Detailed Project Report on double wall corrugated (dwc) hdpe pipes (size upto 1500mm)

DOUBLE WALL CORRUGATED (DWC) HDPE PIPES
(SIZE UPTO 1500MM)
[CODE NO.3193]  

The Double Wall Corrugated Pipes (DWCP) manufactured by most companies are ideal for protecting telecom and electrical cables. Normally, the outer layer has corrugation and the inner layer has smooth and plain surface that gives the best of electrical and mechanical properties for cable ducting. 

We shall hereby discuss the key features of DWCP pipes. To begin with, it needs to be well noted that these pipes are stronger than the GI, RGC, PVC as well as solid wall pipes. The DWCP pipes are known to have longer life span. These pipes are easy to transport and can be handled and installed due to light weight. These pipes have low installation costs and have excellent impact strength. These pipes are known to be flame retardant, UV resistant, leak proof, made from anti-rodent material, environmentally friendly, easy installation, flexible enough to adjust to various obstacles, and much more. 

The DWCP pipes and fittings are manufactured via the use of HDPE polymer. The DWCP pipes are known to be resistant to various chemicals and gases which are produced because of putrefaction of different types of ingredients flowing in the system. Most manufacturers are known to use these pipes as per IS 16098 regulations and have a smooth internal surface as well as an external surface which is corrugated. It needs to be ell understood that the corrugated external surface provides assistance to higher loads, withstands soil movements as well as provides greater stiffness. 

It is important to note the best of features of DWCP pipes, such as (a) Easy to store, handle and transport, (b) Depicting superior performance than RCC pipes, (c) abrasin resistant and corrosion, (d) Anti-rodent material, (e) Available in increased length of 6m that depicts less chances of leakage, and much more. The DWCP pipes have a variety of applications such as in underground drainage, industrial liquid waste, highway and road drainage, sewage, storm water and surface water drainage, and much more. 

Most manufacturers are known to produce DWCP pipes that are environmentally safe to use and are chemically inert in nature. The DWCP pipes are normally corrugated and are used in underground cable protection and management of telecom and signal. These pipes ate known to be manufactured using virgin HDPE and are used as cable protection ducts and in sewer applications. The DWCP pipes are known to depict minimum friction and have smooth inner walls. These pipes are known to have maximum load bearing strength. 

There are various advantages associated with the use of DWCP pipes. These pipes: (a) Depict good resistance to corrosion, (b) Depict good abrasion resistance, (c) Good impact and strength, (d) Smooth innerwall with minimum friction, (e) Availability with anti-rodent non-flame propagating properties, and much more. 

Most manufacturers have successfully expanded their business in the market offering pipes that are environmentally safe and chemically inert. The pipes are used as a cable protection ducts for drainage as well as sewer applications. These pipes depict a very good resistance to corrosion. 

COST ESTIMATION

Plant  Capacity                                                              :     15.00 Ton/day
land & Building (8000 Sq.Mtr)                                     :    Rs. 4.21 Cr
Plant & Machinery                                                          :    Rs. 7.23 Cr
Working Capital for 2 Months                                       :    Rs. 3.79 Cr
Total Capital Investment                                                :    Rs. 15.35 cr
Rate of Return                                                                 :    30%
Break Even Point                                                            :    52%


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:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET