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: mktg@alom.in, 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