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)
