MANUFACTURING PLANT OF EMPTY LPG STEEL CYLINDER VARIES FROM 11KG, 12.5KG, 22.5KG, 44KG, 54.5KG, 104KG ETC. [3672]
LPG Cylinder is an essential item for filling liquefied petroleum gas used for cooking purpose. The body of LPG cylinder is deep drawn in two pieces then these are welded together to make a compact unit without any leak and defect etc. LPG cylinders are in use in 5 Kg., 12 Kg., 14.2 Kg. & 19 Kg. capacities. To ascertain the quality, safety and performance certain regulations are applicable such as BIS standardization and Explosive License etc. While all the cylinders are spray-painted with a signal red colour. BPC cylinders have yellow ring around the bung. HPC cylinders in blue ring and IOC cylinder are fully red. In case of 19 Kg. cylinders the top is painted olive green.
The cylinders carry their complete history with regard to their serial number, Tare/ Gross weight, water capacity, ISE monogram test date, manufacturer identification and year of manufacturing. LP Gas cylinders can come in many different sizes depending on the application. The gross weight of an LP Gas cylinder is often one of the limiting factors in selecting the size, especially for domestic applications.
The diameter is also a very important factor because it has implications with the dimensions of the conveyors in the filling plant, and the pallets and racks used for storage etc. For domestic use, cylinders typically will have capacities ranging from 4kg to 15kg whereas for commercial and industrial use, these will range from 45kg to 50kg. Smaller cylinders i.e. 1kg to 3kg capacities are used for camping equipment and in developing countries where they often serve as an entry level for LP Gas applications in low income households - mainly for cooking. LP Gas cylinders will almost always be used in the vertical position although forklift cylinders are typically designed to be used horizontally with capacities ranging from 15kg to 22kg.
COST ESTIMATION
Plant Capacity 1800 Nos/Day
Land & Building (3000 sq.mt.) Rs. 2.04 Cr.
Plant & Machinery Rs. 7.87 Cr.
Working Capital for 2 Months Rs. 12.54 Cr.
Total Capital Investment Rs. 22.88 Cr.
Rate of Return 64%
Break Even Point 35%
INTRODUCTION
SIZES OF LPG CYLINDER
CONSTRUCTION OF LPG CYLINDER
1. BODY
2. BUNG
3. SHROUD
4. FOOT RING
5. VALVES
(A) SELF-CLOSING, CLIP-ON VALVE
(B) HAND WHEEL OPERATED VALVE
USES AND APPLICATION
B.I.S. SPECIFICATION
QUALITY STANDARD:
PROCESS FLOW CHART
MANUFACTURING PROCESS
MATERIAL
(A) FOR PRESSURE PARTS
(B) NON-PRESSURE PARTS
GENERAL
THE MAIN STEPS ARE GIVEN BELOW
QUALITY CONTROL
(A) MATERIAL SPECIFICATIONS:
(B) WELDING SPECIFICATION
(C) MANUFACTURING PROCESS SPECIFICATION
(A) CYLINDER BODY
(B) VALVE PROTECTION RING-STAY PLATE ASSEMBLY
(C) FOOTRING
(D) HEAT TREATMENT
(E) SURFACE PREPARATION & PAINTING:
(F) TESTING:
(G) SCREEN PRINTING/STENCILLING:
(H) STAMPINGS & PUNCHING:
1. STAMPING ON BUNG:
2. STAMPING ON THE STAY PLATES:
(I) VALVE FIXING:
(J) WEIGHMENT OF CYLINDER:
(K) PACKING:
GLOBAL MARKET OVERVIEW
LPG PRODUCTION GROWTH IS STRONG IN THE US AND CANADA, BUT
OTHER REGIONS ARE ALSO GROWING QUICKLY
THE US MUST EXPORT LPG BECAUSE DOMESTIC DEMAND CAN’T KEEP
UP WITH SHALE-BASED PRODUCTION – EVEN AT LOWER OIL PRICES
THE US WILL REMAIN THE WORLD’S LARGEST LPG EXPORTING COUNTRY
GLOBAL LPG DEMAND GROWTH WILL CONTINUE TO BE LED BY ASIA
AND THE MIDDLE EAST
RESIDENTIAL/COMMERCIAL LPG DEMAND IS GROWING STEADILY BUT CHEMICALS DEMAND IS GROWING FASTER
WITH LATIN AMERICA SATURATED AND EUROPE VERY COMPETITIVE,
MOST INCREMENTAL US EXPORTS WILL NEED TO MOVE TO ASIA
LPG IS A SUPPLY-DRIVEN MARKET. SOME SUPPLY FORECAST UNCERTAINTIES:
REFINING
ASSOCIATED GAS
NON-ASSOCIATED GAS
BIO-LPG
THE LPG MARKET MUST (EVENTUALLY) CLEAR. SOME DEMAND
FORECAST UNCERTAINTIES:
RESIDENTIAL / COMMERCIAL
CHEMICALS
AUTOGAS
INDUSTRIAL
OTHER THINGS THAT KEEP LPG RESEARCHERS UP AT NIGHT…
WATERBORNE LOGISTICS
GEOPOLITICS
SUPPLY DISTANT FROM DEMAND CENTERS
DISRUPTIVE TECHNOLOGIES
CRUDE OIL PRICES: A MODEST GLOBAL OIL PRODUCTION DEFICIT WILL
SUPPORT A GRADUAL, BUT RISING PRICE TREND IN 2017-18
CRUDE OIL SUPPLY DISRUPTIONS: GLOBAL SPARE CAPACITY IS NOW
AT ABOUT ONE THIRD OF ITS 2010 LEVEL
“HIGH-GRADING”: US PROPANE PRODUCTION HAS GENERALLY BEEN FOLLOWING CRUDE OIL PRODUCTION WITH AN INFLUENCE BY NATURAL
GAS – UNTIL RECENTLY…
PERMIAN PRODUCTION: WITH HIGHER RESERVES AND PRODUCTIVITY,
HAVE WE UNDERESTIMATED THE PRODUCTION FORECAST?
GLOBAL LPG DEMAND: WILL ASIAN DEMAND BE STRONG ENOUGH TO CONSUME THE GLOBAL LPG SURPLUS?
DEMAND COMPETITION: WILL A GLUT OF LNG DISPLACE LPG DEMAND
IN KEY COUNTRIES?
US LPG EXPORT CAPACITY: CAPACITY COULD BE TIGHT AGAIN IN
THE 20’S UNLESS THERE IS FURTHER EXPANSION
THE VLGC FLEET: CURRENTLY OVERSUPPLIED, BUT HOW DOES
MARPOL IMPACT THE FLEET?
LARGEST WORLD PRODUCERS
USA HAS BECOME ON OF THE LARGEST EXPORTERS OF LPG
IN THE WORLD.
LARGEST WORLD CONSUMERS
ASIAN CONSUMERS REPRESENT THE BIGGEST SHARE OF THE
GLOBAL DEMAND.
WORLD CONSUMERS BY SECTOR – 2015
LPG FINAL CONSUMPTION BY SECTOR
RESIDENTIAL SECTOR IS THE LARGEST COMPONENT OF THE GLOBAL
DEMAND. ADDITIONALLY, CHEMICAL INDUSTRY IS GETTING MORE
RELEVANT.
LARGEST WORLD EXPORTERS AND IMPORTERS
USA LPG SURPLUS GOES MAINLY TO THE ASIAN MARKET.
PLANT LAYOUT
MANUFACTUERS/SUPPLIERS OF LPG CYLINDER
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF M.S. SHEETS
SUPPLIERS OF LPG CYLINDER VALVE
SUPPLIERS OF BUNG
SUPPLIERS OF SHROUD AND FOOT RING
SUPPLIERS OF MIG WELDING WIRE ELECTRODE
SUPPLIERS OF POWDER COATING PAINT
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF SHEARING MACHINE
SUPPLIERS OF DEEP DRAWING PRESS
SUPPLIERS OF CIRCLE CUTTING MACHINE
SUPPLIERS OF POWER PRESS
SUPPLIERS OF TRIMMING MACHINE
SUPPLIERS OF MIG WELDING MACHINE
SUPPLIERS OF HEATREATMENT FURNACE
SUPPLIERS OF SAND BLASTING MACHINE
SUPPLIERS OF BENCH GRINDER
SUPPLIERS OF DRILLING MACHINE
SUPPLIERS OF LPG CYLINDER TESTING MACHINE
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF DG SETS
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF POWDER COATING MACHINE
SUPPLIERS OF HOT DIP GALVANISING PLANT
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF PAINTING EQUIPMENTS
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)
