PVC PIPE MANUFACTURING, PVC PIPE FITTING AND HDPE PIPE MANUFACTURING
[CODE NO.3424]
PVC is a thermosetting plastic. In other words, it can only be softened and molded into form once. If it is softened and remolded a second time it will lose some of it's favorable characteristics. Recently, 'Fuseable PVC' has come to market to compete with the fuseable properties of HDPE Pipe.
PVC also has a high chemical resistance. While it will react with some chemicals, there are a large number of chemicals it will not react with, making it an excellent product for industrial applications.
Because PVC is mostly a 'rigid' pipe product, PVC pipe is an excellent pipe choice for just about any application that does not require a 'flexible' solution. The most common uses for PVC are:
Water Distribution
Underground Fire Main Distribution
Gravity Sanitary Sewer Collection
Forcemain Sewerage Transmission
Irrigation Mains
Reclaimed Water Distribution
Electrical & Communications Conduit
Numerous Industrial Applications
PVC Pipe fittings are integral and essential part of PVC piping systems. These are required where ever PVC pipes are used.
The efficiency of various PVC piping systems depend largely upon the quality of the fittings used in pipe assembly. The most commonly used PVC pipe fittings are Sockets, Tees elbows, Bends, Joints etc.
PVC pipes are fast replacing the conventional metallic pipes in many applications such as electrical conduits, irrigation, sanitary fittings, portable water etc. They are also used in tube wells and due to their chemical resistance properties they find applications in chemical plants too.
Over 70% of India's rural population does not have access to safe drinking water. Villagers have to trek for miles to get water. It is estimated that at least 24 million people are living at risk in about 34,000 cholera, endemic villages, and small towns. The magnitude of the problem is so enormous that it is essential to have a high performance and low cost scheme to convey extensively the water now available to as many villages as possible. Such as system is now possible with PVC pipe lines. PVC can replace conventional materials like steel, cast iron and asbestos cement and in advanced countries it has already done so.
HDPE pipe market has been witnessing steady rise for the past decade owing to its rise in application in its relevant industry. The product is being activity used across the globe resulting in the quantitative increase in demand which is in turn pushed the revenue generation year on year. In term of types the global HDPE pipe market is segmented into PE80, PE100 pipe. The HDPE pipe market segmented by region include US. Canada, Mexico, Germany, France, UK, Italy, Russia, China, Japan, India, Korea, Australia, Brazil, Middle East and Africa.
COST ESTIMATION
Plant Capacity : PVC PIPE, FITTING
& HDPE PIPE MFG.
land & Building (12000 Sq.mtr) : Rs. 3.25 Cr
Plant & Machinery : Rs. 2.20 Cr
Working Capital for 2 Months : Rs. 2.76 Cr
Total Capital Investment : Rs. 9.16 Cr
Rate of Return : 25%
Break Even Point : 59%
INTRODUCTION
USES OF PVC PIPES
SPECIFICATION OF SELECTED PVC AND CPVC PIPE FITTINGS
INJECTION MOLDED FITTING
SPECIFICATION & TESTING METHOD OF HDPE PIPES
SCOPE
REFERENCES
DESIGNATION
COLOUR
MATERIAL
DIMENSIONS OF PIPES
TABLE 2 OUTSIDE DIAMETER, TOLERANCE AND QUALITY OF PIPES
TABLE 3 WALL THICKNESS OF PIPES FOR MATERIAL GRADE PE 63
TABLE 4 WALL THICKNESS OF PIPES FOR MATERIAL GRADE PE 80
TABLE 5 WALL THICKNESS OF PIPES FOR MATERIAL GRADE PE 100
VISUAL APPEARANCE
PERFORMANCE REQUIREMENTS
SAMPLING, FREQUENCY OF TESTS AND CRITERIA FOR CONFORMITY
TABLE 6 REQUIREMENTS OF PIPES FOR INTERNAL PRESSURE CREEP
RUPTURE TEST
MARKING
EXPLANATORY NOTES
MASTER BATCH
TOLERANCE ON OUTSIDE DIAMETER AND MAXIMUM OVALITY
WALL THICKNESS
INTERNAL PRESSURE CREEP RUPTURE TEST
GENERAL
TEST SPECIMENS
APPARATUS
PROCEDURE
ASSESSMENT OF RESULTS
LONGITUDINAL REVERSION TEST
APPARATUS
PROCEDURE
EXPRESSION OF RESULTS
SPECIFICATION OF PVC PIPES AND TESTING METHOD
UNPLASHCIZED PVC PIPES FOR POTABLE WATER SUPPLIES —
SPECIFICATION (THIRD REVISION)
SCOPE
NORMATIVE REFERENCES
TERMINOLOGY
NOTATION
CLASSIFICATION OF PIPES
COMPOSITION
DIMENSIONS
SEALING RINGS
PIPE ENDS
PHYSICAL AND CHEMICAL CHARACTERISTICS
TABLE 4 INNER DIAMETERS OF SOCKETS FOR USE WITH
ELASTOMETRIC SEALING RINGS
MECHANICAL PROPERTIES
SAMPLING AND CRITERIA FOR CONFORMITY
MARKING
QUALITY CONTROL AND TESTING OF PIPES & FITTINGS
WORKMANSHIP, FINISH, AND APPEARANCE
DIMENSIONS
PHYSICAL PROPERTY TESTS
ASTM TESTS
GLOBAL MARKET POSITION OF PVC PIPES & FITTING
ASIA-PACIFIC PVC PIPE MARKET
GLOBAL MARKET POSITION OF HDPE PIPES
CHINA, UNITED STATES TO DRIVE GLOBAL DEMAND
DEVELOPING COUNTRIES TO ALSO SHOW ROBUST GROWTH
PLASTIC PIPE TO PENETRATE NONTRADITIONAL MARKETS
PRESENT CONSUMPTION PATTERN OF P.V.C. RIGID PIPES
ADVANTAGES OF PVC
CHEMICAL RESISTANCE
STRENGTH
INTERNAL CORROSION RESISTANCE
EXTERNAL CORROSION RESISTANCE
FREEDOM FROM TOXICITY, ODORS, TASTES
CORROSION FREE
LOW FRICTION LOSS
LOW THERMAL CONDUCTIVITY
EASY INSTALLATION AND LOW INSTALLATION COST
MAINTENANCE FREE
STANDARD APPROVED
PROPERTIES OF PVC PIPES AND FITTINGS
PIPE DIMENSIONS EIGHT & OPERATING PRESSURE OF PVC & CPVC PIPE
MANUDFACTURERS/SUPPLIERS OF PVC PIPES FITTINGS AND HDPE PIPES
PVC FOR PIPING INDUSTRY 100
TABLE GENERAL PROPERTIES OF RIGID PVC
PVC
STEPS TO REDUCE THE COST TO PROCESS PLASTIC PIPES INCLUDE
FORMULATION FOR PVC RIGID PIPES
PROCESS OF MANUFACTURE PVC PIPE
PLUMBING PIPES
MANUFACTURING PROCESS OF PVC PIPES
ADDITIVES USED FOR MANUFACTURING
RIGID PVC PIPES
PROCESS FLOW DIAGRAM FOR PVC PIPES
PVC COMPOUND FORMULATION
FORMULATION AND PROCESS OF PVC RIGID PIPES
FORMULATION FOR PVC RIGID PIPES
PVC FLEXIBLE PIPES
PLUMBING PIPES
PROCESS OF MANUFACTURE OF RIGID PIPES
TWIN SCREW EXTRUDERS
EXTRUSION DIES
EXTRUSION LINES
PVC PIPE FITTINGS:-
PLASTICIZER OF PVC
FILLERS OF PVC
STABILIZERS
MANUFACTURING PROCESS OF PVC PIPE FITTINGS
INJECTION MOULDING :-
PROCESS FLOW SHEET FOR THE MANUFACTURE OF PVC PIPE FITTING
RAW MATERIALS FOR HDPE PIPES
A. HDPE GRANULES
B. BLACK MASTER BATCH
C. ANTI-OXIDANT
MANUFACTURING PROCESS OF HDPE PIPES
EXTRUSION PROCESS
WORKING PRINCIPLE
EXTRUSION PROCESS PARAMETERS
ADVANTAGES:
DISADVANTAGES:
INCOMING RAW MATERIAL INSPECTION
RESIN HANDLING FOR MOISTURE CONTENT AND TEMPERATURE
RESIN STORAGE AND CONVEYANCE
RESIN FEEDING
TESTING
(A) TYPE TEST
(B) ACCEPTANCE TEST
(C) LONGLTUDINAL REVERSION PERFORMANCE TEST
APPRATUS
1. AIR OVEN
2. THERMOMETER
TEST SPECIMENS
PROCEDURE
MARKING
PVC PIPES FITTING MOULDS
INJECTION MOLD FOR PVC PIPE FITTINGS & CONNECTORS
TROUBLE SHOOTING GUIDE FOR PIPE EXTRUSION
PIPE EXTRUSION TROUBLESHOOTING GUIDE
PROCESSING DETAILS OF PIPE EXTRUSION
PIPE EXTRUSION
RAW MATERIALS DESCRIPTION
EXTRUSION LINE
RAW MATERIALS HANDLING
EXTRUSION BASICS
EXTRUDERS
BREAKER PLATE/SCREEN PACK
DIE DESIGN
PIPE SIZING
COOLING
PULLERS
TAKE-OFF EQUIPMENT
SAW EQUIPMENT AND BUNDLING
SUPPLIERS OF PLANT AND MACHINERIES
COOLING TOWER
AIR COMPRESSORS
LABORATORY EQUIPMENTS
HORIZONTAL INJECTION MOULDING MACHINE
WATER COOLING UNIT
SCRAP GRINDER MACHINE
PRINTING MACHINES
SUPPLIERS OF RAW MATERIALS
POLLUTION/ENVIRONMENTAL CONTROL
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
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