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)

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