DI MANHOLE COVER AND DI PIPE FITTING [3634]
Ductile iron casting refers to a process in which magnesium / Cerium (as an alloy of magnesium / Cerium) is added to cast iron. It was first manufactured by K.D. Mills in 1943. While most varieties of cast iron are comparatively brittle, ductile iron castings are much more ductile due to the inclusion of nodular graphite. Solidified castings of ductile iron contain nearly perfect spheres of graphite. Ductile iron possesses the processing advantages of grey iron, such as low melting point, good fluidity, castability and machinability, and engineering advantages of steel, including high strength, ductility and wear resistance. Achieving the desired quality consistently at low cost in a production foundry is, however, still a challenge. Addition of small amount of cerium or magnesium to molten cast iron changes the shape of graphite from laminar to spheroidal, giving rise to spheroidal graphite iron or ductile iron. The rapid growth in industrial applications of ductile iron (DI) is driven by its versatility and high performance at low cost. It offers a good combination of tensile strength and ductility. This allows designers to select ductile iron for a wide range of applications. Ductile iron also offers cost savings compared to steel and malleable iron castings through higher yield and thereby lower melting energy. Formation of graphite during solidification leads to lower volumetric shrinkage in ductile iron (compared to steel), necessitating smaller and fewer feeders to prevent the formation of shrinkage defects. Further cost advances can be achieved by eliminating heat treatment of as-cast DI parts. The near-spherical shape of the graphite nodules distributed evenly in the matrix phase of ductile iron enhances its ductility and impact resistance along with tensile and yield strength equivalent to a low carbon steel. While ferritic ductile iron can be used as ‘as-cast’, it may also be annealed to increase its ductility and low-temperature toughness. The pearlitic ductile iron has graphite spheroids in a matrix of pearlite, resulting in high strength, good wear resistance, moderate ductility and impact resistance. The most commonly used ferritic-pearlitic ductile iron containing both ferrite and pearlite in matrix offers a good combination of tensile strength and ductility with good machinability and low production costs. The ductile iron castings are produced in a wide range of weight, from a few grams to a hundred tons or more, greatly varying in shape and size depending on the applications (Figure 1). Many forged and fabricated steel components are getting replaced by ductile iron castings, owing to their good combination of mechanical properties such as strength, wear resistance, fatigue strength, toughness and ductility coupled with economic production. The specifications of ductile irons with ferrite/pearlitic matrix with different grades are shown in Table 1. They are used in safety parts in automobiles, armatures, pumps and machine tools. They are also used in parts subjected to high pressure, such as pressure containers and hydraulics. Many welded assemblies and forgings used in governor housings, armatures and car parts (like brake calipers and gear housings, hydraulic parts, crankcases and blower buckets) are being replaced by ferritic ductile iron castings. Cast or grey iron is an alloy characterized by its relatively high content of carbon flakes (2% to 4%). In contrast, the carbon in ductile iron is in the form of spherical nodules. The formation of such nodules is achieved by the addition of 'nodulizers' like magnesium or cerium into the castings melt. Due to its inherent properties, such nodules resist the creation of cracks and augment its ductility. That is why this process is called as ductile iron casting. In the as-cast condition, the matrix will consist of varying proportions of pearlite and ferrite, and as the amount of pearlite increases, the strength and hardness of the iron also increase. Ductility and impact properties are principally determined by the proportions of ferrite and pearlite in the matrix. The mechanical properties of ductile iron are controlled by the presence of graphite nodules. The Different grades of Ductile Iron Castings are produced by obtaining different matrix microstructures in the Iron. Alloying elements may be added to enhance as cast properties of Ductile Iron. In some special cases Heat Treatment can be employed to achieve the higher properties. The Grades of Ductile Iron Castings are based on the Mechanical Properties of the casting. Ductile iron with high strength and toughness has been available as an engineering material for many years, replacing forging steel, cast steel, and malleable cast-iron. It has undergone a phenomenal development and has become the only ferrous casting material with positive growth rate. The ductile iron will still be an important construction material in the 21st century.
COST ESTIMATION
Plant Capacity 40 MT/Day
Land & Building (10000 sq.mt) Rs. 7.75 Cr
Plant & Machinery Rs. 5.15 Cr
Working Capital for 2 Months Rs. 11.21 Cr
Total Capital Investment Rs. 24.85 Cr
Rate of Return 23%
Break Even Point 67%
INTRODUCTION
COMPOSITION OF DUCTILE IRON CASTINGS
DUCTILE IRON
FIG 1 TYPICAL MICRO STRUCTURE OF DUCTILE IRON
COMPOSITION:
COMMON DUCTILE IRON GRADES
THE FAMILY OF DUCTILE IRON
PROPERTIES OF DUCTILE IRONS
BENEFITS OF DUCTILE IRON
(A) DI MAN HOLE COVER
GRADES
1. LIGHT DUTY (LD-2.5) SQUIRE, CIRCULAR OR REACTANGULAR SOLID TYPE
2. MEDIUM DUTY (MD-10) CIRCULAR, SQUIRE OR REACTANGULAR
(SCRAPPER MAN HOLE)
3. HEAVY DUTY (HD 20) CIRCULAR, SQUIRE OR REACTANGULAR
(SCRAPPER MAN HOLE)
4. EXTRA HEAVY DUTY (EHD 35) CIRCULAR, SQUIRE ORREACTANGULAR
(SCRAPPER MAN HOLE)
(B) DI PIPE FITTING
TYPES OF D.I FITTING
(1) PIPE ADAPTERS
TYPES OF PIPE ADAPTERS:
LOCKING PIPE ADAPTER:
OFFSET PIPE ADAPTER:
MALE ADAPTER:
FEMALE PIPE ADAPTER:
STRAIGHT THREAD ADAPTERS:
(2) PIPE ELBOW FITTINGS
(3) PIPE COUPLING
PARTS OF PIPE COUPLING AS SHOWN BELOW:
(4) PIPE UNION
(5) PIPE REDUCER
(6) PIPE TEE
SIZE OF PIPE FITTING
SIZES OF BEND PIPES
DOUBLE SOCKET BEND
DOUBLE FLANGED BEND
DOUBLE FLANGED 90° LONG RADIUS BEND
DOUBLE FLANGED 90° DUCKFOOT BEND
DUCTILE IRON FITTINGS
SIZES OF PIPE TEE
ALL SOCKET TEE
ALL FLANGED TEE
ALL FLANGED 45° ANGLE BRANCHES
ALL FLANGED RADIAL TEES
ALL FLANGED 'Y' TEES
DOUBLE SOCKET LEVEL INVERT TEE WITH FLANGED BRANCH
DOUBLE SOCKET TEE WITH FLANGED BRANCH
DOUBLE SOCKET TAPER
SIZES OF TAPER (REDUCER)
DOUBLE SOCKET TAPER
DOUBLE FLANGED TAPER
DUCTILE IRON COLLAR
SIZES OF SHORT PIPES
DUCTILE IRON FLANGE
FLANGED PIPE
DOUBLE FLANGED PIPES
FLANGED SPIGOT
FLANGED SOCKET
DUCTILE IRON FITTINGS
DOUBLE SOCKET BEND
SIZES OF ADAPTORS
FLANGE ADAPTOR
DISMANTLING ADAPTOR
FLEXIBLE COUPLING
DIMENSIONS OF FLANGE
USES AND APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS
(A) FOR MAN HOLE COVER
RAW MATERIALS
DESIGN
THE MANUFACTURING
PROCESS
PATTERN MAKING
MOLD PREPARATION
MELTING/POURING
THE MANUFACTURING OF A MANHOLE COVERS USING A SAND MOLD.
COOLING
FINISHING
QUALITY CONTROL (PLEASE REFER IS: 1726:1991)
1. COATING
MARKING
(B) FOR DI PIPE FITTING
MANUFACTURING PROCESS
SUB PROCESS
DESULPHURIZATION
SCRAP ADDITION & SUPER HEATING
MAGNESIUM TREATMENT
LOST FOAM CASTING
PROCESS DESCRIPTION
ADVANTAGES
HEAT TREATMENT
ZINC COATING
HYDROSTATIC PRESSURE TESTING
CEMENT LINING
STEAM CURING
BITUMEN COATING
MARKING AND STENCILING
QUALITY CONTROL (PLEASE REFER IS: 9523:2000)
RAW MATERIAL
INDUCTION FURNACE
LADLE TREATMENT/CONVERTER FOR "MG" TREATMENT
CASTING MACHINE
GANTRY BEFORE ANNEALING FURNACE
ANNEALING FURNACE
SAMPLE CUTTING
ZINC COATING
GROOVE GRINDING
HYDROSTATIC PRESSURE TESTING
CEMENT LINING
CEMENT CURING
BITUMEN COATING
MARKET OVERVIEW OF MANHOLE COVERS
INDUSTRY ANALYSIS
PREFERENCE OF PIPE MATERIALS
INTER LINKING OF RIVERS (ILR) PROJECT
EXPORT POTENTIAL
DOMESTIC MANUFACTURERS OF DI PIPE
DEMAND – SUPPLY GAP:
ECONOMIC GROWTH
DEMAND FOR WATER
URBANIZATION
DEMAND ANALYSIS FOR DI PIPES
INVESTMENT IN WATER PROJECTS AND ROLE OF GOVERNMENT BODIES
EXTERNAL AID
EXPORT OF DI PIPE FITTINGS
IMPORT OF DI PIPE FITTINGS
EXPORT OF DUCTILE IRON MANHOLE
IMPORT OF DUCTILE IRON MANHOLE
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF DI MAN HOLE COVER
MANUFACTURERS/SUPPLIERS OF DI PIPE FITTING
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PIG IRON
SUPPLIERS OF CAST IRON SCRAP
SUPPLIERS OF STEEL SCRAP
SUPPLIERS OF SILICON CARBIDE
SUPPLIERS OF FERRO SILICON
SUPPLIERS OF MAGNESIUM INGOT
SUPPLIERS OF FERRO SILICON
SUPPLIERS OF BENTONITE
SUPPLIERS OF GRAPHITE POWDER
SUPPLIERS OF SILICA SAND
SUPPLIERS OF LIME STONE
SUPPLIERS OF PLANT AND MACHINERIES
SUPPLIERS OF ANNEALING FURNACE
SUPPLIERS OF HEATREATMENT FURNACE
SUPPLIERS OF INDUCTION FURNACE
SUPPLIERS OF ALUMINIUM PATTERNS
SUPPLIERS OF INTENSIVE SAND MIXTURE AND MULLER
SUPPLIERS OF SAND SIEVING MACHINE
SUPPLIERS OF SQUEEZE MOLDING MACHINE
SUPPLIERS OF SHAKEOUT MACHINE
SUPPLIERS OF CORE SHOOTER MACHINE
SUPPLIERS OF DRYING OVEN
SUPPLIERS OF FOUNDRY TOOLS
SUPPLIERS OF MOLDING BOXES
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES
SUPPLIERS OF GRINDING MACHINE
SUPPLIERS OF EOT CRANE
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFLUENT 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
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)
