Detailed Project Report on double wall corrugated (dwc) hdpe pipes

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DOUBLE WALL CORRUGATED (DWC) HDPE PIPES

[CODE NO.4028]

It is a double layer pipe with the outer layer having corrugation and the inner layer with a smooth surface. The outer corrugated layer substantially increases the stiffness of the pipe, which enables the pipe to take same burial load at a fraction of the weight of Solid wall pipes of the same size.

It is a technically superior and cost effective solution for drainage and sewerage systems over conventional DI & RCC pipes with a steep reduction in installation time and equipment hiring cost. These pipes are available in sizes ranging from 100mm DN/ID to 1200mm DN/ID having ring stiffness ranging from SN2.5 to SN16. Inner layer can be in different colours, with the outer layer in black colour.

There are manufactured as per following standards.

• IS 16098 Part II

• ISO-21138 Part III

• IS-14930

• BS EN 50086

QUALITY TESTS PERFORMED

• Density Test

• Mass Melt Flow Rate Test

• Ring Flexibility

• Ring Stiffness

• Impact Strength

• Water Tightness

• Thermal Stability

• Creep Ratio (Oxidation Induction Test)

COST ESTIMATION

Plant Capacity 20 MT/Day

Land & Building (8000 sq.mt.) Rs. 6.64 Cr

Plant & Machinery Rs. 4.62 Cr

Working Capital for 1 Month Rs. 5.34 Cr

Total Capital Investment Rs. 16.91 Cr

Rate of Return 29%

Break Even Point 52%

INTRODUCTION

THERE ARE MANUFACTURED AS PER FOLLOWING STANDARDS.

QUALITY TESTS PERFORMED

DIMENSIONS OF DWC PIPE

DWC PIPE FOR NEW GENERATION

ADVANTAGES OF DWC PIPES

THERE ARE NUMEROUS OTHER FEATURES OF DWC PIPES & THOSE ARE:

USES OF DWC HDPE PIPES

MERITS OF DWC HDPE PIPES

MERITS OF DWC HDPE PIPES:

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

PIPE AND ARTICULATION COMPONENT TESTS

TECHNICAL PROPERTIES OF PE CORRUGATED PIPES

TABLE: TECHNICAL PROPERTIES OF 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:

II. DIE HEAD

III. FORMING MACHINE

IV. SPRAY BATH

V. CUT-OFF UNIT

VI. STACKER

E: MECHANICAL PARTS

MATERIAL OF BARREL & SCREW 38CRMOLAA WITH NITROGEN TREATMENT

II. EXTRUSION DIE HEAD

III. SBZ1000 FORMING MACHINE

IV. SPRAY BATH

V. CUT-OFF UNIT

VI. STACKER

MARKET OVERVIEW OF HDPE PIPES

PRODUCTION OF HDPE IN INDIA

CONSUMPTION OF HDPE IN INDIA

IMPORT OF HDPE

PRESENT MANUFACTURERS/SUPPLIERS OF DWC HDPE 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

PHASE II

EXTRUSION

PHASE III

CORRUGATION

THIS RECENT TECHNOLOGY IS UNDER STUDY.

PHASE IV

CALIBRATION

PHASE V

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

JOINING SYSTEM AND INSTALLATION OF DWC PIPES

JOINTING PROCEDURE

CONSTRUCTION OF BACKFILL ENVELOPE AND BACKFILLING OF THE TRENCHES

TRANSPORTATION, HANDLING AND STORAGE OF DWC PIPES

TRANSPORTATION OF DOUBLE-WALL PIPE TO THE WORKSHOP

STORAGE AND MAINTENANCE OF DOUBLE-WALL CORRUGATED PIPE

INSTALLING DOUBLE-WALL CORRUGATED PIPES

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)

COMPLETE PLANT SUPPLIERS [IMPORTED]

COMPLETE DOUBLE WALL CORRUGATED HDPE PIPE MAKING PLANT & EQUIPMENTS SUPPLIERS

SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS

SUPPLIERS OF EOT CRANES

SUPPLIERS OF DG SETS

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF COOLING TOWER

SUPPLIERS OF ETP PLANTS

SUPPLIERS OF MEASURING AND TESTING INSTRUMENTS

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF HDPE RESIN

SUPPLIERS OF 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)

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