MANUFACTURING OF HDPE, PLB AND DWC HDPE PIPES [3568]
Double Wall Corrugated (DWC) HDPE pipes are similar to normal HDPE pipes except that they have different external & internal surfaces which gives them additional strength and stiffness. These are made with High Density Polyethylene which has very high life expectancy. These are externally corrugated and have smooth surface inside and are available from 75 mm to 1.0 m dia. These pipes are light weight and can be used for non-pressure underground sewerage, drainage & cross drainage (pipe culvert) including rain water harvesting purposes. They are maintenance free and therefore, once installed, will lie underground for years. It is well-known that corrugated pipes can offer exceptional material savings, good hydraulic (flow) properties and high compression strength. For these reasons corrugated pipes have shown high growth rates in recent years resulting in the continued development of its production technology. Here we aim to give you an overview of the main characteristics, types and production technologies of corrugated pipes and show how well the corrugated pipe for sewage and drainage applications acquits itself compared to its two main competitors, the concrete pipe and the solid wall PE pipe. In the early days corrugated pipes benefitted from the growth in demand for telecommunication cable ducting. But in terms of material conversion tonnage, cable ducting has now been overtaken by drainage and sewage pipes for construction and infrastructure. Corrugated pipes can be made of a wide range of different materials such as polyamide (PA),thermoplastic elastomers (TPE), thermoplastic rubber (TPR), polytetrafluoroethylene (PTFE), but the primary raw material in the manufacture of corrugated pipes for water transportation is high-density polyethylene (HDPE), followed by polypropylene (PP) and polyvinyl chloride (PVC). Corrugated pipes can be as small as 1 mm. In the smaller diameter range up to 50 mm they are usually used for cable protection systems in house installations, and the medical, automotive and food industries. Mid-sized corrugated pipes (50 mm ID to 500 mm OD) are commonly used as protection pipes, drainage, sewage, storm water, civil engineering and conveyor pipes. And in the larger sizes up to 3,000 mm, the pipes are employed for storm water, sewage, control shafts, conveyor pipes and manholes. HDPE PLB (Permanently Lubricated) ducts are manufacture using high grade of HDPE with inner layer of antioxidant content and other additives. The inner layer is silicon coated which minimizes friction between OFC and the Duct during the Process of blowing the cable into the ducts, thus providing smooth installation, PLB HDPE Duct consist of two concentric layer. The outer layer being HDPE, Co-extruded with an inner uniform layer of solid silicone permanent lubricant to reduce the internal coefficient of friction, PLB Duct pipes are used as underground cable conduit for optical fiber cables communication cable etc. Corrugated pipes represent the ideal solution for the abduction of any kind of water, chemicals, affluent and sewers, because they combine the advantage of corrosion resistance. Typical properties that result in advantages in Corrugated Pipe can be summarized as follows: Higher mechanical resistance due to the structure of the pipe. Corrosion resistance, both of the external wall and internal wall in contact with the conveyed fluid. No protections such as coating, painting or cathodic are needed. Corrugated pipes are resistant to nearly all chemicals. Very long life, virtually infinite of the material which does not need maintaining. Low weight of pipes lengths that allows for the use of light laying and transport means. Easy installation procedures because laying of corrugated pipes is a simple operation which can be done in short periods of time both above and below ground, since sleeve joints and socket joints enable fast and reliable assembling. Workability of the material on sites employing simple equipment. Possibility of nesting of different diameters of pipe thus allowing additional.
COST ESTIMATION
Plant Capacity 28 MT/Day
Land & Building (5000 sq.mt) Rs. 3.38 Cr
Plant & Machinery Rs. 5.78 Cr
Working Capital for 1 Month Rs. 10.95 Cr
Total Capital Investment Rs. 20.44 Cr
Rate of Return 38%
INTRODUCTION
MERITS OF DWC HDPE PIPES
USES OF DWC HDPE PIPES
ADVANTAGES IN CORRUGATED PIPE
APPLICATION OF DOUBLE CORRUGATED PIPE
B.I.S. SPECIFICATION
PRODUCTION TECHNOLOGIES OF DWC PIPE
SINGLE WALL PIPE
DUAL/DOUBLE WALL PIPE
QUALITY CONTROL FOR HDPE
CORRUGATED PIPE STANDARDS AND SN / SR COMPARISON
POINTS TO BE TAKEN INTO CONSIDERATION
EXAMINATION AND TESTING OF CORRUGATED PIPES
PIPE AND ARTICULATION COMPONENT TESTS
TECHNICAL PROPERTIES OF PE CORRUGATED PIPES
DOUBLE WALL CORRUGATED PIPES
DIMENSIONS AND WEIGHTS FOR STANDARD DOUBLE WALL
CORRUGATED PIPES, WITH AN INTEGRATED COUPLING SLEEVE
RECENT PROJECTS - CORRUGATED PIPES, FITTINGS, MANHOLES, INSPECTION CHAMBERS, DRAINAGE PIPES
COMPARISON OF CORRUGATED PIPE WITH OTHER CONVENTIONAL PIPES
CORRUGATED PIPE VERSUS SOLID WALL PIPE
CORRUGATED VERSUS SPIRAL PIPE
TECHNICAL DETAILS OF CORRUGATED PIPE
TYPICAL PRODUCT SPECIFICATION
DOUBLE CORRUGATED PIPE WALL STRUCTURE
PIPES ENDS
HYDRAULIC SEALING
FITTINGS
MANUFACTURING PROCESS DESCRIPTION
TESTING
PROCESS EQUIPMENT
TECHNICAL DATA
THE COMPOSING OF PRODUCTION LINE
MARKET SURVEY
RESEARCH CATEGORY
WORLD DEMAND TO INCREASE 6.2% ANNUALLY THROUGH 2017
PVC CONTINUES AS MOST WIDELY USED RESIN
HDPE PIPE MARKET POTENTIAL ANALYSIS
DEVELOPMENT OF HDPE PIPE MATERIALS
HDPE PIPE MATERIAL PRODUCTION STATUS
CHINA'S HDPE MARKET PROSPECTS
THE PRESSURE TUBE
INDOOR AND OUTDOOR WATER SUPPLY PIPE
SANDWICH TUBE
NON PRESSURE PIPE
IRRIGATION TUBE
UNDERGROUND DRAINAGE, SEWAGE PIPE
CABLE THREADING PIPE AND CABLE PROTECTIVE SLEEVE
THERE ARE 3 OF CHINA'S HDPE PIPE INDUSTRY PROBLEMS
RAW MATERIAL SUPPLY PROBLEMS
PRODUCTION EQUIPMENT BEHIND
PRODUCT APPLICATION LINK
CONCLUSION
WORLD PLASTIC PIPE MARKET
WORLDWIDE PIPE MARKET TO APPROACH 31 BILLION METERS
WORLD DEMAND TO INCREASE 6% PER YEAR THROUGH 2015
ASIA/PACIFIC TO ACCOUNT FOR MORE THAN 1/2 OF DEMAND
GROWTH STUDY COVERAGE
PRODUCTION OF HDPE PIPES IN INDIA
DETAILED EXPORT DATA OF DWC HDPE PIPES
DETAILED EXPORT DATA OF WALL CORRUGATED PIPES
PRESENT MANUFACTURERS/SUPPLIERS
OF HDPE DOUBLE WALL CORRUGATED PIPES
HDPE/PP/PVC DOUBLE WALL CORRUGATED
PIPE PRODUCTION LINE
MANUFACTURING PROCESS
PREPARATION OF RAW MATERIAL (RM)
APPROVAL OF RM FOR PURCHASE ORDER
RECEIVING / STORAGE
IF THE LOT IS COMPLIANT, IT IS STORED AND REGISTERED.
MIXTURE
EXTRUSION
CORRUGATION
THIS RECENT TECHNOLOGY IS UNDER STUDY.
CALIBRATION
FINISHING AND PACKAGING
CONTROLS AND TESTS
TECHNICAL REQUIREMENT OF
DOUBLE WALLED CORRUGATED (DWC) HDPE DUCT
SCOPE
REQUIREMENTS
GENERAL INFRASTRUCTUR
QUALITY CONTROL
ESSENTIAL MACHINERY & PLANT REQUIRED FOR PRODUCTION
REQUIRED ESSENTIAL MACHINERY & PLANT SHALL BE AS FOLLOWS
ESSENTIAL TESTING EQUIPMENTS REQUIRED FOR QUALITY ASSURANCE
REQUIRED ESSENTIAL TESTING EQUIPMENTS SHALL BE AS FOLLOWS
QUALITY ASSURANCE FLOW CHART FOR DWC HDPE DUCT
PLANT LAYOUT
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)
COMPLETE PLANT SUPPLIERS
DOUBLE WALL CORRUGATED HDPE PIPE MAKING PLANT & EQUIPMENTS
AIR POLLUTION CONTROL EQUIPMENTS
EOT CRANES
DG SETS
POWER TRANSFORMERS
COOLING TOWER
ETP PLANTS
MEASURING AND TESTING INSTRUMENTS
SUPPLIERS OF RAW MATERIALS
HDPE RESIN
HDPE GRANULES
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)
