Detailed Project Report on SS Pipes (202/304)

SS PIPES (202/304)

[EIRI/EDPR/4302] J.C.: 2483XL

INTRODUCTION

Stainless steel is an alloy made of steel with a chromium base. Mixing steel with other components such as chromium, molybdenum, copper, silicon, carbon, and aluminum makes an alloy called stainless steel. Stainless steels are designed materials providing strong resistance to corrosion, power, and properties of production. They will fulfill a wide range of design criteria readily-low maintenance, service life, and load-bearing ability. Stainless Steel has an advantage because of its ability to be milled into sheets, coils, bars, wires, plates, tubes, and pipes.

Since the development of stainless steel over hundred years ago, it has become world’s most used and popular material. Since stainless steel has the notable corrosion resistance that helps in increasing features with chromium content. The resistance can be shown in reducing acids as well as against pitting attacks such as in chloride solutions. It requires low maintenance, and is familiar to luster thus making it an ideal and best material for SS pipes. This versatile material is indispensable in wide industries. This may contain number of application especially for SS pipes that benefit user with positive properties.

Stainless Steel (SS) Pipe is primarily used in piping systems for the transport of fluids or gases. steel pipe are manufactured  from a steel alloy containing nickel as well as chromium, which give stainless steel its corrosion-resistant properties. It was first fabricated in 1905 in New York. Two semi-circular pipe halves were joined by inserting the edges of each into two longitudinal lock-bars with an H-shaped cross section.

COST ESTIMATION

Plant Capacity            4 MT/Day

Land & Building (4405 sq.mt.)    Rs. 3.52 Cr

Plant & Machinery                    Rs. 4.74 Cr

Working Capital for 1 Month    Rs. 1.88 Cr

Total Capital Investment          Rs. 10.54 Cr

Rate of Return                          13%

Break Even Point                      75%

CONTENTS

INTRODUCTION

BASIC SS PIPE TYPES

SEAMLESS PIPE

WELDED PIPE

TYPES OF STAINLESS STEEL PIPES

PRESSURE PIPES AND TUBES

STAINLESS STEEL AIRCRAFT TUBING

HYDRAULIC-LINE TUBING FOR AIRCRAFT

STAINLESS STEEL CORROSION-RESISTANCE TUBING

STAINLESS STEEL SANITARY TUBING

GRADES OF SS PIPES

CHARACTERISTICS

CORROSION RESISTANCE

CRYOGENIC RESISTANCE (LOW TEMPERATURE)

WORK HARDENING

STRENGTH AND FORMABILITY

DUCTILITY

HIGH STRENGTH

MAGNETIC RESPONSE

HIGH AS WELL AS LOW TEMPERATURE SERVICE

HEAT AND FIRE RESISTANCE

HYGIENE

AESTHETIC APPEARANCE

WEIGHT-TO STRENGTH ADVANTAGE

EASE OF FABRICATION

IMPACT RESISTANCE

LONG TERM VALUE

USES/APPLICATION/ADVANTAGES

USES

APPLICATIONS

OIL AND GAS

NUCLEAR POWER

TYPES BASED ON APPLICATION – SANITARY, MECHANICAL, PRESSURE PIPE, POLISHED PIPE

MAIN PURPOSE OF SS IN APPLICATIONS

PRESSURE PIPES

SANITARY PIPES

MECHANICAL PIPE

POLISHED PIPE

MARKET OVERVIEW

BELOW IS THE STRUCTURE OF THE INDIAN STEEL PIPE MARKET

SOME OF THE CHARACTERISTICS OF THESE PIPES ARE

STAINLESS STEEL

DRIVERS

PROPERTIES (TYPICAL)

MECHANICAL PROPERTIES

RAW MATERIAL

BIS SPECIFICATION

MANUFACTURING STEPS/PROCESS FLOW

UNCOILED, LEVELED AND WELDING OF STRIP

STRIPPING

LOOPING

EDGE TRIMMING

FORMING

WELDING

BEAD TRIMMING

SIZING

CUTTING

NORMALIZING

END FACING AND BEVELING

TESTING

ULTRASONIC TESTING

EDDY-CURRENT TESTING

HYDROSTATIC TESTING

MAGNETIC PARTICLE TESTING

RADIOGRAPHIC (X-RAY) TESTING

DYE-PENETRANT TEST

MARKING

PROCESS FLOW

PLANT & MACHINERY

MAIN TECHNICAL PARAMETER

MACHINE MAIN COMPONENTS

UNCOILER

FORMING MACHINE

WELDING MACHINE:

GRINDING SYSTEM FOR OUTSIDE WELDING BEAD

SIZING & STRAIGHTENING DEVICE

CUTTING MACHINE

PRODUCT RACK (RUN OUT TABLE)

ELECTRICAL SYSTEM

MACHINE CONFIGURATION

ROLLERS:

HEAD SQUARE SS PIPE POLISHING MACHINE:

MAIN TECHNICAL DATA:

MATERIAL PARAMETER:

PRODUCT PARAMETER:

OTHER PARAMETER:

DRIVE MOTOR:

HYDRAULIC UNIT:  NORMAL MOTOR AC 15KW

MAIN COMPONENTS

COMPONENTS DESCRIPTION

PAPER COLLECTOR

MATERIAL PLATFORM

HYDRAULIC COIL CAR

SINGLE MANDREL HYDRAULIC UNCOILER WITH HOLD-DOWN ROLL

SHEARER TO CUT IRREGULAR SHEET HEAD

LOOP PIT-I

MANUAL SIDE GUIDE WITH PINCH ROLL

SLITTER

SCRAP RECOILER (2 NOS.)

LOOP PIT -II

HYDRAULIC SYSTEM

ELECTRIC CONTROL SYSTEM

ELECTRIC COMPONENTS

ACCESSORIES LIST

`SLITTING TOOLING

PLANT & MACHINERY SUPPLIER/TURNKEY CONSULTANTS

GENERATOR SET (DG SET)

TRANSFORMER

PACKAGING MACHINE

PREVENTIVE ENVIRONMENTAL MANAGEMENT/ENVIRONMENT IMPACT ASSESSMENT(EIA)

OBJECTIVES OF EIA

PROJECT LEVEL EIA

PROJECT CYCLE

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

UTILITY REQUIREMENT (ESTIMATED) - MONTH

GENERATION & MANAGEMENT OF WASTES/GREEN BELT

WASTE WATER (ESTIMATED)

WASTE (ESTIMATED)

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENT

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

PRELIMINARY PLANT LAYOUT

GIVEN LAND PLOT

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)