DOUBLE WALL CORRUGATED (DWC) PIPES
[CODE NO.4081]
It needs to be well noted that Double Wall Corrugated Pipes (DWC pipes) have much similarity to the HDPE pipes. However, they have different internal and external surfaces which gives them much stiffness as well as strength. These pipes are known to be made with polyethylene of high density – that which has a very high life expectancy. It needs to be well understood and noted that corrugated pipes are used wherein flexibility is much important other than durability and strength.
As corrugated pipes are much flexible, they are suitable and useful for a variety of uses. It is important to note down the features as well as advantages of DWC pipes. The use of these pipes is absolutely on a rise. The industries that use these pipes are more conscious on how to save money with the use and installation of the use of best of these pipes for variety of uses. The DWC pipes are the first preference of most industrialists and this is what they are educated about, as in the advantages and benefits associated with using these pipes.
The DWC pipes have a corrugated shape and offer compression resistance and great strength. The manufacturing of these pipes requires minimum raw material, and thus the effect on environmental aspects is generally reduced. Thus, this product is known to have an added advantage over its contemporary pipe. It needs to be well noted that the use of double wall corrugated pipes much reduces the cost of the project that it is used for. Many organizations are looking forward to the use of these pipes for maximum profitability.
The DWC pipes are known to have good corrosion resistance with decreased wear and tear and increased longetivity. These pipes are known to have good strength and minimum friction. These pipes could have the best of features such as extra inner smooth layer and demand lubricated silicone inner layer. These pipes are known to have the capability to bear heavy loads, and thus are much used in sewage along with many other purposes – that needs to executed underground.
It is extremely important for all industrialists to be aware of the benefits and advantages of using these pipes. A corrugated pipe is actually a pipe with a series of groves and ridges that run parallel to each other on its surface. These corrugated pipes are known to be made of different materials such as high-density polyethylene (HDPE), polyvinyl chloride, steel, iron, and few other materials to be well noted.
The DWC pipes are known to have good durability and are more durable than other pipes. As mentioned before, these pipes are known to have the best durability The inner pipe of a DWC pipe is a “Carrier Pipe” and the outer pipe is “Containment Pipe”. The design and structure of these pipes is to ensure much safety, corrosion resistance, low weight, long life, higher mechanical resistance as well as zero/very low maintenance. Thus, it is worthwhile to know the applications of DWC pipes.
COST ESTIMATION
Plant Capacity 20 MT/Day
Land & Building (8000 sq.mt.) Rs. 6.44 Cr
Plant & Machinery Rs. 6.17 Cr
Working Capital for 1 Month Rs. 5.67 Cr
Total Capital Investment Rs. 18.70 Cr
Rate of Return 34%
Break Even Point 49%
INTRODUCTION
THERE ARE MANUFACTURED AS PER FOLLOWING STANDARDS.
QUALITY TESTS PERFORMED
DIMENSIONS OF DWC PIPE
DWC PIPE FOR NEW GENERATION
ADVANTAGES OF DWC PIPES
THERE ARE NUMEROUS OTHER FEATURES OF DWC PIPES & THOSE ARE:
USES OF DWC HDPE PIPES
MERITS OF DWC HDPE PIPES
MERITS OF DWC HDPE PIPES:
B.I.S. SPECIFICATION
ADVANTAGE OF DWC CORRUGATOR MACHINE
DRAINAGE PIPES
ELECTRICAL DUCTS
AGRICULTURE & IRRIGATION WORK
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
TABLE: TECHNICAL PROPERTIES OF 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:
DIAMETER AND CLASSES
NOMINAL PRESSURE CLASSES IS 1 BAR
DOUBLE CORRUGATED PIPE WALL STRUCTURE
PIPES ENDS
HYDRAULIC SEALING
FITTINGS
MANUFACTURING PROCESS DESCRIPTION:
TESTING
PROCESS EQUIPMENT
TECHNICAL DATA:
II. DIE HEAD
III. FORMING MACHINE
IV. SPRAY BATH
V. CUT-OFF UNIT
VI. STACKER
THE COMPOSING OF PRODUCTION LINE:
E: MECHANICAL PARTS
II. EXTRUSION DIE HEAD
III. SBZ1000 FORMING MACHINE
MODEL OF FORMING MACHINE: SBZ1000 (HORIZONTAL TYPE MACHINE)
IV. SPRAY BATH
V. CUT-OFF UNIT
VI. STACKER
MARKET OVERVIEW OF HDPE PIPES
PRODUCTION OF HDPE IN INDIA
CONSUMPTION OF HDPE IN INDIA
IMPORT OF HDPE
OVERVIEW OF CONSTRUCTION INDUSTRY IN INDIA
THE NATIONAL INFRASTRUCTURE PIPELINE (NIP)
GOVERNMENT INITIATIVES
CONCLUSION
PRESENT MANUFACTURERS/SUPPLIERS OF DWC HDPE PIPES
HDPE/PP/PVC DOUBLE WALL CORRUGATED PIPE PRODUCTION LINE
MANUFACTURING PROCESS
PHASE I
PREPARATION OF RAW MATERIAL (RM)
APPROVAL OF RM FOR PURCHASE ORDER
RECEIVING / STORAGE
IF THE LOT IS COMPLIANT, IT IS STORED AND REGISTERED.
MIXTURE
PHASE II
EXTRUSION
PHASE III
CORRUGATION
THIS RECENT TECHNOLOGY IS UNDER STUDY.
PHASE IV
CALIBRATION
PHASE V
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
JOINING SYSTEM AND INSTALLATION OF DWC PIPES
JOINTING PROCEDURE
CONSTRUCTION OF BACKFILL ENVELOPE AND BACKFILLING
OF THE TRENCHES
TRANSPORTATION, HANDLING AND STORAGE OF DWC PIPES
TRANSPORTATION OF DOUBLE-WALL PIPE TO THE WORKSHOP
STORAGE AND MAINTENANCE OF DOUBLE-WALL CORRUGATED PIPE
INSTALLING DOUBLE-WALL CORRUGATED PIPES
DETAILS OF CORRUGATOR LINE
LAYOUT OF A PRODUCTION LINE:
DOWNSTREAM EQUIPMENT
PRODUCTION TECHNOLOGIES
» UNICOR‘S CLOSED CONSTRUCTION TECHNOLOGY
FEATURES:
» UNICOR‘S SHUTTLE CORRUGATORS
FEATURES:
» UNICOR‘S OPEN HORIZONTAL CHAIN CORRUGATORS
FEATURES:
PRODUCTION TECHNOLOGIES
» DIE HEADS:
› SWESY DIE HEAD FOR SMALL-/MID-SIZED DOUBLE WALL PIPES
SWESY DIE HEAD – ADVANTAGES
› DISC DIE HEAD FOR MID-/LARGE-SIZED DOUBLE WALL PIPES
DISC DIE HEAD – ADVANTAGES
» UNICOR COOLING MANDREL TECHNOLOGY GUARANTEES:
PRODUCTION TECHNOLOGIES
» MOULD BLOCKS
CONNECTION TECHNIQUES
TESTNG METHOD OF DWC PIPES
CREEP RUPTURE STRENGTH - INTERNAL PRESSURE TEST
CONSTANT INTERNAL PRESSURE AT CONSTANT TEMPERATURE
STRESS CRACK RESISTANCE - PIPE NOTCH TEST
SLOW CRACK GROWTH TESTING
RESISTANCE TO RAPID CRACK PROPAGATION - S4 TEST
RCP PHENOMENON SIMULATION IN PLASTIC PIPES
CREEP RUPTURE STRENGTH - INTERNAL PRESSURE TEST
RESISTANCE TO INTERNAL PRESSURE
RECOMMENDED TESTING PROCEDURE FOR HDPE PIPES
PRESSURE TESTING OUTSIDE THE TRENCH:
TESTING IN THE TRENCH:
COMPLETE DOUBLE WALL CORRUGATED HDPE PIPE MAKING PLANT
& EQUIPMENTS SUPPLIERS
SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)
COMPLETE DOUBLE WALL CORRUGATED HDPE PIPE MAKING PLANT
& EQUIPMENTS SUPPLIERS
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF DG SETS
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF ETP PLANTS
SUPPLIERS OF MEASURING AND TESTING INSTRUMENTS
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF HDPE RESIN
SUPPLIERS OF 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)
