Detailed Project Report on stainless steel pipes manufacturing
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STAINLESS STEEL PIPES MANUFACTURING
[CODE NO.3334]
Stainless steels are iron-based alloys usually containing at least 11.5% chromium. Other elements, nickeI being the most Important, may be added in combination with chromium to obtain special properties.
Stainless steels are highly resistant to corrosive attack and to oxidation at high temperatures. in general, resistance to corrosion and oxidation increases progressively, though not proportionately, with the increase in chromium content.
Stainless steel pipe and tubing are used for a variety of reasons: to resist corrosion and oxidation, to resist high temperatures, for cleanliness and low maintenance costs, and to maintain the purity of materials which come In contact with stainless. The inherent characteristics of stainless steel permits the design of thin wall piping systems without fear of early failure due to corrosion. The use of fusion welding to join such piping eliminates the need for threading.
Type 304 stainless is the most widely used analysis for general corrosive resistant tubing and pipe applications, it is used in chemical plants, refineries, paper mills, and food processing industries. Type 304 has a maximum carbon content of .08%. It is not recommended for use in the temperature range between 800° F and 1650° F due to carbide precipitation at the grain boundaries which can result in inter-granular corrosion and early failure under certain conditions.
Type 304L. Is the same as 304 except that.03% maximum carbon content is maintained which precludes carbon precipitation and permits the use of this analysis in welded assemblies under more severe corrosive conditions. Type 318 is much more resistant to pitting than other chromium nickel alloys due to the addition of 2% to 3% molybdenum. it is particularly valuable wherever acids, brines, sulphur water, seawater or halogen salts are encountered. Type 316 is widely used in the sulphite paper industry and for manufacturing chemical plant apparatus, photographic equipment, and plastics.
COST ESTIMATION
Plant Capacity : 4.00 MT./day
land & Building (8000 Sq.Mtrs) : Rs. 4.68 Cr
Plant & Machinery : Rs. 2.28 Cr
Working Capital for 2 Months : Rs. 4.49 Cr
Total Capital Investment : Rs. 12.26 Cr
Rate of Return : 32%
Break Even Point : 47%
INTRODUCTION
SIZES OF PIPES
SIZES FOR STAINLESS STEEL TUBE
RAW MATERIAL
PHYSICAL PROPERTIES OF PIPING MATERIALS
MALLEABILITY
DUCTILITY
BRITTLENESS
ELASTICITY
CONDUCTIVITY
CHEMICAL RESISTANCE/ RESISTANCE TO CORROSION
USES AND APPLICATION
TYPICAL APPLICATIONS FOR STAINLESS STEEL PIPE:
B.I.S. SPECIFICATION
MARKET SURVEY
DOMESTIC DEMAND DRIVERS
CAPACITY EXPANSION BY DOMESTIC PLAYERS
HUGE INVESTMENTS IN THE SOUTH/EAST INDIA
STAINLESS STEEL PIPE 304 IMPORT DATA OF INDIA
EXPORTS OF STAINLESS STEEL PIPE
IMPORTS OF STAINLESS STEEL PIPE
MANUFACTURERS/SUPPLIERS OF S.S. PIPE AND TUBE
MANUFACTURING PROCESS
1. UNCOILED, LAVELED AND WELDING OF STRIP
2. STRIPPING
3. LOOPING
4. EDGE TRIMMING
5. FORMING
6. WELDING
7. BEAD TRIMMING
8. SIZING
9. CUTTING
10. NORMALISING
11. STRAIGHTENING
12. END FACING AND BEVELLING
13. TESTING
ULTRASONIC TESTING
EDDY-CURRENT TESTING
HYDROSTATIC TESTING
MAGNETIC PARTICLE TESTING
RADIOGRAPHIC (X-RAY) TESTING
DYE-PENETRANT TEST
14. PICKLING
15. PASSIVATION
16. POLISHING
DIFFERENCE BETWEEN WET BRIGHT AND DRY BRIGHT:
ADVANTAGES:
ELECTROPOLISHING SUPERIOR THAN MECHANICAL POLISHING:
ELECTROCHEMICAL POLISHING CHARACTERISTICS:
17. MARKING
NOMINAL PIPE SIZE (NOMINAL BORE)
PROCESS FLOW CHART
QUALITY CONTROL
QUALITY ASSURANCE PLAN
PLANT AND MACHINERY
(1) UNCOILER
(2) LAVELER
(3) SHEAR AND WELDER
1. SWITCHGEAR RECTIFYING CABINET
2. INVERTER OUTPUT CABINET
3. CONNECTING OPTICAL FIBER
4. CIRCULATION SOFT WATER COOLING SYSTEM
5. CENTRAL OPERATION CONSOLE
6. MECHANICAL ADJUSTMENT DEVICE
(4) ACCUMULATOR
ACCUMULATOR
THE HORIZONTAL SPIRAL ACCUMULATOR FOR WELDED PIPE LINE
(5) FORMING AND SIZING SECTION
FORMING AND SIZING MILL
MATURE TECHNOLOGY FOR ROLLER COMPATIBILITY
OPTIMIZED FORMING
EDGE BENDING
W-FORMING ON FIRST STAND
(5) HF SOLID STATE WELDER
1. SWITCHGEAR RECTIFYING CABINET
2. INVERTER OUTPUT CABINET
3. CONNECTING OPTICAL FIBER
4. CIRCULATION SOFT WATER COOLING SYSTEM
5. CENTRAL OPERATION CONSOLE
6. MECHANICAL ADJUSTMENT DEVICE
(6) ANNEALING FURNACE
(7) FLYING SAW
FLYING SAW
FLYING SAW ALL DIGITAL CONTROL SYSTEM
(8) FACING AND BEVELING MACHINE
(10) STRAIGHTNER MACHINE
(11) THREADING MACHINE
THREADING MACHINE FEATURES:
(12) HYDRAULIC TESTING MACHINE
PLANT LAYOUT
SUPPLIERS OF PLANT AND MACHINERY
SS PIPE AND TUBE PLANT SUPPLIERS
EOT CRANES
DG SETS
EOT CRANES
DG SETS
POWER TRANSFORMERS
COOLING TOWER
ETP PLANTS
AIR POLLUTION CONTROL EQUIPMENTS
AIR COMPRESSOR
PLATFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
NDT INSPECTION EQUIPMENT
FIRE FIGHTING EQUIPMENTS
ELECTRICAL MEASURING INSTRUMENTS
SUBMERSIBLE WATER PUMP
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF CR SS STRIPS
PACKING MATERIALS
PICKLING CHEMICALS
RESSISTANCE WELDING ELECTRODE
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
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