I ntegrated Mission for Ganga Conservation Alcorr DWC PE Pipe : An Intelligent Wastewater Conveyance...
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Transcript of I ntegrated Mission for Ganga Conservation Alcorr DWC PE Pipe : An Intelligent Wastewater Conveyance...
Integrated Mission for GangaConservation
Alcorr DWC PE Pipe : An Intelligent Wastewater Conveyance Instrument
By Anik RoychowdhuryPrincipal –Advisor (Engineering)
POLY EXTRUSIONS LTD. An ISO 9001 : 2008 certified
Below-par performances of earlier initiatives and the present Socio-environmental Imperatives has compelled the Govt. to Re-launch the project in Cleaning & Protecting Ganga ~~more holistically
The River covers 2500 km length and passes through 5 riparian states that includes 29 big Metropolis ,48 towns & 23 small cities.
The Non-core Features includes RFD, SWM ( on both Banks including open Defication) etc
The Core Elements of the Clean Ganga Mission Comprehensive Convergence of Generated DWF to
Treatment Fields Meticulous Treatment & Disposal of effluent to River
INTRODUCTION
Therefore, proper Accommodation & Smooth transportation of Sewage up to Treatment Unit ~Vital Physical & Financial perspectives of the Dream Mission.
INTRODUCTION….(continued)
The earlier non-performances are majorly attributable to the age-old practice of using conventional rigid Pipes as Gravity Flow Conduits, with antiquated Sewer laying technology.
The entire nation was therefore waiting for advent ofTechno-Commercially viable sewer material to replace the traditional underground piping systems.
Hence Intelligent & Smart sewer material shall Play a vital role in fulfilling the objective of the dream Mission.
EARLIER DEFICIENCIS
Gravity Flow Implies that Sewers need to be Configured much deeper than Pressure Pipe Installations Conventional Rigid Pipes (Small Lengths ~1.0-2.5 m Only), needed to be laid on complicatedly constructed Concrete Cradle Beddings at very deep trenches with S/S Joints at small spacing ~ both operations could not be properly ensured with unskilled workmanship & presence of GWT ~ illicit Joint & Sewer Settlements DWF Generated could not be fully converged to STPs instead polluted surrounding environment ( earth & GW) ~ the STPs Starved
Therefore, the imperative necessity for Frontier Technology sewer materials for the Relaunched Dream Mission.
Intelligent Sewer Material ~Structured Wall Plastics Piping System For Gravity Flow Applications.
Solid Wall Plastic Pipes could have been a solution but the thickness necessary for such pipes at Deep Installation (Structural integrity) demands for the use of unnecessarily expensive High PN category Pressure Pipes to ensure the required Stiffness Number (SN) of the Non-Pressure Gravity Flow links.Therefore, extensive Global Research (ISO & ASTM) has come up with a revolutionary ‘Product & System’ in the form of Structured Wall (Inside smooth –Outside non-smooth) Plastic Piping Systems for non-pressure applications.
Above backdrop inspired APEL to Manufacture Alcorr Double Wall Corrugated (DWC) Polyethylene (PE) Piping System to make its much awaited advent in the national scenario.
Alom Group Overview
Alternative systems
Alcorr DWC HDPE pipes
Comparison Studies
Applications and Uses
Features and Benefits
Quality Control
Certifications and Feedback
GROUP OVERVIEW Market leaders in Aluminum extrusions & DWC Pipe manufacturing
Established since 1980
ISO 9001: 2008 certified
Manage multiple manufacturing facilities for multifarious products
Latest technology and state of theart Infrastructure
Futuristic
Replacing traditional wastewater pipelines across India
Alcorr pipes have enormous cost saving, time saving and Socio-Environmental benefits
Produced with new age technology and materials
Alcorr Double Wall Corrugated HDPE pipes
Certified with BIS standard IS-16098-2 even exceeding its quality
Pioneers of Double Wall Corrugated PE Pipes
Production capacity of 11,000 MT / annum
State-of-the-art Infrastructure & Modern plant facilities
Certified by all relevant Indian/International Standards
Equipped with all Testing Facilities in house
Technical Support & Design Team
Why Alom Poly Extrusions?
THE INFRASTRUCTURE REVOLUTION
Chemically Inert
Long Material life
High Structural Integrity
Favorable Sewer Hydraulics
Ease in Transportation & Handling
Fast & Easy Installation in Typically crowded & narrow Urban Corridors
Minimum Maintenance
Environment Friendly
Cost Effective;• Capital Cost• Annual Costs
Imperatives for Sustainable Urban Gravity Sewers
ALOM POLY EXTRUSIONS LTD.Online Coupling Technology
Alcorr SN 8 DWC PE Pipes
Sizes from 75 – 1000mm ID
Decisively cheaper annual amortized cost
3 times longer life
20 times lighter than Concrete pipes
Ring Stiffness : 8 kN/m2
Ideal solution for Sewerage,Storm drainage, Cross Drainage culvert & Industrial effluents applications
Alcorr PIPES
Very High Hydraulic Efficiency
FEATURES & TECHNICAL KNOW HOW
Pipe Structural Performance
Rigid Pipes : Resists Structural Loads through bending Action within Pipe
Walls. Pipe is Stiffer than surrounding ‘Backfill Envelope’. Pipe Supports the Vertical load (Dead +Live) transmitted
through the Overburden (Cushion) above the Pipe Crown level.
Failure : When Vertical loading exceeds the limit (Very often for DWF Deep Sewer) cracks occur.
• Therefore : Rigid Pipe must be strong enough to support Design Loads. To be laid on stiff Bedding Materials that shall not allow
differential settlements. e.g. Concrete etc
Pipe Structural Performance
Flexible Pipes :Versatile and have distinct Structural Performance Advantages.Have excellent resistance to differential settlements. When Overloaded, will deflect further to generate greater passive earth pressure until system regains equilibrium.
ALOM POLY EXTRUSIONS LTD.Unsurpassed Strength
ALOM POLY EXTRUSIONS LTD.Higher 2nd Moment & Centre of Gravity: Structurally Sound
Outside Corrugated
Inside Smooth
ALOM POLY EXTRUSIONS LTD.Performance Under Load
Alcorr
RCC
Flexible Pipes, are less prone to cracking
ALOM POLY EXTRUSIONS LTD.Effective Load on Pipe
Alcorr
RCC
Rigid pipes being stiffer than the ‘Backfill Envelope’ attracts larger portion of the overburden load
Column
Column
Prism
Effective load in Trench condition
ALOM POLY EXTRUSIONS LTD.High Structural Strength
Chemically Inert
Polyethylene is Chemically & Biologically Inert to all sewage Solids
No Corrosions/Decaying/Abrasion.
‘Crown Corrosion’ is non-existent.
No adherence on inner surface: Maintains almost identical smoothness throughout its Material Life.
CHEMICALLY INERT
0
2
4
6
8
10
12
14
16
1.5
5
14
12
Widest pH rangep
H v
alu
e
PE RCC
Long Material Life
High Strength (8 KN/m2) to counteract External Loads and impacts
Abrasion is negligible throughout its life
UV Protected due to carbon black
ABRASION
LONG LIFE
0
10
20
30
40
50
60
70
80
90
100
Life Expectancy of 100 yearsY
ears
PE
PE
RCP
100
30
Hydraulic Superiority
Average Manning’s ‘N’ of 0.010: stays constant throughout its Material life
RCC Pipes: ‘N’ value deteriorates rapidly with passage of time (5 yr. Interval) due to deposition.
Resulting Benefits of using DWC PE pipes: Increased flow at identical gradients Flatter Gradients, lower trench depths possible Smaller sizes could transport same flow
HYDRAULICS
0
0.005
0.01
0.015
0.02
0.025
0.00900000000000006
0.011
0.011
0.015
Low Manning’s ‘n’ value ensuring efficient flow"
n"
val
ue
HDPE RCP
EASIER HANDLING
• 2.2 times longer but much lighter (5 %) than conventional pipes
Ease in Transport
Simple jointing method - Short installation time
Easy and Simple – 2 MINUTES JOINTING TIME
PIPES MAY BE JOINT USING:1. JOINTING JACK2. CHAIN PULLEY SYSTEM3. MANUAL PUSHING 4. WOODEN SUPPORTS CAN EASILY BE
ASSEMBLED AT G L AND LOWERED IN-TO THE TRENCH
DWC PE Piping Systems Installation Drawing
Carbon Footprint
Lowest Quantum of CO2 Emissions compared to other alternatives
Further minimized considering transportation and Installation resources utilized
Low Carbon Emissions
Carbon footprint
Pipe Size (ID)
(mm)
DWC PE Pipe Solid Wall PE PipeReinforced
Concrete Pipe
Class SN 8 (IS: 16098-2)
PE 80,PN 2.5 (IS: 14333)
Class NP3
(IS: 783)
Weight (Kg/m)
CO2
emission (Kg/m)
Weight (Kg/m)
CO2
emission (Kg/m)
Weight (Kg/m)
CO2
emission (Kg/m)
250 4.90 9.80 5.91 11.82 80 17.8
400 8.4 16.8 15.58 31.16 250.0 55.51
600 21.50 42.78 37.93 75.86 392.89 87.23
800 36.00 72.00 N/A N/A 640.84 142.29
1000 59.00 118.00 N/A N/A 940.57 208.80
CASE STUDY
New Sewerage Projects
CASE STUDY
NP3 RC Vis-à-vis DWC HDPE Pipes
Typical Sewer zone General InformationArea 677.61 hectare
Population Density 70 persons per hectare
Water supply status 135 lpcd
Sewage and sullage conversion 80% of water supply
Area subdivided into 55 sub zones
Inlet Nodes for each sub-zone 56
Inlets linked by sewer segments 55
Backfill density Saturated soil:1960 kg/m3
• Quantum of waste water is same for both studies.• Therefore Flow to Sewage treatment plant and Main Pumping
Station are identical and those are excluded from comparison.
SLS-3
SLS-2
SLS-1
An Arbitrary Urban Sewerage SchemeSewer Links Designed with Class NP3 RC Pipes
SLS-1
SLS-2SLS-3SLS-4
SLS-5
SLS-6
SLS-7
SLS-8
SLS-9
Manning’s ‘n’ 0.014
Minimum Cover
1.0M
Pipe sizes required
150mm to 500mm
Sewage lifting stations
9
SLS-3
SLS-2
SLS-1
An Arbitrary Urban Sewerage SchemeSewer Links Designed with Class SN 8 DWC PE Pipes
Manning’s ‘n’ 0.010
Minimum Cover
0.5 M
Pipe sizes required
150mm to 500mm
Sewage lifting stations
3
Fewer number of pipes – less no of connections
Comparatively Lower sized pipes
Completely water tight - zero Leakage
Fewer sewage lifting station – better hydraulics
Direct capital cost:
about 20% lower
FINANCIALS
Annual amortized cost:
about 28% lower
APPLICATIONS
Sewerage
Storm Drainage
Culvert & Cross Drainage
High Overburden Areas: Rail Crossing
APPLICATIONS
• Storm water Retention• Detention• Rain water harvesting
APPLICATIONS
Effluent Disposal
House Connections
APPLICATIONS
CUSTOMER SITES
2700 acres Film City: KolkataSizes from 250 – 1000mm
CUSTOMER SITES
Rajpur Sonarpur Municipality: KMA
CUSTOMER SITES
Kolkata Municipal Corporation
CUSTOMER SITES
Naihati Municipality : KMA
CUSTOMER SITES
Bidhannagar Municipality : KMA
CUSTOMER SITES
Client: Korba Municipal Corporation, ChhattisgarhPipe Sizes: 170 – 600mm, 11Km total
CUSTOMER SITES
BWSSB: Underground Sewerage
Fitting: Installed conditionFitting, waiting to be installed
CUSTOMER SITES
WBSRDA: Culvert Application
Older RCC Culvert: Damaged in less than 10 years
Replacement: DWC HDPE Pipe from Alom
ALOM POLY EXTRUSIONS LTD.Quality Control Tests
Structural Strength
Ring Stiffness
Ring Flexibility
Creep ratio
Impact Test
Material
Tensile Test
Melt Flow Index
Oxidation Induction
Time
Performance
Water Tightness
Test
Internal Pressure test
Vacuum Test
Tests as per IS 16098-2
PIPE LAYING Quality Control
ALOM POLY EXTRUSIONS LTD.Ring Stiffness
ALOM POLY EXTRUSIONS LTD.Impact Test
ALOM POLY EXTRUSIONS LTD.Impact & Drop Test
ALOM POLY EXTRUSIONS LTD.STATE-OF-THE-ART FACTORY
ALOM POLY EXTRUSIONS LTD.STATE-OF-THE-ART FACTORY
ALOM POLY EXTRUSIONS LTD.STATE-OF-THE-ART FACTORY
ALOM POLY EXTRUSIONS LTD.STATE-OF-THE-ART FACTORY
GLOBAL PRESENCE OF DWC PIPES
OUR VALUED CUSTOMERS
Raipur Development Authority
Border Roads Organisation
Customer Testimonials
Certificates & Approvals
Recommended by CPHEEO,
Ministry of Urban DevelopmentVide ref. no:
Q.16011/200-CPHEEO in
“Recent Trends in Technologies in Sewerage
Systems”. Clause 1.2, Pg. 2
Certificates & Approvals
Certified and marked with
IS – 16098:2
For all sizes:75 – 1000 MM
CM/L No: 5807071
THANK YOU
All rights reserved.This document is the property of Alom Poly Extrusions Limited and it contains confidential information intended for the client only. No part of this document may be reproduced or used without prior permission.
ALOM HOUSE 7B PRETORIA STREET,
KOLKATA – 700071, WB, INDIAPHONE: +91-33-4010 6789,
EMAIL: [email protected], WEB: www.alom.in
BACKUP SLIDES
Efficient Hydraulics
Ref: Corrugated Polyethylene Pipe Association (CPPA)A division of Plastics Pipe Institute, Inc., Washington DC, USA
“DWC HDPE Pipes provide significantly more capacitythan reinforced concrete pipe.
Smooth interior pipe won’t snag debris or encourage sediment, even on shallow grades, and these superior hydraulics allow pipe systems to be downsized compared to traditional materials, reducing material and labour costs.”
Manning’s ‘n’ value of 0.009 – 0.012
Anti Floatation Measures
• Light weight enables ease in handling, transportation & installation.
• The same property also makes it prone to floatation
• External corrugation of DWC PE Pipe enables it to get embedded in soil, reducing floatation possibility. The possibility is much more for other category of plastic piping systems.
• Under specific condition any pipe material and sizes can float
• For Alcorr DWC PE Pipes, minimum recommended cover** for structural protection to prevent flotation:– 300 mm for Pipe ID up to 300mm– 600 mm for Pipe ID above 300mm**Saturated Soil Density – 1990 Kg / m3