Detailed Project Report on brass and ss ball valve

BRASS AND SS BALL VALVE

[CODE NO.4222]  

Ball valves are used to shut-off pressurised media in pipes or hoses

A ball valve is a rotational motion valve that uses a ball-shaped disk to stop or start fluid flow.

The ball performs the same function as the disk in the globe valve. When the valve handle is turned to open the valve, the ball rotates to a point where the hole through the ball is in line with the valve body inlet and outlet. When the valve is shut, the ball is rotated so that the hole is perpendicular to the flow openings of the valve body and the flow is stopped.

Most ball valve actuators are of the quick-acting type, which require a 90??turn of the valve handle to operate the valve. Other ball valve actuators are planetary gear-operated. This type of gearing allows the use of a relatively small handwheel and operating force to operate a fairly.

Some ball valves have been developed with a spherical surface coated plug that is off to one side in the open position and rotates into the flow passage until it blocks the flowpath completely.

Seating is accomplished by the eccentric movement of the plug. The valve requires no lubrication and can be used for throttling service.

The ball valve is a quarter-turn valve suitable for clean gas, compressed air, and liquid service. They also can be used for slurry service, but provisions for prevention of crud buildup must be made. The use of soft-seat materials such as nylon, delrin, synthetic rubbers, and fluorinated polymers imparts excellent sealing ability. 

With fluorinated polymer seats, ball valves can be used for service temperatures ranging from 450 to 500 F ( 270 to 260 C); with graphite seats, service temperatures to 1000 F (538 C) or even higher are possible. Also, with metal backing seats, the valves can be used in fire-safe services. Ball valves are similar to plug valves in operation. They are nonbinding and provide leak-tight closure. The valves exhibit negligible resistance to flow because of their smooth body and port.

COST ESTIMATION

Plant Capacity                                   8000 Nos/Day

Land & Building (2500 sq.mt.)  Rs. 5.14 Cr

Plant & Machinery                             Rs. 2.59 Cr

Working Capital for 2 Months    Rs. 6.34 Cr

Total Capital Investment                  Rs. 14.45 Cr

Rate of Return                                    50%

Break Even Point                               38%

• INTRODUCTION
  
• FIG. 1: BALL VALVE IN CLOSED POSITION
• MATERIALS FOR BALL VALVES
• 1. PVC
• 2. CPVC
• 3. BRONZE AND BRASS
• 4. IRON
• 5. STAINLESS STEEL
• CONSTRUCTION OF A BALL VALVE
• FIG. 2: LUBRICANT-SEAL SYSTEM IN A BALL VALVE
• TYPES OF BALL VALVES
• SPLIT-BODY BALL VALVE
• FIG. 3: BALL VALVES, SPLIT BODY, REGULAR PORT, FLANGED ENDS
• TOP-ENTRY BALL VALVE
• FIG. 4: BALL VALVES, TOP ENTRY, REGULAR PORT, SOCKET WELD ENDS
• END-ENTRY BALL VALVE
• THREE-PIECE — BODY BALL VALVE
• DOUBLE TRUNNION BALL VALVES
• LUBRICATED OR NON-LUBRICATED BALL VALVES
• ADVANTAGES OF BALL VALVES
• DISADVANTAGES OF BALL VALVES
• TYPICAL APPLICATIONS OF BALL VALVES
• B.I.S. SPECIFICATION
• PROCESS FLOW CHART
• MANUFACTURING PROCESS
• 1. PROCUREMENT OF BRASS BILLET
• 2. CUTTING THE BRASS BILLET FOR REQUIRED SIZE FOR BALL AND VALE BODY
• 3. HEATING THE BRASS BILLET UP TO FORGING TEMP.
• 4. CLOSE-DIE FORGING PROCESS
• ADVANTAGES OF CLOSED DIE FORGING:
• HIGH STRENGTH
• LEAK RESISTANCE
• CLOSE TOLERANCES
• LOW OVERALL COST
• 5. TRIMMING AND CLIPPING
• 6. DIP FINISHING
• 7. HEAT TREATMENT
• ANNEALING
• ANNEALING (FULL)
• STRESS RELIEVING
• TEMPER ANNEALING
• 8. MACHINING
• 9. QUALITY CONTROL
• ACTIVITIES
• INSPECTION OF PACKING AND DISPATCH
• INSPECTION OF IN-COMING MATERIALS
• IN-PROCESS INSPECTION
• FINAL INSPECTION
• CONTROL OF MEASURING, INSPECTION TOOLS AND TEST EQUIPMENTS
• 10. TESTING
• HYDROSTATIC TESTING
• LOW PRESSURE GAS SEAT TESTING
• HIGH PRESSURE GAS TESTING
• HIGH TEMPERATURE TESTING
• FUGITIVE EMISSION TESTING
• ANTISTATIC TESTING
• TORQUE TESTING
• CAVITY RELIEF TESTING
• DOUBLE BLOCK & BLEED (DBB) TESTING
• 11. PACKAGING
• MARKET POSITION
• MARKET SIZE ESTIMATION
• MARKET OVERVIEW
• PRINCIPLES OF PLANT LAYOUT
• MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
• PLANT LOCATION FACTORS
• PRIMARY FACTORS
• 1. RAW-MATERIAL SUPPLY:
• 2. MARKETS:
• 3. POWER AND FUEL SUPPLY:
• 4. WATER SUPPLY:
• 5. CLIMATE:
• 6. TRANSPORTATION:
• 7. WASTE DISPOSAL:
• 8. LABOR:
• 9. REGULATORY LAWS:
• 10. TAXES:
• 11. SITE CHARACTERISTICS:
• 12. COMMUNITY FACTORS:
• 13. VULNERABILITY TO WARTIME ATTACK:
• 14. FLOOD AND FIRE CONTROL:
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• 1. DEPRECIATION:
• 2. FIXED ASSETS:
• 3. WORKING CAPITAL:
• 4. BREAK-EVEN POINT:
• 5. OTHER FIXED EXPENSES:
• 6. MARGIN MONEY:
• 7. TOTAL LOAD:
• 8. LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• PLANT LAYOUT
• SUPPLIERS OF BRASS AND SS BALL VALVE
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF BRASS BILLET
• SUPPLIERS OF SS BILLET
• SUPPLIERS OF FKM O-RING AND PTFE SEAL
• SUPPLIERS OF NICKEL INGOT
• SUPPLIERS OF PICKLING ACIDS
• SUPPLIERS OF PACKING MATERIALS
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF BILLET CUTTING MACHINE
• SUPPLIERS OF ELECTROPLATING PLANT
• SUPPLIERS OF ANNEALING FURNACES
• SUPPLIERS OF HEAT TREATMENT FURNACE
• SUPPLIERS OF HARDNESS TESTING MACHINE
• SUPPLIERS OF CLOSE DIE HOT FORGING MACHINE
• SUPPLIERS OF FORGING DIES
• SUPPLIERS OF INDUCTION HEATING FURNACE
• SUPPLIERS OF CNC LATHE MACHINE
• SUPPLIERS OF CNC MACHINING CENTRE
• SUPPLIERS OF METAL TESTING MACHINE
• SUPPLIERS OF DG SETS
• SUPPLIERS OF EOT CRANES
• SUPPLIERS OF POWER TRANSFORMERS
• SUPPLIERS OF ELECTRICAL PANEL
• SUPPLIERS OF ELECTRIC MOTOR
• SUPPLIERS OF COOLING TOWER
• SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
• SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
• SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
• SUPPLIERS OF AIR COMPRESSORS
• SUPPLIERS OF PLATFORM WEIGHING MACHINE
• SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
• SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
• SUPPLIERS OF SHOT BLASTING MACHINE
• SUPPLIERS OF JIGS AND FIXTURE
• SUPPLIERS OF SUBMERSIBLE WATER PUMP

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)