FIRST TIME IN INDIA -HEAVY METAL & LEAD FREE ASTRALCOLUMN PIPES FOR SUBMERSIBLE PUMPS
Chemical resistant
Energy saving
Low installation cost
Reliable for drinking water
(APPLIED FOR PRODUCT PATENT)
Lead Free
& Heavy
Metal Free
ENERGYSAVINGENERGYSAVINGENERGYSAVING
withstud pin
lock system
Design Patent
Pending
01 Introduction ................................................................................... 01
Why Pvc For Column Pipes ? .......................................................... 01
Why ASTRAL Column Pipes ?.......................................................... 01
02 Unique features ............................................................................. 02
Silent features ................................................................................ 02
03 Column Pipe Key Properties .......................................................... 03
Field Of Applications ...................................................................... 03
Column Pipe Sizes .......................................................................... 03
04 Dimensions .................................................................................... 04
05 Comparison Chart With Other Material ......................................... 06
06 Accessories..................................................................................... 07
07 Installation Procedures .................................................................. 08
08 Handling And Storage..................................................................... 09
09 Frequently Asked Questions About Astral Column Pipe................. 10
01
INTRODUCTIONASTRAL have been relentless in its
commitment to quality and service. Through
the years, ASTRAL have broadened and
enhanced its product line to better serve
the customers. ASTRAL was first to
Introduced Flowguard CPVC pipes and
fittings , ASTRAL Aquarius uPVC “Lead Free”
pipes and fittings, ASTRAL Foamcore Pipes and DWV
Click ring type fittings in Indian Market.
Repeting is tradition of introducing new products First Time in
Indian Market, ASTRAL is proud to introduce “Lead Free” and
“Heavy Metal free” uPVC column pipes in Indian Market which is
WHY PVC FOR COLUMN PIPES ?For many years, Metal pipes have been used with submersible
pumps to get the water from ground. These pipes are corrode and
scaled in their life span and giving troubles to the owner in terms of
qty of water and also the pumping cost. PVC has excellent chemical
and corrosion resistance to a broad range of fluids. So PVC can give
trouble free service for many years.
100% safe for drinking water application. In other term, ASTRAL
column pipes keep the water clean from the source itself and not
contributing to any toxicity to the water.
Astral Column Pipes are available in 1” (33 mm OD) to 4” (114 mm
OD) with different class like V4-12.5 Kg, Medium, Standard, Heavy
and Super Heavy with all standard accessories like Top-Bottom
Adapters Sets, Pump Guards, Lowering Jigs etc.
As the full line manufacturer of CPVC &uPVC piping system for
residential and industrial applications, Astral can be your one stop
source for all the plastic piping required for lifetime piping
solutions.
Secondly, among all thermoplastics also, PVC is the material which
can be compounded and modify keeping in the mind of special
characteristics required for pipes to be used with submersible
pumps. This versatility is not observed with other thermoplastics
like Polyethylene (PE). Hence PVC contributes to major usage as
piping material globally.
WHY ASTRAL COLUMN PIPES ?ASTRAL column pipes have been developed as a result of ASTRAL's
constant endeavor to develop superior yet economical piping
solution for submersible pumps. The compound has been
developed at ASTRAL's R & D lab after many trials and constant
research with the help of Japanese technology. ASTRAL's expertise
in introducing better compound in Indian Market, comes true yet
another time with introducing completely Eco Friendly – lead and
heavy metal free – column pipes.
The raw material such developed is processed in state of the art
machines which contribute to highest pipe quality with most
accurate dimensions. Then Pipes will be threaded in very high tech
CNC machines which are very essential for performance of column
pipes. The thread geometry is such designed that it will give highest
strength against vertical column load as well as pressure developed
due to pump operation.
02
LEAD FREE & HEAVY METAL FREE COMPOUNDAstral Column pipes have been manufactured using Lead free and
Heavy Metal free compound – in other word Astral Column pipes
are completely Eco Friendly. Pipes will not pollute the ground water
and will keep it safe for leaching of carsegenic material like Lead.
SPECIAL COMPOUNDASTRAL Column pipes are manufactured from “METAL FREE” uPVC
compound material especially developed by using “JAPANESE
TECHNOLOGY” to sustain best column loads, pressure and also
encounters the high impact developed during handling, storage and
installation. Due to this special compound the TENSILE property of
pipe increase which is being tested rigorously using modern testing
equipment.
STUD LOCK SYSTEM
Every pipe is fitted with coupler having “Stud Lock” a unique system
developed by ASTRAL, which ensures that during installation,
application or removal of system, the coupler will never dethread
from the pipe.
STUD LOCK SYSTEM EPDM ‘O’ RING SQUARE THREAD
DOUBLE LOCKING SYSTEMAstral is the only company in India giving double locking system
which gives highest safety and reliability of the system. Apart from
stud pin lock system, pipes and couplers are joined with special
joining compound which makes lifetime permanent joint without
affecting the thread dimensional stability in longer service life.
ANNEALING ON PIPES
Every pipe is annealed during manufacturing which is a very special
technique developed by ASTRAL. This will really enhanced the
mechanical properties of pipes which make sure that the pipes will
perform best during application.
100% HYGIENIC / SAFE FOR DRINKING WATER
Supply of drinking water is 100% hygienic and safe as being pumped
through ASTRAL uPVC column pipes manufactured from special
METAL FREE compound right from the origin of water source
beneath under the earth at maximum depth.
UNIQUE FEATURES
SQUARE THREADS :Unique square threads made on CNC machines provide sufficient
grip and additional strength against tensile load. Thus the joint
become fairly strong with sufficient factor of safety to take care of
load of entire assembly with pump weight. These specially designed
threads also make it suitable for easy fitment.
THIN AND THICK PROCESS :The pipe ends are specially given the effect of additional wall
thickness by using Thin & Thick process to compensate the strength
and load bearing capacity caused due to threading of pipes. The
effect of Thin & Thick is given to all sizes considering the working
conditions & load factor.
EPDM 'O' RING :Specially designed "O" rings provided on the threads makes the
joints watertight and absorb pump vibrations. These “O” rings are
made from EPDM rubber which is most suitable for drinking water
option.
SALIENT FEATURES
03
COLUMN PIPE KEY PROPERTIES• Manufactured from high quality virgin PVC compound, also
reliable for drinking water
• Chemical and corrosion resistance
• Long life
• Exceeds the performance requirements of ASTM D 1785
standard specifications for PVC pipes
• Smooth inner wall, no scale build up
• Low friction loss, resulting in energy saving, efficient pumping
• 100% leak proof joint with two rubber '0' rings per coupler
• Light in weight, easy to transport
• Fast and easy installation
• Low installation cost. Does not require wrenches, threading tools
or solvent cement
• No curing period, immediate pump testing possible
• High impact resistance
FIELD OF APPLICATIONSWater rising for submersible pump, domestic and industrial applications. Ideally suitable for long term use in salty, sandy and
chemically aggressive water.
CORROSIONRESISTANCE
EASYINSTALLATION
100%LEAK PROOF
LONG LIFELIGHT WEIGHT
COLUMN PIPE SIZESAVAILABLE SIZE :
2• 1"- V4 (12.5 kg/cm ), Medium and Standard2• 1¼", 1½" - V4 (12.5 kg/cm ), Medium,
Standard and Heavy• 2", 2½", 3" & 4" Medium, Standard,
Heavy and Super Heavy
SHORTLY INTRODUCING:2• 2"- V4 (8 kg/cm )
• 5” – Standard, Heavy & Super Heavy
04 05
DIMENSIONSNominal Size
(Inch)Nominal Size
(mm)
Type Wall Thickness (mm)
End Side Middle/Berral Side
Min Max Min Max
Average OutsideDiameter (OD)
(mm)
Length of ThickPortion at Both
Side(mm)
NominalEffectiveLength(mm)
UltimateBreaking
Load(Kg)
Safe PullingLoad with
Chain Pulley(Kg)
Safe AllowableHydrostatic
Pressure2(Kg/cm )
Safe TotalPump
Delivery Head(m)
25 mm
32 mm
40 mm
50 mm
65 mm
80 mm
100 mm
1”
1 ¼”
1 ½”
2”
2 ½”
3”
4”
33.0 ± 0.10
42.0 ± 0.10
48.0 ± 0.10
60.0 ± 0.13
75.2 ± 0.13
88.0 ± 0.15
113.0 ± 0.15
2V4 (12.5 kg/cm )
Medium
Standard
2V4 (12.5 kg/cm )
Medium
Standard
Heavy
2V4 (12.5 kg/cm )
Medium
Standard
Heavy
Medium
Standard
Heavy
2Super Heavy (35 Kg/cm )
Medium
Standard
Heavy
2Super Heavy (35 Kg/cm )
Medium
Standard
Heavy
Medium
Standard
Heavy
3.9
4.5
5.2
4.3
5.5
6.8
7.9
4.7
5.3
6.2
8.1
4.8
6.4
7.9
9.3
5.4
6.7
9.0
10.8
5.9
7.5
10.0
6.4
8.5
12.1
4.1
4.9
5.6
4.5
5.9
7.2
8.3
4.9
5.7
6.6
8.5
5.3
6.8
8.4
9.5
6.0
7.1
9.5
11.1
6.3
8.0
10.5
6.9
9.0
12.6
1.6
3.0
4.2
2.1
3.2
4.3
5.4
2.4
3.8
4.3
6.1
2.6
4.1
5.5
6.8
2.8
4.2
6.5
8.6
3.4
5.2
7.5
4.0
5.9
9.6
1.7
3.3
4.6
2.2
3.5
4.6
5.9
2.5
4.2
4.6
6.5
2.8
4.4
5.8
7.0
3.1
4.5
6.9
8.8
3.6
5.6
7.9
4.4
6.3
10.1
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
300 ± 20
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
3000 + 10
800
1450
1700
1340
2000
2600
3100
1760
2400
3000
4000
2900
3800
5000
5600
3550
5300
7000
8600
5100
7200
10600
7500
10500
16000
440
800
1250
740
1150
1500
1550
970
1250
1700
2000
1550
2100
3030
3500
1930
2860
4200
4800
2800
4110
6350
4100
5800
9500
12.5
16
30
12.5
15
25
35
12.5
15
26
35
13
20
27
35
10
16
26
35
11
17
26
10
15
26
125
160
300
125
150
250
350
125
150
260
350
130
200
270
350
100
160
260
350
110
170
260
100
150
260
06
ASTRAL uPVC riser/drop/column pipes are perfect replacement to conventional Galvanized Iron pipes used in bore wells and hold several
critical advantages over conventional Mild steel or Galvanized steel pipes, which are
COMPARISON WITHOTHER MATERIALS
Property Requirement forDrop/Riser/Column Pipes
ASTRAL uPVC COLUMN Pipes Mild Steel or Galvanized Steel Pipes
Long life ASTRAL uPVC Column pipes do not react with acidic or alkaline water and have a long life in the bore wells.
Steel pipes are prone to rust, corrosion & ultimately get damaged and need to be replaced quickly.
Light weight Pipes are Light in weight and are easy to handle, install and remove.
Pipes are heavy and a great effort is required for installation or maintenance. Difficult to handle.
Smooth Internal Surface Internal surface is smooth, Therefore low head loss due to friction & results in higher discharge of water.
Rough internal surface and head loss is high resulting in less discharge of water.
Leak proof joints Rubber seals are provided with the thread at every joint ensuring 100% leak proof.
Not pressure tight, No rubber seal & hence NOT Leak proof.
Strong threaded joints Specially designed square Threads, which DO NOT corrode, rust or deteriorate.
Threads are prone to rust and corrosion easily.
07
ACCESSORIES
‘O’ RING
1” to 4” ALL SIZE
• V4
• Medium
• Standard
• Heavy
• Super Heavy
uPVC COLUMN PIPE
1” to 4”
TOP BOTTOM ADAPTER SET
1” to 4” CI 3 SS Both
PUMP GUARD SET
1½” to 4”
SIGRI (LOWERING JIG)
2” to 4”
08
FIX THE ADAPTOR
Fix the Adaptor to Pump with wrench support, tightly22CONNECT FLANGES WITH SS RODS
Place 2nd MS Flange on top of PVC SM Piece coupler and connect both Flanges with SS
RODS
Note: Maintain minimum play between both Flanges while tightening the bolts to rods.44
INSERT MS FLANGE
Insert one MS Flange to Bottom Adaptor from bottom side 11
Wash PVC SM Piece male and female Threads with plain water and insert in Adaptor
Square Threads.
WASH WITH SOAP & CLEAN WATER
33INSERT PIPES
Clean the male and female Threads with plain water and insert pipe to pipe till last pipe. 55Drop the pump with one after another pipe with a support of LOWERING ZIG and
manpower.
FIX WITH PUMPS
66FIX WINDING WIRE
Tie the cable to pipe outer walls, with a winding wire loosely, with an extra length of one
foot approximately to each pipe to sustain the Vibration jerks. 77Fix TOP ADAPTOR to final pipe coupler, adjust with GI coupler and bend for regular
usage.
FIX TOP ADAPTOR FOR USAGE
88
INSTALLATION PROCEDURES
09
HANDLING AND STORAGE
The pipe should be handled with reasonable care. Because
Column Pipes are much lighter in weight than metal pipe. There is
sometimes a tendency to throw it around. This should be avoided.
The pipe should never be dragged or pushed from a truck bed.
Pallets for pipe should be removed with a fork lift. Loose pipe can be
rolled down timbers, as long as the pieces do not fall on each other or
on any hard or uneven surface. In all cases, severe contact with any
sharp objects (rocks, angle irons, forks on forklifts, etc.) should be
avoided.
STORAGEIf possible, pipe should be stored inside. When this is not
possible, the pipe should be stored on level ground which is dry and
free from sharp objects. If different schedules of pipes are stacked
together, the pipe with the thickest walls should be at the bottom.
The pipe should be protected from the sun and be in an area
with proper ventilation. This will lessen the effects of ultraviolet rays
and help prevent heat built-up.
If the pipe is stored in racks, it should be continuously
supported along its length. If this is not possible, the spacing of the
supports should not exceed three feet (3’).
When storage temperatures are below 0°C (32°F), extra care
should be taken when handling the pipe. This will help prevent any
problems which could be caused by the slightly lower impact
strength of uPVC pipe at temperature below freezing.
HANDLING
10
FREQUENTLY ASKED QUESTIONSABOUT ASTRAL COLUMN PIPE1. Why Lead Free Column Pipes?
2. Why ASTRAL Column Pipes?
3. What is the expected life of ASTRAL Column Pipes?
4. What is the benefit of stud pin lock system in astral column pipes?
5. Is unique feature of astral column pipe?
6. Why column pipe is not made in 6 mtr length?
7. How do you say that this is better than the traditional GI pipes?
Lead is a metal with no known biological benefit to humans. Too much lead can damage various systems of the body including the nervous and reproductive systems and the kidneys, and it can cause high blood pressure and anemia. Lead accumulates in the bones and lead poisoning may be diagnosed from a blue line around the gums. Lead is especially harmful to the developing brains of fetuses and young children and to pregnant women. Lead interferes with the metabolism of calcium and Vitamins D. High blood lead levels in children can cause consequences which maybe irreversible including learning disabilities, behavioral problems, and mental retardation. At very high levels, lead can cause convulsions, coma and death. Lead can be dissolved in water when lead pipes are used for transportation of water. So use of such pipes may be harmful to human being. So, lead free column pipes are recommended for drawing pure and safe water from bone wells.
Astral is pioneers in India for introducing new plumbing systems since its inception. Astral Column pipes comprises of life long trouble free service with its unique features like Lead free, Stud Pin Lock, Double Locking with Special Adhesive, Annealing on pipes etc. Astral column pipes are most advanced column pipes available in Indian Market today.
ASTRAL Column Pipe system design & standards incorporate significant engineering safety factors which should translate to a long service life ASTRAL Column Pipe System have a design service life span up to 50 years. ASTRAL Column Pipe System is not susceptible to corrosion, scale build up or electrolysis in areas where water, solid and / or atmospheric conditions are aggressive. ASTRAL firmly believes that the system will provide a service life as long or longer than alternative materials in the market.
STUD PIN LOCK SYSTEM will give more grips to pipe and coupler while installing and retrieval time. By joining the coupler it makes one end male Thread and other end Female Thread. This system is user friendly and EXTRA safety in long run.
Especially designed THIN AND THICK process for more safety of threads, “LEAD AND METAL FREE” product made in India for the 1st time, also exported to abroad.
Depends on gravitational calculations and bendable radius of pipe considered and not made in 6 mtrs length.
This is lesser in weight, easy installation, low manpower required, no rust after any number of years, this will give long run and generations will use the pipe, economy, regular availability of raw material, no friction loss, this will support motor, take less load and give expandable life, no electro leakage and finally users can use in full depth also with full confidence.
8. Are you sure that plastic pipe will take a full load of motor and pump including water inside the pipe?
9. What is the capacity on plastic threads?
10. How the selection of the Pipes to be done ?
11. Will ASTRAL Column Pipes Save me Money?
12. If situation demands is it advisable rethreading at site?
13. Is it necessary to provide Full casing in the bore for column pipes?
14. Is it possible to recover water pump from borewell, in case of bone failures?
Yes, this PVC column pipes are made with specially designed square threads, a new technology to sustain the load and pressure at full capacity.
The threads are designed in square to give more sustaining capacity, depends on the lowering depth. The breakable load and safe chain pulley load etc. are considered on depth and pressure rating of the pipe. Any HP Motor and Pump can be installed according to this formula scientifically, Technological Methodology.
The pipes can be selected based on the depth of the bore well, pump delivery head and maximum allowable pressure of the pipes. ASTRAL manufacture different pressure class pipes for different lowering depths which mostly cater all different requirements worldwide. ASTRAL range of pipes is successfully installed up to 1100 ft. Contact out Sales Team / Technical support team for further details.
Yes, ASTRAL column pipes are much cheaper than Metal pipes. Also these pipes offer superior performance due to its higher Hazen William Factor (C= 150). It is not susceptible to corrosion, scales build up and hence gives 20-25 % more water even in long service of life. In other terms it also saves money for power consumption on pumps.
No, it is not allowed to cut or rethread the pipes on site. These pipes are threaded on highly sophisticated CNC machines with highest dimensional accuracy. This type of perfection is not possible at site. Also ASTRAL has complete range of pipes with different lengths of pipe so in most of the cases such operations are not required at site.
It is not compulsory to provide the full casing to the ASTRAL column pipes in normal conditions. But technically it is always better to provide full casing to Column pipes which helps the system performed better. Especially in the areas where loose stones or bolders or loose soils are prevalent, full casing will help to prevent the failure of bore.
It is possible to recover the pump and pipes by applying the force equal or less than the ultimate breaking load. In the cases where the higher forces are required, it is not possible to recover the pipes or pumps.
Note:
Educate customer to DEMAND for TWO SIDES PIN LOCK SYSTEM (STUD PIN LOCK SYSTEM) to prevent conversion to other column pipes by multi product /brand sellers.
ACP/PC/001REV:00/07/13
Spe
ctru
m :
0982
4097
300
Authorised Distributor :
All information contained in this manual is given in good faith and believed to be accurate and reliable. But because of many factors which are outside our knowledge and control and affect use of product, no warranty is given or is to be implied with respect to such information, nor we offer any warranty of immunity against patent infringement. No responsibility can be accepted for any error, omissions or incorrect assumptions. Any specification can change without prior notice.
ASTRAL IS ISO 9001:2008REGISTERED COMPANY
ASTRAL POLY TECHNIK LIMITED Registered & Corporate Office : 207/1, Astral House, B/h. Rajpath Club, Off. S.G. Highway, Ahmedabad-380 059, India.
Phone : +91 79 6621 2000 Fax : +91 79 6621 2121 E-mail : [email protected] Website : www.astralcpvc.com
Mumbai : Unit No.138, Udyog Bhavan, Sonawala Road, Goregaon (E), Mumbai - 400063.
Phone : 022 - 2686 2227 Telefax : 022 - 2686 2397 E-mail : [email protected]
New Delhi : 414, Ansal Chamber - II, 6, Bikaji Cama Place, New Delhi - 110 066.
Phone : 011 - 2616 9461 Telefax : 011 - 2616 8156 E-mail : [email protected]
Bengaluru : No. 102, 1st floor, Bull Temple Road, Next To Ram Krishna Ashram, Bengaluru - 560019.
Telefax : 080-26617236 E-mail : [email protected]
Hyderabad : Plot No. 67, 1st Floor, Paigah Colony, B/h. Anand Theatre, S.P. Road, Secunderabad - 500 003.
Telefax : 040 - 2790 0023 E-mai : [email protected]
Chennai : Flat No. AK6, 2nd Floor, “Natraj Palace”, No. 54(22), Saravanan Street, T. Nagar, Chennai - 600 017.
Phone : 044 - 4350 6384 E-mail : [email protected]
Jaipur : Parijit Appt., Plot No. O-12, Keshav Path, Ashok Marg 'C' Scheme, Nr. Ahinsa Circle, Jaipur - 302001.
Phone : 0141 - 2360236 E-mail : [email protected]
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