Detailed Project Report (DPR) on PVC Pipes and Fittings

PVC PIPES AND FITTING PLANT

[EIRI/EDPR/1623] J.C.: 426, 9997INR

INTRODUCTION

PVC (unplasticized polyvinylchloride) pipes and fittings exhibit excellent resistance to aggressive environments both naturally occurring and as a result of industrial activity. They are resistant to almost all types of corrosion, either chemical or electrochemical in nature. Since PVC is a non-conductor, galvanic and electro chemical effects do not occur in PVC pipes.

PVC Pipes and fittings a often used in the following circumstances:

• For drinking water pipe distribution systems, both main and supply lines

• Sewer and discharge pipe systems

Due to its non-metallic nature, the material used is totally resistant to all forms of metallic corrosion.

Aggressive water resulting from high sulphate soils and low hardness water will not attack PVC pipes.

Our pipes are therefore resistant to a wide range of industrial waters and chemicals and offer an advantage in long-term systems life and manufacture costs.

For more information on the resistance of PVC for specific chemical(s), do not hesitate to let Interplast know. We inform you of the suitable pipe solution necessary.

Being made of a tasteless and odorless material, PVC pipes remain neutral to all transported fluids.

PVC is completely inert and is widely used for transporting liquids made for human consumption.

Because of their mirror-smooth inside surface, PVC pipes have minimum flow head loss. There is also no buildup of inside deposits, a particular advantage in the construction of sewerage systems.

The physical properties of PVC pipes are not affected by neither direct sunshine, nor wind or rain.

However, to avoid surface browning due to long exposure to direct sunlight, it is recommended that the pipes are kept protected from direct sunlight.

Rigid PVC is not conductive to combustion. In the event of a fire, flames are unable to travel on PVC pipes. They therefore offer added safety when used for electrical installations, both domestic and industrial.

PVC pipes are relatively light. Their specific weight 1.43 is one- fifth that of steel pipes. This cuts down transportation costs and facilitates installation when in difficult and remote places. Installation is quick and easy with a complete line of fittings either with the solvent glue weld sockets or the rubber seal socket joints. In either case, a leak-proof joint is assured. Subsequent maintenance work is also carried out with a minimum of complication and cost.

PVC pipe which is made from polymerized vinyl chloride, a synthetic resin, which when plasticized or softened with other chemicals has some rubber-like properties. Derived from acetylene and anhydrous hydrochloric acid. PVC pipe has nominal sizes that are to be used with PVC socket fittings (schedule 40) and PVC socket or threaded fittings (schedule 80).

PVC Pipe and Fittings have got tremendous demand in India as well as in abroad. To manufacture this, all the machinery and raw materials are available indigenously.

A  polyvinyl chloride (PVC) pipe is made from a plastic  and vinyl  combination  material.  The pipes  are  durable,  hard  to damage, and long lasting. A PVC pipe does not rust, rot, or  wear over  time. For that reason, PVC piping is most commonly used  in water systems, underground wiring, and sewer lines.

PVC was first developed in 1925 when a BF Goodrich employee, Dr.  Waldo Semon, attempted to invent a method for bonding metal and rubber. After blending materials together to create a strong and flexible material, Semon discovered PVC. Nonetheless, the product remained virtually useless for another decade. In the late 1930's, PVC  was  found  to  have  great  shock  absorbing abilities. This discovery led to the creation of long lasting PVC tire treads, which were created with flexible forms of PVC.

Two decades later, PVC pipe was invented. By heating the PVC material,  a special machine called an extruder could be used  to push the PVC into hollow pipes. This PVC pipe was extremely solid and  virtually  indestructible. Using PVC  pipes  for  irrigation systems  proved  to  be  effective. PVC pipe has since been considered an affordable and reliable means for water piping.

Due to the ability of PVC pipe to withstand extreme movement and  bending,  it is also increasingly used in  earthquake  prone areas.  PVC pipe can withstand the rigorous shaking of the earth without experiencing any damage. The smooth surface of  the  PVC pipe  is  also resistant to bacterial contamination, such  as  E. coli.  Therefore, many water companies rely on PVC pipe in  their systems in order to keep them free of contamination.

Unfortunately,  the material used in PVC pipe appears to be detrimental to a person's health and safety. Reported cases of PVC  pipe  shattering when used with high-pressured gases have increased drastically. The Federal Government has issued safety warnings, which strongly recommend using alternative piping material. In addition, the heavy metals used to create PVC pipe can leach out when heated. The vapors emitted from the heated PVC pipe are now being linked to certain forms of cancer,  especially lung cancer.

COST ESTIMATION

Plant Capacity            10 MT/Day

Land & Building (10,000 sq.mt.)    Rs. 14.17 Cr

Plant & Machinery                    Rs. 1.77 Cr

Working Capital for 2 Months    Rs. 4.55 Cr

Total Capital Investment          Rs. 20.96 Cr

Rate of Return                          13%

Break Even Point                      64%

CONTENTS

INTRODUCTION

PVC PIPES AND FITTINGS A OFTEN USED IN THE FOLLOWING CIRCUMSTANCES:

PROPERTIES OF PVC PIPES & FITTINGS

ADVANTAGES & LIMITATIONS

HANDLING & STORAGE:-

BUREAU OF INDIAN STANDARDS SPECIFICATIONS PLASTIC PIPES & FITTINGS

PRESSURE PIPES FOR WATER SUPPLY & IRRIGATION

PLUMBING PIPES

APPLICATIONS OF PVC PIPES & FITTINGS

THE MAIN APPLICATION OF RIGID PVC PIPES & FITTINGS ARE:-

1. FOR TRANSPORTATION OF WATER:

2. TUBE WELLS:-

3. CHEMICAL PROCESSING PLANTS:-

4. DUCTING FOR POWER AND COMMUNICATION CABLES:

FOR TRANSPORTATION OF PULVERIZED MATERIALS

ADVANTAGES OF USING PVC PIPES

1. IT IS ECONOMICAL:

2. IT RESISTS CORROSION:

3. NON-ENRUSTATION:

4. LIGHT WEIGHT:

5. EASE OF INSTALLATION:

MARKET SURVEY

PRESENT CONSUMPTION PATTERN OF P.V.C. RIGID PIPES

PVC PIPES OFFERS THE FOLLOWING ADVANTAGES:-

APPARENT CONSUMPTION (IN TONS)

TREND IN INCREASE IN DEMAND

TREND GROWTH RATE IN INCREASE OF DEMAND = 15%

ENHANCED RECYCLING PROPERTIES FOR PVC PIPES

MANUFACTURERS/EXPORTERS OF PVC PIPES

PVC PIPE MANUFACTURERS/EXPORTERS RAW MATERIAL SECTION

PVC RESIN:

FORMULATION FOR PVC RIGID PIPES

FORMULATION -I

PVC FLEXIBLE PIPES

FORMULATIONS

PROCESS OF MANUFACTURE

PLUMBING PIPES

USES & APPLICABILITY OF PVC COMPOUNDS

BUILDING AND CONSTRUCTION:

PACKAGING:

MISCELLANEOUS:-

PROCESS OF MANUFACTURE OF RIGID PIPES

TWIN SCREW EXTRUDERS

EXTRUSION DIES

EXTRUSION LINES:-

PVC PIPE FITTINGS:-

PLASTICIZER OF PVC

FILLERS OF PVC

STABILIZERS

PROCESS FLOW SHEET FOR THE MANUFACTURE OF PVC PIPES

PROCESS FLOW SHEET FOR THE MANUFACTURE OF PVC FITTINGS

PLANT LAYOUT

THE NEW GENERATION OF PVC-O PIPES

MOLECULAR ORIENTATION, A REVOLUTION IN PVC TECHNOLOGY

A PLASTIC WITH UNBEATABLE PROPERTIES

CUTTING-EDGE TECHNOLOGY FOR WATER

MAXIMUM RELIABILITY AND SECURITY

HIGH SHORT AND LONG TERM HYDROSTATIC RESISTANCE

EXCELLENT RESPONSE TO WATER HAMMER

INCREASE HYDRAULIC CAPACITY

MAXIMUM FLEXIBILITY

COMPLETE CORROSION RESISTANCE

TOTAL WATER QUALITY

COMPLETELY WATER TIGHT

LOWER COST AND EASIER INSTALLATION

THE MOST ECO-FRIENDLY PIPES ON THE MARKET

ENERGY EFFICIENT

OPTIMAL USE OF WATER RESOURCES

100% RECYCLABLE

THE BEST MECHANICAL PROPERTIES

TENSILE RESISTANCE

LONG TERM HYDROSTATIC RESISTANCE

PIPING AND MATERIAL MECHANICAL PROPERTIES

OTHER MATERIAL CHARACTERISTICS

UNBEATABLE HYDRAULIC PROPERTIES

HYDRAULIC CAPACITY

WATER HAMMER

A RANGE FOR ALL KINDS OF APPLICATIONS

DIMENTIONS

PACKAGING

JOINTS AND WATER TIGHT SEALS

FITTINGS

TAPPING SADDLES

FLANGE WITH ANTI-TRACTION SYSTEM

FITTINGS WITH PLUGS EURO TYPE

APPLICATIONS

OTHER APPLICATIONS

PRODUCTION OF PVC IRRIGATION PIPE

FIG. 1 ILLUSTRATES THE PROCESS OF THE PRESENT METHOD.

EXAMPLE 1

EXAMPLE 2 (COMPARATIVE)

EXAMPLE 3 (COMPARATIVE)

EXAMPLE 4 (COMPARATIVE)

EXAMPLE 5

EXAMPLE 6 (COMPARATIVE)

TAPPING TOOL FOR PVC PIPES AND FITTINGS

JOINING MECHANISM FOR PVC PIPE

REPAIR PIPE FITTINGS

SUPPLIERS OF PLANT AND MACHINERY OF PVC PIPES

HIGH SPEED MIXER

EXTRUDER

PLASTIC SCRAP GRINDER MACHINE

PLASTIC INJECTION MOULDING MACHINE

STEAM BOILERS

GENERATOR SET

SUPPLIERS OF RAW MATERIALS

PVC RESIN

CALCIUM STEARATE

LEAD STEARATE

PRECIPITATED CALCIUM CARBONATE

PIGMENT DYE

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)