FLO-TEK Manufacturers of pipes, tanks & fittings BOREHOLE CASINGS & SCREENS NO ONE CARRIES WATER LIKE WE DO.CONTENTS Company Profile Introduction Well Casings & Screens Properties Advantages, Features & Benefits Transport, Storage, Handling & InstallationCOMPANY PROFILE FLO-TEK is one of the leading manufacturers of unplasti sed Polyvinyl Chloride (PVC) pipes, High Density Polyethylene (HDPE) pipes and Rotomoulded products in Southern Africa. History Radical Investments (Pty) Ltd, trading as FLO-TEK PIPES & IRRIGATION was established in Botswana in 1998 manufacturing PVC pipes, In July 2003 and June 2004, FLO-TEK commenced manufacturing rotational moulded products and HOPE pipes respectively. FLO-TEK was established in South Africa in 2005. An HDPE pipe factory was started in Clayville in August 2007. FLO-TEK South Africa has since opened a branch in Cape Town and subsidiary companies in Dundee and Port Elizabeth. FLO-TEK also has an established company in Angola. Core Business and Service Proposition FLO-TEK's core business is the manufacturing and distribution of HOPE and PVCU and PVCM Pressure and Sewer pipes and Rotomoulded products, as well as Borehole Casings and Screens, Our ISO 9001:2008 certified factories in Johannesburg and Botswana enable us to manufacture our pipes and tanks as well as to distribute to South Africa, Botswana and other SADC countries. Our factories have fully equipped laboratories which ensure FLO-TEK manufactures to SANS, ISO and SAPPMA specifications. Within our South African and Botswana operations, we have experienced staff who bring a wealth of knowledge and experience. FLO-TEK ensures the best quality product and the highest delivery standards. Broad-Based Black Economic Empowerment FLOCTEK is a BEE compliant company. ‘The principles of broad-based BEE through stakeholder empowerment, have also been integrated into how we do business, and how we can assist and support our Clients in how they do their business. The empowerment of women and the development of skills at lower levels of the organization to facilitate career and personal {growth opportunities and the particular areas that wll continue to receive attention and focus within our own business To date, FLO-TEK has successfully qualified for numerous governmental, parastatal and NGO projects and tenders on grounds of its present BEE status. Progress towards a progressive, but realistic strategic economic empowerment target, both directly and indirectly, is being made fon a broad front. Leadership of the overall transformation programme tests with the management and the stakeholders oversee the application of the Transformation and Broad-based BEE strategies within the organization.WELL CASINGS & SCREENS “To keep loose sand and gravel from collapsing into the borehole it is necessary to use well casing and screens. The screens support the borehole walls while allowing water to enter the pipe from the well. Unslotted casing is placed above the screen to keep the rest Of the borehole open and serve as housing for the pumping equipment. Most boreholes are constructed using PVC casings and screens. PVC has become the material of choice as it is competitively priced, corrosion resistant, light weight and easy to work with, Design of Screens “The screen is the most important single factor affecting the efficiency of the well. The screen is a type of strainer placed in the water bearing rock or sand in a borehole and which allows water to enter the bore of the pipe while preventing sand from entering. The screens have slots cut into the walls of the casing, the width of the slot being chosen to allow very fine sand particles to enter the bore and be pumped out while preventing coarser particles from entering. ‘The widths of the screen slots vary from 0.3 to 2 mm and means that screens can be classified in terms of the percentage of open’ area and hence thelr permeability. This is shown in Tables 1 and 2. The majority of screens have slots with widths of between 0.3 and. 1.0 mm, Table 1 Table 2Design of Screens cont. In rural water supply systems in remote areas the use of screened boreholes is normally employed. This involves driling the borehole down to bedrock and taking accurate logging samples of the rock strata as the driling progresses, this Is very Important as the screens selected should match the formation that is drilled. With this information the use of correctly chosen slot widths and screen permeability can be employed. ‘A typical screen with precision machined slots and threads is shown in fig. 1 fig ‘The slots are cut into the PVC pipe using special equipment designed to give precise, accurate slot widths and consistent quality screens, as shown in fig. 2, below fig.2 apes ‘An end cap which can either be solvent welded to the bottom screen or connected via screw threads, Is used to close off the bottom of the piping. A typical solvent welded end cap is shown Infig. 3. fig3 Screen Specifications ‘These are shown in fig. 4. PPP, = afar = a fig Specifications: Slot size Distance between slots Longitudinal size as per interior circumference Outside diameterCasing De: Casings are designed with regards to their diameter, wall thickness and threads. The diameter is determined by the amount of water required from the well and the size of the equipment used to pump the water from the borehole. ‘The wall thickness of the casing and screens depends on the depth of the borehole and must be sufficient to prevent collapse of the ‘casing once the borehole is operational. Casings are classified according to the depth of the borehole, the deeper the well the greater the external pressure or stress on the wall of the casing. Thus greater depths require greater wall thicknesses as the pipe diameter Increases so as to provide the required stiffness and resistance to buckling. PVC pipes used for Flo-Tek’s casings and screens are made to the rigid quality standards specified for pressure pipes according to SANS 966 Part 1. (Components of pressure pipe systems. Part 1: Unplasticised poly(vinyl chloride) (PVC-U) pressure pipe systems). ‘The design of the standard range of casings follows the pressure classes given In SANS 966-1, Table 3 - Dimensions of PVC-U pressure pipes. Thus 110 mm class 12 casings have a wall thickness of 5.1 mm and a standard dimension ratio (SDR) of 110/5.1 = 22. 160 mm. lass 12, wall thickness 7.3 mm, SDR of 160/73 = 22. ‘The class 12 (SDR 22) pipes are designed to be used at borehole depths of 120m, while class 16 pipes (SDR 16) can be used at depths of up to 160 m. Other classes of pipes, e.g. class 10, can also be made for borehole depths up to 100 m. Thread Designs ‘Casings and screens can be easily joined via trapezoidal threads made to DIN 4925 on diameters 90mm - 225mm and ASTM F480-88 on diameters 20mm - 75mm and 250mm upwards, which provides flush exterior and interior joints between each length of casing. The flush finish promotes easy installation and improved flow of water from the borehole. These threads are shown in fig. 5. figs ‘The threads are made on modern, state of the art equipment as shown in fig. 6. This ensures consistent and accurately cut threads essential for trouble free installation. figs Another popular thread design is made as per ASTM F480:88 and Is mainly used on specially designed ‘inspection’ pipes. These are ilustrated in fig. 7 fig?Class 6 Casing and Screens (Design stress 10.0 MPa) In certain conditions existing in shallow boreholes where there is less external pressure on the casings, a class 6 pipe is sometimes used. It is not possible to thread these thin wall pipes which are therefore belled one end for jointing by solvent cement welding. The screens are, however, slotted with the same precision as thicker wall, higher classes of pipe. Flo-Tek Threaded Casing Pipe and Screens ‘Table 3 shows the various sizes available of Flo-Tek’s flush threaded borehole casings and screens. + Standard slot size 1.0mm *ASTM F480 Flush int/ext + DIN 4925 Trapezoidal flush int/ext Design stress 12.5 MPa (SANS 966-1) + Other sizes available on requestPROPERTIES In summary, borehole casing should have as large a percentage of non-clogging slots as possible, be resistant to corrosion, have sufficient strength to resist collapse, and be manufactured to consistent, high quality standards. PVC is the ideal material to meet these requirements: Table 4 summarises the mechanical properties of Flo-Tek’s PVC casings. Lea SDL) NTL RUNES oe ate) [Specific gravity DIN gm/em* 1.40-1.45_ | DIN 53479 ASTM 1.40 792 |Modulus of elasticity DIN N/mm? 3000-3500 | _DIN54347 [Tensile strength DIN N/mm? 45-55 DIN 53455, ASTM psi 8000.00 638 JNotch impact strength at 20° DIN Ki/mt 3.0- 5.0 DIN 53453 ASTM felb.in 0.65 256 |Vicat softening temp. SABS 966 c 80.00 DIN 534608 [Deflection temp. under load (264 PSI) ASTM. c 70.00 D648 [Yield strength DIN N/mm* 55.60 impact strength DIN No fracture | No fracture | DIN53453 SABS 966 SABS 966-1 Pipe Dimensions Pipes are made to the dimensional requirements of SANS 966 Part 1 for each pressure class. Other Properties ‘The casings meet all the requirements of SABS 966 Part 1 Printing For specific orders, the casings and screens can be printed according to the customer's requirements. ADVANTAGES, FEATURES & BENEFITS ost effective: lower installed cost compared to conventional (steel) casings. Reliable: the trapezoidal threaded joints can be used for over 20 years in demanding conditions. SI eS au Light weight: much lighter than steel casings makes for user friendly installations and savings in time. ee ec ee ee eee ee eee) Internally and externally flush jointed: easy installation in borehole and improved flow of pumped water. Cee ee ee eee eee en eee en ee ee ry eee a eee eee ee oe neyTRANSPORT, HANDLING AND STORAGE Do not store casing pipes and screens in direct sunlight for long periods of time. As far as possible, store in the shade. Stack neatly on flat, smooth surface or on wooden platform with each length on top of the other and not criss-cross. Limit stack height (0 within 1.5 meters - preferably to just 1 meter (fig. 8). Avoid sagging at any point of storage to prevent pipe distortion. The screen pipe is the heart of any water well, thus special care must be taken during transportation and handling and should be stored separately without any superimposed load. Pipes and screens should be examined for any signs of damage before installation. Do not use damaged casings or screen pipes. Always transport and store casing pipes and screens with thread protectors in place. Damaged threads can result in failure during installation, Always use centralizer guides on the casing string, Ensure that the borehole is clear to the proposed depth of installation and free of obstructions before starting installation of the casing pipes. Maintain steady speed during installation of the casing string. Jerky actions damage screens or joint partings. Also, avoid sudden braking during lowering, Do not push, drive or rotate casing pipe against any obstruction within the borehole to prevent damage to the Avoid pouring large quantities of gravel or backfill material at high speeds since this could lead to unnecessary loading on the screen or result in bridging and later collapse which would subject casing pipes, screens and joints to shock loading. All joints should be tightened firmly before installation. Strap wrenches are normally used. During well development and testing, avoid excessive surging. Use extra caution when using compressed air for well development. Replacement of fluid within the casing pipe with fresh water could lead to creation of differential pressure between the drilling mud in the borehole and the water in the ‘casing, resulting in damage to the casing or screen. Select and place grout material carefully. fig.8 & 'Sales Offices No. 31 Keramiek Street, Clayille, Extension 14, Johannesburg, 1665 Tel. No: +27 11 316 6891 Fax No. 427 11 316 6896 45 Gray Street, Dundee, 3000 Tel. Nos 427 34 218 1236 Fax No. 427 34 218 1237 80 Burman Road, Deal Party Estate, Port Elizabeth, 6001 Tel. No: 427 41 486 2770 Fax Noz 427 41 486 2766 Plot 174, GCIP, Gaborone West Industrial, Botswana Tel. No.: +267 397 2001/3/4 Fax No. 4267 397 2014 FLO-TEK Tubos e Irrigoes KM/13, Estrada de Viana, Luanda, Angola. Tel. No. +244 2222 90662 Fax No. 4244 2222 90880 www.flo-tek.net Ip win, FLO-TEK SABS a “The information inthis brochure is correct tothe best of our knowledge. It does not constitute any form of guarantee Specifications are subject to alteration. Subject to change without notice.