Projects

Project:

Design, engineering, erection & commissioning of effluent disposal scheme on turnkey basis consisting of 13 Kms HDPE disposal pipeline (7.0 Km on shore and 6 Kms offshore) with multiport diffuser in Gulf of Cambay – the longest outfall with HDPE pipe in the country.

Location of Disposal:     Gulf of Cambay

Scheme:

• Cross-country on-shore pipeline from factory ETP to landfall point and submarine pipeline with multiport diffuser in sea.
• This 13 km long HDPE pipeline (6 km off-shore and 7 km on-shore) in telescopic
  configuration of 400 mm OD and 315 mm OD is the longest marine outfall pipeline in the country.

Salient Features:

• Special lateral anchoring system to safeguard submarine pipeline against abnormal and hostile currents and tidal waves in the Gulf.
•  Special C.I vertebra armors for HDPE pipeline in tidal zone for protection from sabotage.
•  Underwater trenching and burial below scour level in sea to ensure permanent stability.

Project:

Design, engineering, supply, erection and commissioning of effluent disposal pipeline – onshore for 11.0 km followed by 1.56 km long offshore pipeline and multiport diffuser system in Bay of Bengal – the second longest marine outfall pipeline with HDPE pipe in the country as yet.

Location of disposal:

Off Donipet coast into Bay of Bengal.

Scheme:

• Cross country onshore pipeline from factory ETP to Land Fall Point and submarine pipeline with multi-port diffuser in sea.
• The 11.0 km cross country pipeline traverses through agricultural lands, marshy lands and across canals and rivulets before it reaches the Land Fall Point.
• A 1560 meters long offshore pipeline connects the Land Fall Point to the specially designed  and installed multi-port diffuser in the deep sea.

Salient features:

• Special anchoring system to safeguard the submarine pipeline from abnormal forces during cyclonic turbulence in east coast.
• Multi-port diffuser housed in 3 separate semi-parabolic reaction blocks with concealed nozzles ensures least resistance to fishing activities in the region.
• This outfall pipeline is the second longest of its kind in the country till date.

Project:

Design, engineering, supply, erection and commissioning of effluent collection system with pumping stations and marine disposal pipeline (HDPE) with diffuser system and all allied civil, mechanical, instrumentation and electrical jobs including standby Gen. Sets in all four pumping stations. Offshore pipeline is safe even after the Tsunami.

Location of Disposal:

Off Cuddalore coast in Bay of Bengal- A coast line subjected to periodic cyclonic effects.

Scheme:

• Effluent collection network with HDPE conveyance pipelines of size varying from 110 to 355 mm OD totaling 9 km.
• Four Intermittent collection sumps and pumping stations with generators for backup power.
• Marine outfall system for disposal of 12 MGD treated effluents through submarine pipeline and diffuser in sea.

Salient Features:

• The combined treated effluent from various zones of the industrial complex is pumped out, after final pH correction, through a marine outfall pipeline of 2.2 kms with 1 km long offshore section in Bay of Bengal.
• A multiport diffuser, erected at the terminal end disperses and dilutes the effluent to permissible limits of marine discharge.
• Special anticyclone protection measure, Cuddalore being a cyclone prone area.
• This offshore pipeline withstood the recent Tsunami which devastated the east coast of India.

 Project:

Turnkey implementation of marine outfall scheme for disposal of combined effluents from  4 factories of Lalbhai Group of Industries. Design, engineering, erection & commissioning of submarine effluent disposal gravity main for 10 MGD flow —800 mm ID/ 900 mm OD HDPE pipe with multiport diffuser in Par river estuary in Gujarat.

Location of Disposal:

Par estuary of Arabian Sea.

An estuary with high intensity tidal waves, undulating bottom terrain and abnormal scouring and siltation effects

Scheme:

Submarine outfall pipeline (900 mm OD, 10 MGD flow) with multiport linear diffuser and HDPE ventilation chamber at landfall point.

Salient Features:

• Additional anchoring by underwater in-situ cast concrete blocks of 11 ton at 8 m intervals to counter extra buoyancy effects from dense silt accumulation during pre-monsoon periods.
• Special lateral anchoring at strategic points to counter lateral thrusts during high intensity floods.

 Project:

Turnkey implementation of marine outfall scheme for disposal of combined effluents from  4 factories of Lalbhai Group of Industries. Design, engineering, erection & commissioning of submarine effluent disposal gravity main for 10 MGD flow —800 mm ID/ 900 mm OD HDPE pipe with multiport diffuser in Par river estuary in Gujarat.

Location of Disposal:

Par estuary of Arabian Sea.

An estuary with high intensity tidal waves, undulating bottom terrain and abnormal scouring and siltation effects

Scheme:

Submarine outfall pipeline (900 mm OD, 10 MGD flow) with multiport linear diffuser and HDPE ventilation chamber at landfall point.

Salient Features:

• Additional anchoring by underwater in-situ cast concrete blocks of 11 ton at 8 m intervals to counter extra buoyancy effects from dense silt accumulation during pre-monsoon periods.
• Special lateral anchoring at strategic points to counter lateral thrusts during high intensity floods.

Project:

Survey, design, fabrication and installation of effluent disposal pipelines underwater with staggering diffusers (15 MGD flow through 3 Nos-600 mm diameter M.S outfall pipelines laid in estuary).

Location of Disposal :

Nearby Moovattupuzha river estuary.

Scheme :

Submarine pipeline system with Staggered diffusers.

Salient Features :

• Underwater parallel piping system of 3 steel pipelines with staggered diffuser system .
• This ensured adequate dilution and dispersion of effluent and prevented formation of  ‘colored effluent corridor’
• The inhabitants on the river bank found this solution aesthetically acceptable.
• This epoxy coated parallel steel pipeline system with 15 MGD flow is the largest industrial effluent outfall system till date, in terms of flow rate.

Similar Application:

A similar system designed by Hydroair for Grasim Industries Ltd. Calicut, Kerala, obtained the approval of concerned statutory bodies, who found it environment friendly and ideally suited for such critical applications.

 Project:

Design, engineering, erection & commissioning of effluent disposal marine outfall pipeline 5.8 KM long – 630 / 560 mm HDPE in telescopic configuration, with 0.8 KM pipeline in Gulf of Cambay.

Location of Disposal:

Gulf of Cambay – off Kantiajal coast.

Scheme :

• Turnkey execution of HDPE marine outfall scheme for safe disposal of effluents from viscose fiber plant.
• Pipeline traverses through 5 km long marshy land to reach the landfall point.
• Offshore pipeline of 560 mm OD is laid off Kantiajal coast into Gulf of Cambay.

Salient Features:

• Onshore pipeline is provided with suitably designed concrete counterweights to negate the buoyancy effect from marshy soil.
• Offshore pipeline ballasted with concrete anchor blocks at 1 mt c/c ensures safety and stability of the pipeline in Gulf waters.
• Multiport Diffuser in parabolic reaction blocks (installation differed for want of clearance).

 Project:

Design, engineering, erection & commissioning of submarine effluent disposal marine outfall pipeline with HDPE pipe and special multiport parabolic diffuser in Arabian Sea off Mangalore coast.

Location of disposal:

Off Tanirbavi coast in Arabian Sea – a coastline subjected to high intensity wave action.

Scheme:

HDPE outfall pipeline starting from manhole chamber located on seashore with 700 meter offshore pipeline in Arabian Sea and high efficiency multi-port diffuser at terminal end.

Salient features:

• Specially designed anchoring system was adopted for safeguard against intensive wave action along the coast.
• Specially designed multi-port parabolic diffuser system erected in sea efficiently dilutes the treated effluent to desired levels.
• Special cyclone protection measures were provided to the pipeline to safeguard it from cyclonic effects in the region.

 Project: 

Design, engineering, erection & commissioning of submarine effluent disposal HDPE marine outfall pipeline in offshore segment and C.S pipeline in onshore segment with special multiport diffuser in Bay of Bengal at 20 meter depth.

Location of disposal:

Bay of Bengal – Off Vizag coast, Andra Pradesh

 Scheme: 

• 1.28 Km long offshore HDPE pipeline
• 0.84 Km long onshore HDPE pipeline
• 0.78 Km long onshore C.S pipeline
• Linear multiport diffuser in Sea at 20 meters depth.

 Salient features: 

• Additional ballast weights to safeguard the pipeline against abnormal waves and currents.
• Post lay trenching and burial of pipeline to ensure permanent stability.

 Project:

Design, engineering, erection & commissioning of submarine effluent disposal HDPE marine outfall pipeline with metallic vertebra armour protection in vulnerable areas and multiport diffuser at terminal end in Arabian Sea.

Location of disposal:  Arabian Sea – Off Veraval coast, Gujarat.

Scheme:

• 0.41 Km long creek crossing HDPE pipeline.
• 1.0 Km long offshore HDPE pipeline.
• Multiport diffusers with imported Tide-Flex check valves in Sea.

Salient features:

• Special MS-HDG vertebra armor on the creek crossing pipeline for protection against damages due to boats etc.
• Special C.I vertebra armor protection on offshore pipeline to safeguard pipeline against rocky strata.
• Trenching and Burial of pipeline in creek segment and foreshore/intertidal zone areas.

 Project:

Design, engineering, erection & commissioning of twin HDPE marine outfall pipeline from effluent pumping station to Malcolm channel (Gulf of Cambay) with special multiport diffusers in sea fitted with imported Tide-Flex non return valves on port nozzles.

Location of disposal:

Malcolm channel (Gulf of Cambay), near Bhavnagar, Gujarat.

Scheme:

• Twin pipeline of 355 mm diameter selected for use instead of one large diameter pipe to minimize current thrust and ensure long-term stability in the highly dynamic gulf subject to extreme currents and 10 meter tidal difference.
• Separate multiport diffusers installed at terminal end of both the pipelines ensure proper dilution of the effluent in the gulf waters.

Salient features:

• Ballasting is done with C.I vertebra armor to reduce current thrust on the pipeline and provides extra ballast weight to ensure stability of the pipeline.
• Initial stretch of onshore pipelines is laid over a concrete trestle before getting down to intertidal zone of the gulf and proceed further into the deep waters.
• Imported EPDM Tide-Flex non return valves are provided on the port nozzles of both the diffusers to avoid entry of sand/sediments into the diffuser from the highly turbid gulf waters.

 Project:

Design, engineering, supply installation and commissioning of the first sea water intake pipeline with shore pumping system. Twin HDPE pipelines with SS316L intake screeners laid along the seabed contour draws uninterrupted sea water to the nearby farm located on eastern coast near Sirkali in Tamilnadu.

Location of Intake system:    Bay of Bengal.

Scheme:

• Twin submarine pipelines in HDPE (315 mm OD) with shore pumping system for sea water intake.
• Quantum of intake through twin pipes: 27,000 cubic meters/day.

Salient Features:

• Introduced in the country the innovative concept of sea water through submarine pipeline with shore pumping system.
• Special provisions for sand-free water intake throughout the year.
• Anti-cyclonic protection measures as special safeguard in east coast.
• The pumping system curtailed huge expenditure in laying large gravity flow pipeline by avoiding dredging cost to slope & level and construct deep intake sump for receiving the water from the gravity main etc.

Project:

Fabrication, supply and installation of 1000m dia. under water mild steel pipeline in Ulhas River with special intake strainer at terminal end for unhindered water intake of 20 MGD into the water treatment plant of MIDC.

Location of Intake:

Ulhas River near Shahad.

Salient Features:

• Extended intake pipelines (1000 mm dia, 20 MGD flow) into deep waters with specially designed strainers at terminal ends.
• Strainers prevent entry of marine debris and clogging, thereby allowing unhindered water intake in all seasons.

 HYDROAIR has designed and executed many State-of-the-art diffuser systems to suit the requirement of various situations.

Compact HDPE Multiport diffusers:

• In gulf of Cambay for effluent disposal from Phosphoric Acid Plant of GACL.
• In Bay of Bengal for Distillery effluent disposal from Pondicherry Distillers Ltd.

Linear Multiport Diffuser with SS concealed port nozzles:

• In Bay of Bengal for combined effluent disposal from SIPCOT Industries, Cuddalore.
• Effluent Disposal Through Special Linear Diffuser in Sengar River for GAIL-UPPC-Pata Project,Etawah, Uttar Pradesh
• In Arabian Sea for MRPL Marine outfall pipeline, Mangalore.

Linear Multiport Diffuser with concealed HDPE port nozzles:

• In Par estuary of Arabian Sea for 10 MLD combined effluent disposal from Lalbhai Group of
  Industries, Atul.
• In Daman Ganga estuary of Arabian Sea for distillery effluent disposal of Khemani Distillery, Daman.

Staggered Diffuser System:

• 3 diffusers in staggered arrangement – fordisposalof 15 MGD effluents from Hindustan News Prints, Kottayam.

Parabolic diffuser with concealed port nozzles:

• In Bay of Bengal catering to twin-disposal pipelines for disposal of effluents from Agro Chemicals andPharmaceutical plants of ICI, Ennore.

Special Y-type Diffusers:

• In Daman Ganga estuary of Arabian Sea with 5 meter branches each with concealed port nozzles housed in concrete reaction blocks.

 HDPE Pipeline at Kantiajal, Gujarat. CLIENT: Birla Cellulosic:

•  A 24″ diameter cross-country pipeline traversing for a distance of 5 km across salt- pans, marshy and forest lands was laid for conveyance of 20 MLD treated effluent from the Staple Fiber Plant of Birla Cellulosic’s, Kosamba.

• The cross-country pipeline connects the onshore concrete pipeline with the offshore HDPE outfall pipeline laid off Kantiajal coast.

HDPE Pipeline at Dahej, Gujarat. CLIENT: GACL, Dahej:

•  A 16″ diameterHDPE cross-country pipeline traversing for a distance of 7 km across agricultural and forest lands conveys 6 MLD of treated effluent from industrial complex of GACL located at Dahej.

• The cross-country pipeline connects the factory effluent lagoon to the offshore outfall pipeline laid off Luwara coast in Gulf of Cambay.

HDPE Pipeline at Vizag, Andra Pradesh. CLIENT: Aurobindo, Vizag:

•  A  HDPE cross-country pipeline traversing for a distance of 11.0 km onshore cutting across agricultural lands, marshy lands, canals and rivulets etc was laid for conveyance of pharmaceutical waste from M/s. Aurobindo Pharma Ltd. and Andhra Organic Ltd., located at Pydibheemavaram near Vizag in Andhra Pradesh.

• This cross-country pipeline connects the factory effluent discharge sump to the offshore outfall pipeline laid 11.0 km away – off Donipeta coast.

 In-plant piping for GACL –Dahej, Gujarat:

• Highly complex in-plant piping networks using various sizes of pipes ranging from 32 mm to 400 mm HDPE of 12.5 bar pressure class were fabricated and installed in the effluent treatment lagoon area of GACL’s industrial complex at Dahej.
• This in-plant piping included various suction and delivery headers of pumps in the ETP as well as Disposal Pumps of treated effluent in to the marine disposal system.

In-plant piping for BSES, Port Blair, Noida :

• The Suryachakra Power Plant earlier had CW pipelines made of HDPE of a particular design and configuration which did not meet the requirements of the plant.
• Hydroair designed, engineered and installed new set of in-plant piping replacing the entire old piping networks, thereby providing smooth and unhindered operation of the cooling water system.
• This in-plant piping system executed by Hydroair for M/s. BSES included large diameter suction headers, pump discharge lines as well as return pipelines to cooling tower. It also included over ground and underground piping networks with special polypropylene control valves at requisite points.

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