Detailed Project Report on ductile pipe

DUCTILE PIPE
[CODE NO.3740]


DUCTILE IRON

Ductile iron is a family of cast graphitic irons which possess high strength, ductility and resistance to shock. Annealed cast ductile iron can be bent, twisted or deformed without fracturing. Its strength, toughness and ductility duplicate many grades of steel and far exceed those of standard gray irons. Yet it possesses the advantages of design flexibility and low cost casting procedures similar to gray iron. The difference between ductile iron and gray iron is in the graphite formation. Ordinary gray iron is characterized by a random flake graphite pattern in the metal. In ductile iron the addition of a few hundredths of 1 % of magnesium or cerium causes the graphite to form in small spheroids rather than flakes. These create fewer discontinuities in the structure of the metal and produce a stronger, more ductile iron. This nodular graphite structure inhibits the creation of linear cracks hence the ability to withstand distortion. Fig 1 shows typical micro structure of ductile iron.

 
Fig 1 Typical micro structure of ductile iron

With ductile iron, the safety and reliability of process equipment is improved. The improved mechanical properties increase its resistance to breakage from physical load, or mechanical and thermal shock far above that of gray iron. The corrosion resistance of ductile iron is equal or superior to gray cast iron and to cast steel in many corrosives. Its wear resistance is comparable to some of the best grades of steel and superior to gray iron in heavy load or impact load situations. Since it can be cast with the same low cost procedures used for gray cast iron, it is considerably less expensive than cast steel and only moderately more expensive than gray iron. The substantial advantages obtained from its high yield strength and ductility make it an economical choice for many applications.

Common Ductile Iron Grades

While there are many different ductile iron specifications, foundries routinely offer 3 common grades;

Physical and Mechanical Properties    ASTM A536, Grade 60-40-18    ASTM A536, Grade 65-45-12 ASTM A536, Grade 80-55-06
Tensile Strength, min, psi    60,000    65,000    80,000
Tensile Strength, min, MPa    414    448    552
Yield Strength, min, psi    40,000    45,000    55,000
Yield Strength, min, MPa    276    310    379
Elongation in 2 in. or 50 mm, min %    18    12    6
Density lb/in3    0.256    0.256    0.256
Density g/cm3    7.1    7.1    7.1
Melting Temperature (Degrees F)    2,100 – 2,190    2,100 – 2,190    2,100 – 2,190
Melting Temperature (Degrees C)    1,150 - 1,200    1,150 - 1,200    1,150 - 1,200
Compressive Strength Ksi    429    429    429
Compressive Strength MPa    2960    2960    2960
UNS    F32800    F33100    F33800

The family of ductile iron

Ductile iron is not a single material, but a family of versatile cast irons exhibiting a wide range of properties which are obtained through microstructure control. The common feature that all ductile irons share is the roughly spherical shape of the graphite nodules. These nodules act as crack arresters and give ductile iron ductility and toughness which is superior to all other cast irons, and equal to many cast and forged steels. This feature is essential to the quality and consistency of ductile iron. With a high percentage of graphite nodules present in the structure, mechanical properties are determined by the ductile iron matrix. The importance of matrix in controlling mechanical properties is emphasized by the use of matrix names to designate the following types of ductile iron.

•    Ferritic ductile iron – Graphite spheroids in a matrix of ferrite provides an iron with good ductility and impact resistance and with a tensile and yield strength equivalent to low carbon steel. Ferritic ductile iron can be produced ‘as-cast’ but may be given an annealing heat treatment to assure maximum ductility and low temperature toughness.

•    Ferritic pearlitic ductile iron – These are the most common grade of ductile irons and are normally produced in the ‘as cast’ condition.  The graphite spheroids are in a matrix containing both ferrite and pearlite.  Properties are intermediate between ferritic and pearlitic grades, with good machinability and low production costs.

•    Pearlitic ductile iron – Graphite spheroids in a matrix of pearlite result in an iron with high strength, good wear resistance, and moderate ductility and impact resistance. Machinability is also superior to steels of comparable physical properties.

The above three types of ductile iron are the most common and are usually used in the ‘as cast’ condition, but ductile iron can be also be alloyed and/or heat treated to provide the following grades for a wide variety of additional applications.

•    Martensitic ductile iron – Using sufficient alloy additions to prevent pearlite formation, and a quench-and-temper heat treatment produces this type of ductile iron.  The resultant tempered martensite matrix develops very high strength and wear resistance but with lower levels of ductility and toughness.

•    Bainitic ductile iron – This grade can be obtained through alloying and/or by heat treatment to produce a hard, wear resistant material.

•    Austenitic ductile iron – Alloyed to produce an austenitic matrix, this ductile iron offers good corrosion and oxidation resistance, good magnetic properties, and good strength and dimensional stability at elevated temperatures.

•    Austempered ductile iron (ADI) – ADI, the most recent addition to the ductile iron family, is a sub group of ductile irons produced by giving conventional ductile iron a special austempering heat treatment. Nearly twice as strong as pearlitic ductile iron, ADI still retains high elongation and toughness. This combination provides a material with superior wear resistance and fatigue strength.


COST ESTIMATION

Plant Capacity            400 MT/Day       
Land & Building (200000 sq.mt.)      US$ 21.22 Lac        
Plant & Machinery                      US$ 3.28 Cr     
Working Capital for 2 Months     US$ 1.13 Cr
Total Capital Investment              US$ 5 Cr
Rate of Return            35%                   
Break Even Point             56%                


INTRODUCTION    
DUCTILE IRON    
COMMON DUCTILE IRON GRADES    
THE FAMILY OF DUCTILE IRON    
PROPERTIES OF DUCTILE IRONS    
BENEFITS OF DUCTILE IRON    
DUCTILE IRON PIPE    
HISTORY OF DUCTILE IRON PIPES    
CHARACTERISTICS OF DUCTILE IRON PIPE    
TYPE OF JOINTS    
THERE ARE MAINLY THREE SECTIONS OF DUCTILE IRON PIPE:    
1. SOCKET    
2. BARREL    
3. SPIGOT    
RANGE OF PIPES    
TECHNICAL DETAILS    
PIPE DIMENSION    
ADVANTAGES    
ADVANTAGES OF DUCTILE IRON PIPES    
DISADVANTAGES    
USES AND APPLICATION    
B.I.S. SPECIFICATION    
PRODUCTION PROCESS    
(1) RAW MATERIAL SELECTION    
(2) DESULPHURISATION    
(3) MELTING AND COMPOSITION CONTROL    
(4) MAGNESIUM TREATMENT    
NODULISING:    
(5) INOCULATION    
EFFECT OF INOCULATION    
(6) MOULD CONDITIONING    
(7) CORE MAKING    
(8) CASTING    
CENTRIFUGAL CASTING    
DE LAVAUD PROCESS    
WET-SPRAY PROCESS    
(9) INTERNAL GRINDING    
(10) HEAT TREATMENT    
(11) ZINC COATING    
(12) CUT OFF AND CHAMFERING MACHINE    
(13) HYDROSTATIC PRESSURE TESTING    
(14) CEMENT MORTAR FEEDING AND LINING    
(15) STEAM CURING    
(17) INTERNAL POLISHING    
(17) BITUMEN COATING    
(18) QUALITY CONTROL    
QUALITY CONTROL CHECKS AT EVERY STAGE OF MANUFACTURING    
(19) MARKING AND STENCILING    
(20) STORAGE, PACKING AND DISPATCH    
ELECTRIC INDUCTION FURNACES VERSUS CUPOLAS FOR MELTING IRON    
INDUCTION FURNACE AND IMPORTANT OPERATIONAL ASPECTS    
INDUCTION FURNACE AND IMPORTANT OPERATIONAL ASPECTS    
RAW MATERIALS AND ENERGY SOURCE    
IMPORTANT ASPECTS OF OPERATION    
OTHER ASPECTS OF INDUCTION FURNACE STEEL MAKING    
ENVIRONMENTAL EMISSIONS    
SAFETY AND INDUCTION FURNACES    
MARKET SURVEY FOR DI PIPE    
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    
PLANT LAYOUT    
MANUFACTURERS/SUPPLIERS OF DI PIPE    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PIG IRON    
SUPPLIERS OF CAST IRON SCRAP    
SUPPLIERS OF STEEL SCRAPE    
SUPPLIERS OF SILICON CARBIDE    
SUPPLIERS OF FERRO SILICON    
SUPPLIERS OF MAGNESIUM INGOT    
SUPPLIERS OF FERRO MANGANESE    
SUPPLIERS OF FIRE CLAY    
SUPPLIERS OF BENTONITE    
SUPPLIRS OF COAL DUST    
SUPPLIERS OF GRAPHITE POWDER    
SUPPLIERS OF SILICA SAND    
SUPPLIERS OF LIME STONE    
SUPPLIERS OF PLANT AND MACHINERY    
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 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 EFFULENT 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)