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HDPE Pipes By Perfect Prime Piping & Agritech Private Limited, Rajasthan

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Started to create milestones, we, Perfect Prime Piping & Agritech Private Limited marked our presence in the year 2011 and operate in the manufacturing/servicing of Water Irrigation Systems, Dust …

Started to create milestones, we, Perfect Prime Piping & Agritech Private Limited marked our presence in the year 2011 and operate in the manufacturing/servicing of Water Irrigation Systems, Dust Suppression Systems since 3 years. Our quality services products have been always appreciated by our clients. Our spontaneous attitude and confident approach in offering an excellent range of Water Irrigation Systems, Dust Suppression Systems, Water Supply Network Designs, HDPE Pipe Couplings, HDPE Pipes has deepened our roots in the market. We, Prime Piping & Agritech Private Limited breathe with the aim of fully satisfying our clients with our high-quality products services. We are a unit of highly experienced professionals, all of them contributing at the best of their potentials to offer the highest degree of efficiency and client satisfaction.

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  • 1. YOU ATTENDING PRESENTATION
  • 2. • Perfect Prime Piping & Agritech Pvt . Ltd. ʽP-PALʽ is an incorporated company closely held, registered under companies act located at Jaipur (Rajasthan) • P-Pal engaged in Providing quality products and services for Pipeline energy efficient system for various applications viz: – water supply, – Sewerage & Drainage, – Gas, – chemicals – slurry transportation – Irrigation & agriculture techniques with respect to sprinkler & drip irrigation with world class technology • Catering Pipe fittings & equipments: butt fusion, Electrofusion compression fittings, Saddle,Flanges & valves etc • P-pal’s goal : customer satisfaction INTRODUCTION
  • 3. INTRODUCTION • P-pal team is well qualified and experienced in the relevant field of providing technical & project installation services to our valued customer • P-pal has credentials of past track record of providing quality services. • Executed many piping projects mostly using HDPE Pipes P-PAL’s STRENGTH  Quality Products  Best Hardwares  Technical strength  Financial Strength  Experienced,young & dynamic team OPPORTUNITES  WATER SUPPLY PROJECTS  GAS PROJECTS  EFFLUENT  IRRIGATION PROJECTS • Water Lift / Distribution • Dewatering of Mines • House Service connections • Effluent / Sewage Handling • Chemical Transportation • Slurry Conveyance • Dust suppression systems  COMPITITORS POLICY OF CONCENTRATION ON SUPPLY & NOT ON SERVICES
  • 4. ORGANISATIONAL CHART UPDATE JAN 2013
  • 5. P-PAL Activity Customer Requirement SURVEY Customer Requirement SYSTEM DESIGN CONSIDERATIONS SYSTEM DESIGN & HYDRAULIC CALCULATIONS/ Product design Estimation of cost for useful lifespan of piping system Selection of most economical option Obtaining approval of client Detailed engineering- soil load , buckling, RCC block, support, diffuser Supply & mobilissation of for Execution team & equipments Turnkey Piping Projects Testing and commissioning of system Training, Operation & maintenance manual with As built drawing & After sales services if any Project Planning-Material- Manpower- Execution
  • 6. • SERVICES OFFERED BY P-PAL – Survey: Pipe Route /L section/Network layout Study etc.. – System Design & Hydraulic calculations, Pipeline Optimum Sizing, network distribution system design & system for equitable water distribution. – Pump Selection & Power requirement – Detailed Engineering: • Soil load calculation, • buckling pressure calculation, • Air relief valve locations, • Surge Arrestor, Pipe Safety Equipments. • Bouyancy Calculations, • Pedestal Support, RCC Anchor Block, • Support & clamping of pipe • Intake Header, Off-take Diffuser System, Anti Floatation Blocks, Valve Chambers, Intake Well, Jack Well, Sump, Reservoir Pump House etc. – Execution : • Timely Supply Of Material, • Deployment of Experienced Manpower, P-PAL Strength
  • 7. • EQUIPMENT AVAILBLE FOR PROJECT ACTIVITY • Pipe Welding Equipments • 63mm to 160mm 2 Nos. • 90mm to 315m 3 Nos. • 355mm to 630mm 1 No. • Pipeline Field Testing Equipment 3 Sets. • Road cutter & drilling machine 2 sets each. • Survey equipments 1 Set. • Chain block , tools box and other miscellenous & safety equipments P-PAL Strength As on 30/09/2012 Sr. No. Name Designation Qualification Experience 1 Mr. B. L. Goutam Director & Business Head B.Tech. (Agril.Engg.), MBA,MIE, LMISAE 20+ 2 Mr. R Gopalakrishnan CEO DME, MA English 28+ 3 Mr. Raj Elango Project Manager- South India DME 22+ 4 Mr. Vinod Kumar Project Manager North India BSc 15+ 5 Mr. Baldev Singh Dhurve Site Supervisor BSc 4+ 6 Mr. Karan Shukla Project Coordinator M Sc (Physics) 3+ 7 Mr. Manish Sharma Site Coordinator Diploma 9+ 8 Mr. Suresh Kumar Site Supervisor 12th 5+ 9 Mr. Pramod Ambhore SeniorTechnician ITI 30+ 10 Mr. Rajeev Manjhi Technician ITI 5+ 11 Mr. Abhijeet Ray Technician ITI 5+ 12 Mr. Ram Niwas Technician 12th 3+ 13 Mr. Ram Prakash Technician ITI 3+ 14 Mr. Bhagwati Sharma Site Supervisor 11th 25+ 15 Mr. Kishor Technician 10th 20+ LIST OF TECHNICAL PERSONNEL
  • 8. Our Team Experience • NCP Sanchore & IGNP Bikaner • Irrigation of >11000 Ha installation of 450KM Pipeline
  • 9. Water Pipeline At JK Cement Nimbaheda (Rajasthan) 250mm-12KM (Mines to Factory) Our Team Experience Siphoning System at ERAI Dam Chandrapur Pipe 315& 500mm Treated Effluent Uses for Green belt dvmt CFCL Kota - 350 Ac. Pipe 315- 63mm: 26KM JK Cement Mudhol (Karnataka) 355mm – 7.5Km From GhatPrabha River To Factory & 110 to 355mm – 6KM Inplant
  • 10. Our Team Experience Vizag Sea Port –Dust suppression System Bridgestone ACC- Landscape Irrigation Water Supply – TCV Ladakh Effluent/sewera ge Pipeline HSIIDC-Karnal
  • 11. Prestigious Client base M/s Aanjana Pump Services. M/s Flowmore Limited M/s J K Cement Works M/s Wonder Cement Ltd. M/s IVRCL Infrastructure Projects M/s Blue Star Limited M/s WRT Sales Nagpur M/s Core green Sugar & fuel. Pvt. Limited M/s OCW Pvt Ltd Nagpur for Nagpur Muncipal Corporation The Tibetan Children’s Village Leh-Ladakh M/s Shiv Construction Co. M/s Jindal Reality Pvt Ltd. M/s Tamhankar Patil & Associates Nashik M/s Chambal Fertilizers & Chemical Ltd Kota
  • 12. Design and Installation Reworked for OD & Temp correction Wall thickness = P * D0 / (2 +P) is the Design Stress Material Grade Minimum Required Stress ( MRS)1 after Safety factor correction2 Temp - correction3 Mpa Mpa Mpa PE 63 6.3 5.0 4.0 PE 80 8.0 6.3 5.0 PE 100 10.0 8.0 6.3 Allowable Design Stress() 1 200 C – 50 year life 2 with 1.25 safety factor 3 with temp of 300C and 50yr life ISO Standard BIS Standard
  • 13. Design and Installation Max. Operating Pressure: Temp. / Lifetime (bar) 11.8 19.3 16.2 13.8 9.2 10.8 12.7 15.1 7.4 8.6 10.1 12.1 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0 10°C 20°C 30°C 40°C SDR 11 25 J Fd=1.25 SDR 11 25 J Fd=1.6 SDR 11 25 J Fd=2.0 13.5 16.0 19.0 11.6 14.8 12.5 10.6 9.1 11.9 10.0 8.4 7.2 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0 10°C 20°C 30°C 40°C SDR 11 50 J Fd=1.25 SDR 11 50 J Fd=1.6 SDR 11 50 J Fd=2.0 PE100 - SDR17 - DIN807625 Years 50 Years 12.1 10.1 8.6 7.4 9.4 7.9 6.7 5.8 7.5 6.3 5.4 4.6 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0 10°C 20°C 30°C 40°C SDR 17 25 J Fd=1.25 SDR 17 25 J Fd=1.6 SDR 17 25 J Fd=2.0 7.2 11.9 10.0 8.4 5.6 6.6 7.8 9.3 4.5 5.3 6.2 7.4 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0 10°C 20°C 30°C 40°C SDR 17 50 J Fd=1.25 SDR 17 50 J Fd=1.6 SDR 17 50 J Fd=2.0 PE100 - SDR11- DIN8076
  • 14. Design and Installation d e d pipe diameter e wall thickness Standard Dimension Ratio Relationship of pipe diameter and pipe wall thickness SDR = d / e value without idication Example: Pipe d110 with 10mm wall: 110 / 10 = 11 SDR and PE pipes
  • 15. Design and Installation Material saving 32 % Cost saving 25 % PE 80 and PE 100 - Material and cost difference Example: Pipe Diameter 225 mm PE 80 SDR 11 Water 12.5 bar Gas 5.0 bar Wall thickness 20.5 mm Weight 13.2 kg/m Bore 184.0 mm PE 100 SDR 17.6 Water 10.0 bar Gas 5.0 bar Wall thickness 12.8 mm Weight 8.98 kg/m Bore 199.4 mm
  • 16. Design and Installation Maximum Operating Pressures for PE Pipes (bar) C Material SDR 17 SDR 11 Water PE 63 6 10 PE 80 8 12.5 PE 100 10 16 Gas PE 63 4 6 PE 80 5 8 PE 100 6 10 1.25 2
  • 17. Design and Installation “C” Factor & Its Significance • When a liquid flows through a pipeline mechanical energy is lost due to friction between fluid particles & internal surface of pipe. Energy loss due to this phenomenon can be quantified using hazen william’s Equation as Q = 1002 X C X D2.63 X S0.54 WHERE Q = FLOW RATE IN m³/hr; C = Hazen William factor (smoothness of pipe internal surface); D = Internal Diameter of pipe (MTR); s = Friction loss in m / m length of pipe. • “C” Value for various Pipes are: • HDPE & PVC : 150 • Cast Iron/ Steel (New) : 120 • Cast Iron/Steel(10Years old): 110 • Cast Iron/Steel(15Years old): 100 • Cast Iron/Steel(20Years old): 90 • Cast Iron/Steel(50Years old) : 70 • RCC / ACC : 100 TO 120 Using Modified hazen william eqn.(CPHEEO) F=607.98X(lpm)1.81 /d4.81 OR (Qm³/s/CR)1.81 /994.62/d4.81 Using Hazen william equation ( Our) Q=1002 X C X d 2.63 X S 0.54 Using darcy's equation F=flv² / 2gd f=0.02 As per ISO/TR 10501:93, Fm/m=0.000579 X f X Vm/s 1.8 /dm 1.2 f=1.087 Colebrook's equation Fm/m=91900X f X Qm³/hr 1.83 /dmm 4.83 Other Formulae
  • 18. Design and Installation Selection of most economical Pumping main is important Option - I Option - II Flow m³/Hr 216.00 216.00 Length of pipe m 3000 3000 Static suction m 3.00 3.00 Static suction head m 13.00 13.00 Residual head m 2.00 2.00 Pipe OD mm 280 250 Pressure Class of pipe Kg/cm² 4.0 4.0 Pipe ID considering IS:4984:PE80 mm 261.80 233.80 Velocity m/s 1.11 1.40 Frictional loss ( Including minor losses) m 12.28 21.31 Pump Head (Total dynamic) m 30.28 39.31 Pump Discharge Lps 60.00 60.00 Pump selected Kirloskar make Model 6 UP3-15° 6 UP3-15° Kw 30 37 Capital Cost of pipe & Motor-pump Rs.lac 25.53 21.01 Interest on excess investment Rs.lac 0.45 (@10%pa for 1 year) Pump operating cost per annum Rs.lac 10.95 13.51 (20 Hrs. pumping per day& @Rs.5/Kw-hr) Saving per annum on operating cost Rs.lac 2.56 Net saving per year Rs.lac 2.10 Net saving in20 years Rs.lac 42.1 Note : Energy inflation rate & interest rate variations not considered.
  • 19. Design and Installation
  • 20. Design and Installation Water transportation costs per m3 Diameter (mm) PE offers substantial savings in the dia range between 100 & 400 mm 0 40 80 120 160 100 200 300 400 Steel Ductile Iron PE -40  %ExtraCost ComparedtoPE100 Source: Solvay
  • 21. Design and Installation • Transmission Mains – 30% more economical than DI/CI upto 630mm • Distribution Mains – uPVC Pipes and PE pipes both can be used – depending on the site requirements. • Service Lines – PE pipes most Ideal – smaller dia : available in longer lengths and minimum joints. • Inside Buildings – plumbing – Polypropylene –Random copolymer Pipes : excellent for hot and cold water applications • PE pipes – ideal for high altitude regions – long lengths , less joints , easy fit, and no break under freezing
  • 22. Design and Installation Joint Technology - Possibilities Pipes Couplings Fittings Saddles Valves Hydrants Transitions To join by Push fit joints Compressed joints Flanged joints Fusion joints  not pull out resistant  pull out resistant  permanent  non permanent Pipes Couplings Fittings Saddles Valves Hydrants Transitions
  • 23. Design and Installation JOINTING OF PE PIPES • Butt Fusion welding Butt Welding is time saving, In-expensive,Very simple and reliable. Process is Heat-pressure related, creates homogeneous structure at weld. Needs high grade accuracy. • Socket Fusion welding
  • 24. Design and Installation Joint Technology - Possibilities in distribution • Electro Fusion Welding Heat fusion process where a coupling or saddle fitting contains an integral heating source. After surface preparation, the fitting is installed on the pipe and the heating source is energised. During heating, the fitting and pipe materials melt, expand and fuse together. Heating and cooling cycles are automatically controlled. Method is useful for jointing of pipes from 20mm to 315mm only. • Mechnaical Method • Flange Joints :are made using a stub end and MS slipon flange • Compression Fittings:For a diameter upto 110 mm OD PE pipe, compression fittings are useful as jointing tool. These compression fittings are of push fit type and even can be joined by unskilled fitters. •Transistion Joints :
  • 25. Design and Installation Typical Trench 300MM min D+300mm Depends on traffic load Load on the pipe can be Significantly reduced if Compaction is supervised Trench Compaction
  • 26. Design and Installation Installation Practices Underground installation Trench Width & Depth – Pipe size (mm OD) Minimum trench width (mm) – 75mm to 400mm Pipe OD +300 mm – 450mm to 1000mm Pipe OD +450mm – 1200mm & above Pipe OD + 600mm – The Depth of trench should be 1 mtr. from top of the pipe Rail / Road Crossing – The permissible burial depth for all pressure classes of PE pipes are the same as mentioned above under roads with usual traffic. It is however, recommended to lay PE pipes through RCC Hume pipe when crossing heavy traffic roads or railway tracks. Nallah / Drain / River Crossing – For wide Nallah/ River suitable RCC blocks to be designed to resist against buoyancy force. For small drain / Nallah by using RCC pipe hume pipe.
  • 27. Design and Installation INSTALLATION PRACTICES • Overground / over head installation • PE pipes can be safely laid over ground or on over head racks. The pipe however, should be firmly supported at every 1.5 mtrs and clamped with due precaution so that no sharp edges come in contact with PE pipe surface. It is recommended to use 3 mm rubber pading around all pipe while installing PE pipes overhead installations • Under water installation • Installed by fixing concrete blocks to prevent floatation. Concrete blocks should be installed on shore, line is then floated into location, and sunk into position. Floats may be required if the line is designed with heavy concrete blocks, or to control sinking. However, typical concrete blocks weight design allows an air filled pipeline to float with weight of concrete blocks attached if both ends are sealed with blind flanges. • On shore, concrete block installation can be eased by using a skidway, and sliding concrete blocks -pipe into the waterway. Over water, crane mounted barges may be used to lift and move concrete blocks and pipe. Then the pipeline is move into position with marine craft or by pulling with cables/tie ropes. Temporary anchoring may be used to maintain position during sinking. • Sinking rate must be controlled so the pipe does not bend too tightly and kink.
  • 28. Design and Installation • Testing of PE pipes at field • In length of 1000mtrs or more 100-150 butt welds (i.e joints - depends on site engineers’ confidence) whichever is minimum. • 1.5 times the working pressure for 1 hrs – as given in IS 7634 specifications. Records of test with date of testing should be available on the pipe with the help of Glass marking pencil
  • 29. Repair situation may arise in PE pipes after installation. Damage may include giving away joints, punctures by external forces etc. However, repair of PE pipe after installation is a very easy method which is broadly categorised in 3 parts as under :  Temporary Repair : This type of damage can be arrested by using full wrap- around-type repair clamp with integral gasket. The minimum clamp length must be equal twice the pipe nominal diameter.  Permanent Repair:  By Butt-Fusion Welding (upto 110mm OD) :Small diameter pipe is sufficiently flexible that the pipe ends can usually be moved to one side to facilitate a fusion repair. It is generally not necessary to remove a great deal of the adjacent backfill material beyond the location of the damage  Flange Connections : Flange assemblies comprising of stub ends and MS slip on flanges with gasket is fused Repair of PE Pipes after Installation Design and Installation
  • 30. Specifications SR NO ITEM SPECIFICATIONS 1 For Water Supply IS 4984-95,EN 12201-2, ISO4427 2 For Industrial Effluent,Slurry/Sewarage IS 14333-96 3 For Gaseous Fuel ISO 4437, IS 14885-2001 4 For Sprinkler pipes-Irrigation Equipments (Polyethylene Pipes) IS 14151-Part I : 1999 5 For Sprinkler pipes-Irrigation Equipments (Quick Coupled Polyethylene Pipes) IS 14151-Part II 1999 6 HDPE Material for Moulding & Extrusion IS 7328:1992 7 Choice of material & general recommendation for plastic pipes for potable water supplies. IS 7634(Part I):1975 8 For LDPE IS 3076-1968 9 For HDPE IS 4984-1972 10 Unplsticized PVC IS 4985-1968 11 Injection Moulded HDPE Fittings for Potable Water Supplies IS 8008 12 Fabricated HDPE Fittings for Potable Water Supplies IS 8360 13 Laying,Jointing & testing of PE Pipes for Potable water supplies. IS 7634(Part II):1975 14 Laying & Jointing of PVC Pipes for Potable water supplies. IS 7634(Part III):1975 15 Welding Equipment for Butt fusion of HDPE pipes. ISO 12176 16 Jointing of PE pipes & specials. DVS 2207 17 HDPE Pipes - Dimensions DIN 8074 18 HDPE Pipes- General Quality requirements DIN 8075 19 Flanges BS 10 Table-D & ANSI B16.5 20 Sluice valves 21 50 to 300mm IS 780 22 Above 300mm IS 2906 23 Air valves As per Internal Std. 24 Non return/Check valves 25 Flanged Swing type Bolted cover BS 1868 26 Wafer check valves API 6D 27 Butterfly valves As per IS:13095,BS 5155,AWWAC504,API 609 28 Ball valves BS 5351 29 Pressure Reducing valves 30 Pilot Operated R-Type As per Internal Std 31 Gun Metal Diaphragm operated As per IS 9739 32 Globe/Pressure relief valve AS PER IS:9338/79 33 Foot valve AS PER IS:4038 34 Excavation work As per IS:3764,1992 35 Fusion compatibility ISO 11647 36 Butt Fusion Cycle ISO 11414 37 Butt Fusion Machines ISO 12176 38 High Density Polyethylene Pipes for Water Supply IS 4984-95 39 Polyethylene Pipes DIN 8074/5 40 Polyethylene Pipes for Water Supply ISO 4427 41 Mechanical Joints for PE pipes ISO 14236 42 Code of practice for Plastic Pipe Installation & testing IS 7634 -II SPECIFICATIONS
  • 31. PERFECT PRIME PIPING & AGRITECH PVT LTD 404, Luvkush Apartment, 5, Subhashnagar, Shashtrinagar, Jaipur 302016 (Rajasthan) Telefax:0141-2282944;M-9413332899 email:admin@p-pal.com; blgoutam@gmail.com Contact details: