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

• Perfect Prime Piping & Agritech Pvt . Ltd. ʽP-PALʼ 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

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

ORGANISATIONAL CHART UPDATE JAN 2013

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

• 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

• 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

Our Team Experience
• NCP Sanchore & IGNP Bikaner
• Irrigation of >11000 Ha installation of 450KM Pipeline

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

Our Team Experience
Vizag Sea Port –Dust suppression System
Bridgestone ACC- Landscape Irrigation
Water Supply – TCV Ladakh
Effluent/sewera
ge Pipeline
HSIIDC-Karnal

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

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
1 200 C – 50 year life
2 with 1.25 safety factor
3 with temp of 300C and 50yr life
ISO Standard BIS Standard

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 - DIN8076
25 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

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

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

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

“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(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

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.

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

%
Extra
Cost
Compared
to
PE100
Source: Solvay

• 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

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

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

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 :

Typical Trench
300MM min
D+300mm
Depends on traffic load
Load on the pipe can be Significantly reduced if Compaction is supervised
Trench Compaction

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.

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.

• 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

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

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

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:

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

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