DUCTILE PIPE
[CODE NO.3740]
DUCTILE IRON
Ductile iron is a family of cast graphitic irons which possess high strength, ductility and resistance to shock. Annealed cast ductile iron can be bent, twisted or deformed without fracturing. Its strength, toughness and ductility duplicate many grades of steel and far exceed those of standard gray irons. Yet it possesses the advantages of design flexibility and low cost casting procedures similar to gray iron. The difference between ductile iron and gray iron is in the graphite formation. Ordinary gray iron is characterized by a random flake graphite pattern in the metal. In ductile iron the addition of a few hundredths of 1 % of magnesium or cerium causes the graphite to form in small spheroids rather than flakes. These create fewer discontinuities in the structure of the metal and produce a stronger, more ductile iron. This nodular graphite structure inhibits the creation of linear cracks hence the ability to withstand distortion. Fig 1 shows typical micro structure of ductile iron.
Fig 1 Typical micro structure of ductile iron
With ductile iron, the safety and reliability of process equipment is improved. The improved mechanical properties increase its resistance to breakage from physical load, or mechanical and thermal shock far above that of gray iron. The corrosion resistance of ductile iron is equal or superior to gray cast iron and to cast steel in many corrosives. Its wear resistance is comparable to some of the best grades of steel and superior to gray iron in heavy load or impact load situations. Since it can be cast with the same low cost procedures used for gray cast iron, it is considerably less expensive than cast steel and only moderately more expensive than gray iron. The substantial advantages obtained from its high yield strength and ductility make it an economical choice for many applications.
Common Ductile Iron Grades
While there are many different ductile iron specifications, foundries routinely offer 3 common grades;
Physical and Mechanical Properties ASTM A536, Grade 60-40-18 ASTM A536, Grade 65-45-12 ASTM A536, Grade 80-55-06
Tensile Strength, min, psi 60,000 65,000 80,000
Tensile Strength, min, MPa 414 448 552
Yield Strength, min, psi 40,000 45,000 55,000
Yield Strength, min, MPa 276 310 379
Elongation in 2 in. or 50 mm, min % 18 12 6
Density lb/in3 0.256 0.256 0.256
Density g/cm3 7.1 7.1 7.1
Melting Temperature (Degrees F) 2,100 – 2,190 2,100 – 2,190 2,100 – 2,190
Melting Temperature (Degrees C) 1,150 - 1,200 1,150 - 1,200 1,150 - 1,200
Compressive Strength Ksi 429 429 429
Compressive Strength MPa 2960 2960 2960
UNS F32800 F33100 F33800
The family of ductile iron
Ductile iron is not a single material, but a family of versatile cast irons exhibiting a wide range of properties which are obtained through microstructure control. The common feature that all ductile irons share is the roughly spherical shape of the graphite nodules. These nodules act as crack arresters and give ductile iron ductility and toughness which is superior to all other cast irons, and equal to many cast and forged steels. This feature is essential to the quality and consistency of ductile iron. With a high percentage of graphite nodules present in the structure, mechanical properties are determined by the ductile iron matrix. The importance of matrix in controlling mechanical properties is emphasized by the use of matrix names to designate the following types of ductile iron.
• Ferritic ductile iron – Graphite spheroids in a matrix of ferrite provides an iron with good ductility and impact resistance and with a tensile and yield strength equivalent to low carbon steel. Ferritic ductile iron can be produced ‘as-cast’ but may be given an annealing heat treatment to assure maximum ductility and low temperature toughness.
• Ferritic pearlitic ductile iron – These are the most common grade of ductile irons and are normally produced in the ‘as cast’ condition. The graphite spheroids are in a matrix containing both ferrite and pearlite. Properties are intermediate between ferritic and pearlitic grades, with good machinability and low production costs.
• Pearlitic ductile iron – Graphite spheroids in a matrix of pearlite result in an iron with high strength, good wear resistance, and moderate ductility and impact resistance. Machinability is also superior to steels of comparable physical properties.
The above three types of ductile iron are the most common and are usually used in the ‘as cast’ condition, but ductile iron can be also be alloyed and/or heat treated to provide the following grades for a wide variety of additional applications.
• Martensitic ductile iron – Using sufficient alloy additions to prevent pearlite formation, and a quench-and-temper heat treatment produces this type of ductile iron. The resultant tempered martensite matrix develops very high strength and wear resistance but with lower levels of ductility and toughness.
• Bainitic ductile iron – This grade can be obtained through alloying and/or by heat treatment to produce a hard, wear resistant material.
• Austenitic ductile iron – Alloyed to produce an austenitic matrix, this ductile iron offers good corrosion and oxidation resistance, good magnetic properties, and good strength and dimensional stability at elevated temperatures.
• Austempered ductile iron (ADI) – ADI, the most recent addition to the ductile iron family, is a sub group of ductile irons produced by giving conventional ductile iron a special austempering heat treatment. Nearly twice as strong as pearlitic ductile iron, ADI still retains high elongation and toughness. This combination provides a material with superior wear resistance and fatigue strength.
COST ESTIMATION
Plant Capacity 400 MT/Day
Land & Building (200000 sq.mt.) US$ 21.22 Lac
Plant & Machinery US$ 3.28 Cr
Working Capital for 2 Months US$ 1.13 Cr
Total Capital Investment US$ 5 Cr
Rate of Return 35%
Break Even Point 56%
INTRODUCTION
DUCTILE IRON
COMMON DUCTILE IRON GRADES
THE FAMILY OF DUCTILE IRON
PROPERTIES OF DUCTILE IRONS
BENEFITS OF DUCTILE IRON
DUCTILE IRON PIPE
HISTORY OF DUCTILE IRON PIPES
CHARACTERISTICS OF DUCTILE IRON PIPE
TYPE OF JOINTS
THERE ARE MAINLY THREE SECTIONS OF DUCTILE IRON PIPE:
1. SOCKET
2. BARREL
3. SPIGOT
RANGE OF PIPES
TECHNICAL DETAILS
PIPE DIMENSION
ADVANTAGES
ADVANTAGES OF DUCTILE IRON PIPES
DISADVANTAGES
USES AND APPLICATION
B.I.S. SPECIFICATION
PRODUCTION PROCESS
(1) RAW MATERIAL SELECTION
(2) DESULPHURISATION
(3) MELTING AND COMPOSITION CONTROL
(4) MAGNESIUM TREATMENT
NODULISING:
(5) INOCULATION
EFFECT OF INOCULATION
(6) MOULD CONDITIONING
(7) CORE MAKING
(8) CASTING
CENTRIFUGAL CASTING
DE LAVAUD PROCESS
WET-SPRAY PROCESS
(9) INTERNAL GRINDING
(10) HEAT TREATMENT
(11) ZINC COATING
(12) CUT OFF AND CHAMFERING MACHINE
(13) HYDROSTATIC PRESSURE TESTING
(14) CEMENT MORTAR FEEDING AND LINING
(15) STEAM CURING
(17) INTERNAL POLISHING
(17) BITUMEN COATING
(18) QUALITY CONTROL
QUALITY CONTROL CHECKS AT EVERY STAGE OF MANUFACTURING
(19) MARKING AND STENCILING
(20) STORAGE, PACKING AND DISPATCH
ELECTRIC INDUCTION FURNACES VERSUS CUPOLAS FOR MELTING IRON
INDUCTION FURNACE AND IMPORTANT OPERATIONAL ASPECTS
INDUCTION FURNACE AND IMPORTANT OPERATIONAL ASPECTS
RAW MATERIALS AND ENERGY SOURCE
IMPORTANT ASPECTS OF OPERATION
OTHER ASPECTS OF INDUCTION FURNACE STEEL MAKING
ENVIRONMENTAL EMISSIONS
SAFETY AND INDUCTION FURNACES
MARKET SURVEY FOR DI PIPE
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
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF DI PIPE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PIG IRON
SUPPLIERS OF CAST IRON SCRAP
SUPPLIERS OF STEEL SCRAPE
SUPPLIERS OF SILICON CARBIDE
SUPPLIERS OF FERRO SILICON
SUPPLIERS OF MAGNESIUM INGOT
SUPPLIERS OF FERRO MANGANESE
SUPPLIERS OF FIRE CLAY
SUPPLIERS OF BENTONITE
SUPPLIRS OF COAL DUST
SUPPLIERS OF GRAPHITE POWDER
SUPPLIERS OF SILICA SAND
SUPPLIERS OF LIME STONE
SUPPLIERS OF PLANT AND MACHINERY
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 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 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
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)
