Detailed Project Report (DPR) on hdpe and plb pipe manufacturing unit

HDPE AND PLB PIPE MANUFACTURING UNIT

[CODE NO.4212] 

High-density polyethylene (HDPE) is a polyethylene thermoplastic made from petroleum. It is known for its large strength-to-density ratio. The density of HDPE can range from 0.93 to 0.97g/cm3 or 970Kg/m3. The difference in strength exceeds the difference in density, giving HDPE a higher specific strength. It is also harder and more opaque and can withstand much higher temperatures (120°C for short periods, 110°C continuously). High-density polyethylene, unlike polypropylene, cannot withstand normally required autoclaving conditions. The lack of branching is ensured by an appropriate choice of catalyst (e.g., Ziegler-Natta catalysts) and reaction conditions.

HDPE pipes are important plastic products which have wide range of applications. These have more tensile strength in comparison to other plastic pipes. These are being used for Sprinkler Irrigation System, potable water supply and sewerage purpose. Their low cost, easily installation and better durability make them ideal for the purpose. They also offer very good resistance to most of the chemicals and have excellent electrical insulation properties. These pipes are also used for circulation of acids in various chemical industries due to their acid resistant quality.

The demands of HDPE Pipes are likely to increase due to their wide use in various sectors in India. Apart from its regular uses, such as for irrigation system, water supply, sewerage, it is being used by Department of Telecommunication for conduit for optical fiber cables. Looking to its increased demand, it appears to be good scope for setting up new small scale industries. Hence the product has good market potential.

CLASSIFICATION

(A) Pipes shall be classified according to the grade of materials as MRS; Polyethylene pipes and classified by the raw materials used in the production of attachments. MRS material strength values of 20°C are also shown by the internal pressure for 50 years.

Raw material class MRS(MPa) value

PE 63 6.3

PE  80 8.0

PE  100 10

(B) Pipes by pressure rating (PN) corresponding to the maximum shall be classified permissible working pressure at 3WC, as follows:

The pressure grades available according to European standards are:

• PN 2.5 - max pressure 2.5 bar

• PN 4 - max pressure 4 bar

• PN 6 - max pressure 6 bar

• PN 10 - max pressure 10 bar

• PN 16 - max pressure 16 bar

Color codes used to indicate the pressure grades on the pipes are:

Color Code                                                     PE Pressure Grade 

Yellow                                                                        PN 4

Red                                                                          PN 6

Blue                                                                          PN 10

Green                                                                    PN 1

HDPE Pipes for following grades/sizes/pressure rating

PE 63 PN 2.5 DN 63 to 110

PE 63 PN 4 DN 40 to 110

PE 63 PN 6 DN 32 to 110

PE 63 PN 8 DN 32 to 110

PE 63 PN 10 DN 32 to 110

PE 63 PN 12.5 DN 32 to 110

PE 63 PN 16 DN 32 to 110

PE 80 PN 2.5 DN 90 to 110

PE 80 PN 4 DN 50 to 110

PE 80 PN 6 DN 40 to 110

PE 80 PN 8 DN 32 to 110

PE 80 PN 10 DN 32 to 110

PE 80 PN 12.5 DN 32 to 110

PE 80 PN 16 DN 32 to 110

PE 100 PN 6 DN 50 to 110

PE 100 PN 8 DN 40 to 110

PE 100 PN 10 DN 32 to 110

PE 100 PN 12.5 DN 32 to 110

PE 100 PN 16 DN 32 to 110

COST ESTIMATION

Plant Capacity                               1800 Kg./Day

Land & Building (2000 sq.yard)  Rs. 58 Lac

Plant & Machinery                        Rs. 66 Lac

Working Capital for 1 Month    Rs. 82 Lac

Total Capital Investment            Rs. 2.04 Cr

Rate of Return                               38%

Break Even Point                         62%

• INTRODUCTION
  
• CLASSIFICATION
• THE PRESSURE GRADES AVAILABLE ACCORDING TO EUROPEAN STANDARDS ARE:
• COLOR CODES USED TO INDICATE THE PRESSURE GRADES ON THE PIPES ARE:
• HDPE PIPES FOR FOLLOWING GRADES/SIZES/PRESSURE RATING
• CHARACTERISTICS
• USES AND APPLICATION
• INDUSTRIES
• SPECIAL SERVICES
• APPLICATIONS
• SUBMARINE PIPELINES
• RELINING - NEW PIPES IN OLD
• SEWER PIPES
• SLURRY TRANSPORTATION
• IRRIGATION
• DOMESTIC GAS DISTRIBUTION
• CHEMICAL PROCESS PIPING
• PLB HDPE DUCT
• ADVANTAGES
• PROPERTIES
• B.I.S. SPECIFICATION
• ADVANTAGE AND APPLICATION OF PLB HDPE DUCT
• ADVANTAGES OF HDPE PLB DUCT PIPE:
• STANDARDS:
• SEQUENCES IN HDPE PIPE MANUFACTURING
• ACCUMULATION OF RAW MATERIAL
• MELTING THE RAW MATERIAL
• EXTRUSION AND DYING
• VACUUM AND PRESSURE CALIBRATION
• COOLING BATH
• HAUL OFF UNIT
• CUTTING UNIT
• RESEARCH, DESIGN AND STANDARD ORGANIZATION SPECIFICATION ON PLB HDPE DUCT
• SCOPE:
• REFERENCES:
• ABBREVIATIONS:
• GENERAL REQUIREMENTS:
• OUTER LAYER:
• INNER LAYER:
• REQUIREMENTS OF RAW MATERIALS USED FOR THE DUCT:
• SERVICE CONDITION:
• TECHNICAL REQUIREMENT:
• PLB HDPE DUCT ACCESSORIES:
• COUPLER:
• END PLUG:
• CABLE SEALING PLUG:
• END CAP:
• TOOLS:
• ROTATRY DUCT CUTTER:
• C-SPANNER:
• CHAMFERRING TOOL:
• PACKING REQUIREMENT:
• TYPE TESTS:
• ACCEPTANCE TESTS:
• SAMPLING PLAN:
• ROUTINE TEST:
• INSPECTION:
• ORDERING INFORMATION:
• ANNEXURE – A (DIMENSION OF THE DUCT)
• ANNEXURE – B (ENVIRONMENTAL STRESS CRACKING RESISTANCE TEST)
• ANNEXURE – C (UV STABLISER TEST)
• ANNEXURE – D (CRUSH RESISTANCE TEST)
• ANNEXURE – E (INTERNAL COEFFICIENT OF FRICTION TEST)
• METHOD:
• ANNEXURE – F (MANDREL TEST)
• ANNEXURE – G (COIL SET)
• ANNEXURE – H (HYDRAULIC CHARACTERISTICS)
• ANNEXURE – I (OPTICAL FIBRE CABLE BLOWING TEST)
• ANNEXURE – J (TERMITE RESISTANCE TEST)
• RATING CHART:
• ANNEXURE – K (PULL STRENGTH OF COUPLER)
• ANNEXURE – L (TEST METHOD FOR ASH CONTENT)
• ANNEXURE – M (OXIDATION INDUCTION TEST METHOD)
• INSTRUMENT TEST PROCEDURE:
• ANNEXURE – N (IMPACT STRENGTH TEST):
• ANNEXURE – O (HEAT REVERSION TEST):
• PROCESS OUTLINES OF HDPE PIPES EXTRUSION
• PROCESSING DETAILS OF HDPE PIPES
• EXTRUDER
• FEED HOPPER
• BARREL
• SCREW
• DIE
• WATER COOLING TUB
• PROCESS FLOW CHART
• EXTRUSION PROCESS FOR PLASTICS
• EXTRUSION PROCESS
• WORKING PRINCIPLE
• EXTRUSION PROCESS PARAMETERS
• ADVANTAGES
• DISADVANTAGES
• RAW MATERIALS
• A. HDPE GRANULES
• B. BLACK MASTER BATCH
• C. ANTI-OXIDANT
• QUALITY CONTROL OF HDPE PIPES
• VISUAL INSPECTIONS
• MECHANICAL INSPECTION
• OTHER QC TESTS CAN INCLUDE:
• DESCRIPTION OF MANUFACTURING PROCESS
• 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
• MARKET POSITION OF INDIAN HDPE PIPES
• OPPORTUNITIES OF HDPE PIPES
• MARKET BY APPLICATION
• MARKET BY GRADE TYPE
• MARKET BY DIAMETER TYPE
• MARKET BY PRESSURE RATING
• GLOBAL MARKET POSITION OF HDPE PIPES
• THE INDIAN PLASTIC PIPES MARKET
• TYPES OF PLASTIC PIPES APPLICATION
• WE CAN MAJORLY CATEGORIZE APPLICATION OF PLASTIC PIPES INTO FOUR PARTS:
• MARKET SIZE OF PLASTIC PIPES AS PER APPLICATION
• INDUSTRY ANALYSIS WITH PORTER’S 5 FORCES MODEL
• BARGAINING POWER OF SUPPLIERS
• BARGAINING POWER OF BUYERS
• INTERNAL RIVALRY
• ENTRY
• THREAT OF SUBSTITUTES
• GROWTH DRIVERS OF PLASTIC PIPES INDUSTRY
• OTHER MEASURES
• SWOT ANALYSIS
• STRENGTHS
• WEAKNESSES
• OPPORTUNITIES
• THREATS
• MANUFACTURERS/SUPPLIERS OF HDPE AND PLB PIPE
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF HDPE GRANULES
• SUPPLIERS OF BLACK MASTER BATCH
• SUPPLIERS OF ANTIOXIDANT
• SUPPLIERS OF COMPLETE HDPE PIPE PLANT
• SUPPLIERS OF PRECISION MEASURING TOOLS
• SUPPLIERS OF EOT CRANE
• SUPPLIERS OF POWER TRANSFORMER
• SUPPLIERS OF ELECTRICAL PANEL
• SUPPLIERS OF COOLING TOWER
• SUPPLIERS OF EFFULENT TREATMENT PLANT
• SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
• SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
• SUPPLIERS OF AIR COMPRESSOR
• SUPPLIERS OF PLATFORM WEIGHING MACHINE
• SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
• SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

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)