Contents 01
The Corporation
01
02
Corporate Philosophy
03
03
Jain PE Pipes
04
04
Jain PE Pipes - Design Details & Technical Characteristics
07
05
Jain PE Pipes – Advantages
18
06
Jain PE Pipes – Applications
19
07
Jain PE Pipes for Potable Water Supply
20
08
Jain Insta Tracer Pipe - For precise location after underground burial
25
09
Jain PE Pipes for House Service Connection
26
10
Jain PE Pipes for Disposal Systems
29
11
B-Sure PE Gas Pipes
34
12
Jain PE Landfill Extraction Pipes
39
13
Jain PE Pipe for Sprinkler & Farm Irrigation System
41
14
Jain Silicoat PE OFC Ducts
42
15
B-Sure Corrugated HDPE Pipes and Fittings
46
16
Jain PE – Fittings
50
17
Turnkey Solutions and Project Execution
53
18
Jain PE – Jointing Methods
54
19
Jain PE – Installation Methods
57
20
Jointing – Do’s and Don’ts
67
21
Frequently Asked Questions
73
22
List of Major Customers
92
23
Application Photographs
93
24
Chemical Resistance Chart
100
25
Material Safety Data Sheet
103
26
Specification, Standards & Product Performance Certifications
106
27
Conversion Factors & Formulas
108
The Corporation... Jain Irrigation Systems Ltd. (JISL) derives its name from the pioneering work it did for the Micro Irrigation Industry in India. However, there is more to Jain Irrigation than Irrigation. Jain Piping Division is the largest producer of Thermoplastic piping systems for all conceivable applications with pipes ranging from 3 mm to 1600 mm in diameter and in pressure ratings ranging from 1.00 kgf/cm² to 16 kgf/cm² and above. JISL has a production capacity of over 2,00,000 M.T. per annum and the only manufacturer to own DSIR approved R&D setup with state of the art facilities. The pipes are manufactured confirming to IS, DIN, ISO, ASTM, TEC and other customised specifications. Micro-Irrigation Division manufactures full range of precision-irrigation products, provides services from soil survey, engineering design to agronomic support and nurtures a sprawling 2300 acre Hi-Tech Agri Institute. It undertakes turnkey projects for total agricultural development. Division’s pool of over 800 agri scientists, technologists and technicians are well equipped to render consultancy for complete or partial project planning and implementation e.g. Watershed or Wasteland and/or Crop Selection and Rotation. Tissue Culture Division fully makes Grand Nain Banana plantlets and has established vast primary and secondary hardening facilities and R&D labs. Agricultural and Fruit processing wastes are converted into Organic Manure. Neem-based pesticides are also formulated. Both are critical inputs for Organic Farming. Agro Processed Products Division processes tropical fruits into purees, concentrates, juices, while Dehydration facility dehydrates Onions & Vegetables. The Piping Division also includes PVC range of Pipes and Fittings catering to the urban and rural infrastructure needs of the country apart from irrigation needs of the farmers. Plastic sheet division’s globally marketed products help conserve forests by providing alternative to wood in home building markets. Solar Energy Heating and Lighting Equipments and Bio-Energy sources are new additions. In a nutshell, the Corporation is the only ‘one-stop-shop’ encompassing manufacturing and marketing of hi-tech agricultural inputs and piping services as well as processing of agri produce. No wonder, it has distinguished itself as a leader in the domestic as well as global markets. The corporate product range improves productivity and adds value to the agri-sector. Conservation of scarce Natural resources, protection and improvement of environment emerge as wholesome blessings. Corporation has 16 manufacturing plants and numerous offices across the globe. The Corporation has pioneered and raised a new Micro Irrigation industry in India and thereby helped harbinger Second Green Revolution. The reward has been over millions of smiling farmers and scores of other customers in 107 countries.
1
Corporate Philosophy
Mission :
Guidelines :
Leave this world better than you found it.
Customer and Market
Vision :
• Commit to total customer satisfaction.
Establish leadership in whatever we do at home and abroad.
• Build and maintain market leadership.
Credo :
Quality Excellence
Serve and strive through strain and stress; Do our noblest, that’s success.
• Strive continually to reach and maintain quality in every aspect.
Goal :
Safety and Health
Achieve continued growth through sustained innovation for total customer satisfaction and fair return to all other stakeholders. Meet this objective by producing quality products at optimum cost and marketing them at reasonable prices.
• Secure safety and health of associates and other assets.
Guiding Principle : Toil and sweat to manage our resources of men, material and money in an integrated, efficient and economic manner. Earn profit, keeping in view commitment to social responsibility and environmental concerns. Quality Perspective : Make quality a way of life. Work Culture : Experience : ‘Work is life, life is work.’
2
Environment and Society • Protect, improve and develop environment • Cherish the symbiosis and nurture creative partnership between society and environment. Development of Other Stakeholders • Adopt transparency and fair practices for continuous sustainable growth.
Jain PE Pipes
Production of 1600 mm diameter PE pipe PN6
What is Polyethylene? When scientists first experimented with a reaction between ethylene and benzaldehyde using two thousand atmospheres of internal pressure, their experiment went askew when all the pressure escaped due to a leak in the testing container. On opening the tube they were stunned to find a white waxy substance that looked a lot like some form of plastic. After repeating the experiment, they discovered that the loss of pressure was not due to a leak at all, but was a result of the polymerization process. The residue polyethylene (PE) resin was a milky white, translucent substance derived from ethylene (CH2=CH2). Polyethylene was produced with low to high density. Low-density polyethylene (LDPE) has a density ranging from 910.0 to 930.0 kg/cm². The molecules of LDPE have a carbon backbone with side groups of four to six carbon atoms attached randomly along the main backbone. LDPE is the most widely used of all plastics, because it is inexpensive, flexible, extremely tough, and chemical-resistant. LDPE is molded into bottles, garment bags, frozen food packages, and plastic toys. High-density polyethylene (HDPE) has a density that ranges from 940.0 to 970.0 kg/cm². Its molecules have an extremely long carbon backbone with no side groups. As a result, these molecules align into more compact arrangements, accounting for the higher density. HDPE is stiffer, stronger, and less translucent than low-density polyethylene. HDPE is formed into car fuel tanks, packaging and of course piping. 3
Jain PE Pipes Polyethylene Pipe Polyethylene was first developed in 1933 as a flexible, low density coating and insulating material for electrical cables. It played a key role during World War II - first as an underwater cable coating and then as a critical insulating material for such vital military applications as radar insulation. Because of its light weight, radar equipment was easier to carry on a plane, which allowed the out-numbered Allied aircraft to detect German bombers under difficult conditions such as nightfall and thunderstorms. High density polyethylene, however, is quite a bit different from the polyethylene used in the 1930s. LDPE was discovered in 1935 and it wasn’t until sixteen years later in 1951 that high density polyethylene appeared on the scene. As a relatively newcomer in the piping industry, polyethylene is constantly making its way into applications normally reserved for the older piping technologies. It was not until after the World War, though, that the material became a preferred choice with consumers and from that point on, its rise in popularity has been almost unprecedented. Since the late 1950s and early 1960s, polyethylene has made its way into every corner of our lives launching a multi-billion dollar industry. It became the first plastic in the United States to be sold more than a billion pounds a year and it is currently the largest volume plastic in the world. This is partly due to the fact that there are
Normally metal pipe after 30 to 40 years will become like this
Normally PE Pipe after 50 years will remain same as a new one
certain characteristics (or combinations of characteristics) of high density polyethylene that make it an attractive alternative. Whether it is an issue of installing a new piping system or rehabilitating an existing system, there are certain requirements placed on the piping material: that it be simple to install, that it doesn’t leak or cost a lot to maintain, and will last a very long time. Effectively, as long as polyethylene can satisfy these demands better than any other material, it will continue its gain in popularity.
PE Family In the first generation of PE the curve at 60°C and 80°C always showed a knee before 10,000 h, making it possible to calculate the coordinates of the knee at 20°C by extrapolation. They were generally stiff polymers of high density, but unsatisfactory environmental stress crack resistance (ESCR) at 50°C. With the second (PE80 since 1980) and third (PE100 since 1990) generations of PE there is no knee anymore at 60°C and even at 80°C, with hardly any brittle failure ever before 10,000 h. With second generation (medium density PE80) the ESCR is improved by increasing the chain branching and lowering the density as much as possible. The creep resistance is decreased to its lowest possible value in order to optimize ESCR; the knee
4
Jain PE Pipes Jain Irrigation manufactures PE Pipe and Corrugated plastic pipe for Pipe line networks of Gas, Liquid, Solids & Other applications. What we refer to as PE pipe - also known as Poly Pipe, PE pipe or Polyethylene pipe - is manufactured by extrusion technology in sizes ranging from 3 mm to 1600 mm diameter.
Jointing of PE Pipeline of 280 mm size for Cairn Energy, Barmer
If you are looking for rugged dependability, light weight, long lasting service, trouble-free installation, flexibility, superior flow rates, high chemical resistant and extremely high corrosion resistance without compromising on efficiency Jain PE piping systems are the perfect solution. If you want to know about this piping system, please contact us and we will gladly answer any of your questions.
Applications of Jain PE pipes Liquid Water Supply Drainage & Sewers Industrial Liquids, Chemicals
Gas Gas Piping Land-fill Gas Extractions Ventilation
Solid Dredging Mining
Marine Works, Sea Water Intake and Outfall
Other Electrical Conduits Telecom Cable Ducts Manholes Culverts Geothermal Heating Perforated Pipes
For over twenty-five years we have manufactured plastic pipe for a wide range of industrial, commercial and residential applications. Some of the more popular applications of our PE pipe include Gas pipes, Water mains, Sewers, Drainage and Cable duct.
Colour Coding for PE pipes Sr. No.
Colour
Application
References
1.
Black with blue stripes or Blue
Water Supply
IS 4984
2.
Black
Sewer/ Drainage/ Effluent
IS 14333
3.
Gray
Treated Effluent
General Practice
4.
Black with Red stripes
Fire Fighting Water
General Practice
5.
Yellow, Orange or Black
Natural Gas Distribution
IS 14885 5
Jain PE Pipes Why Choose Jain PE Pipe? Choosing the right kind of piping material for your project is not easy when you require Strength, Durability as well as Light weight, Flexibility for easy handling and installation along with Earthquake resistance. As a total piping solution therefore, Jain PE Pipe is chosen above all others.
Installation of Cross Country PE Pipeline
Until plastic was invented, this was not even a consideration. Piping users were limited to one of two possibilities: either concrete or metal, both of which were strong with limited durability, but difficult to handle and to install due to their weight and stiffness. Prior to the invention of polyethylene in the 1950s, plastic pipe was easy enough to handle and to install, but limited in strength and durability. That all changed with polyethylene. Piping customer now had the best of both worlds, with one added bonus. Not only was PE pipe durable and easy to install, it could be homogeneously joined together by heat fusion making it completely leak free. Leak Statistics in Water Distribution Pipes Pipe Material Installed km % of network Number of Leaks % leaks Leaks / 1000 km Steel 16379 52.1 3337 70.0 203.7 Polyethylene 2240 7.1 58 1.2 25.9 PVC-U 5416 17.2 848 17.8 156.6 Asbestos cement 7395 23.5 522 11.0 70.6 To select the right piping solution for any project, we provide all kinds of technical specifications and support. In addition to the various dealers that we have, our team is ready to assist you with your technical and design questions. You can also contact by e-mail:
[email protected] or postal address: Jain Plastic Park, N.H.No.6, Bambhori, P.O.Box 72, Jalgaon - 425 001, Maharashtra, Phone no. +91-257-225 8011. 6
Jain PE Pipes - Design Details & Technical Characteristics before 50 years @ 20°C disappeared, but the short-term resistance decreased due to the lower density. In third generation (high density PE80 and PE100) ESCR is improved by branching only the long chains, thereby not decreasing the density (maintaining stiffness / creep resistance). Short chain branches inserted on the longer molecules ensure an efficient increase of the resistance to stress cracking in the long term, while creep resistance is maintained through high density (no branches on short chains that crystallize easily). Property of HDPE Pipes Surface feel
Waxy
Usual colour
Black
Sound when dropped
Clatter
Combustibility
Bright flame : Drops continue to burn while falling
Odour of smoke after flame is extinguished
Like candles
Nail test impression
Impression possible
Floats on water
Yes
Notch sensitivity
No
Method of permanent joining
Fusion
Linear expansion in/in/ F
9x10-5
Thermal conductivity kcal/mh0C
0.36 to 0.438
Specific heat kcal/mh C
0.42
Density kg/m³
940.0 to 958.4 (Base Density)
0
0
Tensile strength at 20 C MPa
20-26
Modules of elasticity at 20 C MPa
900
0
0
PE Classification ISO 4427 - 2007(E). Designation PE100 PE80 PE63 PE40
PE 100 In the early 1990s, a new type of PE material was developed in Europe with higher hoop strength giving rise to the PE100 classification. These materials are sometimes termed bimodal or 3rd generation because of the two stage polymerization process used to produce them. PE100 materials produce stronger pipes which are used for higher pressure operation in gas and water distribution systems. A design engineer may wish to apply a greater safety factor depending on operating conditions and environmental considerations.
7
Jain PE Pipes Design Details & Technical Characteristics S.No. Features 1 Life Expectancy
2
Design Value of Frictional coefficient
3
Joint
4
Leak Proof
Characteristics PE Pipe has a Life Expectancy of 50 - 100 years. Measurement Formula Typical Design Value Absolute Roughness Colebrooke 0.000005 ft. Friction Factor “C” Hazen Williams 150 - 155 Roughness Coefficient Manning Equation 0.009 Remains constant throughout its life span PE pipe is normally joined by butt fusion method which creates a joint that is as strong or stronger than the pipe itself, and is virtually leak free. Butt-fused joints create a homogenous, monolithic joint leading to leak proof system. Does not rust, rot, or corrode. Jain PE pipes are non-conducting and inert and hence immune to galvanic and electrochemical corrosion. Jain PE pipes do not rust or corrode, both inside and outside. PE pipes do not degrade due to biological effects. They are not digestible and do not contain ingredients that would attract animals like rodents. The exceptionally smooth and flexible surfaces of the Jain PE pipes do not offer any abrasion effects to rodent’s teeth like steel, CI and DI pipes.
5
Corrosion Resistance & Biological Effects
6
Chemical Resistance
7
UV Protection
8
Impact & Toughness
Tough and good Impact Resistance.
9
Pressure Ratings & Dia.
PE pipe is available in various sizes upto 1600 mm dia. and pressure ratings of PN-2.5, PN-4, PN-6, PN-8, PN-10, PN-12.5 & PN-16 ( PN = kgf/cm²)
10
Lightweight
It is lighter than Metal or Concrete pipe. It is easier to handle & install as compared to above materials.
11
Flexibility
12
Abrasion Resistance
PE pipe has excellent chemical resistance. Black PE pipe containing 2 to 3.0% carbon black can be safely used outside in the sun without damage from UV exposure.
Asbestos cement pipe
Fibr e rein glass forc ed p ipe
pipe rete Conc
PE PVC Clay P ipe
400 000 200 000
Load cycles N
600 000
PE pipe can be bent to a minimum radius of 25 times the pipe diameter. This flexibility of PE pipe allows it to be curved under, over & around obstacles as well as directional changes. Good abrasion resistance as compared to other pipe. The performance ratio is 3:1 in favour of PE
0
0.5
1.0
1.5
2.0
2.5
3.0
Abrasion (mm)
13 8
Coiled Pipe
PE pipe is also available in coil form upto 140mm dia. with specific SDR.
Jain PE Pipes Design Details & Technical Characteristics S.No. Features 14
Earth quake / Soil settlement resistance
15
Water Hammer
16
Average E-Modulus (Mpa)
Characteristics Found good in case of earth quake and soil settlement. Jain PE pipes have excellent resistance to Environmental Stress Cracking which is due to the combined actions of stress and the environment. The strain ability of Jain PE pipes under stress is higher than any conventional pipes, thereby the pipes never fail due to prism loads and soil settlement due to seasonal changes. The water hammer effect in the Jain PE pipes are the lowest when compared to conventional pipes for similar operating conditions, thereby reducing the number of safety appurtenances necessary in the system as well the cost of maintenance. 900 to 1200 Mpa.
Temperature Effect Jain PE pipes perform well over a wide range of temperatures ranging from -40°C to 45°C for pressure applications and upto 80°C for non-pressure gravity-flow applications. However for higher temperature applications, suitable pressure de-ratings should be applied. Exposed to sunlight installations of Jain PE pipes will be subjected to temperature rise and fall during day and night which will cause pipe to change in length as it expands and contracts. Proper precautions should be taken for these linear expansions and contractions to avert damages to the pipe joints. System design should accommodate changes in the pipeline due to linear expansion or contraction. Expansion joints should not be used unless they are specially designed for PE pipe systems. In case of above-ground and over head installations exposed to direct sunlight consult JISL Engineer or authorized dealer for proper installation techniques to be adopted.
Temperature De-rating of PE Pipes (as per IS: 4984-1995 specifications) 1.40
Service Temperature
Multiplication factor for Pressure rating
20°C
1.24
25°C
1.12
30°C
1.00
35°C
0.88
40°C
0.76
45°C
0.64
50°C
0.52
0.40
55°C
0.40
0.20
60°C
0.28
63°C
0.18
Pressure Coefficient
1.20 1.00 0.80 0.60
20
25
30
35
40
45
50
55
60
65
Temperature °C
9
Jain PE Pipes Design Details & Technical Characteristics Regression Curves (Stress / Time curves) PE 80
PE 100
Minimum Required Strength (MRS) and Design Stress The MRS (Minimum Required Strength) classification of pipe is based on a 50 year life-cycle. This does not mean that the pipe will fail at 50 years, because the design stress is calculated using the 97.5% lower confidence limit of the predicted stress, coupled with a minimum safety factor of 1.25 (for water). Consequently when in service, the pipe is operating well below the stress that would cause a failure at 50 years and the actual failure time due to creep is likely to be only after hundreds of years.
10
Jain PE Pipes Design Details & Technical Characteristics All plastic materials used for the manufacture of pipeline systems are classified in accordance with ISO. Classification is achieved by testing pipe samples at different temperatures and internal pressures and recording the time to failure. The data is then extrapolated in accordance with ISO TR 9080 in order to predict the stress over 50 years. This classification system is based on the predicted minimum required strength (MRS), which is the hydraulic stress that would cause failure after 50 years. The MRS value increases at lower temperatures and vice versa. When designing pipelines for use at temperatures above 23°C the correct MRS value must be therefore be used for the given operating temperature. Since these regression curves are the root of the science of plastic piping, a somewhat detailed description is given below. At a fixed temperature the pipe is put under a fixed hoop stress “s” and the failure time “t” is measured. A whole range of hoop stresses is investigated (from 2 to 20MPa, depending on the polymer and the temperature), resulting in a whole range of failure times (from 1 to 10,000 hours). The regression curve is calculated as log s = f (log t) The long term hydrostatic strength sLTHS is the predicted mean strength at a given temperature, calculable over the whole range of time (from 1h to 50 years). It is extrapolated from the 20/40/60/80 degree C curves (failure times measured from 1 hour to 10,000 hours = 416 days). At 60°C and / or 80°C it may be possible to observe the knee before 10000 hours but at 20°C the knee should not be observed before 10000 h - it can only be known through extrapolation. As the behaviour of a resin can not be known before starting its regression curve, the exact failure times can not be predicted. In practice the creation of a regression could take 18 months or more. The permissible design stress is obtained by applying a safety factor (1,25 - 2,5) to the projected burst strength at 50 years. The failure can be either ductile (which corresponds to creep rupture) or brittle (which corresponds to environmental stress cracking). Ductile failure occurs at “high” hoop stress and gives a short failure time. Brittle failure occurs at “low” hoop stress and gives a long failure time. The two kinds of failure give rise to a linear curve made of two branches of different slope : almost horizontal for ductile failure (short failure time), and then steep for brittle failure (long failure time). The transition point between the 2 modes of failure, which is represented by a change of slope on the regression curve, is called the knee of the regression curve. PVC as well as the latest grades of HDPE will not display a “knee” on the curves.
Ductile Failure Ductile failure is a creep induced failure, or plastic deformation - the pipe stretches and deform itself under pressure. Ductile failure resistance can be enhanced by increasing the crystallinity and therefore the density of the polymer. The material is then stiffer. In failure induced by creep, the failure time depends on the applied pressure. This means that a small change in pressure implies a large change in failure time.
Brittle Failure Brittle failure is the result of (ageing induced) environmental stress cracking (slow crack growth) through the disentanglement of the polymeric chains. It can be prevented by increasing the entanglement (higher molecular weight, chain branching) time. On the contrary, environmental stress cracking / slow crack growth corresponds to an ageing induced degradation of the polymer. When the polymer becomes older, the polymeric chains disentangle themselves; micro cracks build and grow, so that the polymer loses its stress resistance. 11
Jain PE Pipes Design Details & Technical Characteristics Operating Pressure Hoop Stress, Internal Pressure & Wall Thickness
Classification of Pipe Material Sr. No.
Material Grade
MRS (Minimum Required Strength) of Material in MPA, at 20°C, 50 Years
Maximum Allowable Hydrostatic Design Stress (r), MPa Water At 20°C
Water At 30°C
For sewage and Industrial Efficient
(1)
(2)
(3)
(4)
(5)
(6)
i)
PE 63
6.3
5.0
4.0
3.0
ii)
PE 80
8.0
6.3
5.0
4.0
iii)
PE 100
10.0
8.0
6.3
5.0
Pressure Rating Pipes shall be classified by pressure rating (PN) corresponding to the maximum permissible working pressure at 30°C, as follows: Pressure Rating of Pipe (PN)
2.5
4
6
8
10
12.5
16
Maximum Permissible Working Pressure (MPa)
0.25
0.40
0.60
0.80
1.00
1.25
1.60
Wall Thickness Minimum wall thicknesses in mm of the pipe has been calculated as follows and rounded off to the next higher 0.1 mm
S=Pxd 2σ + P
where P =
maximum permissible working pressure in MPa at 30°C for 50 years of life;
d =
nominal outside diameter in mm;
σ =
specified maximum allowable hydrostatic design stress, in MPa at 30°C for 50 years of life.
The wall thickness of pipes are based on the maximum allowable hydrostatic design stress (σ) of 4.0, 5.0 and 6.3 MPa at 30°C water temperature for 50 years of life, for the three grades of materials. In case of variation in water temperature, the working pressure needs to be modified. However, occasional rise in temperature as in summer season with concurrent corresponding reduction in temperature during night has no deleterious efffects on the life and working pressure of the pipes. Maximum wall thickness has been calculated as follows: a) For pipes with an outside diameter less than or equal to 355 mm, maximum wall thickness = (1.1 x minimum wall thickness + 0.2 mm). b) For pipes with outside diameter equal to or greater than 400 mm, maximum wall thickness = (1.15 x minimum wall thickness + 0.2 mm). rounded off to the next higher 0.1 mm.
12
Jain PE Pipes Design Details & Technical Characteristics Surge & Fatigue It should be noted that thermoplastics such as modern HDPE and PVC-U respond to high rates of loading, i.e. as occurs with pressure transients, by exhibiting greater strength and stiffness. This is because the materials’ molecular chain structure reacts to resist the deformation. Hence, at high pressurisation rates pipes are better able to resist the higher stress levels associated with surge. The strength of the material will increase with high rates of loading. Surge and fatigue are often combined as a collective term. However, although both phenomena arise from the same events (valves closing quickly, pump shut down etc.)
Typical values of E Material
E (MPa)
HDPE
800 - 1200
PP
800 - 900
PVC-U
3000 - 3500
GRP
10000 - 20000
Typical Physical Properties Physical Properties
Values
Unit
Density (Base Density)
940.0 to 958.40
kg/m³
Melt Flow Index (190°C/2.16kg)
< 0.3
g/10 min.
Melt Flow Index (190°C/5kg)
0.2 to 1.1
g/10 min.
Vicat Softening Point
120 - 130
°C
Crystalline Melting Range
130-133
Viscosity Number
390
°C cm³/g
Mechanical Properties
Values
Unit
Shore D, Hardness
58 - 65
–
Tensile @ Yield
20 - 26
MPa
Ultimate Tensile
30
MPa
Ultimate Elongation at brack
>600
%
Elastic Modulus
900
MPa
Flexural Stress (3.5% Deflection)
13.8 - 20.3
MPa
Notched Impact (Charpy) AcN 23°C
20
KJ/m²
Notched Impact (Charpy) AcN 30°C
6
KJ/m²
Thermal Stability 210°C
>20
min.
Carbon Black content
>2
%
Benefits of PE 100 Operating Pressure
PE80
PE100
Material Saving %
Gain in Cross section %
Gain in Capacity %
Water 10 bar Gas • 100 h Failure time > 165 h Failure time > 1000 h Failure time > 100 h Failure time > 165 h Failure time > 1000 h > 930
Min.
> 20
4 5 6 7 34
g/10 Min 0.2 to 1.1 MPa 15 Min % 350 Min
Test Parameters -PE-100- 12.4 MPa-20°C PE-100- 5.5 MPa-80°C PE-100- 5.0 MPa-80°C PE-80- 9.0 MPa-20°C PE-80- 4.6 MPa-80°C PE-80- 4.0 MPa-80°C 23°C
Test Method ISO-3126
200°C
ISO/TR10837
190°C-5 Kg 23°C 23°C
ISO-4440/1 IS: 14885 IS: 14885
ISO-1167 ISO-1183, ISO-1872/1
B-Sure PE Gas Pipes Gas Pipe Dimensions SDR 17.6
SDR 13.6
Outer Dia. mm
MIN
MAX
MIN
16.0 20.0 25.0 32.0 40.0 50.0 63.0 75.0 90.0 110.0 125.0 140.0 160.0 180.0 200.0 225.0 250.0 280.0 315.0 355.0 400.0 450.0 500.0 560.0 630.0
2.3 2.3 2.3 2.3 2.3 2.9 3.6 4.3 5.2 6.3 7.1 8.0 9.1 10.3 11.4 12.8 14.2 16.0 17.9 20.2 22.8 25.6 28.5 31.9 35.8
2.7 2.7 2.7 2.7 2.7 3.3 4.1 4.9 5.9 7.1 8.0 8.9 10.2 11.5 12.7 14.2 15.8 17.7 19.8 22.4 25.2 28.3 31.5 35.2 39.5
2.3 2.3 2.3 2.3 3.0 3.7 4.7 5.5 6.6 8.1 9.2 10.3 11.8 13.3 14.7 16.6 18.4 20.6 23.2 26.1 29.4 33.1 36.8 41.2 46.3
SDR 11 MAX MIN Wall Thickness mm 2.7 3.0 2.7 3.0 2.7 3.0 2.7 3.0 3.4 3.7 4.2 4.6 5.3 5.8 6.2 6.8 7.4 8.2 9.1 10.0 10.3 11.4 11.5 12.7 13.1 14.6 14.8 16.4 16.3 18.2 18.4 20.5 20.4 22.7 22.8 25.4 25.7 28.6 28.9 32.3 32.5 36.4 36.6 41.0 40.6 45.5 45.5 51.0 51.1 57.3
SDR 9 MAX
MIN
MAX
3.4 3.4 3.4 3.4 4.2 5.2 6.5 7.6 9.2 11.1 12.7 14.1 16.2 18.2 20.2 22.7 25.1 28.1 31.6 35.7 40.2 45.2 50.2 56.2 63.2
3.0 3.0 3.0 3.6 4.5 5.6 7.1 8.4 10.1 12.3 14.0 15.7 17.9 20.1 22.4 25.1 27.9 31.3 35.2 39.7 44.7 50.3 55.8 -
3.4 3.4 3.4 4.1 5.1 6.3 8.0 9.4 11.3 13.7 15.5 17.4 19.8 22.3 24.8 27.8 30.8 34.6 38.7 43.8 49.3 55.5 61.5 -
Application: Jain Polyethylene Gas pipe are suitable for Gas distribution network both for domestic & industrial consumption. PE-100 SDR 7 & 9 are suitable for use in cross country gas conveyance pipeline systems.
Jain Gas Pipe
Jain Gas Pipe in coil
35
B-Sure PE Gas Pipes
36
B-Sure PE Gas Pipes
37
B-Sure PE Gas Pipes
38
Jain PE Landfill Gas Extraction Pipes PE Landfill Gas Pipe Landfill conditions present unique challenges for any piping system. In a landfill, a piping system will have to withstand external loads, be highly resistance to corrosive chemicals and harsh environmental conditions. The flexibility and light weight features of polyethylene pipe make it easy to assemble and install especially where conditions are far from perfect. One of the biggest advantages of using our pipe is its promise of leak free operation. Because our landfill gas pipe can be joined by heat fusion, landfill gas can be transferred to the processing plant without any fear of leakage and harm to the surrounding environment. As with many sanitary landfill projects, corrugated high density polyethylene pipe is used for leachate collection. The inert properties of PE pipe allow it to handle strong leachate solutions ranging in pH from 1.5 to 14. The leak free pipe ensures that the landfill doesn’t violate any regulations by contaminating the groundwater. Features : Jain PE pipes for landfill gas extraction are most suitable for the specific requirements demanded by the waste disposal environment due to their capacity to withstand temperatures beyond 40°C with high resistance to leachate chemical attack. They are flexible enough to withstand the unstable soil structure in the waste dump and have long life with low maintenance. All the above reasons make them most ideal for the application of landfill gas extraction at economical cost.
Jain PE Screen
Type of Screen: The screens are available in horizontal slots configuration as well as perforated (round hole) configuration. Slot sizes of 1.5 mm width or 5 mm diameter round holes onwards are available. Pattern of Screen: The pattern of slotting is available according to site/customer requirement either covering 2/3rd of the pipe or total circumference of the pipe. Size and Range: Jain PE screen is available in all sizes from 50 mm OD through 315 mm OD and higher. Two ranges of pipes are available as per table. Any special requirement will be made available on request. Type of Joints Jain Casing and Screens are available with butt-fusion welding joint for lateral application and with threaded flush joints for well assembly. The joints are also totally corrosion resistant and are free of maintenance. Self-restrained Sure-Loc™ joints are also available on request. Length of Pipe: Jain screens are available from 1 to 6 metres and casing of 5, 6 and 12 metres lengths as per customer/site requirement. PE Specials: Jain Landfill Gas extraction and waste disposal PE pipes are available with complete range of fittings like Bends (30°/45°/60°/90°), Equal Tees, Reducer Tees, Stub Ends, Reducers, End-caps and Blind Flanges. Any other special fittings required for site needs are provided on request and drawing. Specification: Jain PE Landfill Gas extraction pipes are manufactured from PE pipes conforming to IS:4984, DIN: 8074/75 and DIN 19537. Application: Jain PE Landfill Gas extraction pipes are used in municipal waste dumps as tube-well casing and screens for the extraction of methane gas which is used for power generation. 39
Jain PE Landfill Gas Extraction Pipes Dimension (mm) and Pressure Class IS: 4984/95 Wall Thickness (mm) PE - 80 Outer Diameter (mm) (6 Bar) (10 Bar) 50 2.9 4.6 63 3.6 5.8 75 4.3 6.9 90 5.1 8.2 110 6.3 10.0 125 7.1 11.4 140 8.0 12.8 160 9.1 14.6 180 10.2 16.4 200 11.4 18.2 225 12.8 20.5 250 14.2 22.8 280 15.9 25.5 315 17.9 28.7
Dimension (mm) and Pressure Class IS: 4984/95 Wall Thickness (mm) PE - 63 Outer Diameter (mm) (6 Bar) (10 Bar) 50 3.5 5.6 63 4.4 7.0 75 5.3 8.4 90 6.3 10.0 110 7.7 12.3 125 8.8 13.9 140 9.8 15.6 160 11.2 17.8 180 12.6 20.0 200 14.0 22.3 225 15.7 25.0 250 17.5 27.8 280 19.6 31.2 315 22.0 35.0
Dredge Pipe Jain Irrigation manufactures leak free PE pipe which can be used for marine and hydraulic dredging industries. PE dredge pipe is well suited for salt water environments with high levels of chlorine. Polyethylene is inert to salt water and is highly resistant to the chlorine that is frequently added to water intake lines. Its flexibility and light weight make it easy to handle and install in water environments. For the development of waterways, pond dredging, land reclamation, sludge dewatering, trout ponds and the restoration of lakes, ponds, rivers, marsh or swamp environments, PE pipe could be the answer.
Drainage Pipe Applications The main reason for installing drainage pipe is fourfold: to make land more accessible, to conserve land for future use, increasing crop yields and crop diversification. But in addition to its agricultural uses as a drainage tile, drainage pipe can also be used to drain residential lawns and golf courses. PE drainage pipe applications include: • Subsurface Drainage • Ground Water Collection • Building or Foundation Drainage • Landscaping Drainage • Golf Course Drainage • Field Drainage Tile
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Jain PE Pipe for Sprinkler & Farm Irrigation System Jain Irrigation Systems Ltd manufactures PE pipes for Sprinkler & Farm Irrigation System and Drainage applications. Dimensions of PE Sprinkler Pipes of material grades PE 63, 80 & 100 as per IS:14151 (Part-1)-1999 Nominal Outside Dia Dia 40 50 63 75 90 110 125 140 160 180 200
40.0 50.0 63.0 75.0 90.0 110.0 125.0 140.0 160.0 180.0 200.0
Class 1 (0.25 Mpa)
Class 2 (0.32 Mpa)
Class 3 (0.4 Mpa)
Class 4 (0.6 Mpa)
Nominal Tolerance on Outside Dia
Ovality mm
Min
Max
Min
Max
Min
Max
Min
Max
+0.4 +0.5 +0.6 +0.7 +0.8 +1.0 +1.2 +1.3 +1.5 +1.7 +1.8
1.4 1.4 1.5 1.6 1.8 2.2 2.5 2.8 3.2 3.6 4.0
2.0 2.2 2.7 3.1 3.5 3.9 4.4 4.9
2.4 2.6 3.2 3.6 4.1 4.5 5.0 5.6
2.0 2.5 2.9 3.4 3.8 4.3 4.9 5.5 6.1
2.4 2.9 3.4 3.9 4.5 5.0 5.6 6.3 7.0
2.0 2.5 3.0 3.5 4.2 4.8 5.4 6.2 6.9 7.7
2.4 2.9 3.4 4.1 4.8 5.5 6.1 7.0 7.8 8.7
2.3 2.9 3.8 4.5 5.3 6.5 7.4 8.3 9.4 10.6 11.8
2.8 3.4 4.4 5.2 6.1 7.4 8.3 9.3 10.6 11.9 13.2
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Jain Silicoat PE OFC Duct Jain Silicoat PE OFC Duct Range
Micro Duct - Ø 3/1.5, 5/3.5, 7/5.5, 8/4.4, 10/5.5, 10/7.6, 10/8, 12/8, 12/10, 14/10 & 16/10 mm OFC Duct - 29/23, 32/26, 32/27, 32/28, 40/33, 40/34.2, 50/42, 50/43 mm OD/ID
Standards
BSNL (TEC) Specification, inhouse
Length
Available in straight lengths 6/12 meters in all sizes and in coils upto 140mm OD
Material Grade • PE-63 Applications • • • • • •
• •
• PE-80 in different colours
• Optical Fiber Cable (OFC) Ducting for Telecom / Data Networks
Co-Extrusion process was developed in-house by JAINS in their R&D facility during 1993. Jain PE Ducts (Permanently Lubricated) is the result of innovative development in co-extrusion by JAINS. It is the versatile and unique solution for High Speed Air Blowing (HSAB) of Optical Fibre Cable (OFC). Jain Cable Ducts are manufactured with state-of-the-art machinery using latest processing technology and fulfill the performance requirement of National & International specifications. Approved by BSNL under TEC specification GR/CDS-08/02 November 2004. Common sizes are 40/33, 40/34.2, 50/42 & 32/26 Approved vendor and supplier to PGCIL, IOCL, GSPL, BSNL, MTNL Tata Tele, Airtel, Aircel, Vodafone, Hutch in India and also many customers in other countries as well like Alcatel, France. Capable of manufacturing tailor-made as per specifications to suit customer’s requirements. Supplied in coils of various lengths up to diameter 110mm. Supplied with pre-inserted PP rope on request.
Jain Silicoat™ PE OFC Duct Jain Silicoat™ PE OFC Duct is extruded from selected high quality virgin PE material and co-extruded with special lubricant that is distributed uniformly along the entire inner surface of the duct providing a low friction smooth surface for easy cable drawing or blowing. The outer PE make the pipe more tough and durable and enables the duct to withstand the pressure during HSAB of cable as well as retains the roundness under soil pressure and traffic load.
Jain Self Lubricated PE Duct The above ducts are also available with homogenous construction to give a smooth finish and low co-efficient of friction. Jain SLB PE Ducts have the same constructional stability and strength as that of Jain Silicoat™ PE Duct.
Jain Ribbed Walled Duct Jain ducts can also be supplied with inner lubricated area in ribbed form. Ribbed Wall is ideal for pulling or jetting cable, thus reducing surface contact with cable during installation. It is available in various sizes and colours.
Jain PLB Spiro Zoom OFC Duct Is a duct specially designed for rapid and safe blowing of OFC over long distances. 42
• Electric Cable Ducting
Jain Silicoat PE OFC Duct Spirally ribbed construction design has been validated using wind tunnel experiments and the ideal design has been identified. Friction is a critical limiting factor in determining the type and length of cable installation. Longitudinal ribbing results in a reduction of the contact surface between the cable and the conduit wall from an area to a line of contact. Decreasing the area of contact under the same sidewall load results in a higher localized normal force. Within a limited range of sidewall loads, the COF is found to go down – at least until the loading cause’s localized damage to the jacket sheath. Spiral ribbing further reduces the contact area from a line to a series of points. In addition, because the advancing cable is alternately on and off the ribbing, there is an Opportunity for cooling and re-lubrication. Constantly changing the direction of the spiral eliminates the tendency to accumulate spiral-induced torque in the cable. Further the forward spiral blow of air created by the spiral ribs keep the OFC moving and away from the duct walls. The combined effect of above facilitates safe and rapid blowing of above 2100 meters OFC at a time. At the time of replacement the existing cable can be de blown just as easily. The other vital advantage is the stress-free nature of the installation.
Technical Specification for Jain PLB HDPE Duct S.N 1 2 3
Test Tensile Strength Elongation Reversion
Unit N/MM² % %
4 ESCR (As per D1693 5 Impact Strength 6 Crush Resistance
The deflection with load The deflection after recovery
7 Mandrel test 8 9 10 11 12
Oxidation Induction Test Internal Coefficient of Friction Melt Flow Rate (at 5 kg, 190°C) Density (Finished Product i.e. Pipe) Hydraulic Chracteristics at Temp 80°C Type test
Acceptance test 13 Ash Content
Standard Value >20 >500 Not change more than 3% in the longitudinal direction 96 hours Sample should not crack during test period Kg The duct shall not crack or split (at 10 kg load) %
