2-strand cable for feeding power to the computer).

 In many cases, to avoid complications in the electrical board, power feed to the computer should
be provided from a 220 V outlet near the wall of the building. In such case, provide a suitable power
transformer/supplier (usually included in the computer).

Sensor, output connections – Transmissions from the computer


In addition to the electrical connections between the computer and the electrical board, strand
connections should be made (-0.8 1.5 mm²) from the computer to the following points:

1. Hydrometer/water meter
A 2-strand cable to be connected between the computer and the water meter for purposes of reading
water-meter output.

The cable should be installed in one of two manners: Inserted into a plastic or metal protective conduit
and placed next to the assembly under it, parallel to it attached to the interior wall of the building with
a port to the water meter at a height greater than 2.0, or in a planned duct/sleeve in the floor of the
building.

2. Fertilizer controller/fertilizer meter


A 2-strand cable to be connected between the computer and the fertilizer meter for purposes of reading
fertilizer-meter output. The guidelines for alignment are identical to those for the water meter.

If the fertilizer meter is near the water meter (in most cases), 2 cables should be inserted into the same
protective tube or a multi-strand cable should be used.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 45


INSTALLATION OF ELECTRICITY AND CONTROL (continued)
3. Thermostats
Thermostats (if present) should be installed in the exterior wall of the building precisely over the
computer location and connected to it with a 2-strand cable that penetrates the wall of the building and
enters an annular plastic or metal conduit.

4. Venturi booster
If computer control is provided for a Venturi pump booster, the booster should be connected to the
computer using a 2-strand cable (with the option of working with a multi-strand cable reaching the
"fertilizing" area).

5. Electrical fertilizer valves


To be controlled by the computer with a cable – the number of strands will be 2 times the number of
valves. The alignment and protective tube should be based on the guidelines in subsection 1 above.

Electrical connections at a head control without a pump


A standard head control provided with a computer only (and not including a pump or electrical board)
should include all sensor and output/transmission connections as described in the Sensor, output
connections – Transmissions from the computer chapter, page 45. All the electrical connections from the
grid (220 V) to the computer will be provided by the customer, in accordance with the following detail:

1. Overhead 220 V power line to be connected between the electric pole and a point at the top of the
building wall. A main breaker to this line should be installed in the wall of the building – inside the
building.

2. A 220 V line should be placed in a conduit attached to the wall of the building (at a height of at least
1.9 m) from a junction box located next to the switch to a 220 V supply for lighting + work outlet.
The semiautomatic breaker or fuse of the line should be 25 A, in order to enable welding works as
necessary.

3. A pair of strands should lead from a 220 V line in the building to the computer transformer (24 V/220 V),
which will be installed high on the wall from which a pair of 24 V strands descend to the computer
power feed. The transformer should be placed precisely above the computer or the computer's planned
position.

If the computer's power supply includes a transformer – the connection may be made directly from the
computer to a power outlet in the wall of the building.

4. Grounding and lightning protection for the computer should be connected properly using a strand or
cable attached along the support conduit of the computer or the wall; it should leave the building
through a protective conduit to the outside of the building and connect with a suitable electrode.

5. The lightning arrester pole for the building (if required) should be installed as stated in subsection 6,
page 44.

 The use of a DC computer eliminates the need for a grid feed. In this case, ignore subsections
1, 2 and 3 above regarding the computer.

46 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


INSTALLATION OF ELECTRICITY AND CONTROL (continued)

General:
1. A pair of strands should lead to each point or area in the building that constitutes an "active zone" for
control purposes, such as hydrometer or fertilizing unit.

2. It is recommended that the control and communications cables pass through a metal conduit to shield
them from interference and electromagnetic noise during lightning storms – when they are in lightning-
prone locations as mentioned above.

3. The communications cable between computers should be a special shielded cable, protected by a
sleeve or special coating in accordance with the guidelines of the project automation supplier.

4. Each cable/tube must be attached to the assembly, building, pole, etc. with clamps – the space
between the clamps should enable fastening of the cables/tubes to the conductor.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 47


SDI - SUB SURFACE IRRIGATION
INSTALLATION CREW
General
Subsurface burial of dripperlines is an activity that must be performed professionally with maximum
attention to detail. In contrast with deployment of dripperlines on the ground surface or other work, in the
case of subsurface burial there is no going back, and even partially inferior burial cannot be corrected.

1. Preliminary guidelines
Do not begin the burial works without preliminary guidelines or agreements with the designer and/or
the agronomist accompanying the project with respect to:
 Burial method (tools).
 Depth of burial.
 Location of dripperlines relative to the planting rows.
 Method of "tracing your steps" or identification of dripperlines.
 Location of various outlets in the sub-mains and collector pipes (flushing valves, vacuum valves, etc.)

2. Crew, tools and accessories


The crew should include: crew chief, experienced tractor driver and additional worker.

Tools and equipment:

For 2-3 lines without furrowers


 100-120 hp 4-wheel-drive tractor  pruning shears  hoe  short measuring tape (3 m)  water jug

For 3 lines with furrowers


 180 hp 4-wheel-drive tractor  pruning shears  hoe  short measuring tape (3 m)  water jug

Required accessories:
 Case of couplers for the dripperlines
 Marking flags
 A set of tines for the injection shanks
 Several shearing bolts for replacing the shearing bolts that hold the injection shanks on the
beam/angle – in case of breakage during the work.

3. Required speed of operation:


Travel speed of the contractor should be 5-6 km/h with a total travel length of about 30 km per day.
Accordingly, the rate of burial operations will be about 5-7 ha per day.

4. Types of burial
There are 3 types of burial:
a. Superficial burial – intended primarily for vegetables, to protect the dripper equipment.
Depth of burial: 5-10 cm.
b. Intermediate burial – intended primarily for orchards and sugarcane, to protect the dripper equipment
and for irrigation with effluents.
Depth of burial: 15-20 cm.
c. Deep burial – intended primarily for field crops, to protect dripperlines, eliminating the need for
seasonal deployment and rollup works of the dripper equipment and use of effluents.
Depth of burial. 25-45 cm.

48 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


SDI - SUB SURFACE IRRIGATION INSTALLATION CREW (continued)
5. Exceptions

 Do not bury dripper equipment in drainage-channel areas.

 The burial should be performed only in relatively dry areas and it is highly desirable that it be
performed prior to the rainy season.

 In mature orchards (citrus, olives, etc.), it is important to perform burial after trimming the trees.

 In banana plantations, the dripperlines should be buried before installing the growth support cabling
system.

Preparation of the area prior to burial


1. General
It is highly recommended that sub-soiling be performed 3-4 times along the sub-main and collector
piping alignment, to facilitate quick penetration of the injection shank of the dripper into the ground (in
the intermediate and deep burial methods).

2. Superficial burial
Planting beds should be prepared normally as in surface irrigation.
It is very important to obtain a uniform and level substrate (as in preparing a substrate for seeds).

3. Intermediate burial
Intended for orchards – in this case, there is no need for special surface preparations.

4. Deep burial
Preparation of the ground surface includes:
a. Warp and weave sub-soiling to a depth of 60 cm.
b. Plowing to a depth of 30-35 cm (for problematic or compacted soils).
c. Disc with a leveling box.
d. Standard marking of planting beds.
e. Sub-soiling in the dripper-line alignment to a penetration depth of 50 cm with two furrowers to turn
over the bed.

Technical guidelines prior to burial


1. Verify compatibility of the dripperline drums with the burying machine.

 Netafim (small) dripper drums are compatible with the original Netafim burying machine.

 For Netafim equipment provided on rolls (and not drums), it is necessary to provide a special drum
that is compatible with the drippers and the burying machine.

 Thick-walled dripper equipment (such as UniRam) in large drums (2.0-2.25 m) must be deployed on
planting beds in the field with the dripperline injected into the ground afterward through a main line
pipe or special protective tube above the tractor.

2. Verify that there are a sufficient number of dripperlines to complete a full burial procedure.

 In a burying machine that works with small drums, there is space for 3 drums on the device, which is
usually sufficient.

 In dripperlines that are supplied in rolls (for example, Ram), provide several additional rolls on the
burying machine for continued work when the entire line of dripperline has been deployed.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 49


SDI - SUB SURFACE IRRIGATION INSTALLATION CREW (continued)
3. When burying dripperlines in dense planting (approximately every 1 m) between dripperlines in a
1.8-2.0 m planting bed, make sure that furrowers are present beyond the burial shanks for turning over
the bed.

4. In field crops, it is important that the burying machine be compatible with the working tools (sixths or
ninths), to maintain the structure of the beds and prevent the beds from "breaking out."

5. It is recommended that the burial be performed alternately, i.e., burial of every other planting bed and,
only after completing the burial of a particular block, return to the burial area for the dripperlines that
were skipped.

This recommendation is intended to maintain the structure of the planting beds and the precision of the
work.

6. It is highly recommended that the tractor be stabilized on both sides of the burying machine and that
they be stabilized and balanced. The burying machine must be parallel with the ground during the entire
burial process.

7. The dripper drums on the burying machine drums should be placed so that the marking of the arrows on
the dripper drums indicates the opposite direction to that of travel when the arrow is located at the
upper part of the drum. In other words, the dripperline will come from the drum on the top. This will
create a situation where the drippers in the ground always face upward.

8. The nylon wrapping of the drums should be removed only after they have been assembled on the
device, to maintain the stability of the walls of the dripper drum until it is set on the device drum.

9. The brakes of the burying machine should be placed in a direction that allows the drums to rotate freely,
but not so freely that the drums continue to rotate when the tractor stops.

10.Verify that the "deep" wheels of the burying machine are adjusted to the required burial depth before
and during the work.

Burial guidelines
1. The starting line for the burial of the dripperlines should be several meters before the sub-main/collector
alignment and the burial end line should be several meters past the sub-main/collector.

This guideline is intended to allow the placement of the subsurface dripperlines at the required burial
depth in the above-mentioned piping alignment.
2. At the start of the burial process (at the end of the field or block), the tractor driver should begin travel
while an accompanying worker holds the dripperline in his hands. After the tractor has traveled about
3-4 m, the worker should climb on the tractor and sit in the back. The worker must control the burial
process and handle problems that arise (such as running out of dripperline on the drum).

3. It is recommended to check regularly for scraps or stone fragments protruding from the end of the
injection pipe. Such scraps can cause grooving of the subsurface dripper pipe for its entire length.

4. Running out of dripperline on the drum during burial

Such a case should be handled as follows:


a. The worker sitting in the back of the tractor notices that the dripperline is about to run out and signals
the driver to slowly decelerate.
b. The worker makes sure that the end of the dripperline that has been buried is beyond the roller (the
pair of EcoLon wheels that drive the turning of the dripperline during the burial process) and then

50 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


SDI - SUB SURFACE IRRIGATION INSTALLATION CREW (continued)
notifies the driver to stop the tractor. The buried dripper pipe and the new dripper pipe should be
connected (in the gap between the roller and the opening for the dripper injection pipe) with a coupler.
c. After installing the coupler, the driver should begin to travel slowly and carefully for several meters
until the coupler leaves the injection pipe. Then the driver should resume normal travel speed.
It is highly desirable to guide the coupler manually when it enters the injection pipe.

5. Lifting of the injection shank and/or breaking the shearing bolts of the shank

In this case, the location should be marked with a marking flag. At this time, verify the arrival of a
backhoe and/or workers to identify the problematic area and treat it (removal of a large stone or hard
block of soil, etc.).

The tractor driver must raise the burying machine completely above the ground and the worker must
replace the shearing bolt if it has been broken. The work should then continue, as from the beginning of
the burial process.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 51


FLUSHING THE IRRIGATION SYSTEM
FOLLOWING INSTALLATION
General
Action:
Flushing  Head control  Main piping  Sub-mains  Delivery devices

Purposes of flushing:
To remove contaminating agents that have entered the system during installation.

The effect of dirt removal is obtained only after sufficient water flow velocities have been reached in all the
systems.

In order to reach these velocities, the designer will prepare a detailed flushing program for the entire
project. This program will include allocation of the main piping for "flushing operations" (similar to the
irrigation activities table). In the table, flushing valves will be specified that must be open for flushing in
each such operation. For this purpose, all the flushing valves in the program must be marked with an
alphanumeric code.

Preconditions for executing system flushing:


 An available source of water that provides the required flow rate and quantity of flushing water.

 A pumping station, head controls and main lines that have been assembled and are ready for flushing.

 Concrete blocks for anchoring PVC piping that have been prepared properly and undergone the required
curing period from the time of casting to the time of flushing (usually about one week).

Personnel and tools


The system flushing crew should include the farm foreman + several workers, depending on the size
of the project; in principle, 2 workers for each block that is intended to be flushed simultaneously in the
flushing program.

Tools and accessories required for the crew:


 Pruning shears or cutting knife for each crew member
 A sack with couplers for the dripperlines
 A sack with end caps for each worker
 A water jug.

Preparation for flushing – General


1. Check for water availability – available hourly flow rate, total quantity (in the case of a tank or reservoir).

2. Preparation of the crew, vehicles and communication devices.

Inspection of the pumping system:


3. If pumping is performed with a horizontal pump and there is a back-check valve at the bottom of the
suction pipe, check the functioning of the valve (if possible) before filling the reservoir, by filling the
suction pipe with water and testing that it is completely sealed.

4. Close valves that are open on the pressure side of the pump.

5. Verify that a pressure-release valve has been installed in the proper location and that water-discharge
piping has been installed at the correct point together with air-release valves.

52 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


FLUSHING THE IRRIGATION SYSTEM FOLLOWING INSTALLATION (continued)

Testing of pump operation:


6. Start the pumps in order (if there are several pumps, each must be tested in turn).

7. Technical testing of the pumps: pressure + pressure release, electrical current, noise, vibrations and
direction of rotation.

8. Change the order of connections in the electrical board if the direction of rotation of the pump is reversed.

Flushing of the head control


1. Test the serviceability of the filtration system installation (gravel, washers, mesh or any other item).
In principle, pay attention to proper closure of the filter covers and fertilizer tanks (pressure).

2. Test all accessory devices, air release valves, pressure breakers, pressure-release valves. Inspect all
connections and the tightness of bolts to prevent leaks. Perform a further inspection to verify that the
system devices are installed in the correct flow direction.

Verify the closing of various valves and plugs in the head.

3. If the option exists, flush the system in front of the filtration bank using flushing valves or by opening
plugs at the end of nipples together with the work of the pressure release valve.

4. If flushing cannot be performed in front of the filtration system but there is a valve/drainage opening
downstream of the filtration system, verify that the valve leads to a closed area. Start the pump and test
the serviceability of the pressure release valves (adjusting as necessary). Gradually open the flushing
valve downstream of the filters (until clean water is discharged), close the flushing valve and shutting
down the pump.

Flushing of the main lines


This flushing operation should be performed only in accordance with the flushing program provided by the
designer, including all stages. Each step of the installation (main line, sub-main, dripperlines) should be
flushed proir to the connection of the next step an its accessories to it. This is to avoid sawdust, shavings
and dirt from the assembly works contaminating them.

Preparations for flushing the main line


1. The flushing times for each operation should be computed as follows:
Length of the main line (in meters) from the source of water to the furthest active flushing valve, divided by an
average flow velocity of 2.75 m/s and multiplied by a factor of 5. The flushing time is expressed in seconds.

2. Briefing and detailed explanation for the crews participating in the flushing process. Verify that there
are sufficient personnel, vehicles and communication devices between the crews and the manager of
the flushing process at the pumping station (or head control).

3. Inspect pipe coverage all along the main line (partial coverage, i.e., the piling of soil on each pipe is
sufficient for purposes of flushing). If necessary, make adjustments where required.

4. Verify the presence of concrete works in the locations necessary in the required layout and size.

5. Verify that all valves that connect with the sub-mains (other than those that may be required for
purposes of flushing the main line) are closed.

6. Verify the opening and closing of flushing valves on the main line prior to Operation 1 of the flushing
program.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 53


FLUSHING THE IRRIGATION SYSTEM FOLLOWING INSTALLATION (continued)
7. Direct the flushing valve openings to the drainage channel or off-site, if possible.

8. Close the service valves of air valves to prevent dirt from entering them.

9. Deploy the flushing crew in the required locations and return to the head control.

Guidelines for flushing the main line


10.Start the pump opposite the closed main valve (the valve that supplies water to the field).

11. Open the main gate valve very gradually.

12.Open communications with field personnel to obtain an indication of completion of flushing at that stage
(clean water discharge from the flushing valves within the time defined in subsection 1, under
Preparations for flushing the main line, page 53) or malfunctions (bursts, low flushing flowrates, etc.).

13.If everything is serviceable at the stage that has been completed, continue to the next flushing stage
and correct any malfunctions. Re-flush after the repair.

Repeat the instructions in subsections 10, 11, 12 and 13 above upon completion of the main line
flushing process.

After completing each flushing stage (closing of the valves) and before continuing onto the next stage
(opening the following valves), check the water meter to detect flow and indications of a burst.

14. While performing the flushing, check for a drop in pressure on the filtration bank and manually flush if
necessary.

Verify that clean water is being discharged (without mud or foam from the pipe lubricating paste) from
the flushing openings for several minutes. Only after that will it be possible to continue to additional
sections. (It is recommended that the time required for flushing each stage or "operation" be calculated
and executed accordingly.)

Testing the pressure of the main line


Before continuing on to the flushing of the sub-mains and water delivery devices, test the main line
system in the following order:

1. Physically inspect all the main piping to verify that all the flushing valves are closed and that all the
sub-main valves are closed. If there are separation valves on the main line, open them.
2. Neutralize any lack-of-flow protections in the electrical board by adjusting the appropriate timer or bridge
in the electrical board (by an electrician – for testing purposes only). If a pressure-release valve circulates
water downstream of the lack-of-flow protection (back-check valve + micro switch), there is no need to
neutralize the safeguards.

3. Start the pump at the station, reach the required testing pressure in accordance with the project page
and adjust the pressure release valve.

4. Check for flow in the water meter. If there is a flow, wait until the main lines fill completely. If there is
still a flow after a certain amount of time, physically inspect the field to verify that all the valves on the
main line are completely closed or, if there is a leak or burst, locate and repair it.

5. Once the water meter shows no further flow in the system, hermetically close the main valve
downstream of the head.

54 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


FLUSHING THE IRRIGATION SYSTEM FOLLOWING INSTALLATION (continued)
6. Shut off the pump (to create confined pressure in the main line).

7. Test the drop in pressure as a function of time (15 minutes). If the pressure drop in the meter
is 20% lower than the pressure at the start of the test, the system is serviceable.

8. In the case of a rapid pressure drop – locate the source of the malfunction and correct it.

9. Following the repair, repeat the process described in subsections 3, 4, 5, 6, 7 and 8 above.

10.If it becomes apparent during testing that there is leakage in the main piping, sections of the system
can be separated by the separation valves (if present) to quickly identify the location of the assumed leak.

Guidelines for flushing the sub-mains


Before connecting the dripperlines to risers, it is mandatory to flush the sub-main lines.

1. Verify that all sub-main plugs or end valves throughout the project are open.

2. Brief the crew about the flushing process in accordance with the sub-main/dripper-line flushing program.
If guidelines have not been provided regarding the flushing times for each sub-main, flush each sub-
main for at least 5 minutes. (In any case, verify that the flushing time allows discharge of clean water for
several minutes.)

3. Deploy the crew in the field at all sub-main plug or end valve locations throughout the project.

4. Start flushing in accordance with the formal flushing program, opening and closing the sub-main valves
as necessary. During flushing, bypass the hydraulic pilot in the pilot valves (by adjusting the 3-way valve
for drainage to the atmosphere or by disconnecting the tube), to obtain better pressure for flushing (but
no more than 5 atm).

5. If there are 2 line ends (or more) in the sub-main, verify that the flow of water at each line end is strong.
Under conditions of steep topography and relatively low pressure for flushing, a condition may occur
where the high end of the sub-main will not efficiently flush. In such case, close the line end that has
been flushed well and after several minutes allow all the water to discharge from the second line end for
several minutes more.

6. After flushing the entire field, close the flushing valves or plugs at the ends of the sub-mains. If there
are malfunctions at the outlets to the dripperlines or in the sub-main piping, correct them and repeat
flushing after the repair and, in the end, shut off the pump.

7. It is recommended that the identical flushing process described in subsections 2, 3 and 4 above (after
completing flushing of the sub-mains) be performed with the ends of all the sub-mains closed and the
water flushing the PE outlets only.

Guidelines for flushing the dripperlines


1. After completing the flushing of the sub-mains, the dripperlines should be connected to the outlets on
the sub-mains. This activity requires a large number of crew members.

2. Inspect and verify that the ends of all the dripperlines are fully open and enable efficient flushing.

3. Flushing crew members should be stationed at the ends of the dripperlines (1-2 crew members per
flushed block); the foreman is responsible for opening and closing the valves. After opening, he should
travel in his vehicle to the flushing areas and instruct crew members as to when and where to begin to
close the ends.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 55


FLUSHING THE IRRIGATION SYSTEM FOLLOWING INSTALLATION (continued)
4. Flushing crew members stationed at the ends of the dripperlines should measure the time that passes
from the moment water is flowing from all the dripperline ends without air bubbles at a uniform rate.
Several minutes after that point in time, begin to close the ends of the dripperlines in all the flushed
blocks at the same stage, from the point on the dripperlines in which the flow is strongest toward the
point on the dripperlines with the weakest flow.
The number minutes dedicated to this flushing operation will be determined by the farm foreman, in
accordance with the following criteria:
Length of dripperline Flushing time
Up to 100 m 5 min.
100 - 200 m 10 min.
200 - 300 m 15 min.

5. If the flushing crew identifies a dripperline from which no water is flowing or from which the rate is
relatively low at the water-flushing stage – one of the crew members (stationed at the same block)
should walk along that dripperline with a sack of couplers. After identifying the source of the problem
(leak, cut dripperline or unserviceable discharge of water from the sub-main), the problem should be
corrected and the worker should return to the area at the end of the dripperlines. Allow the repaired
dripperlines sufficient time to flush, as explained in subsection 4 above.
6. A situation may occur in certain blocks where the dripperlines that are closed first will not flush properly
(in most cases, because the flushing pressure is insufficient at the valve and/or the dripperlines are too
long and/or are ascending uphill).
In such a case, the farm foreman is responsible for deciding whether or not to flush the dripperlines in
those same blocks in groups, one after the other, where the flushing time for each group will be based
on the aforesaid in subsection 4 above. Each block should be divided into at least 3-4 groups with an
equal number of dripperlines in each group.
For example: In a block with 40 dripperlines – flush 10 dripperlines each time.
7. The dripperlines should be flushed by opening the valves in the parcels – one valve after the other or
one group of valves after the other, in accordance with the dripperlines/sub-main flushing program.

After completing the flushing of each stage, continue on to the next stage until the entire area has been
flushed.
8. The process of flushing the irrigation system following installation is extremely important and its
effectiveness has a significant impact on later system performance. Therefore, cutting corners in this
process is prohibited.
On average, proper flushing a system in the project can easily take one full day, and sometimes even longer.
9. In certain cases, the dripperlines cannot be deployed at the end of the installation for various reasons
(season of the year, purchase dates of the dripperlines, etc.) In such cases, perform the process up
through the stage of dripper-line flushing. Then close the ends of the outlets to the dripperlines with line
ends and wait until the time when the dripperlines are connected.
The issue of responsibility and the manner of flushing the dripperlines when they are connected must
be finalized between the customer and Netafim's representative in the area and this agreement must
put into writing (with a copy to the customer, to Netafim and to the regional Netafim representative).

56 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


TESTING THE IRRIGATION SYSTEM
(COMMISSIONING)
General
Action:
 Testing system performance  Adjustment of pressures  Identification of problems and their solution

Timing:
The commissioning stage follows completion of flushing of the entire system, repair of malfunctions,
reflushing and closing all the line ends and dripper-line ends.

Purpose:
To stabilize the system in optimal working condition and as close as possible to the original plan in terms
of flow rates, pressures and uniformity of water distribution. When the commissioning is complete, the
system must conform to the requirements of the project checklist or performance test for delivery to the
customer.

Crew:
The crew should include the farm foreman, the farm water specialist or supervisor (customer's
representative) + 2-4 workers, depending on the size of the project.

Required tools:
 Small adjustable wrench for adjusting hydraulic pilots  Form for recording system performance
 Map of the area  Checklist
 Pad of paper for recording notes  Pressure gauge + needle or adapters.

Testing the performance of the water distribution system


1. Implement the irrigation plan in accordance with the attached activity table.

2. Open Operation 1 taps in the field.

3. Operate the pump(s) as necessary.

4. Wait for the lines to fill and for pressures to stabilize.

5. Test flowrates with a water gauge and compare with the design map.

6. Adjust pressures at the main valves (at the head control or along the main line), as indicated in the plan.

7. Go out into the field and adjust pressures at the pilot valves in accordance with plan data.
Also check and record the pressures upstream of the valve (this is especially important at critical valves
in the project, where the pressure upstream of the valve is close to that required). Obtain a list of such
critical valves from the project designer.

8. Return to the head control and recheck flowrates in the field and the functioning of the system (pump,
filtration, pressures, flow consumption) while Operation No. 1 is in process and all the pressures are
adjusted according the plan. Record flowrates, pressures and operating flow in the dedicated form.

9. Close Operation No. 1 valves and open Operation No. 2 valves.


Repeat the instructions in subsections 1 to 7 above for all the operations recorded in the map.

10.After testing all the operations, prepare a nominal flow rate table (based on measurements) of the
irrigation system (by valve and operation).

At this stage, after testing and recording all the operational flow rates in the system, there may be two
conditions:

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 57


TESTING THE IRRIGATION SYSTEM (COMMISSIONING) (continued)
a. Operational flow rates are compatible with the design and no modifications whatsoever in the size of
the blocks are known – in this condition, recording of the operational flow rates only is sufficient.

b. The operational flow rates (or the rates for some of the operations) are incompatible with the design
and/or there are known changes in the size of some of the blocks in these operations.

In this condition, flow rate testing must be performed on each valve separately.

This testing may require the use of a pressure release valve (upstream of the water meter) and/or
throttling of the main valve at the head control to reduce operating pressure in the main line.

Do not be concerned of short-term flowrates that are much lower than planned (several minutes), even
if there is no pressure-release valve that circulates water through the pump – as long as the operating
pressures in the system are within the allowable limits or even 20% higher than permissible in the PVC
piping.

To avoid problems of low flow rate in the pump, flow rate can also be measured in individual blocks, by
closing a single gate valve and reducing the flow rate below that obtained during normal operations. Do
this for each valve.

11.In the same table, add the results of the pressure measurements downstream of each valve (after the
pilot), as well as pressure upstream of the valve, if tested.

12.If modifications have been made in the field, either in size or dimensions of the blocks or in the layout
and dimensions of piping and valves (deviating from the plan), a revised map of the situation in the field
(as-made) should be prepared and submitted. The easiest way to mark changes on the existing planning
map is to record the number of the dripperlines connected to each block and the lengths of the selected
dripperlines.

13.If there is any discrepancy between the design in the map and actual execution in the field (operational
pressures and flow rates), try to identify the problems by means of the procedure described in the
folowing paragraph.

Procedure for identifying problems in the system


There are usually three possible conditions of deviation from the design (values that vary by more than 5%
from the design):

a. Operating flow rate that is too high – as a result, it is reasonable to assume that the pressures in the
system are lower than required (sometimes in particular blocks only and not in the pumps or in the head
control; this condition may occur when the source of water is capable of supplying excess flow rate
without a drop in pressure below that required at the head control.)

b. Operating flow rate that is too low – usually accompanied by pressures higher than required or planned
at the pump/head control.

c. Operating flow rate and operating pressures that are too low at the pump.

The following are typical problems associated with these conditions and their solutions:

1. High flow rate/low pressure (after completing filling of the lines and stabilization of pressures) –
possible problems and their solutions.

a. More valves are actually opened than required by the operations plan.
 Physically inspect and make sure that only the required valves are open.

58 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


TESTING THE IRRIGATION SYSTEM (COMMISSIONING) (continued)
b. High operating pressures at the blocks with unregulated drip.
 Inspect and adjust pressures at the pilots as necessary.

c. The ends of the dripperlines or even the sub-main line ends are open.
 Inspect along the ends and line ends to verify that they are closed.

d. Bursts/leaks in the main line or open sub-mains.


 Verify the serviceability of the main line by testing the water meter or test pressure in a condition
where the field valves are closed.
 Then inspect the sub-main alignment and look for bursts. As necessary, test flowrates at another
valve to identify the problem more precisely.

e. Leaks and dripperlines disconnected from the blocks.


 Physically inspect the dripperlines and make repairs where necessary.

f. A block or blocks in the given operation are larger than planned


 Verify the dimensions of the blocks or the number of dripperlines that have been deployed in the
various blocks and compare them with the design.
If there is any discrepancy, contact the project manager or project designer to solve the problem.

g. The water-delivery devices are delivering a higher average flow rate than planned.
 This is a potential condition due to the shipment of incorrect flow rate equipment, damaged
equipment or equipment that has been damaged during installation, flushing or commissioning of
the system (such as penetration of sand into the Ram drippers). Contact the project manager or
project designer to solve the problem.

h. Incorrect spacing of the water-delivery devices.


 The spacing between water-delivery devices along the river lines is denser or there are more
dripperlines in the field than planned. Consult with the project manager/project designer.

i. Improperly calibrated water meter


 This is an extremely rare malfunction in new equipment. In a large project, the water meter may be
replaced with another meter stationed in another parcel for purposes of comparison, to verify that
this is indeed the problem.

2. Low flow rate/high pressure (after filling the lines and stabilization of pressures) –
possible problems and their solutions

a. All the operating valves are not open as required.


 Physically inspect and verify that each open/close valve is completely open.
 Physically inspect and verify that each adjustable valve is adjusted as required.

b. Operating pressures are too low in the water-delivery device blocks (all or some of them)
 Inspect and adjust pressure in the different blocks. Verify that the minimum required pressures are
obtained at the furthest/highest dripperlines. (Pressures in the blocks may be increased only if the
pressure in the main line is higher than that in the block.)

c. Low pressure in the main lines due to higher head losses than allowable or blockage in the filtration
system.
 Thoroughly flush the filters to reach the minimum required head losses. Note that at the start of
this stage of the project there are higher-than-normal quantities of dirt, so it is recommended that
frequent flushing be performed based on P ∆, and not on a fixed time between flushing operations.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 59


TESTING THE IRRIGATION SYSTEM (COMMISSIONING) (continued)
d. Blockage/throttling of the main line system.
 Inspect the entire main line from the head onward, measure pressures at each possible point to
identify the location of the problem (throttled main valve, main valve piloted to a pressure that is too
low, contaminants that have been trapped in devices in the grid, etc.).

e. Problems in the outlet area of the dripperlines from the sub-mains.


 Inspect along the outlets of the dripperlines from the sub-mains and identify dripperlines that are
not discharging water or in which the pressure is very low.
Possible problems: saddles without drilled holes or incomplete holes, PE outlets forcibly kinked, dirt
or foreign objects in the outlets.

f. The area irrigated (blocks) is smaller than designed and/or its dimensions are different.
 Verify the size of the blocks and the length of the dripperlines. If there is any incompatibility
between the plan and what is actually occurring in the field, contact the project manager/project
designer with a drawing of the field conditions + dimensions.

g. Topography in the field is different from that indicated on the map.


 Certain areas in the project are higher than in the plan; these areas have low pressures. Attempt to
revise the map topography and forward this revision to the project manager/project designer.

h. Average flowrates of the water delivery devices are lower than required.
 Check flowrates in about 10 devices in the block that has been identified as problematic.
Possible causes:
 Blockages in the water delivery devices
(usually as a result of inefficient flushing or lack of flushing).
 Water-delivery devices have been sent with a nominal flow rate lower than required.
If this is the problem, notify the project manager and forward samples for testing.

i. Spacing of the water-delivery devices is larger than planned.


 Verify the spacing. If the spacing is larger than planned, the irrigation rate and the operating
flow rate will be reduced as a result. Consult with the project manager/project designer.

j. Discrepancy in the main grid installation.


 Piping diameters that are too small were installed erroneously or had to be installed for lack of
choice or the main piping is longer than planned. Advise and consult with the project manager/
project designer.

k. Design error.
 Pipe/device diameters are small relative to the required flow rate.
 Topography was not considered as required.
 The pressure required according to the map at the source of water is too low.
In case of concern about a possible design error, consult with the project designer.

l. Improperly calibrated or partially blocked water meter.


 See subsection i, page 59. In addition, if the water-meter impeller is clogged by dirt,
dismantle the water meter and try to clean it and release it.

60 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


TESTING THE IRRIGATION SYSTEM (COMMISSIONING) (continued)
3. Flow rate is too low and pressure is too low at the water source.

a. Pump problem.
 The existing pump is unsuitable or there is a problem in the pump/power-supply system to the
pump, or in the pump's water-suction system. Test the pump and check flow rate against pressure
at several operating points. Compare actual pump performance with the pump curves and notify
the party responsible for the pump (the customer or the project manager/project designer at
Netafim). The pump-testing procedure is included in the provided documentation.

b. Combination of various problems.


 After s olving a problem in the pump (of the types described in Procedure for identifying problems
in the system, page 58), it may become clear that there are still problems in the system. In such a
case, continue testing as specified in these sections.

Testing the performance of the pump and its accessories


1. Test all the pumps according to the order in the pump-testing procedure and compare the results with
the pump manufacturer's data curve.
Test at several pressures, flow rates and flow consumption operating points.

2. Test the functioning of the back-check valves – open and close them based on flow regimes in the
system.
If the pumps have a foot valve, verify their seal in a "no-pumping" scenario, by testing the water level in
the pumps or piping several hours after completion of pumping.

3. Test the functioning of the pressure-release valves – opening, closing and maintaining pressure required
in the system. Initiate a rise in temperature in the system beyond the planned operating pressure to
test the required point of operation of the pressure-release valve (usually 3-5 m above normal operating
pressure).

Testing of the functioning of filtration banks


1. Filtration system test
a. Test the filtration system by operating several flushing cycles through the controller.
b. Test functioning of the differential pressure gauge (P ∆ = 5 m).

2. In gravel tanks, check the effective flushing time of the gravel and verify that no gravel is escaping
during flushing.
3. Set the default flushing times:
 Tank flushing duration: 90 seconds
 Dwell time (between flushing one filter and another): 8 seconds minimum
 Time between flushing cycles: 90 minutes

4. Enter a revised flushing program into the controller.

5. Assemble the filter-flushing line at the drainage point agreed with the customer to obtain suitable
drainage of the flushed water or recycle it to the tank at a distance from the suction point of the water (if
there are no clear guidelines in the drawing – at least 25 m).

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 61


TESTING THE IRRIGATION SYSTEM (COMMISSIONING) (continued)

Test the functioning of the fertilizing system


1. Test and use of the fertilizing system by filling the fertilizer tank with water and testing actual injection of
each pump.

2. Test actual performance of the hourly flow rate of each fertilizer unit in normal operating conditions
of the system (according to the operational plan). Record the flowrates and verify compliance with the
requirements in the checklist.

3. If a computer is available, operate the fertilizing pumps and readout of the fertilizer output by the
computer.

4. If the fertilizing is being performed by a pressure tank – verify the option of reading pressures before
and after the main pressure valve. Use of a single pressure gauge on a 3-way valve + tube to connect to
the second testing point is recommended.

General testing of the head control


1. Verify the absence of leaks, the functioning of the air release valves, the functioning of the gate valves
and the presence of stability supports for the system in accordance with the attached drawing.

2. Arrange for protection and drainage of the pump house and the head control as necessary.

3. Repairs of paint and finish:


 Zip ties in the necessary places.
 Protective tubes for pipes and cables.
 Affixing of "Netafim" signs.

Testing the functioning of the electrical board and board protections


To be performed with the accompaniment of an electrician

1. Lack of flow protection


Initiate a flow stoppage in the irrigation system. Verify stoppage of the pump by a limit switch installed
on the back-check valve and adjust its timer as necessary. (If there is no adjustment data – the default
will be 30 seconds.) After stopping the pump – press the Reset button and restart the pump.

2. High/low pressure protection


If there is a point-pressure gauge (pressostat) for high or low pressure, initiate shutdown by adjusting
the pressostat button or increase/decrease pressure beyond the design pressure. Verify shutdown of
the pump after suspending the timer. Adjust the delay time in the timer. If there is no data – use 60
seconds as the default.
Verify startup of the pumps after pressing the appropriate Reset button.

3. Water-level protection
If there are water level floats, test their functioning by changing the position of the float manually
and testing performance of the required operation (startup or shutdown of the pumps as required). If
there are timers for the floats – adjust the timers according to the electrical board drawing. If no data
is available for delay times – adjust to 60 seconds as a default. The Reset button usually protects
minimum water levels only – verify that the pumps can be restarted after pressing it.

4. Verify the serviceability of warning bulbs and [their] operation in the electrical board by initiating various
types of malfunctions.

62 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


TESTING THE IRRIGATION SYSTEM (COMMISSIONING) (continued)
5. Verify the transmission of information to and from the control center and the field (if it exists).

6. Adjust timers – again verify that all the timers are adjusted in accordance with the drawing and system
requirements (minutes, seconds).

7. Adjust voltage and current protection ranges (NVR and OL) in coordination with the electrician in the
field and the data in the electrical board.

8. Inspect and make sure that revised electrical drawings are placed in the board pocket.

9. Seal the electrical board with plugs or other sealant, as necessary (to prevent the entry of animals).

10.In hot locations,verify proper ventilation of the pump house (windows), to avoid temperatures higher
than 45°C.

11.If the option for remote operation (computer, float, remote switch, etc.) is available, operate the pump
and shut it off remotely to verify serviceable operation of the remote control.

Automation
Run the irrigation program and test all the required functions (including those that are still not active such
as fertilizing) for: flow rate, fertilizing, flushing of filters, field valves, main valve, pumps and alerts.

Delivery of the work to the customer


1. Inspect all components of the work with the customer and/or its representative to demonstrate and test
performance.
If there is a checklist in the agreement with the customer – perform the inspection with it.

2. If there are any malfunctions or deviations – correct them immediately or determine a timeframe and
means of solving the problems. Problems that cannot be solved immediately should be discussed
jointly by the installer and the customer's representative and, if the problems are complex, with the
participation of the Netafim project manager/project designer.

3. Have the customer sign the irrigation-system approval and acceptance form in two copies – one for the
regional Netafim representative and the second for Netafim.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 63


APPENDIX 1 - PVC PIPE STORAGE & HANDLING
Appendix 2 – PVC Pipe Storage & Handling
Storage
Fittings, Glue & Lubricant

 Where possible, products should be stored inside their original packaging until ready for use.

 Store in cool dry conditions, preferably under cover to avoid damage of any kind, such as soiling,
UV exposure and contamination by oils, petrol or greases.

 Rubber items should be stored in a cool, dry, dark place.

Pipe & Profiles

 Store away from excessive heat.

 Avoid contamination by oils, petrol or greases.

 uPVC sewer and drainage pipe stored for an


extended period (more than 3 months), should
be completely covered with an opaque UV
resistant material.

 The storage area must be flat and level, with no


sharp objects or projections and able to support Max. 1 m
the complete plan area and weight of the
material being stored. Max. 1 m

 Pipe should be stored in a bundled beehive


configuration not exceeding 1m in height Fig. 23: Pipe in a bundled beehive configuration
(see dimensions in Fig. 23).

 Lengths should be evenly supported at spans not exceeding 1m (see dimensions in Fig. 23).

 Socketed pipes should be stacked with sockets at alternate ends protruding, to ensure that the pipes
are evenly supported (see Fig. 23).

Max. 1 m
Max. 1 m

Fig. 24: Pipe stored in a tapered stack Fig. 25: Pipe stored in a cross stack

64 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


APPENDIX 1 - PVC PIPE STORAGE & HANDLING (continued)

 For temporary storage on site, the ground should be level and free of stones or sharp objects that are
likely to damage the pipe.

 Carefully store pipe in tapered stacks (Fig. 24) or cross stacks (Fig. 25) not more than 1 m high

 It is important that each pipe have an even bearing throughout its entire barrel length.

 Pipes of different sizes should be stacked separately. Where this is not possible, larger diameter pipes
should be placed at the bottom.

Handling
 While uPVC pipes and profiles are light and easy to handle, they should not be maltreated.
The protection of the prepared pipe ends is particularly important.

 Pipes or profiles should never be dropped on hard surfaces.

 Dragging pipes or profiles along the ground is not permitted.

 Pipes should be transported by a suitable vehicle that has a flat and level load bed with no sharp objects
or projections and is able to support the complete plan area and weight of the pipe being transported.

 During transport, pipes should be supported along their length by timber battens no less than 75mm
wide, at spans not exceeding 1 m.

 During transport, all loads should be securely anchored with suitable ratchet webbing load straps,
to prevent movement and chaffing of the pipe.

 The loading and unloading of pipe should be under trained and experienced supervision.

 Wide band slings of a non-metallic material should be used when lifting pipe bundles by crane.
Do not use hooks, chains or hawsers.

 Lifting points along pipe lengths or pipe bundles must be evenly spaced.

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 65


APPENDIX 2 – TYPICAL TRENCH CROSS SECTION
Page

Main line, Ø 63-140 mm 67


Type A1 without bedding
Type A2 with bedding

Main line, Ø 160-315 mm 68


Type B1 without bedding
Type B2 with bedding

Main line, Ø 355-400 mm 69


Type C1 without bedding
Type C2 with bedding

Main line, Ø 160-315 mm 70


Type D1 without bedding
Type D2 with bedding

Main line, Ø 355-400 mm 71


Type E1 without bedding
Type E2 with bedding

Sub-main 72
Type F1 without bedding
Type F2 with bedding

Sub-main, by trencher 73
Type G1 without bedding
Type G2 with bedding

Main + sub-main 74
Type H1 without bedding
Type H2 with bedding

Sub-main + supply line to sub-main 75


Type I1 without bedding
Type I2 with bedding

Flushing collector 76
Type J1 without bedding
Type J2 with bedding

Flushing collector, by trencher 77


Type K1 without bedding
Type K2 with bedding

66 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


APPENDIX 2 – TYPICAL TRENCH CROSS SECTION (continued)

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 67


APPENDIX 2 – TYPICAL TRENCH CROSS SECTION (continued)

68 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


APPENDIX 2 – TYPICAL TRENCH CROSS SECTION (continued)

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 69


APPENDIX 2 – TYPICAL TRENCH CROSS SECTION (continued)

70 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


APPENDIX 2 – TYPICAL TRENCH CROSS SECTION (continued)

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 71


APPENDIX 2 – TYPICAL TRENCH CROSS SECTION (continued)

72 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


APPENDIX 2 – TYPICAL TRENCH CROSS SECTION (continued)

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 73


APPENDIX 2 – TYPICAL TRENCH CROSS SECTION (continued)

74 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


APPENDIX 2 – TYPICAL TRENCH CROSS SECTION (continued)

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 75


APPENDIX 2 – TYPICAL TRENCH CROSS SECTION (continued)

76 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


APPENDIX 2 – TYPICAL TRENCH CROSS SECTION (continued)

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 77


APPENDIX 3 - CONCRETE THRUST BLOCKS
Page

Type A - 90º horizontal bend


Pipe diameter 110-160 mm 79
Pipe diameter 200-315 mm 80
Pipe diameter 355-500 mm 81

Type B - 45º horizontal bend


Pipe diameter 110-160 mm 82
Pipe diameter 200-315 mm 83
Pipe diameter 355-500 mm 84

Type C - 30º horizontal bend


Pipe diameter 110-160 mm 85
Pipe diameter 200-315 mm 86
Pipe diameter 355-500 mm 87

Type D - Reducer
Pipe diameter 110-160 mm 88
Pipe diameter 200-315 mm 89
Pipe diameter 355-500 mm 90

Type E - Tee
Pipe diameter 110-160 mm 91
Pipe diameter 200-315 mm 92
Pipe diameter 355-500 mm 93

Type F - Main line - end line


Main line pipe diameter 75-140 mm 94
Main line pipe diameter 160 mm 95
Main line pipe diameter 225 mm 96

78 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 79


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

80 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 81


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

82 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 83


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

84 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 85


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

86 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 87


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

88 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 89


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

90 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 91


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

92 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 93


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

94 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES 95


APPENDIX 3 - CONCRETE THRUST BLOCKS (continued)

96 OPEN FIELD IRRIGATION GENERAL INSTALLATION GUIDELINES


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