Detailed Project Report on di manhole cover and di pipe fitting

DI MANHOLE COVER AND DI PIPE FITTING [3634]

Ductile iron casting refers to a process in which magnesium / Cerium (as an alloy of magnesium / Cerium) is added to cast iron. It was first manufactured by K.D. Mills in 1943. While most varieties of cast iron are comparatively brittle, ductile iron castings are much more ductile due to the inclusion of nodular graphite. Solidified castings of ductile iron contain nearly perfect spheres of graphite. Ductile iron possesses the processing advantages of grey iron, such as low melting point, good fluidity, castability and machinability, and engineering advantages of steel, including high strength, ductility and wear resistance. Achieving the desired quality consistently at low cost in a production foundry is, however, still a challenge. Addition of small amount of cerium or magnesium to molten cast iron changes the shape of graphite from laminar to spheroidal, giving rise to spheroidal graphite iron or ductile iron. The rapid growth in industrial applications of ductile iron (DI) is driven by its versatility and high performance at low cost. It offers a good combination of tensile strength and ductility. This allows designers to select ductile iron for a wide range of applications. Ductile iron also offers cost savings compared to steel and malleable iron castings through higher yield and thereby lower melting energy. Formation of graphite during solidification leads to lower volumetric shrinkage in ductile iron (compared to steel), necessitating smaller and fewer feeders to prevent the formation of shrinkage defects. Further cost advances can be achieved by eliminating heat treatment of as-cast DI parts. The near-spherical shape of the graphite nodules distributed evenly in the matrix phase of ductile iron enhances its ductility and impact resistance along with tensile and yield strength equivalent to a low carbon steel. While ferritic ductile iron can be used as ‘as-cast’, it may also be annealed to increase its ductility and low-temperature toughness. The pearlitic ductile iron has graphite spheroids in a matrix of pearlite, resulting in high strength, good wear resistance, moderate ductility and impact resistance. The most commonly used ferritic-pearlitic ductile iron containing both ferrite and pearlite in matrix offers a good combination of tensile strength and ductility with good machinability and low production costs. The ductile iron castings are produced in a wide range of weight, from a few grams to a hundred tons or more, greatly varying in shape and size depending on the applications (Figure 1). Many forged and fabricated steel components are getting replaced by ductile iron castings, owing to their good combination of mechanical properties such as strength, wear resistance, fatigue strength, toughness and ductility coupled with economic production. The specifications of ductile irons with ferrite/pearlitic matrix with different grades are shown in Table 1. They are used in safety parts in automobiles, armatures, pumps and machine tools. They are also used in parts subjected to high pressure, such as pressure containers and hydraulics. Many welded assemblies and forgings used in governor housings, armatures and car parts (like brake calipers and gear housings, hydraulic parts, crankcases and blower buckets) are being replaced by ferritic ductile iron castings. Cast or grey iron is an alloy characterized by its relatively high content of carbon flakes (2% to 4%). In contrast, the carbon in ductile iron is in the form of spherical nodules. The formation of such nodules is achieved by the addition of 'nodulizers' like magnesium or cerium into the castings melt. Due to its inherent properties, such nodules resist the creation of cracks and augment its ductility. That is why this process is called as ductile iron casting. In the as-cast condition, the matrix will consist of varying proportions of pearlite and ferrite, and as the amount of pearlite increases, the strength and hardness of the iron also increase. Ductility and impact properties are principally determined by the proportions of ferrite and pearlite in the matrix. The mechanical properties of ductile iron are controlled by the presence of graphite nodules. The Different grades of Ductile Iron Castings are produced by obtaining different matrix microstructures in the Iron. Alloying elements may be added to enhance as cast properties of Ductile Iron. In some special cases Heat Treatment can be employed to achieve the higher properties. The Grades of Ductile Iron Castings are based on the Mechanical Properties of the casting. Ductile iron with high strength and toughness has been available as an engineering material for many years, replacing forging steel, cast steel, and malleable cast-iron. It has undergone a phenomenal development and has become the only ferrous casting material with positive growth rate. The ductile iron will still be an important construction material in the 21st century.

COST ESTIMATION

Plant Capacity                    40 MT/Day  
Land & Building (10000 sq.mt)     Rs. 7.75 Cr
Plant & Machinery                    Rs. 5.15 Cr
Working Capital for 2 Months   Rs. 11.21 Cr
Total Capital Investment          Rs. 24.85 Cr
Rate of Return                         23%
Break Even Point                     67%


INTRODUCTION    
COMPOSITION OF DUCTILE IRON CASTINGS    
DUCTILE IRON    
FIG 1 TYPICAL MICRO STRUCTURE OF DUCTILE IRON    
COMPOSITION:    
COMMON DUCTILE IRON GRADES    
THE FAMILY OF DUCTILE IRON    
PROPERTIES OF DUCTILE IRONS    
BENEFITS OF DUCTILE IRON    
(A) DI MAN HOLE COVER    
GRADES    
1. LIGHT DUTY (LD-2.5) SQUIRE, CIRCULAR OR REACTANGULAR SOLID TYPE    
2. MEDIUM DUTY (MD-10) CIRCULAR, SQUIRE OR REACTANGULAR
    (SCRAPPER MAN HOLE)    
3. HEAVY DUTY (HD 20) CIRCULAR, SQUIRE OR REACTANGULAR
    (SCRAPPER MAN HOLE)    
4. EXTRA HEAVY DUTY (EHD 35) CIRCULAR, SQUIRE ORREACTANGULAR
     (SCRAPPER MAN HOLE)    
(B) DI PIPE FITTING    
TYPES OF D.I FITTING    
(1) PIPE ADAPTERS    
TYPES OF PIPE ADAPTERS:    
LOCKING PIPE ADAPTER:    
OFFSET PIPE ADAPTER:    
MALE ADAPTER:    
FEMALE PIPE ADAPTER:    
STRAIGHT THREAD ADAPTERS:    
(2) PIPE ELBOW FITTINGS    
(3) PIPE COUPLING    
PARTS OF PIPE COUPLING AS SHOWN BELOW:    
(4) PIPE UNION    
(5) PIPE REDUCER    
(6) PIPE TEE    
SIZE OF PIPE FITTING    
SIZES OF BEND PIPES    
DOUBLE SOCKET BEND    
DOUBLE FLANGED BEND    
DOUBLE FLANGED 90° LONG RADIUS BEND    
DOUBLE FLANGED 90° DUCKFOOT BEND    
DUCTILE IRON FITTINGS    
SIZES OF PIPE TEE    
ALL SOCKET TEE    
ALL FLANGED TEE    
ALL FLANGED 45° ANGLE BRANCHES    
ALL FLANGED RADIAL TEES    
ALL FLANGED 'Y' TEES    
DOUBLE SOCKET LEVEL INVERT TEE WITH FLANGED BRANCH    
DOUBLE SOCKET TEE WITH FLANGED BRANCH    
DOUBLE SOCKET TAPER    
SIZES OF TAPER (REDUCER)    
DOUBLE SOCKET TAPER    
DOUBLE FLANGED TAPER    
DUCTILE IRON COLLAR    
SIZES OF SHORT PIPES    
DUCTILE IRON FLANGE    
FLANGED PIPE    
DOUBLE FLANGED PIPES    
FLANGED SPIGOT    
FLANGED SOCKET    
DUCTILE IRON FITTINGS    
DOUBLE SOCKET BEND    
SIZES OF ADAPTORS    
FLANGE ADAPTOR    
DISMANTLING ADAPTOR    
FLEXIBLE COUPLING    
DIMENSIONS OF FLANGE    
USES AND APPLICATION    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
(A) FOR MAN HOLE COVER    
RAW MATERIALS    
DESIGN    
THE MANUFACTURING    
PROCESS    
PATTERN MAKING    
MOLD PREPARATION    
MELTING/POURING    
THE MANUFACTURING OF A MANHOLE COVERS USING A SAND MOLD.    
COOLING    
FINISHING    
QUALITY CONTROL (PLEASE REFER IS: 1726:1991)    
1. COATING    
MARKING    
(B) FOR DI PIPE FITTING    
MANUFACTURING PROCESS    
SUB PROCESS    
DESULPHURIZATION    
SCRAP ADDITION & SUPER HEATING    
MAGNESIUM TREATMENT    
LOST FOAM CASTING    
PROCESS DESCRIPTION    
ADVANTAGES    
HEAT TREATMENT    
ZINC COATING    
HYDROSTATIC PRESSURE TESTING    
CEMENT LINING    
STEAM CURING    
BITUMEN COATING    
MARKING AND STENCILING    
QUALITY CONTROL (PLEASE REFER IS: 9523:2000)    
RAW MATERIAL    
INDUCTION FURNACE    
LADLE TREATMENT/CONVERTER FOR "MG" TREATMENT
CASTING MACHINE    
GANTRY BEFORE ANNEALING FURNACE    
ANNEALING FURNACE    
SAMPLE CUTTING    
ZINC COATING    
GROOVE GRINDING    
HYDROSTATIC PRESSURE TESTING    
CEMENT LINING    
CEMENT CURING    
BITUMEN COATING    
MARKET OVERVIEW OF MANHOLE COVERS    
INDUSTRY ANALYSIS    
PREFERENCE OF PIPE MATERIALS    
INTER LINKING OF RIVERS (ILR) PROJECT    
EXPORT POTENTIAL    
DOMESTIC MANUFACTURERS OF DI PIPE    
DEMAND – SUPPLY GAP:    
ECONOMIC GROWTH    
DEMAND FOR WATER    
URBANIZATION    
DEMAND ANALYSIS FOR DI PIPES    
INVESTMENT IN WATER PROJECTS AND ROLE OF GOVERNMENT BODIES    
EXTERNAL AID    
EXPORT OF DI PIPE FITTINGS    
IMPORT OF DI PIPE FITTINGS    
EXPORT OF DUCTILE IRON MANHOLE    
IMPORT OF DUCTILE IRON MANHOLE    
PLANT LAYOUT    
MANUFACTURERS/SUPPLIERS OF DI MAN HOLE COVER    
MANUFACTURERS/SUPPLIERS OF DI PIPE FITTING    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PIG IRON    
SUPPLIERS OF CAST IRON SCRAP    
SUPPLIERS OF STEEL SCRAP    
SUPPLIERS OF SILICON CARBIDE    
SUPPLIERS OF FERRO SILICON    
SUPPLIERS OF MAGNESIUM INGOT    
SUPPLIERS OF FERRO SILICON    
SUPPLIERS OF BENTONITE    
SUPPLIERS OF GRAPHITE POWDER    
SUPPLIERS OF SILICA SAND    
SUPPLIERS OF LIME STONE    
SUPPLIERS OF PLANT AND MACHINERIES    
SUPPLIERS OF ANNEALING FURNACE    
SUPPLIERS OF HEATREATMENT FURNACE    
SUPPLIERS OF INDUCTION FURNACE    
SUPPLIERS OF ALUMINIUM PATTERNS    
SUPPLIERS OF INTENSIVE SAND MIXTURE AND MULLER    
SUPPLIERS OF SAND SIEVING MACHINE    
SUPPLIERS OF SQUEEZE MOLDING MACHINE    
SUPPLIERS OF SHAKEOUT MACHINE    
SUPPLIERS OF CORE SHOOTER MACHINE    
SUPPLIERS OF DRYING OVEN    
SUPPLIERS OF FOUNDRY TOOLS    
SUPPLIERS OF MOLDING BOXES    
SUPPLIERS OF METAL TESTING MACHINE    
SUPPLIERS OF PRECISION MEASURING TOOLS    
SUPPLIERS OF PRECISION MEASURING TOOLS    
SUPPLIERS OF NDT INSPECTION EQUIPMENT    
SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES    
SUPPLIERS OF GRINDING MACHINE    
SUPPLIERS OF EOT CRANE    
SUPPLIERS OF POWER TRANSFORMERS    
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)