Detailed Project Report on manufacturing of hdpe, plb and dwc hdpe pipes

MANUFACTURING OF HDPE, PLB AND DWC HDPE PIPES [3568]

Double Wall Corrugated (DWC) HDPE pipes are similar to normal HDPE pipes except that they have different external & internal surfaces which gives them additional strength and stiffness. These are made with High Density Polyethylene which has very high life expectancy. These are externally corrugated and have smooth surface inside and are available from 75 mm to 1.0 m dia. These pipes are light weight and can be used for non-pressure underground sewerage, drainage & cross drainage (pipe culvert) including rain water harvesting purposes. They are maintenance free and therefore, once installed, will lie underground for years. It is well-known that corrugated pipes can offer exceptional material savings, good hydraulic (flow) properties and high compression strength. For these reasons corrugated pipes have shown high growth rates in recent years resulting in the continued development of its production technology. Here we aim to give you an overview of the main characteristics, types and production technologies of corrugated pipes and show how well the corrugated pipe for sewage and drainage applications acquits itself compared to its two main competitors, the concrete pipe and the solid wall PE pipe. In the early days corrugated pipes benefitted from the growth in demand for telecommunication cable ducting. But in terms of material conversion tonnage, cable ducting has now been overtaken by drainage and sewage pipes for construction and infrastructure. Corrugated pipes can be made of a wide range of different materials such as polyamide (PA),thermoplastic elastomers (TPE), thermoplastic rubber (TPR), polytetrafluoroethylene (PTFE), but the primary raw material in the manufacture of corrugated pipes for water transportation is high-density polyethylene (HDPE), followed by polypropylene (PP) and polyvinyl chloride (PVC). Corrugated pipes can be as small as 1 mm. In the smaller diameter range up to 50 mm they are usually used for cable protection systems in house installations, and the medical, automotive and food industries. Mid-sized corrugated pipes (50 mm ID to 500 mm OD) are commonly used as protection pipes, drainage, sewage, storm water, civil engineering and conveyor pipes. And in the larger sizes up to 3,000 mm, the pipes are employed for storm water, sewage, control shafts, conveyor pipes and manholes. HDPE PLB (Permanently Lubricated) ducts are manufacture using high grade of HDPE with inner layer of antioxidant content and other additives. The inner layer is silicon coated which minimizes friction between OFC and the Duct during the Process of blowing the cable into the ducts, thus providing smooth installation, PLB HDPE Duct consist of two concentric layer. The outer layer being HDPE, Co-extruded with an inner uniform layer of solid silicone permanent lubricant to reduce the internal coefficient of friction, PLB Duct pipes are used as underground cable conduit for optical fiber cables communication cable etc. Corrugated pipes represent the ideal solution for the abduction of any kind of water, chemicals, affluent and sewers, because they combine the advantage of corrosion resistance. Typical properties that result in advantages in Corrugated Pipe can be summarized as follows: Higher mechanical resistance due to the structure of the pipe. Corrosion resistance, both of the external wall and internal wall in contact with the conveyed fluid. No protections such as coating, painting or cathodic are needed. Corrugated pipes are resistant to nearly all chemicals. Very long life, virtually infinite of the material which does not need maintaining. Low weight of pipes lengths that allows for the use of light laying and transport means. Easy installation procedures because laying of corrugated pipes is a simple operation which can be done in short periods of time both above and below ground, since sleeve joints and socket joints enable fast and reliable assembling. Workability of the material on sites employing simple equipment. Possibility of nesting of different diameters of pipe thus allowing additional.

COST ESTIMATION

Plant Capacity                           28 MT/Day  
Land & Building (5000 sq.mt)     Rs. 3.38 Cr
Plant & Machinery                    Rs. 5.78 Cr
Working Capital for 1 Month    Rs. 10.95 Cr
Total Capital Investment          Rs. 20.44 Cr
Rate of Return                         38%




INTRODUCTION    
MERITS OF DWC HDPE PIPES    
USES OF DWC HDPE PIPES    
ADVANTAGES IN CORRUGATED PIPE    
APPLICATION OF DOUBLE CORRUGATED PIPE    
B.I.S. SPECIFICATION    
PRODUCTION TECHNOLOGIES OF DWC PIPE    
SINGLE WALL PIPE    
DUAL/DOUBLE WALL PIPE    
QUALITY CONTROL FOR HDPE    
CORRUGATED PIPE STANDARDS AND SN / SR COMPARISON    
POINTS TO BE TAKEN INTO CONSIDERATION    
EXAMINATION AND TESTING OF CORRUGATED PIPES    
PIPE AND ARTICULATION COMPONENT TESTS    
TECHNICAL PROPERTIES OF PE CORRUGATED PIPES    
DOUBLE WALL CORRUGATED PIPES    
DIMENSIONS AND WEIGHTS FOR STANDARD DOUBLE WALL
  CORRUGATED PIPES, WITH AN INTEGRATED COUPLING SLEEVE    
RECENT PROJECTS - CORRUGATED PIPES, FITTINGS, MANHOLES, INSPECTION CHAMBERS, DRAINAGE PIPES    
COMPARISON OF CORRUGATED PIPE WITH OTHER CONVENTIONAL PIPES    
CORRUGATED PIPE VERSUS SOLID WALL PIPE    
CORRUGATED VERSUS SPIRAL PIPE    
TECHNICAL DETAILS OF CORRUGATED PIPE    
TYPICAL PRODUCT SPECIFICATION    
DOUBLE CORRUGATED PIPE WALL STRUCTURE    
PIPES ENDS    
HYDRAULIC SEALING    
FITTINGS    
MANUFACTURING PROCESS DESCRIPTION    
TESTING    
PROCESS EQUIPMENT    
TECHNICAL DATA    
THE COMPOSING OF PRODUCTION LINE    
MARKET SURVEY    
RESEARCH CATEGORY    
WORLD DEMAND TO INCREASE 6.2% ANNUALLY THROUGH 2017    
PVC CONTINUES AS MOST WIDELY USED RESIN    
HDPE PIPE MARKET POTENTIAL ANALYSIS    
DEVELOPMENT OF HDPE PIPE MATERIALS    
HDPE PIPE MATERIAL PRODUCTION STATUS    
CHINA'S HDPE MARKET PROSPECTS    
THE PRESSURE TUBE    
INDOOR AND OUTDOOR WATER SUPPLY PIPE    
SANDWICH TUBE    
NON PRESSURE PIPE    
IRRIGATION TUBE    
UNDERGROUND DRAINAGE, SEWAGE PIPE    
CABLE THREADING PIPE AND CABLE PROTECTIVE SLEEVE    
THERE ARE 3 OF CHINA'S HDPE PIPE INDUSTRY PROBLEMS    
RAW MATERIAL SUPPLY PROBLEMS    
PRODUCTION EQUIPMENT BEHIND    
PRODUCT APPLICATION LINK    
CONCLUSION    
WORLD PLASTIC PIPE MARKET    
WORLDWIDE PIPE MARKET TO APPROACH 31 BILLION METERS    
WORLD DEMAND TO INCREASE 6% PER YEAR THROUGH 2015    
ASIA/PACIFIC TO ACCOUNT FOR MORE THAN 1/2 OF DEMAND
  GROWTH STUDY COVERAGE    
PRODUCTION OF HDPE PIPES IN INDIA    
DETAILED EXPORT DATA OF DWC HDPE PIPES    
DETAILED EXPORT DATA OF WALL CORRUGATED PIPES    
PRESENT MANUFACTURERS/SUPPLIERS    
OF HDPE DOUBLE WALL CORRUGATED PIPES    
HDPE/PP/PVC DOUBLE WALL CORRUGATED    
PIPE PRODUCTION LINE    
MANUFACTURING PROCESS    
PREPARATION OF RAW MATERIAL (RM)    
APPROVAL OF RM FOR PURCHASE ORDER    
RECEIVING / STORAGE    
IF THE LOT IS COMPLIANT, IT IS STORED AND REGISTERED.    
MIXTURE    
EXTRUSION    
CORRUGATION    
THIS RECENT TECHNOLOGY IS UNDER STUDY.
CALIBRATION    
FINISHING AND PACKAGING    
CONTROLS AND TESTS    
TECHNICAL REQUIREMENT OF    
DOUBLE WALLED CORRUGATED (DWC) HDPE DUCT    
SCOPE    
REQUIREMENTS    
GENERAL INFRASTRUCTUR    
QUALITY CONTROL    
ESSENTIAL MACHINERY & PLANT REQUIRED FOR PRODUCTION    
REQUIRED ESSENTIAL MACHINERY & PLANT SHALL BE AS FOLLOWS    
ESSENTIAL TESTING EQUIPMENTS REQUIRED FOR QUALITY ASSURANCE    
REQUIRED ESSENTIAL TESTING EQUIPMENTS SHALL BE AS FOLLOWS    
QUALITY ASSURANCE FLOW CHART FOR DWC HDPE DUCT    
PLANT LAYOUT    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)    
COMPLETE PLANT SUPPLIERS    
DOUBLE WALL CORRUGATED HDPE PIPE MAKING PLANT & EQUIPMENTS    
AIR POLLUTION CONTROL EQUIPMENTS    
EOT CRANES    
DG SETS    
POWER TRANSFORMERS    
COOLING TOWER    
ETP PLANTS    
MEASURING AND TESTING INSTRUMENTS    
SUPPLIERS OF RAW MATERIALS    
HDPE RESIN    
HDPE GRANULES    

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)