JINDAL SAW LIMITED

Total Pipe Solutions

Topic-1 :DUCTILE IRON PIPE & FITTINGS

(Double Chamber Restrained Joint)

Topic-2: SURGE ANALYSIS

(Large Diameter Pipes)
 INDEX-TOPIC 1
DOUBLE CHAMBER RESTRAINED JOINT- INTRODUCTION & IT’S REQUIREMENT

DOUBLE CHAMBER RESTRAINED JOINT- DESIGN AND MANUFACTURING

DOUBLE CHAMBER RESTRAINED JOINT- JOINTING & INSTALLATION

RESTRAINED JOINT - PIPE LENGTH CALCULATION

 INDEX-TOPIC 2
SURGE- INTRODUCTION

SURGE - PUMPING MAIN ANALYSIS

SURGE- GRAVITY MAIN ANALYSIS

SURGE –SELECTION OF SURGE PROTECTION DEVICES

 JINDAL SAW LIMITED - DUCTILE IRON PIPE & FITTINGS

Plant Jindal SAW Limited, India Jindal SAW Gulf LLC, UAE Jindal SAW Limited, India (Fitting Plant)
Size Range DN 80 - DN 1200 DN 100 - DN 2200 DN 80 - DN 2200
C Class & K Class C20, C25, C30, C40,
C Class & K Class C20, C25, C30, C40, C50, K12 & K14 and other class as per IS 9523 &
Class of pipes C50, C64, K7, K9, PP, PN20, PN 35 &
C64, K7, K9, PP, PN20, PN 35 & FLCL International standard
FLCL
Push-on Socket and Spigot Joint, Self- Push-on Socket and Spigot Joint, Mechanical
Push-on Socket and Spigot Joint, Self-anchored
Joints anchored Restrained Joint -JSAW Lock & Joint (Collars), Self-anchored Restrained Joint
Restrained Joint -JSAW Lock
Flange Pipe -JSAW Lock, Flange Pipe, Puddle Pipes etc.
ISO 2531, ISO 7186, BSEN 545, BSEN ISO 2531, ISO 7186, BSEN 545, BSEN 598,
Confirming Standards ISO 2531, BSEN 545, BSEN 598, IS 9523.
598, AS/NZS 2280, IS 8329 AS/NZS 2280

Type of Linings SRC, OPC, BFSC, HAC & Seal Coat SRC, OPC, BFSC, HAC & Seal Coat OPC,BFSC, SRC, HAC

Type of Coatings Zn & Zn-AI Coatings Zn & Zn-AI Coatings Zn Coatings

Finishing Layer Blue/Red Epoxy or Black Bitumen Blue/Red Epoxy or Black Bitumen Blue/Red Epoxy or Black Bitumen

External and Internal Polyurethane

External and Internal Polyurethane Coatings as
Special Coatings Coatings as per BS EN 15189 and BS FBE
per BS EN 15189 and BS EN 15655
EN 15655
DOUBLE CHAMBER
RESTRAINED JOINT
INTRODUCTION & IT’S
REQUIREMENTS
 NORMAL PUSH-ON JOINTS

The Normal Push-on Joints are not axially restrained

(does not provides significant restraint against longitudinal separation)
 RESTRAINED DOUBLE CHAMBER PIPES

JSAW –LOCK DI pipes are designed in such a way that

individual pipes are connected using the lock system to
form one complete system without need of welding,
screwing, surface treatment or without having problem
of loosening.
The Restrained joint pipes are axially restrained.
 INTERNATIONAL & IS STANDARDS
Sr. no. International Standard Description
1 ISO 2531 Ductile iron pipes, fittings, accessories and their joints for water applications
2 BS EN 545 Ductile iron pipes, fittings, accessories and their joints for water pipelines —
Requirements and test methods
3 ISO 7186 Ductile iron products for sewerage applications
4 BS EN 598 Ductile iron pipes, fittings, accessories and their joints for sewerage
pipelines — Requirements and test methods
5 ISO 10804 Restrained joint systems for ductile iron pipelines — Design
rules and type testing
IS 8329:
6.4 Restrained Joints
The design of restrained joints for ductile iron pipelines and its requirements shall be subject to agreement
between the purchaser and the manufacturer as agreed at the time of enquiry and order. Their spigot
external diameters DE and their tolerances shall be in accordance with requirements of 15.
RESTRAINED JOINT PIPES TO
TAKE CARE THE
UNBALANCING FORCE
 STRAIGHT PIPE
Axial components acting on a plane perpendicular to the pipe through a straight
section of the pipe are balanced internally by the force acting on each side of the
plane.
 UNBALANCING FORCE
In the case of a bend, the forces, PA, acting axially along each leg of the bend are not
balanced. The vector sum of these forces is shown as T or Fr. This is the thrust force. To prevent
separation of the joints, a reaction equal to and in the opposite direction of “T” or “Fr” must be
established.
 RESULTANT FORCE
Fx = PA(1- cos ɵ)

Fy = PA sin ɵ
2 2
Fr= √(Fx) + (Fy)

Fr= 2PA Sin (ɵ/2)

 UNBALANCED THRUST FORCES
The unbalanced thrust forces are generated in following conditions:-
o Change in directions
o Thrust at Bends – Horizontal/Vertical
o Thrust at a Tee of Wye
o Thrust at a Reducer
o Thrust at a Dead End or Valve.

There are two ways to take care the unbalancing above thrust load:

a) Thrust Block/ Concrete Block

b) Restrained Pipe
 THRUST BLOCK
Checks:
Sliding,
Overturning
& SBC

Resistance is provided by transferring the thrust force to the soil through the larger bearing
area of the block such that the resultant pressure against the soil does not exceed the bearing
strength of the soil.
RESTRAINED LENGTH REQUIREMENT-HORIZONTAL BEND

ɵ ɵ 𝟏 ɵ
𝑷. 𝑨. 𝐬𝐢𝐧 = 𝑭𝒇 . 𝑳. 𝐜𝐨𝐬 + . 𝑹𝒔 . 𝑳. 𝐜𝐨𝐬
𝟐 𝟐 𝟐 𝟐

Restrained joints pipes works on the principal that the resultant of the unbalanced
thrust forces should be safely transmitted to the soil through friction and bearing.
PIPELINE ANCHORING ON SLOPE
 PIPELINE ANCHORING ON SLOPE

Nos of Slope anchor can be reduced in case of use of Double chamber restrained Pipes.
 ADVANTAGES OF RESTRAINED JOINT
❑ Overall cost of restrained joint pipes and fittings is lower than concrete thrust
block;

❑ Jointing of restrained pipes can be done in less time as compared to

construction and curing of thrust block for a minimum period of 28 days;

❑ No risk of settlement in case of soil movement or settlement of soil;

❑ Restrained joint pipes are environmentally sustainable option as compared to

concrete thrust block, which requires consumption of cement, steel, sand and
need more space;
DESIGN AND MANUFACTURING
 RESTRAINED DOUBLE CHAMBER PIPES

JSAW –LOCK DI pipes are designed in such a way that

individual pipes are connected using the lock system to
form one complete system without need of welding,
screwing, testing, surface treatment or without having
problem of loosening.
LOCKING CHAMBER & GASKET SEATING GROOVE
JOINTING & INSTALLATION
INSTALLATION- DOUBLE CHAMBER RESTRAINED PIPE
1. Position the Socket 2. Cleaning the Socket 3. Gasket Insertion

Position the Socket

4. Lubrication
 INSTALLATION- SPIGOT PREPARATION
5. Cleaning the Spigot 6. Lubrication
 INSTALLATION- ASSEMBLY

Assembled Joint Lock Insertion

• Nos. of Lock plates are different for different size of Pipes.

 WRAPPING BELT & SLACK

All Lock Inserted

Pull Back all the locking segment & Wrapping belt
outside direction until they are in
contact and pressed against the
slope of the retaining chamber.
Then wrap the wrapping belt
around the outside periphery of
locking segments

Pull the pipe out of the joint until weld bead comes to rest
against the segment (Remove Slack).
 PERMISSIBLE DEFLECTION
• Deflect, if required, within the permissible limits.

• ( Permissible limit as recommended by Manufacturing Catalogue)

RESTRAINED JOINT PIPE
LENGTH CACULATION
RESTRAINED LENGTH REQUIREMENT
ɵ ɵ 𝟏 ɵ
𝑷. 𝑨. 𝐬𝐢𝐧 = 𝑭𝒇 . 𝑳. 𝐜𝐨𝐬 + . 𝑹𝒔 . 𝑳. 𝐜𝐨𝐬
𝟐 𝟐 𝟐 𝟐

ɵ
𝑺𝒇 . 𝑷. 𝑨. 𝒕𝒂𝒏
𝐿= 2
𝟏
(𝑭𝒇 + 𝑹𝑺 )
𝟐
Unit Frictional Force Fs
RESTRAINED LENGTH REQUIREMENT

ɵ
𝑺𝒇 ×𝟐×𝑷×𝑨×𝐭𝐚𝐧 𝟐
L1= 𝟏 -L
𝑭𝒇 + 𝑹𝒔
𝟐

AWWA M41 & ISO 21052

SURGE
 INTRODUCTION-SURGE
• Water hammer or surge or hydraulic transients is a phenomenon occurring in closed conduit or
pipe flows, associated with Rapid changes in discharge in the pipe

Change in velocity
• Valve Closer & Opening
Change in Pressure
• Starting of Pumps
• Stopping of Pumps Wave velocity Propagation
• Power Failure
• Single Pump Failure
 POWER FAILURE

Power Failure

Motor Speed Starts Dropping Rapidly

Pump Discharge and Head Reduce

Down surge pressure wave travels

Up-surge pressure wave travels

 COLUMN SEPARATION
Power Failure

Motor Speed Starts Dropping Rapidly

Pump Discharge and Head Reduce

Down surge pressure wave travels

Vapour pressure occurs at Peak of Alignment

Pressure control at the location, it functions as a

Column Separation Pseudo-Reservoir, segregating the flow upstream and
downstream of the location
 PUMPING MAIN- STEADY STATE

Maximum Pressure in Pipeline (Without Surge) < PFA (or AOP)

PUMPING MAIN- HEAD CURVE (SURGE CONDITION)

Maximum Pressure (Including Surge) in pipeline < PMA (or MOP)

PUMPING MAIN- PRESSURE CURVE (SURGE CONDITION)

Class of
Pipes shall
be decided
based on the
pressure and
head profile;
DESIGN OF DUCTILE IRON PIPE - HYDROSTATIC
Gravity Main- Steady State

Maximum Pressure in Pipeline (Without Surge) < PFA (or AOP)

GRAVITY MAIN- HEAD CURVE (SURGE CONDITION)

Maximum Pressure (Including Surge) in pipeline < PMA (or MOP)

GRAVITY MAIN- PRESSURE CURVE (SURGE CONDITION)

Class of
Pipes shall
be decided
based on
the
pressure
and head
profile;
SURGE PROTECTION DEVICE
• Surge/Air Vessel

• Zero Velocity valves

• Air Cushion/ Vacuum breaker Valves

• One way Surge Tanks

• Control Valves/ By- Pass Valves

 TYPE TESTS - DI PIPES
Tests Test requirements Test Conditions
Positive internal Test Pressure : (1.5 x PFA + 5 ) Joint of maximum annulus,
hydrostatic bar; aligned and withdrawn, with
pressure Test duration: 2h; shear load
No Visible leakage Joint of maximum annulus,
deflected
Negative internal Test pressure: -0.9 bar; Joint of maximum annulus,
pressure Test duration: 2h; aligned and withdrawn, with
Maximum pressure change shear load
during test period: 0.09 bar Joint of maximum annulus,
deflected
 TYPE TESTS -DI PIPES
Tests Test requirements Test Conditions
Cyclic internal 24 000 cycles; Joint of maximum annulus,
hydraulic pressure Test pressure: between aligned and withdrawn, with
PMA and (PMA – 5) bar shear load
No visible leakage;
THANK YOU