Detailed Project Report on inner grooved copper tube

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INNER GROOVED COPPER TUBE

[CODE NO 4045]

Inner grooved tube is enhanced with grooves by increasing the inner surface area. Due to its high efficiency of heat transfer, it is used widely in power generation, air conditioning and many other applications. Heat exchanger is one of the example that uses inner grooved tube to enhance rate heat transfer. Precision in production of inner grooved copper tube is very important because it affects the tube's performance due to various tube parameters. Therefore, it is necessary to carry out analysis in optimizing tube performance prior to production in order to avoid unnecessary loss.

Ongoing rise of Air Conditioners and Refrigerators in the market and production in GCC and other part of the world and Heat Transfer Systems in engineering industries and automobile sectors all over the world, makes Copper tubes an essential and unmatched engineering material as Copper possesses superior heat transfer properties with excellent corrosion resistant. Seamless Copper Tubes meeting the specification requirements of ASTM B68, ASTM B280 and JIS H3300 for ACR applications are in a commanding and challenging position in the market. Conventional technology and tube mills are getting outdated as superior new generation software based tube mills have already shaped up and proved their efficiency and quality in production in this technology era and provides platform for producing superior quality tubes. As old companies with conventional machines struggle for their survival, as Quality and Cost are the prime concern governing the market and business world today, new ventures are shaping up and establishing bases to conquer the market. Process technology: An existing plant at Sultanate of Oman cannot hold its position strong as far the market trend is concerned as its lack of symmetry in the process equipments to produce tubes meeting the requirements of primary users.

Benefits to use Inner Groove Copper Tube:

1. Leak Proof

2. Long Lasting

3. Accurate Groove Designs

4. Corrosion Resistant

5. High Metallurgical Strength

6. High Temperature Resistant

7. High Pressure Resistant

8. Excellent Heat Transfer Property

9. Good Electrical Conductivity etc.

COST ESTIMATION

Plant Capacity 35 MT/Day

Land & Building (15,000 sq.mt.) Rs. 18.58 Cr

Plant & Machinery Rs. 7.16 Cr

Working Capital for 2 Months Rs. 119.53 Cr

Total Capital Investment Rs. 146.22 Cr

Rate of Return 50%

Break Even Point 28%

INTRODUCTION

INNER GROOVED COPPER TUBE SPECIFICATION

INTERNALLY GROOVED COPPER TUBE TOLERANCES

BENEFITS TO USE INNER GROOVE COPPER TUBE:

USES AND APPLICATION

B.I.S. SPECIFICATION

PROCESS FLOW DIAGRAM

MANUFACTURING PROCESS

METHOD OF INNER GROOVE

REVOLUTION MECHANISM

FLOATING FRAME

UNWINDING BOBBIN

FIRST GUIDE CAPSTAN

FIRST DRAWING DIE

FIRST REVOLVING CAPSTAN

TURNING FLYER

SECOND REVOLVING CAPSTAN

SECOND DRAWING DIE

SECOND GUIDE CAPSTAN

WINDING BOBBIN

QUALITY CONTROL

QUALITY ASSURANCE PLAN

DESTRUCTIVE TESTS

1. TENSILE TEST

2. DRIFT EXPANDING TEST

NON-DESTRUCTIVE TESTING

1. EDDY-CURRENT TEST

2. HYDROSTATIC TEST

3. PNEUMATIC TEST

4. HYDROGEN EMBRITTLEMENT TEST (FOR CU-DHP AND CU-DPA GRADES)

PACKING

MARKING

MARKET POSITION

MARKET OVERVIEW

PLANT LAYOUT

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:

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

SUPPLIERS OF INNER GROOVED COPPER TUBE

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF COPPER BILLET

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF BILLET CUTTING MACHINE

SUPPLIERS OF BILLET STRAIGHTNING MACHINE

SUPPLIERS OF REHEATING FURNACE

SUPPLIERS OF COMPLELE TUBE PLANT

SUPPLIERS OF METAL TESTING MACHINE

SUPPLIERS OF PRECISION MEASURING TOOLS

SUPPLIERS OF NDT INSPECTION EQUIPMENT

SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS

SUPPLIERS OF DG SETS

SUPPLIERS OF EOT CRANES

SUPPLIERS OF POWER TRANSFORMER

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF ELECTRIC MOTOR

SUPPLIERS OF COOLING TOWER

SUPPLIERS OF EFFLUENT 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)

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