Non Corrosive, Hi-tech, Hi-tensile Column Pipes for submersible pump Ashirvad Pipes Pvt. Ltd., Bangalore are the pioneers in the design, manufacture and development of high tensile, high impact unplasticised PVC threaded pipes for use in column pipes with submersible pumps in the world. In the past only galvanized steel pipes were used in the column application. The following chart demonstrates the advantages of Ashirvad high tensile, high impact column pipes over the conventional galvanized steel pipes and HDPE pipes.? (C) COPY RIGHT. Deepak Poddar 2004.? All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing it in any medium by electronic means and whether or not transiently or incidentally to some other use of this publication) without the written permission of the copyright owner. Applications for the copyright owner's written permission to reproduce any part of this publication should be addressed to the copy right owner.? Warning: The doing of an unauthorized act in relation to a copyright work may result in both a civil claim for damages and criminal prosecution.? Disclaimer: Due care and diligence has been taken while editing and printing the book. Neither the author nor the publishers of the book hold any responsibility for any mistake that may have inadvertently crept in. Publishers shall not be liable for any direct, consequential, or incidental damages arising out of the use of the book. In case of binding mistake, misprints, or for missing pages etc. Printed and bound in India.? Moral Rights of the Author are asserted.? The Author reserves all rights and liberty to modify, change or alter the design drawings of the products as and when he deems appropriate and necessary without any prior notice to the users.
COMPARATIVE CHART Material property requirement for Column pipes ASHIRVAD PIPES MILD STEEL or GALVANIZED STEEL PIPES HDPE PIPES Rigidity requirement so that column pipes & pump is vertical for proper NRV function Pipes are rigid Pipes are rigid Pipes are flexible hence not suitable for column application. Pipes are also soft & over long term use with heavy pump set they elongate & loose their shape permanently. In the process of elongation they become thin & break. Strong threaded joints required for holding the column & submersible pump load & leak proof joints required for saving every drop of water Specially designed square threads have very high load holding capacity & these threads do not corrode or rust or detoriate even up to 50 years of use. Special rubber seals are provided with the thread to ensure 100% leak proof at high pump pressure. The threads are prone to corrosion & rusting. Since the threads do not have layer of Galvanisation, after 2-3 years of use the old thread have to be cut out & new threads have to be made on the pipes on lathe machine due to rusting problem. The users ends up with a short pipe, money & effort spent for making new threads on pipes. These threads are not pressure tight and do not have any rubber sealing system. The threads cannot be formed as these pipes are soft and therefore the jointing of the pipe with the pump or at the top with any fixture is simple push type joint & are very weak and open up during use. Head loss comparison can be seen from Table No. 4 & 5. 2
COMPARATIVE CHART Water discharge is more by 10-30% compared to steel pipes. Material property requirement for Column pipes ASHIRVAD PIPES MILD STEEL or GALVANIZED STEEL PIPES HDPE PIPES Head loss due to internal friction Since the internal surface is very smooth therefore head loss due to friction is very low and water discharge is more by 10% - 30% Internal surface is rough & head loss is high. Internal surface not as smooth as Ashirvad Pipes. Weight of pipe & ease of handling Pipes come in 3 metres standard length and are light weight for easy handling both during pump fitment and also removal Pipes are very heavy and great effort is required for installation and removal of pumps. In deeper bore wells the column of pipe becomes very heavy and are prone to accidents during handling. Becomes hard and can not be rolled back during removal. Pulling with tractor disturbs the crop. Long life Ashirvad column pipes do not react with acidic or alkaline water and also have a very long life inside the bore well. Steel pipes are prone to rusting, corrosion & ultimately they get damaged and have to be replaced very quickly. Strength of material being very less, very thick pipes are required for high pressure application. This reduces the internal area for water flow considerably. Hence thin pipes are used for high pressure application and the pipes burst in 2-3 yrs. 3 Always First Always Best
FEATURES Special technical features of Ashirvad high tensile, high impact submersible column pipes. SQUARE THREADS The joint of pipes have been specially designed with square threads & rubber rings to ensure proper gripping, no chance of slipping & 100% leak proof joint. These threads are high friction threads on load, which do not open even on constant forward and reverse torque generated by starting & stopping the pump. They are made on specially imported CNC machines with special tools to ensure perfect dimensions and good & easy fitment. All threads are checked thoroughly with special gauges to ensure 100% accuracy. Material - Stainless Steel WIRE LOCK W i r e l o c k c o u p ler d e s i g n : ( W I R E L O C K : The Guarantee for your Pump Safety) The couplers are fitted on the pipe sizes from 48mm OD (1 ½ ) up to 140mm OD (5 ). The couplers are locked with special wire lock system (applied for patent) to ensure that during installation and removal of pumps the coupler does not come out, resulting in column slippage. The wire lock system with the unique design made by only Ashirvad Pipes Pvt. Ltd., is a further development of the product. 4
FEATURES BI-AXIAL ORIENTATION Bi-axial orientation during column pipe extrusion : Ashirvad has developed a unique Bi-axial orientation technique used during pipe extrusion, which gives higher drop impact and notch impact strength to the pipes. This orientation technique is a result of constant Research and Development at Ashirvad only. Thick Threaded Ends Material removed to form threads. Thin Barrel t THICK & THIN Special thick & thin construction of pipes : This special technique for making pipes thicker in the threading portion end to compensate for material removal due to threads is an innovation made only by Ashirvad. This technique saves on the raw material consumption and at the same time provides much higher strength to the pipes. t 53
SPECIAL FORMULATION FEATURES Ashirvad high tensile, high impact column pipes are made with specially designed formulation, so that pipes are capable of handling both internal hydro static pressure as well as huge vertical tensile load on the pipes due to the column and pump weight. The special formulation ensures that the threads do not get brittle and break / chip even after loosening and tightening several times during the life span. Special raw materials are used in very well defined processing techniques to make these pipes. DUAL FUNCTION OF ASHIRVAD COLUMN PIPE Ashirvad column pipes have dual function to perform. On one hand it has to withstand the pump delivery hydro static 2 pressure, which is maximum in the first pipe connected to the pump and may be as high as 35 Kg / cm and on the other hand, the top most pipe bears the load of the entire column filled with water & pump which may range up to 2 tons. This dual type of loading application makes this product unique and requires special manufacturing techniques which is available only with Ashirvad Pipes (P) Ltd. - Bangalore. INTERTEK ISO 9001:2000 Accredited by the Dutch Council for Certification An ISO 9001/2000 Company Ashirvad column pipes are manufactured within the world class quality management systems as laid down in ISO 9001-2000. However Pipe specifications & test procedures have been developed by Ashirvad Pipes (P) Ltd. 6
LOAD & PRESSURE TECHNICAL CHART Technical chart for all sizes and types of Ashirvad column pipes from 1" up to 5" has been given here below, which shows the ultimate breakage load of pipes, safe pulling load with chain pulley or crane and also the safe allowable hydro static pressure to be used in the pipes. TYPE & SIZE OD - Outside Dia NB - Nominal Bore Ultimate breaking load Safe pulling load with chain pulley Safe allowable hydrostatic pressure (kg/cm2) Safe Total Pump Delivery Head (m) OD: 33mm (1") ND: 25mm 2 V4-15 Kg/Cm 1000 Kgs 700 15 150 Crystal 1400 Kgs 770 16 160 Standard 1800 Kgs 1300 30 300 OD: 42mm (1¼") ND: 32mm 2 V4-15 Kg/Cm 1500 Kgs 1000 15 150 Crystal 2100 Kgs 1200 15 150 Standard 2600 Kgs 1500 25 250 Heavy 3100 Kgs 1550 35 350 OD: 48mm (1½") ND: 40mm 2 V4-15 Kg/Cm 2000 Kgs 1200 15 150 Crystal 2500 Kgs 1300 15 150 Standard 3000 Kgs 1700 26 260 Heavy 4000 Kgs 2000 35 350 OD: 60mm (2") ND: 50mm Medium 2800 Kgs 1500 13 130 Standard 3800 Kgs 2100 20 200 Heavy 4700 Kgs 2850 27 270 Super Heavy 5600 Kgs 3500 35 350 OD: 75mm (2½") ND: 65mm Medium 3500 Kgs 1900 10 100 Standard 5000 Kgs 2700 16 160 Heavy 7000 Kgs 4200 26 260 2 Super Heavy - 35 Kg/Cm 8600 Kgs 4800 35 350 2 Super Heavy - 40 Kg/Cm 9900 Kgs 5500 40 400 OD: 88mm (3") ND: 80mm Medium 5000 Kgs 2750 11 110 Standard 7000 Kgs 4000 17 170 Heavy 9500 Kgs 5700 26 260 Super Heavy 11900 Kgs 6600 35 350 OD: 113mm (4") ND: 100mm Medium 7500 Kgs 4100 10 100 Standard 10300 Kgs 5700 15 150 Heavy 16000 Kgs 9500 26 260 Super Heavy 19800 Kgs 11000 35 350 OD: 140mm (5") ND: 125mm Medium 10600 Kgs 5900 10 100 Standard 16000 Kgs 9000 16 160 7 CHART -1 Important: V4 pipes to be used with only V4 (100mm) pumps. Pump total delivery head is available in the pump performance chart supplied by the pump manufacturer. It is the maximum head of pump at which discharge becomes zero(nil). We can manufacture other pressure rating pipes upon your request.
TYPICAL LOAD TECHNICAL CHART Technical comparison for total load on the top pipe and ultimate breakage load of Ashirvad standard pipes. This is just an indication of the loads to explain that in the design of the pipes adequate factor of safety has been considered. Size Weight of Weight of Weight of Total Ultimate Pipe 500 Water Pump Weight Breaking Feet Column in Approx Load of 500 ft Pipe Maximum in kg in kg in kg in kg in kg 33mm OD (1") 82 75 100 257 1800 42mm OD (1 ¼") 113 135 100 348 2600 48mm OD (1 ½") 132 190 125 447 3000 60mm OD (2") 166 320 150 636 3800 75mm OD (2 ½") 216 530 200 946 5000 88mm OD (3") 303 720 250 1273 7000 113mm OD (4") 450 1225 300 1975 10300 Ashirvad Hi-Tech Hi-Tensile Submersible Pump Pipes Note: The total weight of the assembly is considerably reduced due to buoyancy when immersed in Bore well water. This is not considered above. CHART -2 only upvc column pipes offers installation upto 335 * meters * Condition apply 8
TECHNICAL CHART Specification for Ashirvad Column pipes for submersible pumps. SPECIFICATION FOR SUBMERSIBLE PUMP PIPE Size & Type OD - Outside Dia ND - Nominal Dia Wall Thickness in mm End Min/Max Barrel Min/Max Outer 0D in mm Min/Max Nominal Effective Length in mm Thick Portion of Both Side in mm 9 OD: 33mm (1") ND: 25mm } V4-15 Kg/Cm2 ( Bell Type ) 3.2 / 3.4 1.9 / 2.3 32.6 / 33.2 3000 ± 10 mm Crystal ( Bell Type ) 3.6 / 4.0 2.5 / 3.0 32.6 / 33.2 3000 ± 10 mm 200-250 Standard ( Bell Type ) 4.95 / 5.3 4.0 / 4.5 32.6 / 33.2 3000 ± 10 mm OD: 42mm (1¼") ND: 32mm V4-15 Kg/Cm2 ( Bell Type ) 3.7 / 3.95 2.4 / 2.65 41.5 / 42.2 3000 ± 10 mm V4-15 Kg/Cm2 ( Socket Type ) 4.2 / 4.4 2.4 / 2.6 41.5 / 42.2 3000 ± 10 mm } Crystal ( Bell Type ) 4.0 / 4.35 2.9 / 3.3 41.5 / 42.2 3000 ± 10 mm Crystal ( Socket Type ) 4.8 / 5.0 2.8 / 3.0 41.5 / 42.2 3000 ± 10 mm 200-250 Standard ( Bell Type ) 5.2 / 5.6 4.1 / 4.5 41.5 / 42.2 3000 ± 10 mm Standard ( Socket Type ) 6.3 / 6.5 4.1 / 4.3 41.5 / 42.2 3000 ± 10 mm Heavy ( Bell Type ) 6.4 / 6.9 5.2 / 5.8 41.5 / 42.2 3000 ± 10 mm OD: 48mm (1½") ND: 40mm 2 V4-15 Kg/Cm ( Bell Type ) 4.0 / 4.3 2.7 / 3.0 47.5 / 48.2 3000 ± 10 mm 2 V4-15 Kg/Cm ( Socket Type ) 4.5 / 4.7 2.7 / 2.9 47.5 / 48.2 3000 ± 10 mm Crystal ( Bell Type ) 4.7 / 4.9 3.4 / 3.6 47.5 / 48.2 3000 ± 10 mm Crystal ( Socket Type ) 5.3 / 5.5 3.5 / 3.7 47.5 / 48.2 3000 ± 10 mm Standard ( Bell Type ) 5.3 / 5.7 4.1 / 4.5 47.5 / 48.2 3000 ± 10 mm } 200-250 Standard ( Socket Type ) 6.6 / 6.8 4.1 / 4.4 47.5 / 48.2 3000 ± 10 mm Heavy ( Bell Type ) 7.1 / 7.6 5.9 / 6.4 47.5 / 48.2 3000 ± 10 mm Heavy ( Socket Type ) 8.4 / 8.6 5.9 / 6.1 47.5 / 48.2 3000 ± 10 mm OD: 60mm (2") ND: 50mm Medium ( Socket Type ) 5.1 / 5.4 2.6 / 2.9 59.5 / 60.1 3000 ± 10 mm } Standard ( Socket Type ) 6.4 / 6.8 3.9 / 4.3 59.5 / 60.1 3000 ± 10 mm 200-250 Heavy ( Socket Type ) 7.9 / 8.4 5.3 / 5.7 59.5 / 60.1 3000 ± 10 mm Super Heavy ( Socket Type ) 9.0 / 9.2 6.5 / 6.7 59.5 / 60.1 3000 ± 10 mm OD: 75mm (2½") ND: 65mm Medium ( Socket Type ) 5.1 / 5.4 2.6 / 2.9 74.5 / 75.2 3000 ± 10 mm Standard ( Socket Type ) 6.5 / 6.9 4.0 / 4.4 74.5 / 75.2 3000 ± 10 mm } Heavy ( Socket Type ) 8.5 / 9.3 6.3 / 6.8 74.5 / 75.2 3000 ± 10 mm 200-250 Super Heavy - 35 Kg/Cm2 ( Socket Type ) 10.8 / 11.0 8.3 / 8.5 74.5 / 75.2 3000 ± 10 mm Super Heavy - 40 Kg/Cm2 ( Socket Type ) 12.3 / 12.5 9.7 / 9.9 74.5 / 75.2 3000 ± 10 mm OD: 88mm (3") ND: 80mm } Medium ( Socket Type ) 5.7 / 6.1 3.2 / 3.5 87.5 / 88.2 3000 ± 10 mm Standard ( Socket Type ) 7.5 / 7.8 5.0 / 5.5 87.5 / 88.2 3000 ± 10 mm 200-250 Heavy ( Socket Type ) 9.8 / 10.3 7.3 / 7.8 87.5 / 88.2 3000 ± 10 mm Super Heavy ( Socket Type ) 12.4 / 12.8 9.7 / 10.1 87.5 / 88.2 3000 ± 10 mm OD: 113mm (4") ND: 100mm } Medium ( Socket Type ) 6.3 / 6.6 3.8 / 4.3 112.5 / 113.2 3000 ± 10 mm Standard ( Socket Type ) 8.2 / 8.5 5.7 / 6.2 112.5 / 113.2 3000 ± 10 mm 200-250 Heavy ( Socket Type ) 11.9 / 12.3 9.4 / 10.0 112.5 / 113.2 3000 ± 10 mm Super Heavy ( Socket Type ) 15.1 / 15.4 12.6 / 13.0 112.5 / 113.2 3000 ± 10 mm OD: 140mm (5") ND: 125mm Medium ( Socket Type ) 7.3 / 7.7 5.0 / 5.4 139.5 / 140.2 3000 ± 10 mm 200-250 Standard ( Socket Type ) 10.1 / 10.7 7.6 / 7.85 139.5 / 140.2 3000 ± 10 mm Extra thickness shell be given in pipes 1", 1¼" & 1½" at the ends to incorporate 'O' ring type sealing system } CHART -3
FRICTIONAL HEAD LOSS The height to which the water is to be pumped has to be precisely estimated. This is most important specially on long upward inclined terrains. The length of the pipeline and the height to which the water is to be pumped together with the depth to low water level and frictional head loss in pipes decide the total head of the pumpset. Approx frictional head lost in Ashirvad Submersible Column Pipes in (m) per/100 m TYPE&SIZE Discharge of pump in LPM 40 60 80 100 120 150 180 240 300 360 400 500 Pipe Size 1" V4 ( 1 2 5 Kg/Cm) 3.0819 6.5350 11.1257 16.8263 23.5749 35.644 1 49.965 7 85.1054 128.6754 180.3764 219.2364331.3869 1" Cr ystal 3.7303 7.9100 13.466620.366528.535 1 43.1437 60.4785 103.0116 155.7488 218.3277 265.3638401.1108 1" Regular 6.4792 13.7388 23.390 1 35.3746 49.5625 74.9362 105.045 1 178.920 7 270.5198 379.2131 460.9 101 696.6888 1/4 2 1 " V4 5 ( 1Kg/Cm) 0.9302 1.9725 3.3582 5.0788 7.1158 10.7588 15.0816 25.688238.8393 54.444 7 66.1742 100.0256 1/4 1 " Cr ystal 1.0768 2.2833 3.8872 5.8789 8.2369 12.453 7 17.4576 29.735 1 44.9580 63.02 19 76.5992 115.7836 1/4 1 " Regular 1.4774 3.1328 5.3335 8.0662 11.3014 17.0872 23.952 7 40.798 1 61.6849 86.4695 105.0983158.86 14 1/4 1 " Heavy 2.0714 4.3923 7.4779 11.3093 15.8452 23.95 72 33.583 1 57.2012 86.4856 121.2349 147.3536 222.732 4 1/2 2 1 " V4 5 ( 1Kg/Cm) 0.4773 1.0121 1.7231 2.6060 3.6512 5.5204 7.7384 13.1807 19.9286 27.9358 33.954251.3235 1/2 1 " Cr ystal 0.5193 1.1011 1.8746 2.835 1 3.9721 6.005 7 8.4187 14.339 4 21.6806 30.39 17 36.939255.8355 1/2 1 " Regular 0.6625 1.4047 2.3915 3.6169 5.0675 7.6619 10.7403 18.293 7 27.6593 38.7726 47.1258 71.2330 1/2 1 " Heavy 1.0578 2.2430 3.8186 5.7752 8.0914 12.2339 17.1494 29.2101 44.1643 61.9092 75.2469 113.739 4 2" Medium 0.1435 0.3043 0.5181 0.7836 1.0979 1.6600 2.3270 3.9635 5.992 7 8.4005 10.2102 15.4333 2" Regular 0.1849 0.392 1 0.6675 1.0095 1.4144 2.1384 2.9977 5.1058 7.7198 10.8215 13.1529 19.8813 2" Heavy 0.2454 0.5203 0.885 7 1.3396 1.8769 2.8377 3.9779 6.775 4 10.2441 14.3602 17.4539 26.382 4 2" Super Heavy 0.3143 0.6665 1.1347 1.7161 2.4044 3.6354 5.0960 8.6799 13.1237 18.396 7 22.360033.7983 1/2 2 " Medium 0.0440 0.0934 0.1589 0.2404 0.3368 0.5092 0.7138 1.2157 1.8381 2.5767 3.1318 4.7338 1/2 2 " Regular 0.053 7 0.1138 0.1938 0.2930 0.4106 0.620 7 0.8702 1.4821 2.2409 3.1413 3.8180 5.7712 1/2 2 " Heavy 0.0768 0.1629 0.2773 0.4194 0.5876 0.8884 1.2453 2.1211 3.2071 4.495 7 5.4642 8.259 4 1/2 2 2 " Super Heavy ( 35 ) Kg/Cm 0.1061 0.2249 0.3832 0.5793 0.8120 1.2275 1.7205 2.9312 4.4313 6.2111 7.5494 11.4128 1/2 2 2 " Super Heavy ( 40 ) Kg/Cm 0.1363 0.2888 0.4920 0.7437 1.0425 1.5759 2.2089 3.7633 5.6892 7.9743 9.6925 14.6526 3" Medium 0.0202 0.0429 0.0731 0.1105 0.1548 0.234 1 0.328 1 0.5589 0.8450 1.1846 1.4398 2.1763 3" Regular 0.0252 0.0534 0.0909 0.1375 0.1927 0.2914 0.4084 0.695 7 1.0518 1.4745 1.7921 2.7089 3" Heavy 0.0342 0.0724 0.1233 0.1865 0.2613 0.395 1 0.5538 0.9433 1.4262 1.9993 2.4300 3.6731 3" Super Heavy 0.0480 0.1017 0.1733 0.2619 0.3672 0.5550 0.7780 1.3254 2.003 7 2.8085 3.4137 5.1606 4" Medium 0.005 7 0.0121 0.020 7 0.0312 0.0438 0.0662 0.092 7 0.1580 0.2389 0.3348 0.4070 0.6151 4" Regular 0.0069 0.0146 0.0248 0.0375 0.0526 0.0795 0.1115 0.1899 0.2871 0.4025 0.4892 0.7395 4" Heavy 0.0099 0.0211 0.0359 0.0543 0.0761 0.1150 0.1613 0.2747 0.4153 0.5822 0.7076 1.0696 4" Super Heavy 0.0141 0.0298 0.050 7 0.0767 0.1075 0.1626 0.2278 0.3882 0.5868 0.8225 0.999 7 1.5113 5" Medium 0.0020 0.0043 0.0073 0.0111 0.0155 0.0235 0.0329 0.056 1 0.0848 0.1189 0.1445 0.2184 5" Regular 0.0025 0.0053 0.009 1 0.0137 0.0192 0.0290 0.040 7 0.0692 0.1047 0.1468 0.1784 0.2696 CHART - 4 10
FRICTIONAL HEAD LOSS Approx. frictional head lost in steel pipe head lost in m. per 100 m discharge in lpm Discharge in lpm Pipe Nominal Bore Q 40 50 65 80 100 Imp (nominal dia mm) 40 1.15 0.38 0.10 0.03 0.01 60 2.57 0.84 0.22 0.08 0.03 80 4.58 1.50 0.40 0.14 0.05 100 7.16 2.36 0.63 0.22 0.07 120 10.30 3.38 0.91 0.32 0.11 150 16.10 5.30 1.42 0.50 0.17 180 23.20 7.60 2.05 0.72 0.24 240 41.25 13.52 3.64 1.29 0.42 300 64.45 21.12 5.69 2.01 0.66 360 30.41 8.19 2.90 0.95 400 37.55 10.11 3.58 1.17 500 15.80 5.59 1.83 CHART - 5 Friction in long pipeline is to be calculated. Technical chart - 4 gives friction losses per 100 metre of pipeline for Ashirvad Column Pipes & Technical chart - 5 give frictional head loss for steel pipes. From table it can be seen that higher diameter pipes have lower frictional head loss. This helps to reduce load on pump and thus increase its life. Following examples will help you to calculate friction head for different length. CALCULATION 1. Head Loss & discharge comparison for 2 (60 mm OD) Ashirvad Standard Column pipes & GI pipe for installation at 450 ft (137 metres) depth. Considering that water will not be lifted higher than the ground level (i) Head Loss due to depth of pump = 137 meters = 450 ft both incase of Ashirvad Column pipes & steel pipes. 11 (ii)head Loss due to friction in Ashirvad Column pipes as per technical chart - 4
Taking working range of discharge as 18 m3 / hr for FRICTIONAL HEAD LOSS 18 m3 / Hr = 300 lpm As per Technical chart 4 frictional head loss is = 7.71 meters / 100 meters of depth for 2" (60mm Ashirvad Standard Pipes For 137 meters frictional Head loss 137 x 7.71 = 10.56 meters 100 Total head load on pump with Ashirvad Column pipe = 137+10.56 = 147.56 meters (ii) Head loss due to friction in Steel pipes As per Technical chart 5 = 21.12 mtrs / 100 mtrs For 137 meters frictional = 137 x 21.12 100 Head loss = 28.93 mtrs Total head load on pump with Steel pipes = 137 + 28.93 = 165.93 mtrs. In the same working condition the head load on pump is different than in the case of Ashirvad column pipes and steel pipes. As per pump chart 10% to 30% extra water discharge is available with Ashirvad Column pipe in comparison to steel pipes depending upon depth and discharge of pump. This means great power saving and less pumping time. 2) Even combination of Ashirvad Standard and Heavy pipes have lesser frictional Head than steel pipes. It has been debated that Ashirvad heavy pipes have lesser Internal diameter because of more thickness and therefore water discharge will be less in comparison with steel pipe. Comparison of Technical chart 4 & 5 shows that Ashirvad Super Heavy Pipes also have lesser frictional loss compared to steel pipes. Even 2 super heavy pipe has almost 33% lesser frictional loss than 2 steel pipe. 12
PIPE SELECTION V4 10 1", 1¼", 1½" Upto 100mm Sub. Pump V4 15 1", 1¼", 1½" Upto 100mm Sub. Pump Medium 1",1¼", 1½" Upto 100mm Sub. Pump 2", 2½" & 3" Upto 150mm Sub. Pump 3", 4" Upto 200mm Sub. Pump Standard 1", 1¼", 1½" Upto 100mm Sub. Pump 1¼", 1½", 2", 2½" Upto 150mm Sub. Pump 3", 4" Upto 200mm Sub. Pump Heavy 1¼", 1½", 2, 2½" & 3" Upto 150mm Sub. Pump & Super Heavy 3, 4 Upto 200mm Sub. Pump CHART -6 Selection of Pipes : The pipe to be selected from V4, Medium, Standard and Heavy class so that the pump delivery pressure does not exceed the hydrostatic allowable pressure of the pipe. In the column for every 33ft or 10 meters above the pump there is pressure drop of 1 kg / cm2. Therefore in deep bore wells with high pressure pumps two classes of pipes of same size may be used to save on the cost. Heavy pipes may be attached directly to the pump and after some height and loss of delivery pressure, standard pipes may be used in the top. A typical calculation is given here below. For combination systems do not use V4 (15), Medium or Crystal Range of Pipes. Combination to be made with Standard / Heavy and Heavy / Super Heavy pipes only. CALCULATION Example Pump delivery pressure 25kg/cm2 Pipe size (Nominal Bore 50mm) (2 ) Standard pipe allowable pressure = 20 kg / cm2 As per Technical Heavy pipe allowable pressure = 27 kg / cm2 } Chart - I (more than 25 kg / cm2 pump pressure) 25-20 = 5 kg / cm2 Extra pressure over Standard pipes. 5 x 10 = 50 mtrs (10m for 1 kg / cm2) Therefore 50 mtrs of heavy pipe to be used with the pump & rest of the pipes on top to be Standard. The pump delivery pressure will always remain 25 kg / cm2 at the pump discharge point irrespective of the depth of installation. Even if the pump is installed at the lower depth still 50 mtrs of heavy pipes should be used for connection with pump first to withstand the high pressure. 13 Pump Delivery Pressure: This is the max. delivery head of the pump. In the pump performance chart the value of head at which delivery becomes nil (zero) is the max. head in metres. 10 metres of head is equivalent to 1 Kg/cm2. Sometimes the delivery head per stage of pump is mentioned. In this case the factor to be multiplied with total stage to arrive at the max. pump delivery head.
SERVICE CONDITION PIPE SELECTION These pipes give the best service in bore wells which have full casing or bore wells which are free from loose bolders & stones. In such areas where loose bolders & stones are prevalent then full casing or sightly larger bore should be made so that the pump does not get stuck. Bore collapse problem occurs in some areas & it can also be tackled by giving full casing pipes. This happens in areas with loose soil & silt. Care should also be taken during drilling of the bore wells that it is vertical straight down without any bend. Note: Any Design & Specifications are subject to change without any prior notice. 14
ACCESSORIES - BOTTOM ADAPTORS Ashirvad Pipes Pvt. Ltd. also supplies TM APPL marked bottom and top adaptors for fitment with column pipes. Bottom adaptors are available in cast iron & stainless steel for connecting the bottom pipe with the submersible pump. Without flange Sizes 1" 1¼" 1½" 2" 2½" 3" 4" 5" Sizes 1" 1¼" 1½" 2" 2½" With flange Reducing type Sizes 1¼ x 1" 1½ x 1¼" 1½ x 1" 2 x 1½" 2½ x 2" 3 x 2½" 4 x 3" 5 x 4" 15
ACCESSORIES - TOP ADAPTORS Top adaptors are made both from welded steel pipe or from cast iron and are used to connect the column top pipe with bend fitting. Without flange (Cast Iron) Sizes 1" 1¼" 1½" 2" 2½" 3" 4" Sizes 1" 1¼" 1½" 2" 2½" 3" 4" 5" With flange and single coupling length (Steel pipe or Cast Iron) With flange and double coupling length (Steel pipe or Cast Iron) Sizes 1" 1¼" 1½" 2" 2½" 3" 4" 5" During every removal of pump for maintenance, both top & bottom adaptors should be carefully checked for corrosion, rusting etc. and if found unsuitable to be replaced immediately. 16
ACCESSORIES PUMP GUARD A special pump guard which can be used between the bottom pipe and bottom adaptors is recommended for areas with excessive pump vibration due to sand pumping, sub standard pumps, other local conditions. Photographs of pump guard is shown here below. ASSEMBLY PHOTO OF BOTTOM ADAPTOR PUMP GUARD & PIPE SS Rod MS Flange Quarter Pin 17
ACCESSORIES - JIG Inner & outer jig for extraction of pump from bore well incase of bore collapse, pump jamming due to bolders, small pieces of stones etc. Inner Jig Sizes 1" 1¼" 1½" 2" 2½" 3" 4" 5" Sizes 1" 1¼" 1½" 2" 2½" Outer Jig The inner & outer jig have been specially designed by Ashirvad Pipes Pvt. Ltd., to help the farmers / Customers / Mechanics to retrieve the pump out of the bore well in difficult conditions. Lowering Fixture Sizes 1" 1¼" 1½" 2" 2½" 3" 4" 5" Special lowering fixture has been developed by Ashirvad Pipes Pvt. Ltd., for lowering or extracting the column pipes from Borewell. The fixtures are from 1 to 5 size to be tightened on the coupler side. 18
IMPORTANT TIPS PIPE & PUMP SAFEGUARD AGAINST DRY RUNNING A) In places where the bore well yield is less, then after sometime the pump starts running dry which may heat up the connected Ashirvad column pipe. A correct assessment of bore yield should be done and timer switch should be used so that pump shuts off and on automatically after a certain amount of preset time and again gets on automatically as per the setting of the timer. This will ensure that water is always in the bore well and pump does not run in dry condition. B) During pump dry running the submersible pump gets heated up & may damage the first connected Ashirvad Column Pipe Another way of handling pump dry running is to use 3 metres of steel pipe in the bottom connected to the pump so that the heated pump is in contact with steel pipe which will dissipate the heat till the time it reaches the connected column pipe. C) Also the dry running condition may be tackled by installing a hand-operated valve at the top of the bore well and keeping it partially open so as to limit the water flow that the pump does not get dry. D) Whenever there is dry running & pump over heating problem then there is a chance of deformation of the first pipe connected to the pump only. Incase, any other pipe other than the first pipe bulges / deforms then it is a clear case of high pressure of pumps & wrong selection of pipes. PREVENTION OF WATER HAMMER It is suggested out of experience to make a 3mm hole in the pump NRV for deep bore wells, 500 ft & above. Due to this, water hammering will not take place in the bottom pipe at the time of pump stoppage & pipes will remain safe. 19
FAQ'S 1. What is upvc? upvc means unplasticised poly vinyl chloride. Unplasticised gives rigidity to the product. Ashirvad column pipes are made with modified upvc compound to give very high impact strength & tensile strength. Pipes made of modified compound does not get brittle over long term use. 2. What is the life span of upvc pipes? Under proper usage conditions & proper storage away from sunlight the upvc pipes in India have shown a life span of more than 50 years. 3. What are the benefits of upvc pipes? (a) We save on cost of pipes, (b) We save on handling time, (c) We save on power & get more water upto 30% (d) Working life of pipes is much more. 4. How does it affect on the quantity and quality of water? Yes, we get more water. Over a period of use, the steel pipes get corroded, rusted & the water quality deteriorates. In Ashirvad pipes since there is no corrosion throughout the depth of column pipe the water quality remains good & fresh forever. 5. Why only Ashirvad upvc pipes? Ashirvad group, the leading PVC pipe manufacturer in the country since 1975. The first to pioneer & develop the technology to make threaded upvc column pipes in the world. The company is credited by ISO 9001-2000, accredited by leading quality registrar KPMG. It has innovated & developed several new products to suit the farmers & customers requirements and these products are well accepted across the country. Ashirvad is well represented all over the country from North to South & East to West. They have a all India presence with a very well developed distributor, dealer & service network. 6. Can upvc pipe's strength be compared to a steel pipe? 3 3 The specific gravity of upvc is 1.4-1.45 gm / cm where as that as steel has 8 gm / cm. Taking the strength of the material into consideration the pipes are optimally designed to make them light without any compromise in its strength requirements. 7. Can the pipes take load of the pump? Ashirvad Column pipes are designed to hold several times the weight of entire column filled with water & pump assembly. All the type of pumps of different sizes have been considered and the Ashirvad Column pipes are made accordingly in the class of Medium, Standard & Heavy. 8. Up to what depth can the pipes be lowered? The pipes may be used after careful selection based on pump delivery head & maximum allowable pressure in the pipes. The depth of the bore well may differ from place to place depending upon the water level in the bore well. Ashirvad offers a range of pipes to suit the customer's requirement of various depths & they have been successfully used for 2 Super Heavy up till 1100 ft. Proper selection of Ashirvad pipes can be made for various depth application after careful study of technical booklet. 9. Does column pipes need full casing in the bore? These pipes give the best service in bore wells which have full casing or bore wells which are free from loose bolders & stones. In such areas where loose bolders & stones are prevalent then full casing or slightly larger bore should be made so that the pump does not get stuck. Bore collapse problem occurs in some areas & it can also be tackled by giving full casing pipes. This happens in areas with loose soil & silt. Care should also be taken during drilling of the bore well that it is vertical down without any bend. 10. How to choose from the range of pipes offered? Right selection of pipes can be made after consulting technical leaflets. 11. There is variation in thickness of the pipes. Why? The pipe thickness of the barrel has been designed by taking the pump weight, water column weight and pump delivery pressure into consideration. The end of the pipes are made thicker so that even after making the threads and removal of material the same barrel thickness remains under the threads so that the strength of pipe can be maintained equal in end & barrel. 12. Are the pipes breakable? The pipes do not break under normal handling conditions. 13. What happens if a bore collapse? The pump & the pipes can be pulled out only in cases where the pump can be pulled out by applying a force within the ultimate breaking strength of the pipe as mentioned in the chart. Normally the strength is adequate. In case of severe bore collapse & bolder problems even steel pipes cannot be retrievable from the bore. 20
21 FAQ'S 14. What about after sales service? District level dealers are fully equipped & have trained mechanics for correct installation of pipes. These mechanics are always available for all types of service support. 15. Is tripod required for lowering? Yes, tripod is required specifically for use of column pipes in the installation of V6 & V8 pump sets, considering the heavy load requirements. However it is important to note that handling of upvc pipes is much simpler in comparison to steel pipes. 16. How to tighten the pipes? The pipe is tightened on the principle of screw system. Tighten the pipe with hand & rope (holding the coupler) so that the rubber seal fully enters in to the coupling pipe. Total description of fitment is provided in company installation booklet. 17. Any adhesives required during joining of pipes? No solvent or adhesive required. 18. Do we need extra rope to hold the pipes? No rope is required. Pipe has adequate strength. 19. Can we cut the pipes? No, pipes cannot be cut for short length requirement. Special request has to be made to the company. The company does however stock shorter length of 1.5 M of few standard running sizes, which can be made available on demand. 20. Can we re-thread the pipes? Under normal use, re-threading of pipe will not be required. Special threads cannot be made at site. 21. Can metal pipe join with upvc pipe? Metal pipe can be connected with the upvc only with use of APPL marked adaptors. 22. Can we use any other metal adapters? The quality of APPL marked adaptors are carefully checked in the lab for (a) Value of hardness, (b) Quality of casting, (c) Blow holes and other casting defects, (d) Sufficient thickness & (e) Properly designed threads. Any accessory to be used with Ashirvad column pipes should be supplied by Ashirvad with APP L mark. 23. Why to use pump guard? Areas with excessive sand pumping or defective unbalanced pump results in excessive vibration in the bottom which may lead to pipe breakage near the adaptor. Pump guard has been designed to be used in these type of areas & problems so that even after breakage of column pipes the pumps can be easily retrievable. 24. How to select a top adaptor? Top adaptors with flange are generally used in deep bore wells so that the flange on top may be used as a support to hold the column. With even higher depths & bigger pump assembly, top adaptor flange type with double coupling length may be used so that two pipe clamps may be used on top to support the column load. For low depth bore well top adaptor without flange may also be used. 25. Why only Ashirvad column pipes? Only Ashirvad has the correct knowledge & understands the requirements for the development of upvc column pipes. This product has been designed & developed after considerable R&D and more than 28 years of expertise by the APPL team. All other manufacturer who are trying to copy the product do not understand the basics and the technicality of the design which may lead to severe failure & problems for the customer in the long run. Since, this is an engineered product other upvc pipe manufacturer may not have the capability for meeting the desired design specification required in Column Pipes. 26. What makes Ashirvad "Always First. Always Best"? Ashirvad has more than 28 years of expertise in the field of PVC pipe processing. The team of Ashirvad comprises of fully dedicated Engineering department to cater to the engineering needs of the product. This product has been conceived, designed, developed & marketed for the first time by APPL in the world. Ashirvad understands the customer requirements and converts them into products, which have proven track record & mass acceptance all over the country.
THE FIRST FROM ASHIRVAD PIPE Innovators in PVC pipe industry since 1975, Ashirvad Pipes Pvt. Ltd. is the pioneer in bringing the upvc column pipes a miracle for the farmers of today. COUPLING Due to coupling installation of pipes becomes very easy. Only Ashirvad has easy installation system. 'O' RING The 'O' ring, sealant and gripping system provides leak proof fitting and also absorbs the vibrations of the pump. Resulting in extended life of motor and pump bearings. Only Ashirvad has unique gripping system. WIRELOCK System for extra pump safety Design registered (Patent Pending) Material - Stainless Steel In this unique wirelock system developed by Ashirvad Pipes Pvt. Ltd., the coupler (1½" & above) is fitted to the pipe and locked with special aluminium wire, thus eliminating the chances of coupler loosening & column slipping during dismantling process & also excessive tightening of coupler with pipe. BIAX TECHNOLOGY for super strength This technique has been developed for the first time in India by Ashirvad Pipes Pvt. Ltd., where in during the process the PVC molecular chain get linearly & diametrically oriented. This results in higher impact strength. www.incledon.co.za 22