Detailed Project Report on lpg valve manufacturing

LPG VALVE MANUFACTURING
[CODE 3747]  

    
Valves are a type of mechanical device that are implemented to regulate flow, pressure, or both, within a system. They an integral aspect of any piping system that requires a fair amount of control. The primary functions of a conventional valve comprise flow control in the form of rate of flow and the direction of flow. Valves are thus used to prevent back flow, and relieving pressure. The various valve types, designs, and models can be functional in specific industrial, commercial, and residential applications.

LPG valves may need to be designed especially for maintaining high pressure within the cylinder and to let out the gas at a rate specified and within regulatory permission. These valves are also designed to withstand the possible damage they may take during transportation. An additional cap is often screwed over the valve in order to further reduce the likelihood of gas leakage when the cylinder is not in use.

The gas cylinder valve is the primary safety mechanism on a gas cylinder and shall not be tampered with. It is a device used to contain the contents of the cylinder that is under pressure. Cylinder valves are fitted with pressure relief valves of different types (depending on the cylinder) to protect against catastrophic failure of the cylinder valve.

Cylinder valves open in an anticlockwise direction and close in a clockwise direction. Valves shall never be opened without a regulator attached. Always open cylinder valves slowly

There two basic types of LP Gas cylinder valves for vapour service, namely, self-closing, clip-on valves and hand wheel operated valves. They can come with or without pressure relief valves depending on local regulations.

1. Self-Closing, Clip-on Valve

These are typically used for domestic cylinders where low cost and fit for service valves are required. Common types in the market are compact, bayonet, or snap on (snap tight) valves. They can be fitted with excess flow limiters and/or anti-dirt tubes (also called education tubes). Because these valves are open-topped, plastic dust caps are recommended to be fitted during storage and transportation to prevent entry of foreign matter.

Performance Requirements

i.    The valve shall be of the self-closing type, closed by gas pressure in the cylinder assisted by a small stainless steel spring.

ii.    The valve shall be completely gas-tight and shall have no regulating function that can restrict high filling rates.

iii.    The 13kg and 50kg cylinder valves shall be with a safety relief valve. The 3kg and 6kg cylinder shall be fitted with camping valves.

iv.    If it is with a safety relief valve, then the safety relief valve shall be of pop-action type and shall have a set pressure of 2.55 MPa.

v.    The safety relief valve shall open to allow blow-off should the cylinder pressure under extreme conditions reach 2.94MPa.

vi.    The capacity of the safety relief valve when fully open shall be 5.0 cubic meters of air per minute.

vii.    The spindle shall be able to move freely.

2. Hand Wheel Operated Valve

These valves are used both with domestic and commercial cylinders and are designed for different applications i.e. liquid fill, liquid service and vapour service. The outlet connection of hand wheel operated valves can come in different forms e.g. CGA 510 (or F.Pol), CGA 555 (or M.Pol), ACME, NPT, etc. When both vapour and liquid connections are on the same valve, they must be designed differently for clear distinction. Liquid service valves are fitted with a tube and an excess flow limiter. Hand wheel operated valves can accidentally be opened and it is recommended to fit a gas tight plug after filling while the cylinder is in transport or storage.

COST ESTIMATION


Plant Capacity                  4000 Pieces/Day       
Land & Building (4050 sq.mt.)      Rs. 68 Lac         
Plant & Machinery                      Rs. 48 Lac     
Working Capital for 1 Months     Rs. 65 Lac
Total Capital Investment              Rs. 1.95 Cr
Rate of Return            60%                   
Break Even Point             53%                

INTRODUCTION    
1. SELF-CLOSING, CLIP-ON VALVE    
PERFORMANCE REQUIREMENTS    
2. HAND WHEEL OPERATED VALVE    
PARTS OF LPG VALVE    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
THE MAIN STEPS ARE GIVEN BELOW:    
1. PROCUREMENT OF RAW MATERIAL    
2. TESTING OF RAW MATERIAL    
3. CUTTING THE BRASS BILLET FOR REQUIRED SIZE FOR BALL
     AND VALE BODY    
4. HEATING THE BRASS BILLET UP TO FORGING TEMP.    
5. CLOSE-DIE FORGING PROCESS    
CLOSED DIE FORGING PROCESS OPERATIONS    
UPSETTING    
VIEW    
ADVANTAGES OF CLOSED DIE FORGING:    
HIGH STRENGTH    
LEAK RESISTANCE    
CLOSE TOLERANCES    
LOW OVERALL COST    
6. TRIMMING AND CLIPPING    
7. DIP FINISHING    
8. MACHINING    
9. QUALITY CONTROL    
ACTIVITIES    
INSPECTION OF PACKING AND DESPATCH.    
INSPECTION OF IN-COMING MATERIALS    
IN- PROCESS INSPECTION    
FINAL INSPECTION    
CONTROL OF MEASURING, INSPECTION TOOLS AND TEST EQUIPMENTS    
10. TESTING    
(A) TESTING OF BRASS MATERIAL    
1. TENSILE STRENGTH AND ELONGATION    
2. IMPACT STRENGTH    
3. STRESS CORROSION TEST    
4. HYDROSTATIC TESTS    
(B) TESTING OF NON-METALIC MATERIAL    
(C) TESTING OF SPRING    
TEST METHOD    
2. RUST PROOFNESS TEST (NITRIC ACID IMMERSION TEST)    
(D) TESTING OF ASSEMBLE VALVE    
1. DIMENSION TEST    
1. PNEUMATIC TEST    
2. TIGHTNESS OF JOINT PACKING (IN VALVE OUTLET) AND VALVE SPINDLE.    
4. TIGHTNESS OF VALVE SPINDLE AND VALVE HOUSING    
5. TIGHTNESS OF JOINT PACKING AND HOUSING    
6. CYCLE TEST    
7. OPERATION TEST    
PROCEDURE    
8. IMPACT TEST    
PROCEDURE    
9. EXTERNAL LEAKAGE TEST    
10. SEAT LEAKAGE TEST    
11. ENDURANCE TEST    
12. HYDROSTATIC STRENGTH TEST    
11. MARKING    
MARKET SURVEY    
LPG IN INDIA    
PRADHAN MANTRI UJJWALA YOJANA    
PAHAL    
GIVE IT UP    
INDIA LPG MARKET (2012-2026): INCREASING CONSUMPTION OF LPG TO PRODUCE VARIOUS CHEMICAL COMPONENTS - RESEARCH AND MARKETS    
MAIN INDUSTRY    
INDIAN LPG SCENARIO    
ANALYSIS OF IMPORT OF LPG VALVE    
TOTAL VALUE & VOLUME OF IMPORTS IN INDIA    
ANALYSIS OF EXPORT OF LPG VALVE    
TOTAL VALUE & VOLUME OF EXPORTS IN INDIA    
MANFACTURERS/SUPPLIERS OF LPG CYLINDER VALVE    
CHINA SUPPLIERS FOR COMPLETE PLANT    
SUPPLIERS OF PLANT AND MACHINERIES    
SUPPLIERS OF BRASS BILLET CUTTING MACHINE    
SUPPLIERS OF CLOSE DIE HOT FORGING MACHINE    
SUPPLIERS OF FORGING DIES    
SUPPLIERS OF INDUCTION HEAING FURNACE    
SUPPLIERS OF CNC LATHE MACHINE    
SUPPLIERS OF CNC MACHINING CENTRE    
SUPPLIERS OF SHOT BLASTING MACHINE    
SUPPLIERS OF METAL TESTING MACHINE    
SUPPLIERS OF HARDNESS TESTING MACHINE    
SUPPLIERS OF NDT INSPECTION EQUIPMENT    
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS    
SUPPLIERS OF AIR COMPRESSORS    
SUPPLIERS OF PLATFORM WEIGHING MACHINE    
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF BRASS BILLET    
SUPPLIERS OF NITRILE RUBBER SEAL    
SUPPLIERS OF PICKLING ACIDS    
SUPPLIERS OF VALVE SPRING    
SUPPLIERS OF PICKLING ACIDS    
PACKAGING MATERIALS    
PLANT LAYOUT


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)