Ball and Butterfly Valve Manufacturing (Production Capacity: 300 Numbers Per Day)

BALL AND BUTTERFLY VALVE MANUFACTURING

[EIRI/EDPR/4720] J.C.: 2940XL

A valve is a device that regulates controls or directs the flow of a fluid by opening, closing, or partially obstructing fluid flow. A valve is a device that regulates, directs or controls the flow of a fluid (gases, liquids, fluidized solids or slurries) by opening, closing or partially obstructing various passageways. Valves are technically called as valves fittings, but are usually discussed as a separate category. In an open valve, fluid flows in a direction from higher to lower pressure. The word is derived from the Latin word “valva”, the moving part of a door, in turn from volvere, to turn, roll.

Basically, it controls flow & pressure. Different types of valves are used to serve these functions. There are mainly about 9 Different Types of Valves used in Piping such as Gate Valve, Globe Valve, Check Valve, Plug valve, Ball Valve, Butterfly Valve, Needle Valve, Pinch Valve and Pressure Relief Valve. The item proposed is basically a casting, machined & assembled product. The castings of metals and alloys of copper, zinc, tin, aluminium, lead, alloy steel, CI etc. come under the group of non-ferrous & Ferrous castings. Some of the prominent valve castings are Brass, Bronze, Aluminium Bronze, Gun Metal, Stainless Steel, Cast Iron etc. are used to manufacture various types of valves for domestic and industrial applications.

The industrial valves market is segmented on the basis of type, function, material, accessories, size and application. The growth among segments helps to analyse niche pockets of growth and strategies to approach the market and determine your core application areas and the difference in your target markets.

On the basis of type, the industrial valves market is segmented into gate valve, globe valve, ball valve, butterfly valve, diaphragm valve, check valve, plug valve, pinch valve, needle valve, pressure relief valve and others.

On the basis of function, the industrial valves market is segmented into isolation, regulation, safety, relief valve, special purpose and non-return.

On the basis of material, the industrial valves market is segmented into ductile iron, carbon steel, plastic, brass, bronze, copper, aluminium and others.

The industrial valves market is also segmented on the basis of accessories into hydraulic filter, power cable, mounting screws and bolts, seal kits, dust protection cover and others.

On the basis of size, the industrial valves market is segmented into 1 inch to 6 inch, 6 inch to 12 inch, 12 inch to 24 inch, 24 inch to 48 inch and above 48 inch.

COST ESTIMATION

Plant Capacity            300 Nos/Day

Land & Building (1 Acre)    Rs. 1.18 Cr

Plant & Machinery                    Rs. 1.31 Cr

Working Capital for 2 Months    Rs. 4.60 Cr

Total Capital Investment          Rs. 7.39 Cr

Rate of Return                          32%

Break Even Point                      50%

CONTENTS

INTRODUCTION

FIG. 1: BALL VALVE IN CLOSED POSITION

HSN CODE OF THE PRODUCT: 

NIC CODE OF THE PRODUCT:   

GOVERNING INTERNATIONAL SPECIFICATION:

VALVES ARE CATEGORIZED AS FOLLOWS:

WAYS OF OPERATING VALVES:

HAND WHEEL & LEVER OPERATED:- 

ACTUATOR OPERATED VALVES:- 

LIMIT SWITCH OPERATED VALVES:- 

THE INDIAN STANDARDS ARE MAINLY FOLLOWED ARE AS MENTIONED BELLOW:

DIFFERENT TYPES OF VALVES:

TYPES OF VALVES & SPECIFICATIONS

DETAILS OF THE PRODUCT LICENCE TO BE OBTAINED:

THE TECHNOLOGY EXISTING FOR MANUFACTURING OF THE PRODUCT

INDIA INDUSTRIAL VALVES APPLICATION AREA:

SUGGESTED MODERN TECHNOLOGY FOR IMPLEMENTATION OR AVAILABLE IN THE MARKET:

RAW MATERIAL REQUIRED AND AVAILABILITY COVERING RAW MATERIAL STANDARDS INDIAN/INTERNATIONAL STANDARDS -

MATERIALS USED IN VALVES

SPECIFICATIONS:

A) BRASS VALVES

B) BRONZE VALVES:

C) CAST IRON VALVES:

D) STAINLESS STEEL:

MATERIALS FOR BALL VALVES

1. PVC

2. CPVC

3. BRONZE AND BRASS

4. IRON

5. STAINLESS STEEL

CONSTRUCTION OF A BALL VALVE

FIG. 2: LUBRICANT-SEAL SYSTEM IN A BALL VALVE

TYPES OF BALL VALVES

SPLIT-BODY BALL VALVE

FIG. 3: BALL VALVES, SPLIT BODY, REGULAR PORT, FLANGED ENDS

TOP-ENTRY BALL VALVE

FIG. 4: BALL VALVES, TOP ENTRY, REGULAR PORT, SOCKET WELD ENDS

END-ENTRY BALL VALVE

THREE-PIECE — BODY BALL VALVE

DOUBLE TRUNNION BALL VALVES

LUBRICATED OR NON-LUBRICATED BALL VALVES

ADVANTAGES OF BALL VALVES

THE FOLLOWING ARE THE ADVANTAGES OF BALL VALVES:

DISADVANTAGES OF BALL VALVES

TYPICAL APPLICATIONS OF BALL VALVES

B.I.S. SPECIFICATION

PROCESS FLOW CHART

MANUFACTURING PROCESS

THE MAIN STEPS ARE GIVEN BELOW:

1. PROCUREMENT OF BRASS BILLET

2. CUTTING THE BRASS BILLET FOR REQUIRED SIZE FOR BALL AND VALE BODY

3. HEATING THE BRASS BILLET UP TO FORGING TEMP.

4. CLOSE-DIE FORGING PROCESS

ADVANTAGES OF CLOSED DIE FORGING:

HIGH STRENGTH

LEAK RESISTANCE

CLOSE TOLERANCES

LOW OVERALL COST

5. TRIMMING AND CLIPPING

6. DIP FINISHING

7. HEAT TREATMENT

ANNEALING 

ANNEALING (FULL) 

STRESS RELIEVING 

TEMPER ANNEALING

8. MACHINING

9. QUALITY CONTROL

ACTIVITIES

INSPECTION OF PACKING AND DISPATCH

INSPECTION OF IN-COMING MATERIALS

IN-PROCESS INSPECTION

FINAL INSPECTION

CONTROL OF MEASURING, INSPECTION TOOLS AND TEST EQUIPMENTS

10. TESTING

HYDROSTATIC TESTING 

LOW PRESSURE GAS SEAT TESTING 

HIGH PRESSURE GAS TESTING

HIGH TEMPERATURE TESTING

FUGITIVE EMISSION TESTING

ANTISTATIC TESTING

TORQUE TESTING

CAVITY RELIEF TESTING

DOUBLE BLOCK & BLEED (DBB) TESTING

11. PACKAGING

MARKET POSITION

MARKET SIZE ESTIMATION

TOP KEY PLAYERS IN INDIA FOR INDUSTRIAL VALVE MARKET

MARKET OVERVIEW

KEY MARKET DRIVERS

GROWING INFRASTRUCTURE DEVELOPMENT

INCREASING DEMAND IN THE OIL AND GAS INDUSTRY

EMPHASIS ON WATER AND WASTEWATER MANAGEMENT

KEY MARKET CHALLENGES

ECONOMIC VOLATILITY AND POLITICAL UNCERTAINTY

INFRASTRUCTURE GAPS AND REGIONAL DISPARITIES

INTENSE COMPETITION AND PRICE PRESSURE

KEY MARKET TRENDS

INCREASING EMBRACE OF DIGITALIZATION AND SMART VALVES

SUSTAINABILITY AND ENVIRONMENTAL COMPLIANCE

SEGMENTAL INSIGHTS

MATERIAL TYPE INSIGHTS

APPLICATION INSIGHTS

BEST BUTTERFLY VALVE MANUFACTURERS IN INDIA

1. DOMBOR

2. L&T VALVES

3. KIRLOSKAR VALVES

4. AMCO INDUSTRIAL VALVES

5. AMTECH VALVES

6. BRAY INDIA PVT. LTD.

7. VIP INDUSTRIAL VALVES

8. HAWA VALVES

9. PROLINE INDUSTRIAL VALVES

10. SVR VALVES

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

PLANT LAYOUT

VALVE MANUFACTURERS

DETAILS OF RAW MATERIALS SUPPLIERS

DETAILS OF MACHINERY SUPPLIERS

SUPPLIERS OF BRASS BALL VALVE

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF BRASS BILLET

SUPPLIERS OF FKM O-RING AND PTFE SEAL

SUPPLIERS OF NICKEL INGOT

SUPPLIERS OF PICKLING ACIDS

SUPPLIERS OF PACKING MATERIALS

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF BILLET CUTTING MACHINE

SUPPLIERS OF ELECTROPLATING PLANT

SUPPLIERS OF ANNEALING FURNACES

SUPPLIERS OF HEAT TREATMENT FURNACE

SUPPLIERS OF HARDNESS TESTING MACHINE

SUPPLIERS OF CLOSE DIE HOT FORGING MACHINE

SUPPLIERS OF FORGING DIES

SUPPLIERS OF INDUCTION HEATING FURNACE

SUPPLIERS OF CNC LATHE MACHINE

SUPPLIERS OF CNC MACHINING CENTRE

SUPPLIERS OF METAL TESTING MACHINE

SUPPLIERS OF DG SETS

SUPPLIERS OF EOT CRANES

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

LIST OF DOCUMENTS REQUIRED TO GET FOR LICENSES 

DOCUMENTS:

OTHER LICENSES REQUIRED FOR THE SETUP:

IMPLEMENTATION SCHEDULE

ORGANIZATION CHART

STATUTORY APPROVALS FROM GOVERNMENT

SCHEMES AND CONSULTANCY SERVICES

EXISTING SCHEMES AVAILABLE AND THEIR DETAILS

PROPOSED SCHEMES (IF EXISTING IS NOT SUITABLE)

DETAILS OF AGENCIES WHO CAN PROVIDE GUIDANCE (CSIR, MSME, SECTOR COUNCILS ETC.)

DETAILS OF TEST FACILITIES AVAILABLE IN INDIA

SWOL ANALYSIS

STRENGTHS

OPPORTUNITIES

WEAKNESS

LIMITATIONS

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)